XL 5000 Installation Guide

XL 5000 Installation Guide
INSTALLATION
& OPERATION
MANUAL
5000 SERIES
LIGHT BAR
TM
LIGHT BAR
Contents:
Introduction......................................................... 2
Unpacking & Pre-Installation .............................. 2
Siren Speakers ................................................... 2
Mounting Light Bar ............................................. 3
Wiring Instructions .............................................. 3
Maintenance ....................................................... 4
Options ............................................................... 6
Warranty ............................................................. 8
all instructions and warnings before installing and using.
IMPORTANT: Read
INSTALLER: This manual must be delivered to the end user of this equipment.
Introduction
The XL 5000 TM lightbars provide a highly visible warning light that meets or exceeds all SAE specifications.
The bars have a strong extruded aluminum frame and shock resistant polycarbonate lenses. The bars are of
a modular design that allows them to be customized to meet any requirement.
!
WARNING!
The use of this or any warning device does not insure that all drivers can or will observe or
react to an emergency warning signal. Never take the right-of-way for granted. It is your
responsibility to be sure you can proceed safely before entering an intersection, driving
against traffic, responding at a high rate of speed, or walking on or around traffic lanes.
The effectiveness of this warning device is highly dependent upon correct mounting and
wiring. Read and follow the manufacturer’s instructions before installing or using this
device. The vehicle operator should insure daily that all features of the device operate
correctly. In use, the vehicle operator should insure the projection of the warning signal is
not blocked by vehicle components (i.e.: open trunks or compartment doors), people,
vehicles, or other obstructions.
This equipment is intended for use by authorized personnel only. It is the user’s responsibility to understand and obey all laws regarding emergency warning devices. The user
should check all applicable city, state and federal laws and regulations.
Public Safety Equipment, Inc., assumes no liability for any loss resulting from the use of this
warning device.
Proper installation is vital to the performance of this warning device and the safe operation
of the emergency vehicle. It is important to recognize that the operator of the emergency
vehicle is under psychological and physiological stress caused by the emergency situation.
The warning device should be installed in such a manner as to: A) Not reduce the output
performance of the system, B) Place the controls within convenient reach of the operator
so that he can operate the system without losing eye contact with the roadway.
Emergency warning devices often require high electrical voltages and/or currents. Properly
protect and use caution around live electrical connections. Grounding or shorting of
electrical connections can cause high current arcing, which can cause personal injury and/
or severe vehicle damage, including fire.
PROPER INSTALLATION COMBINED WITH OPERATOR TRAINING IN THE PROPER
USE OF EMERGENCY WARNING DEVICES IS ESSENTIAL TO INSURE THE SAFETY
OF EMERGENCY PERSONNEL AND THE PUBLIC.
Unpacking & Pre-installation
Carefully remove the light bar from the shipping carton and place on a flat surface, taking care not to damage
the wire cable coming out of the bottom. Examine the unit for transit damage, cracked lenses, dented speaker
cover, etc. If convenient, you may wish to bench test the unit before installing. Before applying voltage to the
bar, be sure you have read and understand the wiring instructions attached to the cable. Standard light bars
operate on 12 volt D.C. negative ground (earth) systems only. If you have a positive ground (earth) vehicle, or
any other type of system, and have not ordered a specially wired bar, contact the factory for instructions.
Siren Speakers
It is generally easier to install siren speakers before mounting the bar on the vehicle. No. 8 sheet metal
screws will easily break through the metallic tape and thread into the prepunched holes in the frame. To
install a speaker, remove the hex head screws that secure the center cover to the frame and remove it to
reveal a prewired terminal block. The center area is 1/8" aluminum and may be drilled almost anywhere, if
other than a Code 3 speaker is used. Before drilling, however, we suggest turning the light bar over and
removing the wire track cover plate from the bottom of the frame by removing the retaining screws. With the
wires exposed, drill carefully to avoid damaging the wires. After mounting the speaker and connecting the
leads to the terminal block, reinstall the wire track cover. Replace the center cover.
