Maintenance Instructions for Jet JLX Series LED Lightbars

Maintenance Instructions for Jet JLX Series LED Lightbars
2562020A
REV. A 105
Printed in U.S.A.
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FOR
JET™ JLX SERIES LED LIGHT BARS
SAFETY MESSAGE TO INSTALLERS
OF
FEDERAL SIGNAL LIGHT SYSTEMS
WARNING
People’s lives depend on your safe installation of our products. It is important to
read, understand and follow all instructions shipped with the products. In addition, listed below are some other important
safety instructions and precautions you
should follow:
•
•
•
To properly install a light assembly:
you must have a good understanding of
automotive electrical procedures and
systems, along with proficiency in the
installation and use of safety warning
equipment.
When drilling into a vehicle structure,
be sure that both sides of the surface
are clear of anything that could be
damaged.
A light system is a high current device.
In order for it to function properly, a
separate ground connection must be
made. If practical, it should be connected to the negative battery terminal. At a minimum, it may be attached
to a solid metal body or chassis part
that will provide an effective ground
path as long as the light system is to be
used.
•
Locate light system controls so the
VEHICLE and CONTROLS can be
operated safely under all driving
conditions.
•
This product contains high intensity
LED devices. To prevent permanent
eye damage, DO NOT stare into the
light beam at close range.
•
You should frequently inspect the light
system to ensure that it is operating
properly and that it is securely attached to the vehicle.
•
File these instructions in a safe place
and refer to them when maintaining
and/or re-installing the product.
Failure to follow all safety precautions and
instructions may result in property damage,
serious injury, or death to you or others.
I.
UNPACKING.
After unpacking the light bar, inspect it for damage
that may have occurred in transit. If the unit has been
damaged, file a claim immediately with the carrier,
stating the extent of damage. Carefully check all
envelopes, shipping labels and tags before removing or
destroying them.
II.
INSTALLATION.
The basic light bar is completely wired at the
factory and does not require any additional internal
wiring. All the conductors necessary for control of any
and all basic and optional functions are contained in the
cable. Installation of options will require additional
wiring in the light bar.
The basic light functions of the unit must be controlled by a user supplied control head.
Before proceeding, ensure that the light bar has
been installed on the vehicle roof in accordance with the
instructions packed with the mounting kit. Route the
light bar cable as described below.
WARNING
Light system controls must be located so
that VEHICLE and CONTROLS can be
operated safely under all driving conditions.
WARNING
When installing equipment inside air bag
equipped vehicles, the installer MUST
ensure that the equipment is installed
ONLY in areas recommended by the vehicle manufacturer.
Failure to observe this warning will reduce
the effectiveness of the air bag, damage the
air bag, or potentially damage or dislodge
the equipment, causing serious injury or
death to you or others.
A. Route the control cable into the vehicle and
under the dash, near the eventual location of the usersupplied control head.
B. For proper light operation, the control cable
must be properly terminated inside the user-supplied
control head. Using figures 1 and 2 as a guide, select the
appropriate wiring diagram for your model and complete the applicable electrical connections for the
1A
2A
1C
2C
2E
1E
1B
2B
1D
2D
JLX4800 SERIES
OPEN OPEN OPEN #1C RED & #1D RED #2C RED & #2D RED #1C BLK & #1D BLK #1E BLACK #2C BLK & #2D BLK #2E BLACK TCL (BLUE/WHT WIRE) "PATTERN SELECT" FROM FLASHER OPEN -
