Code 3 SuperVisor User Manual
INSTALLATION MANUALS FOR THE SUPERVISOR
Click below to go to the appropriate model. For all others, contact Customer Service at
(314) 426-2700.
Ford Crown Victoria
Chevy Impala
Ford Explorer
Chevy Tahoe
INSTALLATION
& OPERATION
MANUAL
SUPERVISOR™
SuperVisor™
Interior Lighting System
Ford Crown Victoria
Including 2005 Model
CONTENTS:
Introduction..........................................................................2
Unpacking & Pre-Installation...............................................3
Installation & Mounting .....................................................3-7
Wiring Diagram & Instructions .......................................... 8-9
Fusing and MR8 Lamp Installation.................................... 10
LED Flash pattern selection & Troubleshooting............... 11
Exploded View & Parts List.............................................. 12
Notes............................................................................ 13 -15
Warranty ............................................................................ 16
For future reference record your product's serial no. here __________________________________________
Read all instructions and warnings before installing and using.
INSTALLER:
This manual must be delivered to the end user of this equipment.IMPORTANT:
Introduction
The SuperVisor™ is an interior lighting system that fits in the visor area near the top of the windshield. It delivers an amazing warning
signal, including MR8 powered takedown lights.
The SuperVisor is designed on a modular basis, which means that the light bar can be customized to meet most any requirements.
The SuperVisor has room for up to eight LED lightheads plus two MR8 takedowns. Each lighthead is individually wired for any flash
pattern or combination of flash patterns required.
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
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
!
WARNING!
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 current arcing,
which can cause personal injury and/or severe vehicle damage, including fire.
Any electronic device may create or be affected by electronmagnetic interference. After installation of any electronic
device operate all equipment simultaneously to insure that operation is free of interference. Never power emergency warning equipment from the same circuit or share the same grounding circuit with radio communication
equipment.
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.
All devices should be mounted in accordance with the manufacturer's instructions and securely fastened to vehicle
elements of sufficient strength to withstand the forces applied to the device. Driver and/or passenger airbags (SRS)
will affect the way equipment should be mounted. This device should be mounted by permanent installation and
within the zones specified by the vehicle manufacturer, if any. Any device mounted in the deployment area of an air
bag will damage or reduce the effectiveness of the air bag and may damage or dislodge the device. Installer must
be sure that this device, its mounting hardware and electircal supply wiring does not interfere with the air bag or the
SRS wiring or sensors. Mounting the unit inside the vehicle by a method other than permanent installation is not
recommended as unit may become dislodged during swerving, sudden braking or collision. Failure to follow
instructions can result in personal injury.
2
Unpacking & Pre-installation
Carefully remove the SuperVisor™ and place it on a flat surface, taking care not to scratch the lenses or damage the cable coming out of the
side. 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). Some units may be factory wired for control by a LED
flasher in which case the cable's wire tag should be consulted. 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.
Utilizing non-factory supplied screws and/or mounting brackets and/or the improper number
WARNING!
Mounting Hardware - All mounting hardware is packed in a small box inside the main carton. There are four brackets used to mount
the visor bar to the vehicle. These are discussed in detail later.
!
Removing Sun Visors
Begin the installation by removing the Crown Victoria's driver and passenger sun visors. Identify each visor with tape or other
marking to indicate the driver from the passenger side unit. They are not identical. There are three screws that hold the pivotal
arm of the sun visor to the headliner. Remove each screw using a small torx screwdriver starting with the lower screw as shown in
Figure 1. Then unclip the sun visor and rotate it over to expose the two upper screws.
of screws may result in loss of warranty coverage on the equipment.
