Page 1
INSTALLATION
& OPERATION
MANUAL
FOR CODE 360
LIGHTBARS
PATENT PENDING
®
®
CODE 360
TRI-LEVEL LIGHT BAR
CONTENTS:
Introduction...................................................................................2-3
Unpacking & Pre-Installation.........................................................4
Installation & Mounting..........................................................4-6
Wiring Instructions.................................................................6-7
Options & Specifications.....................................................7-12
Maintenance...........................................................................12-16
Parts List (Replacement Parts / Exploded View).................17-20
Trouble Shooting.................................................................21-22
Notes....................................................................................22-23
Warranty..............................................................................24
For future reference record your lightbar's serial no. here __________________________________________
IMPORTANT:
Read all instructions and warnings before installing and using.
INSTALLER: This manual must be delivered to the end user of this equipment.
1
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Introduction
The Code 360
from Code 3
360 Degrees of Light, the Nth Degree of Protection!
Check out all the exciting features of your new Code 360
√√
√
√√
√√
√ 360 degrees of coverage
√√
√√
√ Outstanding safety features available including:
√√
√√
√ Corner pods allow forward positioning of:
√√
Three levels and four rows of lights
√√
√ Alley lights
√√
√√
√ ArrowStik
√√
√√
√ OsciLaser™
√√
√√
√ T actical T akedowns™
√√
√√
√ X-Fire upper- and lower-level strobes
√√
√√
√ X-Sweep dual halogen intersection lights
√√
®
®
Light Bar
®
√ Available in:
√ All Strobe
√ All Halogen
√ Strobe/Halogen combination
√ Can accommodate up to 10 locations for stationery lights
®
light bar:
Code 360® Quality Assurance means that each light bar has been individually tested and approved
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 daily that all
!
WARNING!
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.
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Page 3
!
WARNING!
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)
3
Page 4
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 a negative 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 with 3/8" long Flat Head Screw and Nylock nuts. See
Figure1. 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. Now would be a good time to insert the 3 1/2" long carriage bolt through the mounting brackets. If desired, you can also
unbundle the lightbar cable and feed it through the drivers' side mounting bracket. Locate the vehicle on a level surface. Place the
lightbar 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. If necessary
bend the mounting bracket feet to match the contour of 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.
Black nylon spacers are provided to level lightbar. Place spacer between rubber foot and mounting bracket and use longer flat head
screws provided to secure foot to bracket.
FIGURE 1
5/16" x 3 1/2"lg Carriage Bolt
5/16" Split Lockwasher
5/16" Nut
Bottom of Lightbar
5/16-18 Carriage Bolt
Mounting Bracket
Nylock Nut
Gutter Hook
5/16" Nylock Nut
Rubber Feet
Flat Head Screw
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Page 5
Curved Feet on
Curved Portion
Vehicle Gutter
FIGURE 2
Insert the carriage bolts through the holes in the gutter hooks, and into a 5/16" Nylock 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 carriage bolt provided is sized for the most
common installations, but longer and shorter bolts are available at any hardware store. Tighten the nuts onto the carriage bolts 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.
Vehicle Roof
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).
5/16-18 Carriage Bolt
Bottom of Lightbar
Mounting Bracket
Customer Supplied Bolt
Rubber Feet
Figure 3
S81912 - Mounting Kit without
Adaptor Bracket
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Page 6
Curved Roof
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.
Flat Roof
FIGURE 4
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 the
!
WARNING!
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.
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 CODE 360® with optional ArrowStik® and a conventional CODE 360, 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.
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Arrowstik® / Narrowstik®
OPTIONAL HALOGEN ARROWSTIK® (7-wire) / L.E.D. NARROWSTIK® (11-wire) WIRING AND CONTROL HEAD INST ALLA TION After installation of the lightbar, route the smaller of the two power cables through the vehicle to the location chosen for the control head. Cut
the cable to length and strip back the outer insulation to expose the seven or eleven colored wires. Strip back 1/8” - 1/4” of colored
insulation from each of the wires in the cable. Connect these wires to the seven position / eleven position terminal plug enclosed in the user
parts bag, according to the diagram on the bottom of the control head.
- Refer to the control head manual packaged with the lightbar for control
head installation and operation instruction.
OPTIONAL STROBE WIRING INSTRUCTIONS - For all configurations the strobe power supply(s) will be
powered by the #14 AWG Red and Red/Black wires in the lightbar main cable. For 2 or 4 head configurations
only the Red or Red/Black wire will be utilized. For 6, 8, 10 and 12 head configurations both wires will be utilized.
