Code 3 RockerPak 440L4, RockerPak 440L5 User Manual

INSTALLATION
& OPERATION
MANUAL

Introduction

The Rocker Max PakTM Switchbox is a 4 or 5 switch control center protected by 2 circuit breakers and 4 or 5 fuses, relative
to the model ordered.

Procedure

Wiring Instructions:

1) The installer needs to first determine the current load in amps of each of the devices to be switched by the Rocker
Max Pak Switchbox.

2) Connect the devices to the desired switch, noting the current limitations of each switch and group of switches.

3) An 8 gauge wire should be run from the Red 8 gauge Switchbox input wire, and a 10 gauge wire should be run
from the Red/Black 10 gauge Switchbox input wire to a user supplied fuse, then to the (+) side of the battery,
the alternator, or the stud on the battery side of the solenoid. The user supplied fuse should be located as close
to the battery as possible and sized to 125% of the total load carried by the Rocker Max Pack Switchbox (i.e.:
if the total load carried is 40 amps; 40 amps x 125% = 50 amp fuse). A circuit breaker is not recommended here,
they are very sensitive to high ambient temperatures and will false trip when mounted in hot environments or
operated close to their capacity. Do not use 1/4" dia. glass fuses as they are not suitable for continuous duty
in sizes above 15 amps.

4) The white/black wire powers the backlighting, connect it to (+) 12 volt ignition switched circuit. Connect the black
wire to vehicle chassis (earth).

Larger wires and tight connections will provide longer service life for components. For high

!

WARNING!

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 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.

IMPORTANT:

Read all instructions and warnings before installing and using.

INSTALLER: This manual must be delivered to the end user of this equipment.

customer supplied fuses

(sized to 125% of

complete load)

40 Amp circuit breaker

10 GA. Red/Black input

Battery

(+)12 volt ignition circuit

white/black wire

vehicle chassis (earth)

16 GA. black wire

8 GA. Red input

15 Amp Fuses

orange

4

switches are 10 amps each

65

7

maximum 30 amps

blue

green

yellow

brown

8

40 Amp circuit breaker

relay

1

relay

purple

1

relays are 15 amps each

maximum 35 amps

2

relay

3

red

23

white

panel backlighting

WARRANTY

This product 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. guarantees all
parts and components except the lamps for a period of 1 year from the date of purchase or delivery, whichever
is later. Units demonstrated to be defective within the warranty period will be repaired or replaced by the factory
or at a factory authorized service center at no cost.

Use of a lamp or other electrical load of a wattage higher than installed or recommended by the factory
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

In order to provide you with faster service, if you are going to return a product for repair
or replacement*, please contact our factory to obtain a Return Goods Authorization Number
(RGA number) before you ship the product to PSE. 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.

*PSE reserves the right to repair or replace product at its discretion. PSE assumes no responsibility or
liability for expenses incurred for the removal and/or reinstallation of products requiring service and/or repair.

Problems or Questions? Call our Technical Assistance HOTLINE - [phone]

St. Louis, Missouri 63114-2029—USA

Revision 1, 02/2006 - Instruction Book Part N0. T04920

Rocker Max Pak is a trademark of Code 3, Inc. Code 3 is a registered trademark of Code 3, Inc a subsidiary ofPublic Safety Equipment, Inc.
3M is a registered trademark of 3M Company

10986 N. Warson Road

Code 3, Inc.

www.code3pse.com

©1995-2006 Code 3, Inc. Printed in USA