Federal Signal Corporation JetSolaris JLX Series Installation And Service Manual
LED JetSolariS® Lightbar
with ROC™ Technology
JLX 48”, 54”, 60”, and 72” Series
TM
2562335D
REV. D 1112
Printed in U.S.A.
Installation and Service Manual
Contents
Chapter 1: Safety Messages ......................................................................................... 5
Safety Messages to Installers and Service Personnel of Warning Light Equipment ................ 5
Safety Message to Operators of Warning Light Equipment ................................................ 8
Chapter 2: An Overview of the JLX JetSolaris ............................................................. 10
Lightbar Specications ...............................................................................................10
Unpacking the Product ...............................................................................................11
Before You Begin .......................................................................................................11
Chapter 3: Installing the JLX JetSolariS ....................................................................... 12
Connecting the Power Leads for the Standard JLX ..........................................................12
Control Wires For the Standard JLX Lightbar .................................................................13
Wiring the Controls for White Light and Front/Rear Cutoff ...............................................14
Selecting Flash Patterns for Primary and Secondary Mode ...............................................15
Operating in Dim Mode ...............................................................................................19
Chapter 4: Installing the SignalMaster (Option) ......................................................... 20
Assembling and Mounting the Control Head ..................................................................20
Wiring the Control Head .............................................................................................21
Operating the Control Head ........................................................................................22
3
Chapter 5: Servicing the Lightbar ............................................................................... 23
Cleaning the Plastic Domes .........................................................................................23
Cleaning the Reectors ..............................................................................................24
Replacing the Halogen Lamps ......................................................................................24
Aiming the Halogen Lamps .........................................................................................27
Replacing an End Board ..............................................................................................28
Replacing the Control Board ........................................................................................29
Replacing a Fuse .......................................................................................................31
Replacing a Center Board ...........................................................................................32
Chapter 6: Ordering Parts and Service ....................................................................... 33
Ordering Replacement Parts ........................................................................................33
Returning a Product to Federal Signal ...........................................................................33
Returning a Product to Federal Signal ...........................................................................33
Tables
Table 3.1: 11-conductor cable wires (12 AWG) (Standard JLX) ............................................14
Table 3.2: Lightbar Flash Patterns for Standard JLX ROC Lightbars .......................................18
Table 4.1: SignalMaster control cable wires .......................................................................22
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Contents
Figures
Figure 3.1: Location (circles) of screws securing end dome .................................................16
Figure 3.2: Location (circle) of S1 PROGRAM button ...........................................................17
Figure 4.1: SignalMaster control head ..............................................................................20
Figure 4.2: Connections for SignalMaster control head ........................................................22
Figure 5.1: Halogen worklight and takedown replacement types ..........................................25
Figure 5.2: Alley lamp replacement PN 8107241 ................................................................26
Figure 5.3: Adjustment screw for aiming the halogen lamp .................................................27
Figure 5.4: Center board and end board exploded view.......................................................28
Figure 5.5: Control board removed from bracket ................................................................30
Chapter 1: Safety Messages
For your safety, read this manual thoroughly before installing, operating, and servicing the
Legend® lightbar. The safety messages presented in this chapter and throughout the manual
are reminders to exercise extreme care at all times. To download copies of the manual, go to
www.fedsig.com or call the Federal Signal Service Department at 1-800-433-9132, 7 am to 5 pm,
Monday through Friday (CT).
Safety Messages to Installers and Service Personnel of Warning
Light Equipment
People’s lives depend on your proper installation and servicing of Federal Signal
products. It is important to read and follow all instructions shipped with this product.
In addition, listed below are some other important safety instructions and precautions
you should follow:
5
Before Installation or Service
Qualications
• To properly install or service this equipment, you must have a good understanding of
automotive mechanical and electrical procedures and systems along with prociency in the
installation and service of safety warning equipment. Always refer to the vehicle service
manuals when performing equipment installations on a vehicle.
Light Hazards
• To be an effective warning device, this product produces bright light that can be hazardous
to your eyesight when viewed at a close range. Do not stare directly into this lighting
product at a close range or permanent damage to your eyesight may occur.
• Do not install the light system in an area that would block, impair, or blind the driver’s
vision. Ensure that the light system is mounted in a position that is outside of the driver’s
eld of vision, so the driver can safely operate the vehicle.
• Federal Signal power supplies and light heads are designed to work together as a system.
Combining light heads and a power supply from different manufacturers may reduce the
warning effectiveness of the lighting system and may damage the components. You should
verify or test your combination to ensure the system works together and meets federal,
state, and local standards or guidelines.
Electrical Hazards
• Strobe systems present a shock hazard because they use high voltage to operate. Do not
handle strobe cables, the power supply, or bulbs or remove the lens while the equipment
is connected. Strobe systems can also hold their charge even after they have been turned
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Chapter 1: Safety Message to Installers and Service Personnel
off. After disconnecting power to the unit, wait ve minutes before handling any parts of the
strobe system.