These wires will supply DC power to each strobe power supply(s) so all user supplied switches and wiring
connected to the Red and/or Red/Black wires should be rated for a minimum of 10 Amps and fused at a
maximum of 15 Amps, for each wire used. Two additional wires in the main cable (typically Green and Green/
Black) are used to control the flash mode of the power supply. These wires are low current connections at
typically less than 1 Amp. (See lightbar "wire tag" for wire color).
OPTIONS & SPECIFICA TIONS
Many options are available for the LED X 2100. This section is designed to describe the function of the various LED X 2100 options.
LED W ARNING MODULES
L.E.D. Fusing Considerations
Although the average current draw per module is very low, due to the type of circuit used to power each module the instantaneous
peak current to a module can be significantly higher during low voltage conditions. To avoid prematurely blowing ATO style fuses or
tripping breakers it is recommended the following rule-of-thumb be used to size fuses or breakers. This is especially important in
lightbars with many LED modules running off a single fused source wire,
Minimum fuse size calculation:
1.5 x (number of modules being fused)
Example:
Excalibur Lightbar with 2 corner modules (2 per module) and 4 directional modules.
Minimum fuse requirement for single fuse - 1.5 (2+2+4) = 10A minimum
WARNING!
!
This Product contains high intensity LED devices. To prevent eye damage, DO NOT stare into
light beam at close range.
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Page 8
Dim Operation
Lightbar LED modules are equipped with a low power "Dimming" mode as standard. Dimming will be controlled by applying
+12V by way of the appropriate wire(color) in the wire harness/wire list. When DIM is engaged the LED's will operate in a
reduced power mode.
For safety purposes, the corner modules in lightbars are not connected to the dimming circuit. This
ensures that when corner modules are turned on, full 360 degree coverage and compliance with
SAE warning light standards is provided.
The DIM control wires( two white wires) located on each of the modules are connected from one module to the
next. To disable the dimming function on a particular module, disconnect the white wires. Then
reconnect the white wire to the white wire on another module that has dimming enabled.
The Dim setting reduces the light output of emergency warning lights reducing the effectiveness of them
!
WARNING!
especially in brightly lit areas. Failure to use adequate light for the circumstances can cause motorists to
fail to see the emergency vehicle and lead to serious personal injury or death. Never use the DIM
setting in a brightly lit area. Use of the DIM setting may cause emergency lights to not comply with
applicable emergency warning light standards. Use caution when using the DIM setting to assure that
motorists can clearly see the emergency vehicle.
Code 3® OPTIX™ 360 DEGREE CORNER MODULES
The Code360™ Lightbar may be equipped with Code 3® OPTIX™ 360 degree corner LED modules that provide a full 360
degree of warning.The optic has been designed to exceed all applicable requirements for 360 degree warning devices in Red,
Blue, and Amber. The new OPTIX corner module is a ( 1" X 6" ) module and uses larger, higher efficiency, TIR optics to produce
an enhanced corner signal over the exisitng ( 1" X 4" ) Code 3 LED X™ corner module. While the OPTIX will become the standard
corner module for most configurations, the LED X corner module will still be available and may be required for some configurations.
Installation and Operation for both modules will be the same. Consult the factory for further information.
Operating Specifications for 360 degree module:
Operating Voltage: 10-16 VDC, Reverse Polarity Protection
Current Draw : Red/Amber - .5A avg @ 12.8 Volts
Blue/White - .8A avg @ 12.8 Volts
Available Colors - Red, Blue, Amber and White
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Page 9
Master/Slave Operation
Each 360 degree corner module consists of a "master" and a "slave" driver circuit board, 360 degree optics and LED light engines
along with a single integrated heatsink bracket.
The "master" circuit board (rear position) must always be powered for the "slave"(front position) to flash. The "master" is always
located in the rear position of the module. The lightbar is wired to allow running only the rear facing LED on each module by
removing power to the front facing "slave" module. This gives a "front-cutoff" function. The flash pattern for each corner pair can be
selected by shorting together the 2-pin header J1, on the "master" , momentarily and releasing. The module is set-up for
"Cycleflash" as a standard. Holding down the 2-pin header for 5 sec., or longer, and releasing will return the pattern to Cycleflash.
The following chart describes the available patterns and order;
360 Degree Module Flash Pattern - Table 1
See Figure 5, page 10, for header location.