- OPEN
- OPEN
- OPEN
- #1A RED
USE JUMPER
- #1B RED
- #2A RED
USE JUMPER
- #2B RED
- #1A BLK
USE JUMPER
- #1B BLK
- #2A BLK
USE JUMPER
- #2B BLK
- BROWN FROM CABLE
- BLUE FROM CABLE
- YELLOW FROM CABLE
}
}
}
}
290A5123
1A
2D
1D
2C
2B
1C
1B
2A
JLX5400 SERIES
OPEN OPEN OPEN #1C RED & #1D RED FLASHER ORANGE WIRE 1 OUT #2C RED & #2D RED FLASHER WHITE WIRE 2 OUT #2A & #2B BLACK #2C & #2D BLACK USE JUMPER
OPEN (BLUE/WHT WIRE) "PATTERN SELECT" FROM FLASHER OPEN OPEN OPEN -
{
- OPEN
- OPEN
- OPEN
- #1A RED
USE JUMPER
- #1B RED
- #2A RED
USE JUMPER
- #2B RED
- #1A & #1B BLACK
USE JUMPER
- #1C & #1D BLACK
- (T-WIRE W/RING TERM.,BLK)
- BLUE FROM CABLE
- YELLOW FROM CABLE
- BROWN FROM CABLE
- BRN/WHT FROM CABLE
}
}
}
290A5124
1E
2E
1F
2F
1G
2G
2D
1A
1D
2C
1C
2B
1B
2A
JLX5498 SERIES
OPEN OPEN #1E & #1F RED #1G RED & FLASHER ORANGE WIRE 1 OUT #2E & #2F RED #2G RED & FLASHER WHITE WIRE 2 OUT #2A & #2B BLACK #2C & #2D BLACK USE JUMPER
#2E & #2F BLACK (T-WIRE W/RING TERM.) & #2G BLACK CONNECT T-WIRE TO EXTRUSION (BLUE/WHT WIRE) "PATTERN SELECT" FROM FLASHER OPEN OPEN OPEN -
{
- OPEN
- OPEN
- #1A & #1B RED
USE JUMPER
- #1C & #1D RED
- #2A & #2B RED
USE JUMPER
- #2C & #2D RED
- #1A & #1B BLACK
USE JUMPER
- #1C & #1D BLACK
- #1E & #1F BLACK
USE JUMPER
- #1G BLACK
- BLUE FROM CABLE
- YELLOW FROM CABLE
- BROWN FROM CABLE
- BRN/WHT FROM CABLE
}
}
}
}
290A5125
Figure 1.
-2-
1D
2D
1E
2E
2C
1A
1
1C
2
2B
1B
2A
JLX5499
OPEN OPEN #1E RED FLASHER ORANGE WIRE 1 OUT #2E RED FLASHER WHITE WIRE 2 OUT #2A & #2B BLACK #2C & #2D BLACK USE JUMPER
#2E BLACK OPEN (BLUE/WHT WIRE) "PATTERN SELECT" FROM FLASHER OPEN TCL #1 (PURPLE WIRE) TCL #2 (WHT WIRE) -
{
- OPEN
- OPEN
- #1A & #1B RED
USE JUMPER
- #1C & #1D RED
- #2A & #2B RED
USE JUMPER
- #2C & #2D RED
- #1A & #1B BLACK
USE JUMPER
- #1C & #1D BLACK
- (T-WIRE W/RING TERM.) & #1E BLACK - CONNECT T-WIRE TO EXTRUSION
- OPEN
- BLUE FROM CABLE
- YELLOW FROM CABLE
- BROWN FROM CABLE
- BRN/WHT FROM CABLE
}
}
}
290A5126
1E
1A
2D
1D
2C
1C
2B
1B
2A
JLX6000 SERIES
USE JUMPER
{
OPEN OPEN OPEN #1C RED & #1D RED #1E & FLASHER ORANGE WIRE 1 OUT #2C RED & #2D RED FLASHER WHITE WIRE 2 OUT #2A & #2B BLACK #2C & #2D BLACK (T-WIRE W/RING TERM.) CONNECT GROUND TO EXTRUSION (BLUE/WHT WIRE) "PATTERN SELECT" FROM FLASHER OPEN OPEN OPEN -
- OPEN
- OPEN
- OPEN
- #1A RED
USE JUMPER
- #1B RED
- #2A RED
USE JUMPER
- #2B RED
- #1A & #1B BLACK
USE JUMPER
- #1C & #1D BLACK
- #1E BLACK
- BLUE FROM CABLE
- YELLOW FROM CABLE
- BROWN FROM CABLE
- BRN/WHT FROM CABLE
}
}
}
290A5127
Figure 2.
-3-
functions installed in your light bar. Switch current
capacities should be at least 15 amps.
WARNING
To provide safe operation, the user supplied power control switch and wiring
must be capable of handling the rated
current of the fuse at the source.
NOTE
Any of the light bar functions can be activated
by applying 12VDC to the appropriate control
line. The heavy black lead (-) must be connected
to vehicle ground, to perform a function check.
3.
Programming.
The flasher will provide the end user with
two preselected flash patterns. The preselected flash
patterns are to be chosen from the ten factory programmed patterns provided with each flasher. It is
recommended that the preselected flash patterns be
determined and programmed during installation.
C. Connect the black lead to chassis ground.
WARNING
If wires are shorted to the vehicle frame or
each other, high current conductors can
cause hazardous sparks resulting in
electrical fires and molten metal.
The red/green LED as indicated in figure 1
will be illuminated green when an SAE approved flash
pattern is selected. When an unapproved SAE flash
pattern is selected, the LED will be illuminated red. The
red/green LED may alternate between red and green for
several flash patterns.
