Code 3 21TR, 21TR Plus User Manual
INSTALLATION
& OPERATION
MANUAL
21TRTM AND 21TR PLUSTM LIGHTBAR
21TR
For future reference record your lightbar's serial no. here __________________________________________
IMPORTANT:
TM
CONTENTS:
TM
and 21TR Plus
LIGHTBAR
Introduction...................................................................................2
Unpacking & Pre-Installation.........................................................2
Installation & Mounting..........................................................3-4
Wiring Instructions - 21TRTM..............................................................5-8
Wiring Instructions - 21TR PlusTM...................................................9-12
Takedown & Alley Lights..................................................................13-14
Maintenance.........................................................................15
Parts List (Replacement Parts / Exploded View) & Troubleshooting.............16
Warranty.....................................................................................17
Read all instructions and warnings before installing and using.
INSTALLER: This manual must be delivered to the end user of this equipment.
1
Introduction
The 21TR™ & 21TR PlusTM 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 through the use of newly designed Torus TechnologyTM optics. The low prole
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 light bar is designed on a
modular basis, which means that the light bar can be customized to meet any requirement. It has room for numerous halogen and
LED options, and offers the ultimate exibility 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 trafc, responding at a high rate of speed, or
walking on or around trafc 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.
!
WARNING!
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 cur-
rent arcing, which can cause personal injury and/or severe vehicle damage, including re.
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)
Unpacking & Pre-installation
Carefully remove the light bar and place it on a at 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 (ashers, etc.) may not operate normally when powered by a battery charger. If problems occur at
this point, contact the factory.
2
Installation & Mounting
Utilizing non-factory supplied screws and/or mounting brackets and/or the improper
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.
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 nger tight so they support the weight
of the light bar, but can still be positioned. 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.
number of screws may result in loss of warranty coverage on the equipment.
5/16" Cap Screw
5/16" Nut
Curved Feet on
Curved Portion
Vehicle Gutter
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
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 lock washer 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.
3
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 nger 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
Flat Roof
FIGURE 3
FIGURE 4
Curved Roof
5/16-18 Carriage Bolt
Bottom of Lightbar
Mounting Bracket
Customer Supplied Bolt
Plastic Shim (if needed)
Rubber Foot
Place Feet on
Curved Portion
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.
4
Wiring Instructions
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.
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. underhood) will signicantly 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
!
WARNING!
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.
Routing
Route the wiring cables 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
WARNING!
This Product contains high intensity LED devices. To prevent eye damage, DO NOT
!
stare into light beam at close range.
Fusing - 21TR
The light bar should be installed with an external fuse or circuit breaker in the RED lead of the 11 conductor cable. The recommended
external fuse size for the light bar is 15A. The internal circuitry of the Central Controller is reverse polarity protected. Each output on
the Central Controller board is protected against over current and over heating with automatically resetting output devices.
Wiring - 21TR
Connect the black lead to a solid frame ground (earth), preferably the (-) or ground (earth) side of the battery, and the power wire to
the +12V terminal of the battery. Connect the remaining wires in the 11 conductor cable as shown in Table 1.
Note: All control inputs are +power enabled.
Control Input Function Denition
Wire Color Function Description
BLUE
ORANGE
YELLOW #1 (18 GA)
LIGHT BLUE Take Down lights Take Down Lights Steady Burn (overrides Take Down Flash)
YELLOW #2 (20 GA) ******Not Used****** ******Not Used******
YELLOW/BLACK Left Alley Light Left Alley Steady Burn (overrides Alley Light Flash)
WHITE Light Bar Dimming Dims All Lighthead Modules in Lightbar Except for Corners
GREEN Pattern Select Light Bar Flash Pattern Select Wire & Diagnostic Test
BLACK Ground Ground
RED Power +12V Input Supply
BROWN Right Alley Light Right Alley Steady Burn (overrides Alley Light Flash)
Flash Pattern Selection - 21TR
The Pattern Select wire is the Green wire in the 11 conductor control cable and is activated by momentarily touching the wire to +12V.
There are seven total combinations of unique ash patterns that can be dened with a unique ash pattern. It is also important to understand whether the light bar will be controlled by a progressive style switching controller, or individual switches.
This often leads to confusion in selecting patterns and may result in the end user not achieving the desired outcome. This is
discussed in the section titled "Progressive vs. Independent Switching".
TM
TM
Level Control Wire
Table 1 - Control Wire Denitions - 21TR
Energizes light heads per the pattern chosen by the end user or, if left
unchanged, per the defaults set at the factory (see Table 2).
TM
TM
Diagnostic Test
There is also a diagnostic test that can be run using the Green pattern change wire. Apply +12V to the Green wire (only). The lights
will turn on one at a time and then turn off. At the end it should ash all emergency lights at the same time three times. Note that
it can only be activated by applying power to the Green wire at start up. If the unit has been energized with any other wire, power
needs to be removed entirely from the light bar before applying power to the Green wire to enter into this mode again.
6
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