Flash Pattern Description
Cycle Flash Cycles through various patterns @ 70 fpm
Five Flash Five Pulses per flash @ 70 fpm
Quad Flash Four Pulses per flash @ 70 fpm
NFP A Four Pulses, 70% Duty Cycle @ 75 fpm
Triple Flash Three Pulses per flash @ 70 fpm
Quad Pop Flash Four Pulses per flash ( 3 equal, 1 extended) @ 70 fpm
Both heads will be in the mode selected. Both heads will flash together unless in Front Cut-off mode.
LED DIRECTIONAL MODULES
In addition to the 360 warning modules the lightbar may be equipped with a number of single head
directional warning LED modules. These modules are available in either the existing LED X™ ( 1" X 4" ) or the new Code 3®
OPTIX™ ( 1" X 6" ) and LC-LED directional modules in stationary and flashing versions ( see figure 8). The stationary versions can
be flashed by connecting the module(s) to any flasher that does not require ground through the load (example: Code 3® 700
series relay flasher). The flashing modules will have "Cycleflash" as the standard pattern. The OPTIX and LEDX flash pattern can
be changed by shorting the 2-pin header, J1 as shown in Figure 5, momentarily then releasing. Table 2 shows the available
patterns and the order when stepping through patterns. The module can be reset to "Cycleflash" by shorting the header for greater
than 5 sec. and releasing.
Operating Specifications for directional module:
Operating Voltage: 10-16 VDC, Reverse Polarity Protection
Current Draw : Flashing Module
Red/Amber - .25A avg @ 12.8 Volts
Blue/White - .4A avg @ 12.8 Volts
Steady Burn Module
Red/Amber - .5A avg @ 12.8 Volts
Blue/White - .8A avg @ 12.8 Volts
Available Colors - Red , Blue, Amber, and White
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Page 10
Directional module Flash Pattern - Table 2
Flash Pattern Description
Cycle Flash Cycles through various patterns @ 70 fpm
Steady-Burn Steady-Burn
Five Flash Five Pulses per flash @ 70 fpm
Quad Flash Four Pulses per flash @ 70 fpm
Triple Flash Three Pulses per flash @ 70 fpm
Double Flash Two Pulses per flash @ 70 fpm
Fast Double Flash Two Pulses per flash @ 85 fpm
NFP A Four Pulses, 70% Duty Cycle @ 75 fpm
Quad Pop Flash Four Pulses per flash ( 3 equal, 1 extended) @ 70 fpm
Triple Pop Flash Three Pulses per flash ( 2 equal, 1 extended) @ 70 fpm
Double Pop Flash Two Pulses per flash ( 1 equal, 1 extended) @ 70 fpm
PCB
Momentarily short and release
to change patterns
J1
Flash Pattern Header for OPTIX/LEDX
FIGURE 5
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Page 11
STROBE CONNECTIONS
POWER CONNECTION
For all configurations the strobe power supply(s) will be powered by the #16AWG RED, and/or RED/BLK wires. For 2 or 4 head
configurations, one wire will be used, 6, 8, 10 and 12 head configurations will use two wires. These wires supply power to each
strobe power supply. All user switches and wiring connected to the RED,RED/BLK and or RED/WHT wires must be rated for a
minimum of 10 Amps and fused at a maximum of 15 Amps for each wire used.
Flash Patterns - All power supplies offer "Quad Flash" and "Random Flash". The flash patterns are controlled by jumpers on the
power supply and can be changed by first removing the power supply from the lightbar and then setting the jumpers. Refer to the
following tables:
6-Head Flash Patterns (FIG.10)
4-Head Flash Patterns (FIG.10)
Jumper
J9
J36
Quad
2 - 3
2 - 3
Random
1 - 2
2 - 3
Jumper Quad
J31
2 - 3 1 - 2
Random
YELLOW
Rear Only Flash Pattern
Connect the RED and/or RED/BLK wire in the 16 wire cable to +12 VDC through a user supplied
switch.
4/6 Head: Rear inboard and outboard strobes on each side will flash at a minimum rate of 70 FPM
(flashes per minute).
2 Head: If front or rear inboard strobes are present, strobes will flash at a minimum rate of 70 FPM.
Alternating Flash Pattern
Connect the RED and/or RED/BLK wire and GREEN wire in the 16 wire cable to +12 VDC through a
user supplied switch. This mode overrides REAR ONLY MODE.