• A light system is a high current system. In order for the system to function properly, a
separate negative (–) connection and positive (+) connection must be made. All negative
connections should be connected to the negative battery terminal and a suitable fuse
should be installed on the positive battery terminal connection as close to the battery
as possible. Ensure that all wires and fuses are rated correctly to handle the device and
system amperage requirements.
• Never attempt to install aftermarket equipment that connects to the vehicle wiring without
reviewing a vehicle wiring diagram available from the vehicle manufacturer. Ensure that
your installation will not affect vehicle operation or mandated safety functions or circuits.
Always check the vehicle for proper operation after installation.
• The lighting system components, especially light bulbs, strobe tubes, LEDs, and the outer
housing, get hot during operation. Be sure to disconnect power to the system and allow the
system to cool down before handling any components of the system.
• Halogen light bulbs and strobe tubes are pressurized and if broken, can burst and result in
ying glass. Always wear gloves and eye protection when handling these components.
• Do not mount a radio antenna within 18 inches (45.7 cm) of the lighting system. Placing
the antenna too close to the lighting system could cause the lighting system to malfunction
or be damaged by strong radio elds. Mounting the antenna too close to the lighting system
may also cause the radio noise emitted from the lighting system to interfere with the
reception of the radio transmitter and reduce radio reception.
• Do not attempt to wash any unsealed electrical device while it is connected to its power
source.
During Installation and Service
• DO NOT get metal shavings inside the product. Metal shavings in the product can cause the
system to fail. If drilling must be done near the unit, place an ESD-approved cover over the
unit. Inspect the unit after mounting to be sure there are no shavings present in or near
the unit.
• DO NOT connect this system to the vehicle battery until ALL other electrical connections are
made, mounting of all components is complete, and you have veried that no shorts exist.
If the wiring is shorted to the vehicle body or frame, high current conductors can cause
hazardous sparks resulting in electrical res or ying molten metal.
• DO NOT install equipment or route wiring (or the plug-in cord) in the deployment path of an
airbag.
• Before mounting any components, check the manual to be sure that the component you are
installing is suitable for use in that area of the vehicle. Many components are not suitable
for use in the engine compartment or other extreme environmental exposure areas.
• Service life of light bulbs and strobes tubes will be shortened if the glass portion is touched
during installation. Use gloves when handling these components. If the glass portion has
been touched, clean the glass carefully with isopropyl alcohol.
Chapter 1: Safety Message to Installers and Service Personnel
• When drilling into a vehicle structure, be sure that both sides of the surface are clear of
anything that could be damaged. Remove all burrs from drilled holes. To prevent electrical
shorts, grommet all drilled holes through which wiring passes. Also, ensure that the
mounting screws do not cause electrical or mechanical damage to the vehicle.
• Refer to the manual packed with the lighting system for proper electrical connections,
additional precautions, and information.
• Because vehicle roof construction and driving conditions vary, do not drive a vehicle with
a magnetically mounted warning light installed. The light could y off the vehicle causing
injury or damage. Repair of damage incurred because of ignoring this warning shall be the
sole responsibility of the user.
• To avoid denting the roof of the vehicle, place the lightbar mounting feet as close to the
outer edge of the roof as possible.
• Roof damage can occur if the hook adjustment bolts are over-tightened. Tighten
adjustment bolts 6 to 7 ft-lb to prevent the JLX lightbar from sliding front-to-back when
pulling on the mounting bracket. Install keeper plates.
• Locate the light system controls so the VEHICLE and CONTROLS can be operated safely
under all driving conditions.
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After Installation or Service
• After installation, test the light system to ensure that it is operating properly.
• Test all vehicle functions, including horn operation, vehicle safety functions, and vehicle
light systems, to ensure proper operation. Ensure that the installation has not affected the
vehicle operation or changed any vehicle safety function or circuit.
• Scratched or dull reectors, mirrors, or domes will reduce the effectiveness of the
lighting system. Avoid heavy pressure and use of caustic or petroleum based products
when cleaning the lighting system. Replace any optical components that may have been
scratched or crazed during system installation.
• Do not attempt to activate or de-activate the light system control while driving in a hazardous
situation.
• You should frequently inspect the light system to ensure that it is operating properly and
that it is securely attached to the vehicle.
• After installation and testing are complete, provide a copy of these instructions to
instructional staff and all operating personnel.
• File these instructions in a safe place and refer to them when maintaining or re-installing
the product.
Failure to follow all safety precautions and instructions may result in property
damage, serious injury, or death.
RETAIN AND REFER TO THIS MESSAGE
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Chapter 1: Safety Message to Installers and Service Personnel
Safety Message to Operators of Warning Light Equipment
People’s lives depend on your safe use of our products. Listed below are some
important safety instructions and precautions you should follow:
• Do not attempt to activate or de-activate the light system control while driving in a hazardous situation.