FIGURE 1
3
Attach brackets to sun visor retaining clips
In order to remove the sun visor retaining clip, unscrew the one torx screw holding it in place. Place the inner bracket on the retaining
clip as shown in Figure 2. Attach to the inner bracket and retaining clip to the headliner as illustrated in Figure 3. Do not tighten these
screws at this time.
the Crown Vic. To confirm that you have a 2005 vehicle with the changes, measure the distance between the mounting screws
fastening the two inner sun visor clips, if the distance between the clips measures 11 1/4" the vehicle was built before the
change, if the distance measures 13 1/4" it is the new 2005 version and has the change
Figure 3 are for vehicles built before the change and will not work for the newer vehicles. The inner mounting brackets shown
in Figure 3A will work in both the new and old vehicles. The basic installation is the same except when mounting the
SuperVisor to the inner brackets install the 1/4-20 x1/2" mounting screws into the slot in the inner mounting bracket that is
nearest the mating hole in the SuperVisor's Outer panel see Figure 3B.
Note: Some time between January 1st and January 10th of 2005, Ford made changes to the 2005 model of
. The inner mounting brackets shown in
FIGURE 2
FIGURE 3
FIGURE 3A
FIGURE 3B
Attaching the pivot arm brackets
Attach the outer brackets that are supplied noting the difference between passenger and driver side brackets (see Figure 4).
Position the bracket on the passenger sun visor's pivot arm as shown in Figure 5. Rotate the pivot arm on the passenger sun visor
and verify the orientation of the bracket as shown in Figure 6. Note that the thicker portion of the pivot arm hinge aligns to the upper
inside hole. Attach the first two torx screws as shown in Figure 6 and Figure 7. Next, move the sun visor over in order to gain access
to install the final screw into the lower position as shown in Figure 8. Repeat this operation for the driver sun visor and outer bracket.
FIGURE 4
FIGURE 5
FIGURE 7 FIGURE 8
FIGURE 6
Mounting the SuperVisor™
Once all four brackets and sun visors are attached, the SuperVisor is now ready to be installed. Position the SuperVisor in the
center of the windshield as shown in Figure 9.
FIGURE 9
The two center brackets should line up with the holes in the SuperVisor's lower chassis. Using the supplied 1/4"-20 bolts and internal
tooth lock washers, loosely install them as shown in Figure 10.
FIGURE 10
6
Mounting the SuperVisor™(continued)
Next, if necessary, slightly loosen the three pivot arm bracket and sun visor retaining clip torx screws in order to align the pivot arm
bracket's hole with the mating chassis hole on the end of the SuperVisor. Finally, thread the supplied bolts and the internal tooth
lock washers through the pivot arm bracket's hole into the hole on the end of the chassis, shown in Figure 11. Tighten all pivot arm
and sun visor retaining clip torx screws.Using a tape measure and a level, center the SuperVisor from side to side and locate a
position on the headliner where the SuperVisor is level. Finally, tighten all four bolts securely. Do not overtighten.
FIGURE 11
Caution: The bracket fasteners make excellent hard mounting points for radar guns and
video cameras etc. Drilling into the housing of the light bar could damage wiring or
other internal components.
7
Wiring Diagram
8
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.
Route the wiring cable into the passenger compartment as shown in Figure 12. 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 the remaining power wires to the +12V terminal of the
battery, power switches, siren or RLS controller. The MR8 takedowns may be installed to a flasher. The fan should be wired to
operate continuously whenever the takedowns are in operation, either flashing or steady burn. Each light head is wired
independently to allow complete flexibility of control.
FIGURE 12
9
LED 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 light bars with many LED modules running off a single fused source,
Minimum fuse size calculation:
For LED 12 volt electrical current only
1.5 x (number of modules being fused)
Example: 2 intersection modules and 6 directional modules.