4/6 Head: Front and Rear inboard and outboard strobes on each side will flash at a minimum rate of
70 FPM (flashes per minute).
2 Head: Front or rear inboard strobes will flash at a minimum rate of 70 FPM.
Pursuit Flash Pattern
Connect the RED and/or RED/BLK wire and GREEN/BLACK wire in the 16 wire cable to +12 VDC
through a user supplied switch. This mode overrides ALL OTHER MODES.
4/6 Head: Front inboard and outboard strobes on each side will flash at a minimum rate of 70 FPM.
2 Head: If front inboard strobes are present, strobes will flash minimum at a rate of 70 FPM.
PSE 490E (FIG.10A)
Quad
N/C +12
Random
INTERSECTION LIGHTS - A high intensity 120° oscillator, located in the lower outboard corner of the light bar. Maintenance of
these units is much the same as for a typical rotator. Two mounting screws hold the assembly in place. Caution: Never install a
black worm on the 120° Intersection Light.
X-SWEEP - Dual halogen intersection lights, mounted one above the other on a common bracket, located in the lower outboard
corners of the lightbar.
X-FIRE - Upper-and lower-level strobes, mounted one above the other, 90 degrees to one another, located in the outboard
corners of the lightbar.
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ALLEY LIGHTS - Located in the mid section of the light bar at each end, to provide light to the side of the vehicle. The lamps used
are a bayonet type. The mounting bracket and reflector are adjustable to allow aiming the unit.
HIGH SPEED ROTATOR - A rotator that produces twice as many flashes as a conventional assembly. Maintenance is the same
as for a typical rotator.
Multi-Functional Control Module - Using standard lighting controls the operator can select the operation of the Intersection
Lighthead assemblies.
STATIONARY LAMPS/TAKEDOWN LIGHTS - A stationary reflector assembly used for ArrowStik® flashing, takedown, and/or
work light applications. These are located in the lower section of the light bar. Lamps in these units are bayonet type and the units
are mounted with two screws.
STOP/TURN/TAIL LIGHTS - Located in the upper section of the light bar facing rear, one on the driver side, one on the passenger
side, these lights provide stop, turn and tail signals to following traffic when connected to the vehicle lighting system. Lamps 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. Lamps are
wedge base '194' type.
TM
OSCILASER
it's field of illumination at least once per second. It has an up and down as well as a side to side signal. Maintenance for these units
is much the same as a typical rotator. The lamps used are bayonet type. This unit is located in the upper center section and/or in
the center position in the outboard sections of the light bar.
- This is a highly effective warning light that features a constant 35 watt halogen signal that covers every area within
TACTICAL TAKEDOWN
Available in front and rear corners of lightbar.
TM
LIGHTS - A Flashing or steady burn takedown light that moves at a 15 degree angle when activated.
Maintenance
Lens Cleaning
Use plain water and a soft cloth, or Code 3® lens polish and a very soft paper towel or facial tissue. Because plastic scratches
easily, cleaning is recommended only when necessary (about every six months). Do not subject the lenses to car washes that use
brushes, as these will scratch the lenses.
Lens Removal
First, disengage the lens clips
(4 per lens) as shown in Figure 6. Finally, insert a screwdriver into the inside edge or corner of the lens, and twist the screwdriver
to lift the lens.
Pry Up to
Remove Lens
Clip
Changing Rotating Reflector Lamps
Twist to Lift
Lens
Figure 6
WARNING!
Remove the lens as outlined above. Next, inspect the lamp and compare to Figure 7 to determine lamp type. It may be necessary
to remove any rotating or cylindrical filters to make access easier. Note: Make sure lamp is cool before attempting to change it. Also,
when installing a new lamp, be sure not to touch the glass with fingers. If contact is made, clean the glass with a soft cloth after
inspection.
H-1: Style. First grasp lamp at base and turn until retaining clip tab is accessible. Using a blade screwdriver, remove retaining clip
and pull lamp straight up. Replace with new lamp. Insure that the power lead and retaining clip is fully seated. (See figure 7)
!
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.
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Page 13
The following are optional features that may or may
not be included in your control head depending upon
which model you purchased.
"Fast Speed" Mode: Fast speed and Dim Modes
are combined. Pushing the button marked "Fast" will
cause each of the 4 patterns of the ArrowStik to
operate at a faster rate, with the same amount of light
intensity.
