Star Headlight & Lantern 200ADHL User Manual

INSTALLATION AND INSTRUCTION MANUAL

200AHL and 200AH8L Series 360° LED Lights

(4-LED Non-Rotating) (8-LED Rotating)

Please Note: These instructions are provided as a general guideline only. Specific mounting, wiring, and/

or weather-sealing may be necessary and are the sole responsibility of the installer. Star Headlight &
Lantern Co., Inc. assumes no responsibility for the integrity of the installation for this or any of its products.

featuring the

These lights are standard negative ground. Isolated or floating units for
positive ground vehicles are clearly labeled and are available upon request.
In this case connect the power to the proper polarity as marked on the wires.

CAUTION: All of our DC powered warning lights are polarity sensitive.
These lights are polarity protected only if the appropriate fuse is used.
All wires connected to the positive terminal of the battery should be
fused at the battery for their rated load. Testing the light before this

fuse is properly installed will void the warranty on the light.

PLIT447 REV. B 6/15/12

Toggle Wing Mounted Models

1. Your new warning light comes complete with a rubber mounting gasket, 2 toggle wings,
2 threaded rods, 2 neoprene washers, 2 steel washers, 2 nuts, and 2 self-locking nuts.

2. Mark two mounting holes on
7” centers and mark a spot

5

" DIA.

8

for the wire hole centered
directly between them.

7" CENTERS

3. Drill a 5/8" hole in the outer two marked locations. Then drill a 3/8" hole in the center
marked location for your wires to run through. CAUTION: Take care not to drill through
the headliner of the vehicle.

NUT

STEEL WASHER

RUBBER WASHER

THREADED ROD

4. Attach the rubber mounting gasket
around the base of the light.

5. Carefully remove the lens by
removing the three screws at the base
of the lens. Lift off the lens and
remove it taking care to ensure you do
not lose or destroy the lens gasket.

6. Attach a toggle wing to one end of one

of each of the threaded rods.

7. Place the rubber and steel washers

around each of the threaded rods
according to the diagram to the left.

Screw toggle wing

and threaded rod

together

TOGGLE WING

one steel washer, and

one nut on each rod

8. Then push the toggle wing through the top of one of the outer holes in the mounting
surface until it opens under the mounting surface.

3

" DIA.

8

5

" DIA.

8

Insert the threaded rod

and toggle wing

through the mounting

surface

MOUNTING SURFACE

Route wires through center hole, slide

light over rods, and secure with nuts

Tighten the nut,

securing the rod in

place

9. Tighten the nut down such
that it seats the steel washer
firmly against the rubber
washer, and the mounting
surface, holding the rod in
place. Repeat this for each
threaded rod.

10. Route the wires through the center hole, align
the outer holes in the base with the threaded
rods and slide the base onto the rods.

11. Fasten one of the
self-locking nuts to
each of the threaded
rods and tighten
until snug.

12. Once all of the nuts are tight and the base is
secure, reattach the outer lens(es).

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SELF -LO CKI NG NUT

BASE

MOUNT ING

GAS KET

MOUN TING

SURF ACE

Plastic Base Mounted Models

Remove the 4 screws in the
side of the Aluminum housing
and slide the plastic base out

Gasket

Plastic Mounting Base

3 Locate the various knockouts on the bottom

of the base and determine which mounting
holes will work best for your application.
Clear the knockouts using a punch or other
appropriate tool.

4. Using the plastic mounting base as a
template, mark the appropriate holes on the
mounting surface. Take care to ensure that
the base does not move while you are
marking each of the holes.

1. Remove the four screws in the side
of the aluminum housing.

2. Slide the plastic base out of the
aluminum case. Take care not to
damage the gasket when separating
the plastic base from the aluminum
case.

0.196" Diameter

on 2.975" Radius

3 @ 120°

0.264" Diameter
on 2.5" Radius

2 @ 180°

101-AP

0.261" Diameter

on 3.125" Radius

3 @ 120°

1" NPT THREADED

PIPE MOUNT

0.189" Diameter
on 1.75" Radius

2 @ 180°

5. Remove the plastic mounting base and drill a 3/8" hole in the marked locations. Then, if
applicable, drill a 3/8" hole for the wires in the center of the outer holes.

CAUTION: Take care not to drill through the headliner of the vehicle below.

6. Push the enclosed rubber well nuts through the outer holes until the
bottom side of the wider lip rests on the surface of the vehicle.

7. Route the wires through the center hole, if applicable and align the holes with the well
nuts. Install the screws through the base, into the well nuts, and tighten until snug.

8. Once the plastic mounting base is installed on the vehicle, you may replace the light on

the base and reinstall the four screws that affix the light to the plastic mounting base.

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