When using two siren speakers, follow speaker manufacturer's instructions for correct phasing of speakers.
2
Sirens are an integral part of an effective audio/visual emergency warning system. However, sirens are only short range secondary warning devices. The use of a siren does not
insure that all drivers can or will observe or react to an emergency warning signal, particularly at long distances or when either vehicle is traveling at a high rate of speed. Sirens
should only be used in a combination with effective warning lights and never relied upon as
a sole warning signal. Never take the right of way for granted. It is your responsibility to be
sure you can proceed safely before entering an intersection, driving against traffic, or
responding at a high rate of speed.
WARNING! The effectiveness of this warning device is highly dependent upon correct mounting and
SIREN PRODUCTS: wiring. Read and follow the manufacturer's instructions before installing or using this
device. The vehicle operator should check the equipment daily to insure that all features of
the device operate correctly.
To be effective, sirens must produce high sound levels that potentially can inflict hearing
damage. Installers should be warned to wear hearing protection, clear bystanders from the
area and do not to operate the siren indoors during testing. Vehicle operators and occupants should assess their exposure to siren noise and determine what steps, such as
consultation with professionals or us of hearing protection should be implemented to protect
their hearing.
This equipment is intended for use by authorized personnel only. It is the user’s responsibility to understand and obey all laws regarding emergency warning devices. The user
should check all applicable city, state and federal laws and regulations.
Public Safety Equipment, Inc., assumes no liability for any loss resulting from the use of this
warning device.
Proper installation is vital to the performance of this warning device and the safe operation
of the emergency vehicle. It is important to recognize that the operator of the emergency
vehicle is under psychological and physiological stress caused by the emergency situation.
The siren system should be installed in such a manner as to: A) Not reduce the acoustical
performance of the system, B) Limit as much as practical the noise level in the passenger
compartment of the vehicle. C) Place the controls within convenient reach of the operator
so that he can operate the system without losing eye contact with the roadway.
Emergency warning devices often require high electrical voltages and/or currents. Properly
protect and use caution around live electrical connections. Grounding or shorting of
electrical connections can cause high current arcing, which can cause personal injury and/
or severe vehicle damage, including fire.
PROPER INSTALLATION COMBINED WITH OPERATOR TRAINING IN THE PROPER
USE OF EMERGENCY WARNING DEVICES IS ESSENTIAL TO INSURE THE SAFETY
OF EMERGENCY PERSONNEL AND THE PUBLIC.
!
Mounting Light Bar
Mounting
To mount lightbar refer to instructions included with the mounting kit.
Remounting
When moving the light bar from one vehicle to another, we suggest that new 5/16" mounting bolts and
rubber feet be used. These are standard hardware items that can usually be found at any hardware
store, or they can be ordered from the factory. The special hooks are stainless steel and should be
saved and reused.
NOTE! If different holes must be used to mount the brackets, tape over the usual holes with duct tape on
the inside to prevent dirt and water from entering the light bar.
Wiring Instruction
Run at least a #10 AWG wire to the battery or to the stud on the battery side of the starter solenoid or
alternator. Be sure to calculate light bar's power draw and provide proper protection for short circuits.
Below is a quick chart and equation for calculating light bar load.
3
35 Watt Lamp = 3 Amp Load
50 Watt Lamp = 4 Amp Load
100 Watt Lamp = 8 Amp Load
Motors and Electronics Boxes = Negligible Load
Total watts in light bar divided by 13 volts equals amperage draw or:
Watts / 13 Volts = Amp Draw
If the light bar has a speaker section, the blue wires go to the siren amplifier and are to be connected in
accordance with the siren manufacturer's instructions. Test the unit for proper operation.