"Dim" Mode: Dim and Fast speed Modes are
combined. Pushing the button marked "Dim" will
cause each of the 4 patterns of the ArrowStik to
operate at a lower intensity level. This is for use at night
when 100% intensity is too much, or daytime when current
draw needs to be reduced.Bayonet Style: Push down and turn to
remove lamp. Install a new lamp the same way. (SEE FIGURE 7)
Note: If attempting to clean the reflector, use only a mild glass cleaner and a very soft cloth. Do not attempt to use any wax type
products as these will burn onto the reflector.
Changing Lower Unit Lamp and/or Filter
Refer to Figure 10. Remove the reflector assembly by removing the appropriate fasteners, then remove the snap-on filter if
necessary. In most cases, these lamps will be a bayonet style, so simply push in and turn counterclockwise to remove.
Replacement for Upper and Lower Level Components
Figure 7
See exploded view "Parts Section" for fastener removal, component location, and assembly
configuration. Caution, extreme care must be taken when installing components to prevent pinching wire connections
and to avoid interference with moving assemblies.
!
High voltages and/or temperatures are present inside the unit. Disconnect from power and wait 10 minutes
prior to servicing or troubleshooting. Use hand and eye protection when changing halogen lamps or
flashtubes.
WARNING!
Strobe Filter Replacement
Refer to figure 8. The filter can be removed by unsnapping it from the light head and by removing the mirror if present for clearance. Prying
the filter from the front may damage the glass strobe tube or reflector.
T o replace the filter , reverse the above procedure. The filter should be fully engaged on the light head assembly . Care should be taken to
not damage the strobe tube or to scratch the reflective surface of the reflector when replacing the filter.
Strobe Light Head Replacement
Refer to figure 8. Disconnect the light head assembly wiring from the strobe power supply and remove the filter if any. Unfasten the screws
attaching the light head mounting bracket to the light bar chassis and remove the light head from the light bar. On a bench or other work
suitable work surface unfasten the screws attaching the strobe light head assembly from the light head mounting bracket. Install the new
strobe light head assembly to the light head mounting bracket and reinstall the light head back onto the light bar chassis. Reconnect the light
head wiring to the strobe power supply and reattach the filter. It is important to reroute and secure the wiring as close as possible to its
original position.
Caution, verify that no wires are interfering with the operation of the fan located at the end of the power supply.
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Electronics Module Removal
In the event that the power supply or a strobe lamp assembly must be returned to the factory for service, mark each wire with a tag
to identify each function and note the proper location before disconnecting the wiring. Figure 9 can be used to mark the locations of
the individual connections as well.
Refer to Figure 9 for power supply removal. Remove the four (4) screws holding the power supply. Disconnect the wire leads, and
move the power supply to the side. Remove the 2 screws holding the capacitor assembly and lift the strobe power supply/capacitor
assembly from the lightbar as a unit. To reinstall the power supply reverse the above steps.
Caution: Verify that wires are not pinched or damaged when reinstalling power supply.
Strobe Lighthead
Assembly
REAR
3
4
1
2
+12V(RED)
GND(BLK)
N/C(GREY)
FRONT(GRN)
REAR(BLUE)
FRONT
RANDOM
FLASH
(YEL)
5 N/C
Passenger's Side Front
(Org,Blk,Blk/Wht)
Driver's Side Front
(Brn,Blk,Blk/Wht)
Passenger's Side Rear
(Grn,Blk,Blk/Wht)
Driver's Side Rear
(Yel,Blk,Blk/Wht)
Control Wire Harness
(Yel/Blk,Brn/Blk)
+12VDC
(Red)
Filter
(if supplied)
4-Head Power Supply
FIGURE 8
Ground Wire
(Blk)
Rear Aux. Output
(Red,Blk,Blk/Wht)
Rear Output
(Grn,Blk,Blk/Wht)
Rear Output
(Yel,Blk,Blk/Wht)
Control Wire Harness
(Yel/Blk,Brn/Blk)
+12VDC
(Red)
FIGURE 9
PSE 490E
FIGURE 10A
Front Output
(Brn,Blk,Blk/Wht)
Front Output
(Org,Blk,Blk/Wht)
Front Aux. Output
(Wht,Blk,Blk/Wht)
Ground Wire
(Blk)
6-Head Power Supply
MAXIMUM 27W
FIGURE 10
14
Page 15
Multi-Functional Intersection Control System - This system allows multiple lighting options with a single pair of intersection lights. The
control center of the system is the Multi-Functional Control Module located in the lower section of the light bar. This combined with the
Sensing Lighthead Assemblies, located in the front lower section, allows the operator to select (4) four modes of operation - intersection,
driver side alley, passenger side alley and takedown positions.