• Although your warning system is operating properly, it may not be completely effective.
People may not see or heed your warning signal. You must recognize this fact and continue
driving cautiously.
• Also, situations may occur which obstruct your warning signal when natural and man-made
objects are between your vehicle and others, such as raising your hood or trunk lid. If these
situations occur, be especially careful.
• All effective sirens and horns produce loud sounds that may cause, in certain situations,
permanent hearing loss. You and your passengers should consider taking appropriate safety
precautions, such as wearing hearing protection.
• In order to be an effective warning device, this product produces bright light that can be
hazardous to your eyesight when viewed at a close range. Do not stare directly into this
lighting product at a close range or permanent damage to your eyesight may occur.
• It is important that you fully understand how to safely operate this warning system before
use.
• You should only operate your vehicle and its light/sound system in accordance with your
department’s Standard Operating Procedures.
• If a selected function does not perform properly or if any of the lamps remain illuminated
when the control is off, disconnect the power connector from the control unit and contact
the nearest service center.
• At the start of your shift, you should ensure that the entire warning light system and the
siren system is securely attached and operating properly.
• Suction cup mounting is for temporary applications only. The unit should be removed from
the window and stored securely when not in use. Temperature changes and sunlight can
cause suction cups to lose holding power. Periodically check the unit to be sure the suction
cups have a rm grip on the mounting surface. An improperly secured light could fall off of
the vehicle causing injury and damage.
• Holding power of magnetic mounting systems is dependent upon surface nish, surface atness, and thickness of the steel mounting surface. Therefore, to promote proper magnetic
mounting:
✓
Mounting surface and magnets must be kept clean, dry, and free of foreign particles that
prevent good surface contact.
✓
Ensure that mounting surface is at.
Chapter 1: Safety Message to Installers and Service Personnel
✓
A magnet mounting system should not be used on vehicles with vinyl tops.
✓
To prevent sliding of light assembly on mounting surface, quick acceleration and hard
stops should be avoided.
Failure to follow all safety precautions and instructions may result in property
damage, serious injury, or death.
RETAIN AND REFER TO THIS MESSAGE
9
10
Chapter 2: An Overview of the JLX JetSolaris
The JetSolariS® is an LED lightbar that can be used in a variety of applications for Fire/Rescue,
Police, DOT, and Tow/Recovery. The JetSolariS features the latest in SolariS® LED and ROC
(Reliable Onboard Circuitry) technology. ROC substantially reduces wiring and connections
with its consolidated design of printed circuit boards, and the SolariS LED reectors provide
maximum LED performance. SolariS LED and ROC technology improves the performance and
virtually eliminates any maintenance while being supported by a ve year warranty on the LED
components.
The standard JetSolariS comes with 40 selectable ash patterns, including a test pattern. The
LEDs are available in amber, blue, red, white, and green. Dome colors are available in amber,
blue, red, and clear. Halogen worklight options are also available.
Lightbar Specications
Dimensions (H x L x W):
JLX 48" 4.7 in x 47.5 in x 11.2 in (119 mm x 1207 mm x 284 mm)
JLX 54" 4.7 in x 54 in x 11.2 in (119 mm x 1372 mm x 284 mm)
JLX 60" 4.7 in x 60 in x 11.2 in (119 mm x 1524 mm x 284 mm)
JLX 72" 4.7 in x 72 in x 11.2 in (119 mm x 1829 mm x 284 mm)
Current Draw:
Three-button Solaris LED
reector (any color)
Six-button Solaris LED
reector (any color)
Trafc Clearing Light: 4.3 A
Halogen Worklight: 4.0 A
Stop/Tail/Turn Light: 0.32 A
Voltage: 12 Vdc
Cable Length: 15 ft (457.2 cm)
Shipping Weight:
JLX 48" 32.0 lb (14.5 kg)
JLX 54" 33.5 lb (14.2 kg)
JLX 60" 35.0 lb (16.3 kg)
JLX 72" 38.0 lb (17.2 kg)
Approvals: NFPA 1901 compliant models are available.
0.5 A
1.0 A
SAE J1318, J595, and J845 Class 1
Chapter 2: An Overview of the JLX JetSolaris
Unpacking the Product
After unpacking the product, examine it for damage that may have occurred in transit. If the
product has been damaged, le a claim immediately with the carrier stating the extent of
damage. Carefully check all envelopes, shipping labels, and tags before removing or destroying
them.
Before You Begin
AIRBAG DEPLOYMENT
Locate the controls for the light system so that the vehicle and control can be operated
safely under all driving conditions.
Failure to heed this precaution could result in driver distraction or driver error while
operating the vehicle.
Before you begin, ensure that the lightbar has been installed on the vehicle roof according to the
instructions included with the mounting kit. An installer-supplied control head controls the basic
functions of the lightbar.
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