Route the wiring cable into the engine or passenger compartment, taking care to use grommets and to
apply sealant around openings to keep water out. It is advisable to leave an extra loop of cable when
installing the light bar to allow for future changes or reinstallations. Connect the black lead to a solid
frame ground (earth), preferably, the (-) or ground (earth) side of the battery and bring the other wires to
the control head or switches. Connect the wires to the control head or switch (as directed by the wiring
instructions on the cable). Caution - Operating a siren with a live speaker can inflict hearing
damage--always use hearing protection.
!
WARNING!
Larger wires and tight connections will provide longer service life for components. For high
current wires it is highly recommended that terminal blocks or soldered connections be used
with shrink tubing to protect the connections. Do not use insulation displacement
connectors (e.g. 3M® Scotchlock type connectors). Route wiring using grommets and
sealant when passing through compartment walls. Minimize the number of splices to reduce
voltage drop. High ambient temperatures (e.g. under hood) will significantly reduce the
current carrying capacity of wires, fuses, and circuit breakers. Use "SXL" type wire in engine
compartment. All wiring should conform to the minimum wire size and other
recommendations of the manufacturer and be protected from moving parts and hot surfaces.
Looms, grommets, cable ties, and similar installation hardware should be used to anchor and
protect all wiring.
Fuses or circuit breakers should be located as close to the power takeoff points as possible
and properly sized to protect the wiring and devices.
Particular attention should be paid to the location and method of making electrical
connections and splices to protect these points from corrosion and loss of conductivity.
Ground terminations should only be made to substantial chassis components, preferably
directly to the vehicle battery.
The user should install a fuse sized to approximately 125% of the maximum Amp capacity in
the supply line to protect against short circuits. For example, a 30 Amp fuse should carry a
maximum of 24 Amps. DO NOT USE 1/4" DIAMETER GLASS FUSES AS THEY ARE NOT
SUITABLE FOR CONTINUOUS DUTY IN SIZES ABOVE 15 AMPS. Circuit breakers are
very sensitive to high temperatures and will "false trip" when mounted in hot environments or
operated close to their capacity.
Maintenance
Lens Removal
Force 4TM XL 5000 TM series light bars are assembled with 1/4" Hex Head Screws. A 1/4" Socket or Nut
Driver is ideal, but a phillips screwdriver may be used.
4
Force 4 XL Light Bars
TM
TM
Remove the hex head screws along the lower front and rear edge of the speaker cover. Remove the
speaker cover by carefully pulling slightly forward and upward from the front lower edge, then lift it off to
the rear, taking care not to drag the cover on the lenses. Remove all of the screws form the lower front
and rear edge of the lenses and carefully lift them off. NOTE: If ambulance clips have been installed at
the rear of the lenses, only the front screws need to be taken off. Then lift the lens up and over the clips.
Force 4 XL Beacons
TM
TM
Remove all screws securing the lens and lift off.
Reassembly - All Products
When reassembling, check the lens perimeter gasket and replace if damaged. To reassemble, reverse
the previous procedures. It should be noted that a slight downward pressure on the lens may be
required during assembly. All screws should be hand tight. Excessive torque is not needed and may
strip hole.
Lamp Replacement
Remove the lens as outlined above. Next inspect the bulb and compare to Figure 1 to determine bulb
type. It may be necessary to remove any rotating or cylindrical filters to make access easier.
!
WARNING!
Lamps are extremely hot! Allow to cool completely before attempting to remove. Gloves
and eye protection should be worn when handling halogen lamps as they are pressurized
and accidental breakage can result in flying glass.
BAYONET TYPE BULB
H-1 TYPE BULB
FIGURE 1
H-1: First grasp bulb at base and turn until retaining clip is accessible. Using a blade screwdriver,
remove the retaining clip and pull bulb straight up. Grasp the power lead with long nose pliers and
remove the bulb. Replace with new bulb, insuring that the power lead is fully inserted into the bulb.
Insert into the rotator and insure the retaining clip is fully inserted.
S-795 (Bayonet Style): Push down and turn to remove bulb. Install new bulb the same way.