WIRE FUNCTION
GRN ALLEY
BLK GROUND
YEL TAKEDOWN
RED POWER
Sensing Lighthead Assembly - As with the standard intersection lights, these are high intensity 120 degree oscillating light assemblies. With addition of the Position Sensing module these lights can be placed in the takedown or alley positions. (Figure 11)
Note: If the gear assembly is replaced, care must be taken to insure that the flat nylon washer is seated between the gear and the
bottom plate to prevent premature wear and failure.
* - see wire tag for
exact wire color code.
Figure 11
S50690 - Driver side assembly
S50691 - Passenger side assembly
Multi-Functional Control Module - Using
standard lighting controls the operator can select the
operation of the Lighthead assemblies.
S55401 - Multi-Functional Control Module
Figure 12
15
Page 16
Operation: The Multi-Functional Intersection Control System will allow the user to obtain T akedown, Intersection and Alley functions with
a single pair of intersection modules. The operation is as follows;
NOTE: Wiring Colors May Vary, Refer To Wire Tag For Exact Colors.
Passenger Side Alley - When the ( YEL/BLK ) wire is connected to a source of +12VDC the passenger’s side intersection module will
move to the alley position.
Driver Side Alley - When the ( YEL ) wire is connected to a source of +12VDC the driver’s side intersection module will move to the alley
position.
Intersection - When the ( WHT/BLK ) wire is connected to a source of +12VDC both intersection modules will oscillate. When Intersection mode is selected the Passenger side and Driver side Alley mode will be overridden. The user cannot obtain Alley
functions while in Intersection mode.
Takedown - When the ( ORG/BLK ) wire is connected to a source of +12VDC both intersection modules will move to the takedown
position. When in Takedown mode, the Alley and Intersection modes are overridden.
NOTE: ALL DEVICES USED TO SWITCH +12VDC TO EACH CONTROL WIRE
MUST BE RATED FOR A MINIMUM OF 10A.
PROBLEM POSSIBLE CAUSE SOLUTION
Lighthead oscillates when selecting Lighthead not sensing position.
Alley and/or T akedown modes. Check the following:
Bad wiring harness Replace wiring harness
Bad connection Check connections (Figure 10 & 1 1)
Failed position sensor Replace lighthead assembly
Lighthead doesn’t move when Alley Failed lighthead assembly Replace lighthead assembly
and/or T akedown mode is selected,
but moves in Intersection mode
Lighthead does not move when any Bad motor wire to module Check connections / Replace wire
mode is selected. Failed light bar wire harness Check light bar wiring harness
No power to control module Check +12VDC switching control
Failed lighthead assembly Replace lighthead assembly
Failed control module Replace control module
Lighthead operates properly , Lamp burnt out Replace lamp (50W maximum)
but lamp is not on Bad lamp wire to module Check connections / Replace wire
Driver side lighthead oscillates and Driver side lighthead not sensing
Passenger side lighthead does not Check for the following:
move when T akedown is selected. Bad wiring harness Replace wiring harness
Note: In Takedown mode,Passenger Bad wiring harness connection Check connections (Figure 10 & 1 1)
side lighthead will not move until Failed position sensor Replace lighthead assembly
Driver side lighthead has located
Intersection mode selected, Driver No problem Normal operation, Intersection mode
and Passenger side Alley modes overrides Alley mode.
do not function
T akedown mode selected, no No problem Normal operation, T akedown mode
other modes operational overrides all other modes
16
Page 17
CODE 360 EXPLODED VIEW
3
2
1
7
17
8
11
10
9
13
4
6
5
Page 18
23
24
12
14
15
17
18
19
16
20
21
FIGURE 13
22
18
Page 19
Parts List
(Reference numbers identify items shown in Figures on previous pages)
Ref No. Description Part No.
