For future reference record your light bar'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.
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Introduction
The DEFENDER® (Patent-Pending) Light bar Features the truly unique, TriCore® (Patent-Pending) Technology which constitutes a quantum leap
forward in signal brightness far exceeding the intensity and quality of any system. Unlike traditional LED Light bars that drop off at key angles, TriCore maintains it's astonishing visibility a full 360 degrees. TriCore is also designed so that brightness won't fade. Watt for Watt, TriCore is the most
efcient emergency warning light ever made.
The DEFENDER is approximately 2.2" high, yet delivers 360° of unobstructed warning signal. The low prole and aerodynamic lines reduce air drag,
which results in fuel savings and stability at high speeds. The DEFENDER light bar also has an extruded internal frame that is 2X stronger, shockresistant polycarbonate lenses with an intermolded solar barrier, a modular lens design that enables almost any light bar length which can be created
from 3 lens lengths, and warning signals that exceed SAE standards.
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.
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.
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 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)
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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 note that some electronic op-
tions (ashers, etc.) may not operate normally when powered by a battery charger. If problems occur at this point, contact the factory.
Utilizing non-factory supplied screws and/or mounting brackets and/or the improper number of
screws or modifying the supplied parts may result in loss of warranty coverage on the equipment.
WARNING!
Installation & Mounting
MOUNTING HARDWARE - Mounting hardware is usually packed in a small box inside the main carton although some mounting kits may be shipped separately. Refer to the Installation Manual included in the mounting kit for mounting instructions. 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.
Wiring Instructions
Before attempting to connect wiring, refer to wire tag attached to the light bar's main cable. Each wire in the cable controls a separate function of the
Central Controller 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. under hood) 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 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
WARNING!
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.
Options & Specications
Fusing Considerations
The DEFENDER Light bar should be installed with an external fuse or circuit breaker in the RED lead of the two conductor 10 AWG power cable.
The recommended external fuse size for the light bar is 30A. The internal circuitry of the Central Controller is reverse polarity protected. Each
TriCore output on the Central Controller board is protected against over current and over heating with automatically resetting output devices.
Dim Operation
The DEFENDER® features a low power "Dimming" mode. Dimming will be controlled by applying +12V by way of the appropriate wire (Blue) in the
wire harness/wire list. Dimming can also be controlled by an optional photo cell. When DIM is engaged, the TriCore® light heads will operate in a
reduced power mode. Note: For light bars with software T116XXV5 or lower, T117XXV5 or lower and T118XXV1 or lower, the corner mounted
light heads are excepted from this function and will not Dim.
The Dim setting reduces the light output of emergency warning lights reducing the effectiveness of them 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
WARNING!
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.
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WARNING!
This Product contains high intensity TriCore devices. To prevent eye damage,
DO NOT stare into light beam at close range.
Selecting Flash Patterns
Use the following instructions for lightbars without programmable light head pairs.
Note: If you have purchased a light bar with programmable light head pairs,
For lightbars with all single color light heads, please see supplement T16406 (800Series Software).
For lightbars with any multi-color light heads, please see supplement T54006 (950Series Software).
STEP 1
The Pattern Select wire is the BLK/RED wire in the sixteen conductor light bar control cable and is activated by momentarily touching the wire to
+power. Select the desired 3-Level mode to program by applying +power to the appropriate wire in the 16 conductor cable.
Make sure +12v is only applied to the function you are trying to program - otherwise program function will not operate.
There are seven possible 3-Level modes (see Table 1). The factory default is different for each of the 3 -Level modes. The standard progressive
switch will use the Level-1, Level-2 and Level-3 modes. The defaults for Level-1, Level-2 (L1 + L2) and Level-3 (L1 + L2 + L3) are identied in Table
1A. When using individual switches, make sure to select patterns for all switch combinations.
TABLE 1: 3-LEVEL MODES OF OPERATION
MODE NUMBERWIRES ACTIVATED
L1GRN/BLK (LEVEL-1)
L2WHT/BLK
L1 + L2GRN/BLK & WHT/BLK (LEVEL-2)
L3RED/BLK
L1 + L3GRN/BLK & RED/BLK
L2 + L3WHT/BLK & RED/BLK
L1 + L2 + L3GRN/BLK, WHT/BLK, & RED/BLK (LEVEL-3)
STEP 2
Observe the ashing pattern operation and determine which pattern is in operation for Level-1. Refer to Table 1A. This table shows the available
ash patterns. Note: the Factory Default is different and identied in the table for each of the ash mode Levels (L1, L2, L3). Once the ash pattern
has been determined, proceed to Step 3
.