Minimum fuse requirement for single fuse - 1.5 (8) = 12 A
For MR8 takedown and fan 12 volt electrical current only
Total wattage (1 MR8's = 35W, fan = 5W) divided 12volts = Amperage
Example:2 MR8's and 1 fan = (75W/12) = 6.25 A
Total 12 volt electrical current
12A (for LED's) + 6.25A (for MR8's and fan) = 18.25 A
Product Features
LED-X light head options: Red, Blue, Amber, White;
Directional or Wide Optics;
Flashing or Steady Burn Control
6 LED Optix light head options: Red, Blue, Amber, White;
Directional or Wide Optics;
Flashing or Steady Burn Control
3 LED Optix light head options: Red, Blue, Amber, White;
Directional, Wide or Hybrid Optics;
Flashing or Steady Burn Control
33 Optix light head options: Two 3-LED Heads with one 6-LED Optic
Red, Blue, Amber, White;
Directional , Wide or Hybrid Optics;
Flashing or Steady Burn Control
LC-LED light head options: Red, Blue, Amber;
Flashing or Steady Burn Control
MR8 Specs: 35w Halogen with 13° spot
Size: 45.50" long x 2.00" tall x 7.25" deep
Weight: 7.5 lb
WARNING!
!
This Product contains high intensity LED devices. To prevent eye damage, DO NOT stare
into light beam at close range.
MR8 Takedown Light Assembly
Refer to Figure 13 for lamp replacement. Remove the lamp assembly from the product by disconnecting the two electrical wires and
removing the appropriate fastener. Remove the fastener clamping the lamp and then remove the lamp from the mounting bracket.
Disconnect the lamp from the ceramic connector and reinstall a new lamp. The lamp lens should be cleaned to remove fingerprints
then reinstall the lamp assembly in the light bar and reconnect the electrical wires. Reassemble the components in reverse order.
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.
FIGURE 13
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
NFPA 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
Momentarily short and release
to change patterns
FIGURE 33
J1
PCB
Flash Pattern Header for OPTIX/LEDX
Troubleshooting
All SuperVisors 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.
Follow the guide below for information on repair and troubleshooting.
TROUBLESHOOTING GUIDE
Note: LED modules must be replaced as a module. There are no user serviceable parts.
PROBLEM
QUESTIONS POSSIBLE CAUSE
SOLUTION
LED module not
operating when
powered.
N/A
a. Bad power/ground
connection.
b. Defective module.
11
a. Fix connection.
b. Replace module
Parts List
Reference Number Part Description Part Number
1 +12V Cooling Fan T05612
2 *LED Module *Contact Code 3, Inc for P/N
3 MR8 lamp T09600
4 Chassis T09618
5 Outer Panel T09625
5 Outer Panel 2005 T09799
Not Shown Inner Mtg. Brkt. Crown Vic T09607
Not Shown Inner Mtg. Brkt. Crown Vic 2005 T09796
Not Shown Outer Mtg. Brkt. Crown Vic Pass T09608
Not Shown Outer Mtg. Brkt. Crown Vic Dr. T09610
Not Shown Outer Mtg. Brkt. Crown Vic Pass 2005 T09797
Not Shown Outer Mtg. Brkt. Crown Vic Dr.2005 T09798
12
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 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. 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.
NEED HELP? Call our Technical Assistance HOTLINE - (314) 996-2800
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.
Revision 3, 11/05 - Instruction Book Part No. T09604
©2004 Public Safety Equipment, Inc. Printed in USA
16
INSTALLATION &
OPERATION
MANUAL
SPLIT SUPERVISOR
™
Split SuperVisor
Interior Lighting System
Ford Crown Victoria
CONTENTS:
™
For future reference record your product's serial no. here
__________________________________________
Read all instructions and warnings before installing and using.
IMPORTANT:
INSTALLER:
Introduction ................................................................... 2
Unpacking & Pre-Installation ........................................ 3
Installation & Mounting ..............................................3-8
Wiring Diagram & Instructions ................................. 9-10
Fusing and MR8 Lamp Installation ............................. 11
LED Flash pattern selection & Troubleshooting......... 12
Exploded View & Parts List ........................................ 13
Warranty ..................................................................... 16
This manual must be delivered to the end user of this equipment.
Introduction
The SuperVisor™ is an interior lighting system that fits in the visor area near the top of the windshield. It
delivers an amazing warning signal.