9 #8 x .250" Sheet Metal Screw T05029
#8 x .270" Sheet Metal Screw T01215
1 #8 x .375" Sheet Metal Screw T00243
5/16" Cable Clamp T00346
1/2" Cable Clamp T00903
3/8" Cable Clamp T00938
H-1 Lamp Retaining Clip T00928
H-1 55W 12V Halogen Lamp T01543
Bayonet 35W 12V Halogen Lamp T09301
Bayonet 27W 12V Halogen Lamp T05093
Bayonet 20W 12V Halogen Lamp T05092
1156 28W 12V Incandescent Lamp T01538
6&11 Rotator Motor Assy--(Does not include Reflector Assy)
Rotator Motor Assy 55W H-1 Std Speed S95978
Rotator Motor Assy 55W H-1 Fast Speed S95979
Rotator Motor Assy 50W Bayonet Std Speed S95980
Rotator Motor Assy 50W Bayonet Fast Speed S95981
Rotator Motor Assy 24V S95982
10 Rotating Filter
Green S95988M
Red S95989M
Blue S95990M
Amber S95991M
2,4 Code 360
Inboard or Center Position
®
1/2 Cyl. Filter Assy (Front and Rear)
Green S50870M
Red S50872M
Blue S50873M
Amber S50874M
Bla ck S50871M
Outboard Front
Green S81922M
Red S81923M
Blue S81924M
Amber S81925M
Outboard Rear
Green S13526M
Red S13523M
Blue S13524M
Amber S13525M
Lens Clip T01777
Code 360® Top Outboard Lens DS Code 360® Top Outboard Lens PS
Clear T06841 Clear T06831
Red T06842 Red T06832
Blue T06843 Blue T06833
Amber T06844 Amber T06834
Code 360® Top Center Lens
Clear T02131
Red T02132
Blue T02133
Amber T02134
20,24 Code 360® Lower Outboard Lens DS - Clear S81874M
Code 360® Lower Outboard Lens PS - Clear S81875M
19
Page 20
21 Code 360® Bottom Center Lens - Clear S50858M
Code 360® Full Diamond Mirror S81887M
Code 360® 2-Step Cascade Mirror Dr. Front Flash S50791M
Code 360® 2-Step Cascade Mirror Pass Front Flash S50792M
Code 360® Flat Mirror Dr. Front or Pass Rear Flash S50787M
Code 360® Flat Mirror Dr. Rear or Pass Front Flash S50788M
Code 360® 104° V-Mirror S50793M
Code 360® Multi-function int. module S81891
15 Code 360® Intersection module S81929
16 Code 360® Tactical takedown front DS S81918
Code 360® Tactical takedown front PS S81917
8 Code 360® Tactical takedown rear S81919
17 Code 360® x-sweep int. module DS S81931M
Code 360® x-sweep int. module PS S81930M
Code 360® 20W Halogen Stationary Module S50849M
Code 360® 27W Halogen Stationary Module S50850M
Code 360® 28W Incandescent Stationary Module S50851M
13 Code 360® 28W Incandescent Arrowstik Module S50848
Code 360® 20W Halogen Alley Light Driver S50855
Code 360® 20W Halogen Alley Light PASS. S50856
12 Code 360® 27W Halogen Alley Light Driver S50863
Code 360® 27W Halogen Alley Light PASS. S50864
19 Halogen Lower Light Head Filter
Green T05170
Clear T05171
Red T05179
Blue T05173
Amber T05174
Code 360® External D.O.T. Strip Assembly S50838M
Code 360® Stop/Turn/Tail Light W/Adapter Plate S50837M
OsciLaser Module 35W S50343M
Upper Level 50W Halogen Stationary Module S50839M
5 Strobe 2-Head Power Supply S80318M
Strobe 4-Head Power Supply S80313M
7 Strobe Upper Light Head Assembly – Corner T09424
Strobe Up Lt Hd Assy – End Sig Pos Mirror – DS Frt/PS Rr T09409
Strobe Up Lt Hd Assy – End Sig Pos Mirror – PS Frt/DS Rr T09406
Strobe Upper Light Head Assy – Corner Filter
Red T09442
Blue T09443
Amber T09444
Strobe Upper Light Head Assembly – Front/Rear T09425
Strobe Upper Light Head Assy – Front/Rear
Red T09432
Blue T09433
Amber T09434
18 Code 360® corner lower strobe head DS S81866M
Code 360® corner lower strobe head PS S81914M
Code 360® x-fire strobe module S81920M
12 Strobe Lower Front/Rear Light Head Assembly S50888M
Strobe Lower Light Head Tube Assembly 4" T03893
Strobe Lower Light Head Filter
Green S50880M
Red S50882M
Blue S50883M
Amber S50884M
23 Multi-Functional Intersection lighthead DS S50690M
Multi-Functional Intersection Lighthead PS S50691M
3 Rotating Reflector Assembly S95977
20
Page 21
Troubleshooting
All CODE 360
during installation or during the life of the product, follow the guide below for information on repair and troubleshooting. Additional information may be obtained from the factory technical help line at 314-426-2700 ext. 2131.