STEP 3
Scroll to the next ash pattern by momentarily holding the Pattern Select wire (BLK/RED) to +power for ~1 sec. The light bar will stop ashing when
the wire is connected to +power. Release the wire and the next pattern as listed in Table 1A will begin to ash. The new pattern is automatically
stored each time. Repeat this procedure for each of the seven possible 3-level modes.
NOTE: To restore the Factory Default Emergency Warning Flash Patterns (see Table 1A), hold the pattern select wire to +power for ~four
(4) seconds.
SEE FLASH PATTERN SELECTION NOTES ON FOLLOWING PAGES
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Control Input Function Denition (Note: All control inputs are +power enabled
Wire ColorFunctionDescription
GRN/BLKLevel 1Level 1 Emergency Mode
WHT/BLKLevel 2Level 2 Emergency Mode
RED/BLKLevel 3Level 3 Emergency Mode
ORG/BLKTake Down lightsTake Down Lights Steady Burn (overrides Take Down Flash)
Null Flash (no ashing LEDs - only Steady Burns if equipped
Rapid Quad Flash Picket Fence
Table 1A
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FLASH PATTERN SELECTION NOTES:
*When the ArrowStik® Left and ArrowStik Right wires are both connected to +power, the Center-Out ArrowStik function is activated.
**When the Pattern Select wire is connected to +power and all other inputs are off, test mode is enabled to exercise all outputs in
sequence until +power is removed from the wire.
If the light bar is equipped with Steady Burning TriCore® light heads, these heads are enabled with the 3-Level input wires. The
jumper plug must be moved to JP1, JP2 or JP3 to select the 3-Level input which will enable the Steady Burning TriCore heads, (see
Figure 1).
The Steady Burn function for both the Take Down and Alley lights will always override the Wig/Wag Flash function.
The Cruise Light function is mutually exclusive with all other functions. If any other input has +power applied, the Cruise Lights will
be turned off. Light bars with software T116XXV6 or greater, T117XXV6 or greater or T118XXV2 or greater or T514XXV0 or greater can
operate the Cruise Light Function and the Dim Function together. The Dim Function has no affect on the Cruise Lights.
Steady Burn Setting
The DEFENDER's® Steady Burn feature allows up to two (2) of the light bar's TriCore® light heads to be designated to operate in Steady Burn
mode. The Steady Burn TriCore light heads are always connected to connectors P9 & P10.
The Steady Burn outputs are enabled by the 3-Level control inputs. The DEFENDER may be congured so that Steady Burn TriCore light heads
are on when either L1, L2 or L3 are active (JP1 position); when L2 or L3 are active (JP2 position) or just when L3 is active (JP3 position). Simply
move the jumper to the appropriate location (JP1, JP2 or JP3). Refer to the detail in Figure 1.
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ArrowStik® Modules
Selecting the ArrowStik® Pattern
The Central Controller is designed to offer user selectable trafc directing and trafc warning ash patterns. Each of the ArrowStik® functions
(LEFT, CENTER-OUT, RIGHT or FLASH) can be programmed individually for unique patterns and ash rates. This allows the greatest exibility
when controlling the various light bar congurations available. The light bar can be ordered with a 5, 6, 7 or 8 lighthead conguration. The light bar
will come from the factory with the Building Fast pattern as the default for LEFT, CENTER-OUT and RIGHT. The default pattern for FLASH is the
Standard Flash. If it is desired to change the pattern for any of the functions, follow the programming procedure below.
STEP 1:
Power-up the light bar. Select the ArrowStik function that you wish to program (LEFT, CENTER-OUT, RIGHT or FLASH).
Make sure +12v is only applied to the function you are trying to program - otherwise program function will not operate.
STEP 2:
Continue applying power to the wire from Step 1. Refer to Table 2 for the available ash patterns.
