Code 3 2100 User Manual
INSTALLATION
& OPERATION
MANUAL
LED X™ 2100
LIGHTBAR
LED X ™2100
LIGHTBAR
CONTENTS:
Introduction...................................................................................2
Unpacking & Pre-Installation.........................................................3
Installation & Mounting..........................................................3-5
Wiring Instructions..............................................................5-6
Options & Specifications.................................................6-10
Maintenance.........................................................................10-11
Parts List (Replacement Parts / Exploded View).................12-13
Trouble Shooting.................................................................14-15
Warranty.....................................................................................16
For future reference record your lightbar's serial no. here __________________________________________
Read all instructions and warnings before installing and using.
IMPORTANT:
INSTALLER: This manual must be delivered to the end user of this equipment.
1
Introduction
The LED XTM 2100 Light Bar is a light bar that is approximately 2" high, yet delivers unobstructed 360° warning and more signal
power and versatility than any other light bar of its size.
The low profile and aerodynamic lines reduce air drag, which results in fuel savings and stability at high speeds. This light bar has a
strong extruded internal frame, shock-resistant polycarbonate lenses, and warning signals that exceed SAE standards.
The LED X 2100 is designed on a modular basis, which means that the light bar can be customized to meet any requirement. The
LED X 2100 has room for numerous halogen, incandescent and LED options. While we do not recommend a light installed in every
location, the design of the LED X 2100 offers the ultimate flexibility in the location of warning and auxiliary lights.
The use of this or any warning device does not ensure 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
!
WARNING!
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.
Code 3, 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.
Wiring Instructions (read
Carefully Before Installation)
2
Unpacking & Pre-installation
Carefully remove the light bar and place it on a flat surface, taking care not to scratch the lenses or damage the cable coming out of
the bottom. Examine the unit for transit damage, broken lamps, etc. Report any damage to the carrier and keep the shipping carton.
Standard light bars are built to operate on 12 volt D.C. negative ground (earth) vehicles. If you have an electrical system other than
12 volt D.C. negative ground (earth), and have not ordered a specially wired light bar, contact the factory for instructions.
Test the unit before installation. To test, touch the black wire to the ground (earth) and the other wires to +12 volts D.C., in
accordance with the instructions attached to the cable (an automotive battery is preferable for this test). A battery charger may be
used, but please note that some electronic options (flashers, stingrays, etc.) may not operate normally when powered by a battery
charger. If problems occur at this point, contact the factory.
Installation & Mounting
WARNING!
MOUNTING HARDWARE - All mounting hardware is packed in a small box inside the main carton. Four standard kits are available:
(1) Hook-On Type, (1) Tow and Recovery and (2) Permanent Types. These are discussed in detail later. Note: Hook-on mounting
for "gutterless" type vehicles will require a special hook for mounting. Several special application hooks are available. Contact the
factory for details.
!
Utilizing non-factory supplied screws and/or mounting brackets and/or the improper number
of screws may result in loss of warranty coverage on the equipment.
Hook-on Mounting
Begin the installation by attaching the rubber feet to the mounting brackets using the black 1/4" carriage bolts and 1/4" nuts
provided. See Figure 1. (Do not install shims at this time). Place the light bar upside down on a table or other work surface,
being careful not to scratch the lenses. Slide the 5/16" carriage bolts into the frame. Secure the mounting brackets finger tight
so they support the weight of the light bar, but still are positionable. Locate the vehicle on a level surface. Place the light
bar on the roof of the vehicle. Place a soft pad in the center of the roof to protect the paint. The mounting brackets must be
placed so that the rubber feet are resting on the curved section of the roof, see Figure 2. This is the strongest part of the roof.
Once the light bar is centered, tighten the mounting bracket to the light bar. Using a tape measure and a level, center
the light bar from side to side and locate a position on the roof where the light bar is level.
5/16" Cap Screw
5/16" Nut
5/16-18 Carriage Bolt
Bottom of Lightbar
Mounting Bracket
1/4-20 Carriage Bolt
Gutter Hook
5/16" Split Lockwasher
5/16" Trim Nut
(Do Not Overtighten)
Plastic Shim (if needed)
Rubber Foot
1/4" Acorn Nut
FIGURE 1
3
Curved Feet on
Curved Portion
Vehicle Gutter
Vehicle Roof
FIGURE 2
The shims provided may be used here to help level the light bar, see Figure 1. Also, the tabs on the mounting brackets may be
bent at any angle to match the curvature of the roof. Select the appropriate length cap screw and insert through the holes in
the gutter hook and mounting bracket, and into a lockwasher and acorn nut as shown in Figure 1. If a special hook for a
"gutterless" vehicle is used, refer to the instructions for that hook at this time. The stainless steel cap screws supplied are sized
for the most common installations, but longer and shorter bolts are available at any hardware store. Tighten the cap screws on
both sides evenly keeping the light bar centered and level.
NOTE: Tighten only until the bar is secure (bar does not move when bumped sharply with the heel of the palm). It is NOT
necessary to dimple the roof to obtain a stable attachment. If the light bar "bows" more than 3/16" (determined by placing a
straightedge along the front, bottom part of the frame and measuring downward at the center of the frame), loosen the 5/16"
trim nut sightly.
Re-Installation: When moving a light bar from one vehicle to another, we suggest that new rubber feet be used. These are
standard hardware items, and can usually be found at any hardware store, or can be ordered from the factory. The special
hooks are stainless steel and should be saved and reused. Mounting kit parts are available to permit remounting on vehicles of
different design or make. Consult your local dealer or Code 3 , Inc. for detailed information.
Permanent Mounting
Typical Mounting: Refer to Figure 3. Place the light bar upside down on a table or other work surface, being careful not to
scratch the lenses. Slide the 5/16" carriage bolts into the frame. Secure the mounting brackets finger tight so they
support the weight of the light bar. Place the unit on the roof of the vehicle. Place a soft pad in the center of the roof to
protect the paint. The mounting brackets must be placed so that they are resting on the curved section of the roof, see
Figure 4. This is the strongest part of the roof. Once the light bar is centered, tighten mounting brackets to light bar.
Using a tape measure and a level, center the light bar from side to side and locate a position of the roof where the light
bar is level. The shims provided may be used here to help level the light bar. Also, the tabs on the mounting bracket may
be bent at any angle to match the curvature of the roof (see Figure 4).
5/16" Nut
5/16-18 Carriage Bolt
Bottom of Lightbar
Mounting Bracket
Customer Supplied Bolt
Plastic Shim (if needed)
Rubber Foot
FIGURE 3
4
Flat Roof
Once the light bar is level and centered, mark the holes through the mounting tabs and remove the
light bar from the vehicle. Make sure that the drill will not damage anything when penetrating the roof.
Drill the mounting holes and remove any burrs. Attachment can be made using 1/4" cap screws,
toggle bolts, or other fasteners as may be convenient. Use sealant as necessary to prevent water
leakage into the vehicle.
Wiring Instructions
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
!
WARNING!
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. underhood) 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.
FIGURE 4
Curved Roof
Place Feet on
Curved Portion
Before attempting to connect wiring refer to wire tag attached to the lightbar's main cable. Each wire in the cable controls a
separate lightbar function as described in the wire tag.
The only significant difference between the LED X™ 2100 with optional ArrowStik® and a conventional LED X 2100, is the
additional, thinner cable exiting the bottom of the lightbar. The larger cable is the lightbar power cable. 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 as directed by the wiring instructions on the cable.
5
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