The SuperVisor is designed on a modular basis, which means that the light bar can be customized to meet
most any requirements. The SuperVisor has room for up to eight LED lightheads. Each lighthead is
individually wired for any flash pattern or combination of flash patterns required.
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 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 current arcing, which can cause personal injury and/
or severe vehicle damage, including fire.
Any electronic device may create or be affected by electronmagnetic interference. After
installation of any electronic device operate all equipment simultaneously to insure that
operation is free of interference. Never power emergency warning equipment from the
same circuit or share the same grounding circuit with radio communication equipment.
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.
All devices should be mounted in accordance with the manufacturer's instructions and
securely fastened to vehicle elements of sufficient strength to withstand the forces applied
to the device. Driver and/or passenger airbags (SRS) will affect the way equipment should
be mounted. This device should be mounted by permanent installation and within the
zones specified by the vehicle manufacturer, if any. Any device mounted in the deployment
area of an air bag will damage or reduce the effectiveness of the air bag and may damage
or dislodge the device. Installer must be sure that this device, its mounting hardware and
electircal supply wiring does not interfere with the air bag or the SRS wiring or sensors.
Mounting the unit inside the vehicle by a method other than permanent installation is not
recommended as unit may become dislodged during swerving, sudden braking or collision.
Failure to follow instructions can result in personal injury.
2
Unpacking & Pre-installation
Carefully remove the SuperVisor™ and place it on a flat surface, taking care not to scratch the lenses or
damage the cable coming out of the side. 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). Some units may be factory wired for control by a LED flasher in which case the cable's wire tag
should be consulted. 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.
Utilizing non-factory supplied screws and/or mounting brackets and/or the
WARNING!
Mounting Hardware - All mounting hardware is packed in a small box inside the main carton. There are four
brackets used to mount the two visor bars to the vehicle. These are discussed in detail later.
!
improper number of screws may result in loss of warranty coverage on the
equipment.
Removing Sun Visors
Begin the installation by removing the Crown Victoria's driver and passenger sun visors. Identify each
visor with tape or other marking to indicate the driver from the passenger side unit. They are not identical.
There are three screws that hold the pivotal arm of the sun visor to the headliner. Remove each screw
using a small torx screwdriver starting with the lower screw as shown in Figure 1. Then unclip the sun
visor and rotate it over to expose the two upper screws.
FIGURE 1
3
Attach brackets to sun visor retaining clips
In order to remove the sun visor retaining clip, unscrew the one torx screw holding it in place. Place the
inner bracket on the retaining clip as shown in Figure 2. Attach to the inner bracket and retaining clip to the
headliner as illustrated in Figure 3. Do not tighten these screws at this time.
FIGURE 2
FIGURE 3
Attaching the pivot arm brackets
Attach the outer brackets that are supplied noting the difference between passenger and driver side
brackets. Position the bracket on the passenger sun visor's pivot arm as shown in Figure 4. Rotate the
pivot arm on the passenger sun visor and verify the orientation of the bracket as shown in Figure 5. Note
that the thicker portion of the pivot arm hinge aligns to the upper inside hole. Attach the first two torx
screws as shown in Figure 5 and Figure 6. Next, move the sun visor over in order to gain access to install
the final screw into the lower position as shown in Figure 7. Repeat this operation for the driver sun visor
and outer bracket.
Inner mounting bracket modified
to fit all 2005 Crown Victorias
4
FIGURE 4
Outer mounting bracket modified
to fit all 2005 Crown Victorias
FIGURE 5
5
FIGURE 6
FIGURE 7
6
Mounting the SuperVisor™
Before mounting the SuperVisor, apply gasket stripping to the front edge of the lower chassis in order to
prevent scratching the windshield. See Figure 8. Once all four brackets and sun visors are attached, the
two SuperVisors are now ready to be installed. Position the Driver Side SuperVisor to center between the
Driver Side Brackets and align with the mounting holes as shown in Figure 9. Repeat for Passenger Side.
FIGURE 8
FIGURE 9
7
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