Scroll to the next ash pattern by momentarily holding the Pattern Select wire (BLK/RED) to +power for ~1 sec. The light bar will stop ashing when
the wire is connected to +power. Release the wire and the next pattern as listed in Table 2 will begin to ash. The new pattern is automatically
stored each time.
Notice that for the LEFT, CENTER-OUT and RIGHT functions there are four pattern choices (Building, Building with 3 Flash for the end lightheads,
Traveling Ball with 3 Flash for the end lightheads, and Build/Collapse) and three speeds (Fast, Medium and Slow). There are a total of twelve
possible selections for each function and then you return to the top selection.
For the FLASH function there are nine trafc warning patterns available. Flash patterns marked with an asterisk “*” can be selected in Fast, Medium
or Slow ash rate.
NOTE: To restore the Factory Default ArrowStik Flash Patterns, hold the BLK/RED wire to +power for ~four seconds.
STEP 3:
Repeat steps 1 through 2 for the other ArrowStik functions as desired.
Patterns with the * have a fast,
medium, or slow speed.
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Take Down and Alley Flash
Selecting Flash Patterns:
The Take Down and Alley Lights can be programmed to ash at different rates.
STEP 1:
Power-up the light bar. Select the Take Down Flash Mode (BLK) or the Alley Flash Mode (BLU/WHT) by applying +power to the appropriate wire. .
NOTE: Make sure +12v is only applied to the function you are trying to program - otherwise program function will not operate.
STEP 2:
Observe the ash pattern and determine which pattern is in operation (see Table 3). This table shows the available ash patterns. Once the ash
pattern has been determined, proceed to Step 3. NOTE: The default ash pattern for Take Down and Alley Lights is Medium Single 115FPM.
STEP 3:
Scroll to the next pattern by momentarily holding the BLK/RED wire to +power for ~one (1) second. The light bar will stop ashing when the wire
is connected to +power. Release the wire and the next pattern as listed in Table 3 will begin to ash. The new pattern is automatically stored each
time. NOTE: To restore the Factory Default Take Down and Alley Flash Patterns, hold the BLK/RED wire to +power for ~four (4) seconds.
TABLE 3
TAKE DOWN AND ALLEY FLASH PATTERNS
PATTERN NUMBERPATTERN DESCRIPTION
1FAST QUAD 80FPM
2SLOW QUAD 60FPM
3FAST SINGLE 375FPM
4MEDIUM SINGLE 115FPM
5SLOW SINGLE 60FPM
6FAST DOUBLE 115FPM
7SLOW DOUBLE 60FPM
8FAST SIX 80FPM
9SLOW SIX 60FPM
10VARIABLE RATE SINGLE
11NFPA QUAD 75FPM
12CYCLE FLASH
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Maintenance
Lens Cleaning
Use plain water and a soft cloth, or Code 3® lens polish and a very soft paper towel or facial
tissue. Plastic scratches easily, as a result, 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
With a Phillips screwdriver, remove the (4) #8 X 5/8" Phillips Pan Head Hi-Lo Screws W Neoprene Washer (See Figure 2). Then gently lift the lens off. When nished carefully replace the
lens making sure the lens gasket is not misplaced, then replace the lens mounting screws making sure the neoprene washers are in place.
Light Head Removal
Unplug the TriCore® light head's power wire/wires from the light bar's wiring harness. Then with
a 1/4" Hex Bit Driver, remove the #8 X .270" 6 Lobe Hex Washer Head Screws that attach the
light head mounting brackets to the light bar. Note: For front or rear facing light heads there
are (2) screws holding each light head and for corner light heads there are (6) screws
holding the light head. Then remove the light head (See Figure 3).
FIGURE 2
FIGURE 3
DEFENDER® - EXPLODED VIEW
FIGURE 7
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Parts List
(Reference numbers identify items shown in Figure 7)
Ref No. Description Part No.