Verify that no short circuits exist before
connecting to the Positive (+) battery
terminal.
DO NOT connect this system to the vehicle
battery until ALL other electrical connections are made and mounting of all components is complete.
The following procedures demonstrate the
programming and operating features of the flasher:
SEE NOTE #3
Failure to observe this WARNING will
result in fire, burns and blindness.
D. Connect the light bar’s red power lead to a fuse
or circuit breaker rated at 20 amperes. Connect the
other side of the fuse /circuit breaker to the +12VDC
supply.
OUT 1
1.
CHANNEL 1
CUT-OFF
General.
NOTES:
The flasher has two (2) light circuits with a
current capacity of up to 10-amperes (maximum) per
side, 20-amperes total. The flasher is designed to
operate on any 12VDC (negative ground) vehicle
electrical system. The flasher operates as a high side
switch, switching the +DC supply to the load.
2.
OUT 2
+12
E. Flasher (see figure 3).
1) SWITCHES, FUSE
AND MOUNTING
HARDWARE ARE
USER SUPPLIED.
PROGRAMMING
PINS
PROGRAM
PROGRAM
2) "
" DESIGNATES
CHASSIS GROUND
CONNECTION.
3) LIGHTING DEVICE IS
USER SUPPLIED.
Wiring.
MODE1 / MODE2
LED
+12
GND
CAUTION
The device WILL NOT light up or flash if
improperly grounded. Be sure that the device
ground is attached to a good vehicle ground. A
ground termination at the flasher is provided.
+12VDC
Refer to figure 3 when performing the
following procedure.
FLASHER
POWER
PATTERN
SELECT
OPEN = PRIMARY MODE
CLOSED = SECONDARY MODE
290A5121B
The flasher has two outputs, Out 1 and Out
2. These outputs switch the +DC source from source to
the load.
Figure 3.
-4-
Turn on the flasher by applying Power (+)
and Ground (-). The flasher can be programmed at the
flasher by either shorting the programming pins
together momentarily or remotely done by connecting
the program pin to ground. The flasher will begin to
flash in Mode 1(Primary Pattern). By shorting the
PROGRAM pin to GND, the flasher will switch to the
next pattern. The flasher will step through the patterns
each time the program pin is shorted, returning to the
top once after the last pattern is displayed. To lock in a
chosen pattern, allow the pattern to run for 15-seconds
and it is now programmed.
B. Lamp Replacement.
WARNING
A serious injury may result if lamp is
touched when hot. Always allow lamp to
cool before removing. Halogen lamps are
pressurized and if broken can result in
flying glass. Always wear gloves and eye
protection when handling the lamps.
CAUTION
Service life of lamp will be shortened if glass
portion is touched. If glass has been handled,
clean carefully with a grease solvent.
To turn on the flasher in Mode 2 (Secondary
Pattern), turn the flasher system on and connect the
Pattern Select connection to Power (+). By shorting the
PROGRAM pin to GND, the flasher will switch to the
next pattern. The flasher will again step through the
patterns each time the program pin is shorted, returning to the top once after the last pattern is displayed. To
lock in a chosen pattern, allow the pattern to run for 15seconds and it is now programmed.
See figure 4. To replace the lamp, Twist to
unlock and then pull the defective lamp out of the
socket. Install a new lamp of the same type in the
socket.
C. Cleaning Reflectors and Mirrors.
Use a soft tissue to clean the reflector and
mirrors. Avoid heavy pressure and the use of caustic or
petroleum base solvents which will scratch or dull the
surface.
Channel 1 may be cutoff while the flasher
continues to run and channel 2 continues to flash. +12V
is applied to cutoff 1 to cutoff the channel.
The flasher is now programmed. When
power is applied to the flasher, it will flash in Mode 1
(Primary Pattern). To operate the Mode 2 (Secondary
Pattern) switch +DC to the Pattern Select Pin. Releasing the switch returns the flasher to flashing Mode 1
(Primary Pattern).
DO NOT TOUCH
THE GLASS PORTION
OF LAMP
LAMP
III. BASIC MAINTENANCE.
A. Cleaning the Plastic Domes.
SOCKET
Ordinary cleaning of the plastic domes can be
accomplished by using mild soap and a soft rag. Should
fine scratches or a haze appear on the domes, they can
ordinarily be removed with a non-abrasive, high quality,
automotive paste wax.
290A5122
Figure 4.
CAUTION
The use of other materials such as strong
detergents, solvents, petroleum products, etc.
can cause crazing (cracking) of the plastic
domes.
-5-
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