INSTALLATION
& OPERATION
MANUAL
Basic SAE Amber Tow Bar
(Shown with Std. PERMX mounting feet)
SAE Amber Tow Bar with LED work lights and STT lights
Basic SAE Red/Blue Emergency Bar
CODE 3 RANGER TM LIGHTBAR
Code 3 RANGER
LIGHTBAR
CONTENTS:
Introduction...................................................................................2
Unpacking & Pre-Installation.........................................................2
Installation & Mounting.......................................................3-5
Wiring Instructions...................................................................................................5 - 6
Flash Pattern Selection.................................................................................................7
Maintenance and Troubleshooting................................................................................8
Note Pages.............................................................................................................9 -11
Warranty ..................................................................................................................12
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.
TM
1
Introduction
The RangerTM Light Bar is designed utilizing the 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, shockresistant 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 with available options designed for this light bar such as STT lights and additional directional
LED modules.
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 Red & Red/White 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,
If problems occur at this point, contact the factory.
2
Installation & Mounting
WARNING!
!
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.
PERMX Std. mounting kit: (Provided with the light bar) For at roof installations.
1. Mount the PERMX mounting feet to the bottom of the light bar frame using the stainless steel hardware
supplied in the kit. Carriage bolts are slid into the frame ends to the desired location on the frame rails.
2. Position the bar onto the vehicle roof and center in desired location.
3. Mark the roof using the holes in the mounting feet as a template for screw hole locations.
4. Remove the light bar from the roof of the vehicle and center punch the (4) mounting holes using a center
punch. (This will prevent drill (walking) during drilling operations)
5. Drill roof of vehicle to accept mounting screws being installed.
6. Set bar onto roof and check for levelness of bar front to back using a level.
7. Place shims under feet of mounting foot if needed to acheive level attitude.
8. Install (4) foam pads under mounting feet to prevent etching of painted surfaces.
9. It is recommended that a bead of silicone sealant be used around each mounting hole in roof to assure
against any water inltration.
10. Install mounting bolts through vehicle roof up into mounting feet of light bar.
OTHER MOUNTING OPTIONS:
Mounting Hardware
All mounting hardware is packed in a small box inside the main carton. The standard kit included with the bar is the PERMX mount. Other
mounting options can be bought separately such as: : (1) Hook-On Type, (1) Tow and Recovery and a second Permanent Type. 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.
3
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.
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).
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
Flat Roof
FIGURE 4
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.
Curved Roof
Place Feet on
Curved Portion
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.
5
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 Red and Red/Whiite leads 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.
WARNING!
!
Wiring - Ranger
Note: All control inputs are +power enabled.
Control Input Function Denition
Wire Color Function Description
RED (16 GA)
RED / WHITE (16 GA)
BLUE (18 GA) Take Down lights Take Down Lights Steady Burn
ORANGE (18 GA) PS Alley Light PS Alley Steady Burn
YELLOW (18 GA) DS Alley Light DS Alley Steady Burn
BROWN (18 GA) Front directional and corner lights Provides power for all front facing directional and corner light heads
VIOLET (18 GA) Rear directional and corner lights Provides power for all rear facing directional and corner light heads
TM
GROUND GROUND
This Product contains high intensity LED devices. To prevent eye damage, DO NOT
stare into light beam at close range.
Table 1 - Control Wire Denitions - Ranger
TM
Flash Pattern Selection - Ranger
The Pattern Selection is accomplished by setting of each light head individually.
1. Remove the upper lens clips using a at blade screwdriver. (care should be given so that the lens gasket is not damaged during
lens removal.)
2. The light head PCB has two prongs facing forward on the top edge of each LED module. While under power, a at blade screwdriver or other metal object placed between these two prongs will change the pattern to the next setting. Each head will need to be
changed separately.
3. Once each head has been set to the desired ash pattern, re-install the upper lens and lens clips to the light bar.
TM
Bars with STT option installed:
Stop Turn Tail lights are powered through a separate 3 wire cable.
1. Run wire for DS light head to turn signal LED light to junction for Driver side turn signal light on vehicle.
2. Run wire for PS light head to turn signal LED light to junction for Passenger side turn signal light on vehicl.e
3. Run wire for Stop signal to brake light switch on vehicle wiring harness.
6
Factory Defaults - Flash Patterns
Table - Flash Patterns - Ranger
Pattern Number Flash Pattern Description
1 Cycle Flash 70 FPM
2 NFPA Quad 80 FPM
3 Quad 70 FPM
4 Steady Burn
5 Five 70 FPM
6 Triple 70 FPM
7 Double 70 FPM
8 Single 70 FPM
9 Quad Pop 70 FPM
10 Triple Pop 70 FPM
11 Mod Flash (Variable Single Flash)
12 Action Flash
13 Cycle Flash 150 FPM
14 Five 150 FPM
15 Quad 150 FPM
16 Triple 150 FPM
17 Double 150 FPM
18 Single 150 FPM
19 Single 250 FPM
20 Single 375 FPM
TM
7
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.
Twist to
Lift Lens
Pry Up to
Remove
Lens Clip
Lens Removal
First, disengage the lens clips (4 per lens) as shown in Figure 5. Finally,
insert a screwdriver into the small slot in the lens clip pocket or the lens edge,
and twist the screwdriver to lift the lens.
FIGURE 5
Light Head Removal and/or Lamp Replacement
Directional/Corner: Remove screws securing the light head assembly to the frame, lift light head assembly, and then remove the
control wire (s). Reference Figure 6.
LED TD/Alley: Remove the two screws securing the light head assembly to the frame and the one screw from the black ground wire,
lift light head assembly, and then disconnect the red wire from the control wire by decoupling the quick slides (make sure to pull on
the quickslides only, not the wires). Reference Figure 6.
Alley light assembly when no
corners on light bar.
Rear Directional
DS Rear Corner
DS Alley light
PS Rear Corner
PS Alley light
Rear Directional
PS Front Corner
Front Directional
Take Down Lights
Front Directional
FIGURE 6
DS Front Corner
Troubleshooting
All lightbars 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.
8
Pages 9-11 are intentionally left blank for installation notes:
9
Notes:
10
Notes:
11
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, LED Lighthead modules to a period of 5 years (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 the 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 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.
Problems or Questions? Call The Technical Assistance HOTLINE - (314) 996-2800
Code 3, Inc.
www.code3pse.com
Code 3 is a registered trademark of
Code 3, Inc.
St. Louis, Missouri 63114-2029—USA
Ph. (314) 426-2700 Fax (314) 426-1337
Revision 1, 03/12 - Instruction Book Part No. T56582
©2010 Public Safety Equipment, Inc. Printed in USA
10986 N. Warson Road
Code 3,® Inc., a subsidiary of
Public Safety Equipment, Inc.
12
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