1 Outboard Upper Lens
Green T51160
Clear T51161
Red T51162
Blue T51163
Amber T51164
2 Center Long Upper Lens
Green T51150
Clear T51151
Red T51152
Blue T51153
Amber T51154
2 Center Short Upper Lens
Green T51140
Clear T51141
Red T51142
Blue T51143
Amber T51144
3 Outboard Lower Plate T51137
4 Center Lower Plate-Long T51136
Center Lower Plate-Short T51135
5 Outboard Lower Plate Mtg Brkt T51131
6 Center Lower Plate-Long Mtg Brkt T51130
Center Lower Plate-Short Mtg Brkt T51129
7 Lens Mtg Screw W Neoprene Washer T51179
8 6-UP TriCore® Light Head
Red, Blue, Amber, White, Green
6-UP TriCore® Light Head Dual Color
Red/Blue, Red/Amber, Blue/Amber
Red/White, Blue/White, Amber/White
9 3-UP TriCore® Light head
Red, Blue, Amber, White, Green
3-UP TriCore® Light Head Dual Color
Red/Blue, Red/Amber, Blue/Amber
Red/White, Blue/White, Amber/White
3-UP TriCore® Take Down or Alley Light Head
White
CALL FACTORY
10 3-UP Take Down Half Blank T51176
11 PCB, DEFENDER® with ArrowStik® control T11564PCB, DEFENDER® with ArrowStik® control for dual color T55490PCB, DEFENDER® with ArrowStik® sister control for dual color T55491
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Any disassembly of any of the TriCore® light heads will result in loss of warranty coverage on the
equipment.
WARNING!
Troubleshooting
All DEFENDER® Light bars are thoroughly tested prior to shipment. However, should you encounter a problem 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 314-996-2800.
TRICORE® LIGHT HEAD
TROUBLESHOOTING GUIDE
Note: LED light heads must be replaced as a module. There are no user serviceable parts. Warranty is void if module is disassembled
PROBLEMQUESTIONSPOSSIBLE CAUSESOLUTION
TriCore Front Module
not operating
Are all heads out
in front or in back,
and not just a
single module out?
YesNoa. Front and/or Rear Cut Function powered
a. Defective module
b. Cable/Connector unplugged
TriCore Corner
Module has one
head out.
Cruise Lights do not
operateNAa. No power on Cruise wire
NAa. Defective module
b. Cable/Connector unplugged
b. Another Central Controller Function is on
Notes:
a. Remove power (turn off) Front and/or Rear Cut
a. Replace module
b. Check cable & connector
a. Replace module
b. Check cable & connector
a. Connect Cruise wire to switch
b. Turn off other functions
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WARRANTY
This product with TriCore® Technology 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®, Inc. warrants all parts and components (with the exception of all incandescent and halogen bulbs) of the
product to be free of defects in material and workmanship for a period of one (1) year and TriCore light heads
for a period of ve (5) years from the date of purchase. This Warranty excludes normal wear & tear. Units
demonstrated to be defective within the warranty period will be repaired or replaced at the factory service
center at no cost. Code 3, Inc. will return the repaired product with transportation cost prepaid. Code 3, Inc.
assumes no liability for expenses incurred in the packaging, handling, and shipping of the product to the Factory
Technical Service Department for repair. For in-warranty product return authorization, questions regarding
product warranty coverage or questions regarding out-of-warranty repair quotes, contact the Factory Technical
Service Department.
The TriCore light heads are sealed as part of the quality control process. This Warranty is void if, in the
judgment of Code 3, Inc. (1) an attempt has been made to break the light head seal or repair the light head,
and/or (2) the product has been used with inappropriate or inadequate wiring or circuit protection, and/or (3)
the product has failed as a result of abuse or unusual use and/or accidents.
CODE 3, INC. SHALL IN NO WAY BE LIABLE FOR ANY OTHER DAMAGES RELATING TO THE
PRODUCT INCLUDING BUT NOT LIMITED TO CONSEQUENTIAL, INCIDENTAL, INDIRECT OR SPECIAL DAMAGES OR LOST PROFITS OR REVENUE; NOR ANY EXPENSES INCURRED IN THE REMOVAL AND/OR RE-INSTALLATION OF PRODUCTS REQUIRING SERVICE AND/OR REPAIR.
EXCEPT AS SET FORTH ABOVE, CODE 3, INC. MAKES NO OTHER EXPRESS OR IMPLIED
WARRANTIES WHATSOEVER, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE OR MERCHANTABILITY, WITH RESPECT TO THIS PRODUCT.
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 sufcient 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. Code 3®, Inc. 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 returned to sender after the service has been rendered.
Code 3® is a registered trademark of Code 3, Inc.
PRODUCT RETURNS
For Technical Support / Service, please call 314-996-2800.