DO NOT LUBRICATE: The bearings used in rotating lights are permanently lubricated with a highperformance synthetic oil that is not compatible with many lubricants. Mixing lubricants may result in a
gummy mixture that will freeze in cold weather.
5
Options
Many options are available for the XL TM Light Bar. This section is designed to describe the function of,
and maintenance for, the various options.
Stingray: The Sting Ray is a modified rotating lamp which produces a patented three-mode signal that
(1) oscillates to the rear, (2) rotates conventionally, and (3) oscillates to the front. Lamp and reflector
maintenance is the same as for a typical rotating lamp.
Alley Lights: Located at each end of the light bar, to provide light to the side of the vehicle. This smaller
unit is held in a metal bracket that is attached to the frame with 2 screws.
High Speed Rotating Lamps: A rotating lamp that produces twice as many flashes as conventional
assembly. The only significant differences between this unit and a normal assembly are that a black
worm and worm gear are used. Maintenance is the same as for a typical rotating lamp.
Stop/Turn/Tail Lights: Located in the light bar facing rear, one on the passenger side, these lights
provide stop, turn, and tail signals to following traffic when connected to the vehicle lighting system.
Bulbs used are an 1157 bayonet type.
D.O.T. Lights: A set of three marker lights as required by the Department of Transportation for truck
application. Bulbs are wedge base '194' type.
Flasher: The table below shows the different models and their functions.
FLASHER TYPE
FEATURES
100W (2 lights),
Alternating Flash
200W (4 lights),
Alternating flash,
rear only or front &
rear
360RS
360RD
360RDK
700
710/711
X
X
X
X
X
200W (4 lights),
Alternating flash,
rear only, front &
rear, or steady burn
front/rear flash
200W Heavy duty
Alternating flash
X
200W Heavy duty
Programmed flash
X
X
6
NOTES:
7
WARRANTY
This product was tested and found to be operational at the time of manufacture. Provided this
product is installed and operated in accordance with the manufacturer's recommendations, Code 3
guarantees all parts and components except the lamps for a period of 1 year from the date of
purchase or delivery, whichever is later. Units demonstrated to be defective within the warranty
period will be repaired or replaced at the factory service center at no cost.
Use of a lamp or other electrical load of a wattage higher than installed or recommended by the
factory, or use of inappropriate or inadequate wiring or circuit protection causes this warranty to
become void. Failure or destruction of the product resulting from abuse or unusual use and/or
accidents is not covered by this warranty.
Code 3, Inc. shall in no way be liable for other damages including consequential, indirect or
special damages whether loss is due to negligence or breach of warranty.
CODE 3, INC. MAKES NO OTHER EXPRESS OR IMPLIED WARRANTY INCLUDING,
WITHOUT LIMITATION, WARRANTIES OF FITNESS OR MERCHANTABILITY, WITH RESPECT
TO THIS PRODUCT.
PRODUCT RETURNS
In order to provide you with faster service, if you are going to return a product for repair or
replacement*, please contact our factory to obtain a Return Goods Authorization Number (RGA
number) before you ship the product to Code 3. Write the RGA number clearly on the package near
the mailing label. Be sure you use sufficient packing materials to avoid damage to the product being
returned while in transit.
*Code 3, Inc. reserves the right to repair or replace product at its discretion and assumes no responsibility or liability
for expenses incurred for the removal and/or reinstallation of products requiring service and/or repair.
NEED HELP? Call our Technical Assistance Hotline - (314) 996-2800
Code 3, Inc.
10986 N. Warson Road
St. Louis, Missouri 63114-2029—USA
www.code3pse.com
Force 4, SD 4000, and XL 5000 are trademarks and Code 3 is a registered trademark of Code 3, Inc. a subsidiary of Public Safety Equipment, Inc.
Revision 3, 03/2006 - Instruction Book Part No. T04998
©2004-6 Code 3, Inc. Printed in USA
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