NO STROBE LIGHTS IN THE LIGHTBAR OPERATE - Check the following: 1) +12 VDC source connection for the control switch box
and any in line fuse 2) Connection of the RED and RED/BLK or RED/WHT wire at the control switch box 3) Check the 15 Amp ATO fuse
on each power supply. If the fuse is blown, replace it with another 15 Amp fuse and test the lightbar. If the fuse continues to blow, return
the power supply only, NOT the entire lightbar, to the factory for service. For instructions on power supply removal see the " Electronics
Module Removal " section of this manual.
®
lightbars are thoroughly tested prior to shipment. However, should you encounter a problem
!
Do not replace the fuse with one of a higher rating. This will damage the power supply and void all
warranties.
WARNING!
ONE STROBE LIGHT MODULE DOES NOT OPERATE - Check the defective strobe light module by switching it with a module that is
known to be working.
STROBE OPTION
TROUBLESHOOTING GUIDE
PROBLEM
Light heads do not
fire.
Only front
strobes flash.
CAUSE
a. Harness that connects power
supply to strobe head has loose
connections or damaged
harness.
b. Faulty strobe Lighthead.
c. High voltage shorting to ground
(earth) through harness.
a. GREEN/BLACK control wire
connected to +12VDC overrides
other modes.
a. Check all connections.
Check harness by switching harness with functioning
strobe head.
Replace harness.
b. Check with known good lighthead.
c. Isolate shorted harness by disconnecting one at a time.
Replace harness.
a. See "Strobe Lighting Connections" section.
Reconnect switching.
SOLUTION
No DIM a.Module White wire not connected a. Connect White wire to a switched source of +12V
to source of +12V
21
Page 22
Follow the guide below for information on repair and trouble shooting for the arrowstik option.
ARROWSTIK OPTION
TROUBLESHOOTING GUIDE
PROBLEM
ArrowStik® does not
function when turned on
Lamp does not come on
when it should.
Right most lamp does
not come on in Arrow
Left mode or left most
lamp does not come on
in Arrow Right mode.
QUESTION
Are LED's functioning
properly?
Ye s
No
Are LED's functioning properly?
Ye s
No
CAUSE
a. Plug in rear of control box is
loose or disconnected.
b. Poor ground connection
a. Power from battery has been
disconnected or the control
box has been damaged.
a. Lamp has burned out.
b. Bad wiring connection.
a. Control box has been
damaged.
a. Normal operation
SOLUTION
a. Reconnect plug.
b. Reconnect ground.
a. Check connections at the battery
and plug. If connections are good
and voltage is at least 10 volts, the
control box has been damaged.
Repair or return to Code 3®.
a. Replace lamp.
b. Repair connection.
a. Repair or return to Code 3.
a. None
ArrowStik runs opposite
pattern than selected.
Lamp looks dim.
a. Defective Wiring.
b. Control box has been
damaged.
a. Defective lamp.
b. Low voltage.
c. Poor ground
d. Product is in "Dim" mode.
NOTES:
a. Check that the cable exit is on the
driver's side
b. Repair or return to Code 3.
a. Repair or return to Code 3.
a. Replace lamp.
b. Check connections or battery.
c. Check ground and wire gauge.
d. Select appropriate mode.
22
Page 23
NOTES:
23
Page 24
WARRANTY
Code 3®, Inc.'s emergency devices are tested and found to be operational at the time of manufacture. Provided they
are installed and operated in accordance with manufacturer's recommendations, Code 3®, Inc. guarantees all parts and
components except the lamps to a period of 1 year (unless otherwise expressed) 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 a factory
service center at no cost.
Use of 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
If a product must be returned 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®, Inc. 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 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.; nor for the packaging, handling, and shipping: nor for the handling of products return to sender after the service has been rendered.
St. Louis, Missouri 63114-2029—USA
Ph. (314) 426-2700 Fax (314) 426-1337
10986 N. Warson Road
www.code3pse.com
Code 3®, Inc.
Code 3 is a registered trademark of Code 3, Inc. a subsidiary of Public Safety Equipment, Inc.
24
Revision 8, 7/05 - Instruction Book Part No. T07514
©2005 Code 3, Inc. Printed in USA
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