Star Headlight & Lantern 400B User Manual

INSTALLATION INSTRUCTIONS

20, 200, 240, 241, 400B, & 450B SERIES

20ZI & 200Z

SERIES

241S SERIES

21ZI & 201Z

SERIES

240S SERIES

200S

SERIES

20FI, 20RH, 20RI, 200J,

& 200U SERIES

240C and, 240A

SERIES

241SF SERIES

450BH SERIES

240SF/240ZF SERIES

400B SERIES 200B SERIES

240CF and 240AF

SERIES

PLITSTR43 REV. N 2/3/10

PERMANENT MOUNT INSTALLATION INSTRUCTIONS

Your new warning light comes complete with a foam mounting gasket, mounting screws, lock

Take

outer holes

The black or white wire is the ground lead and should be connected to a good chassis ground.

for all models

Leave the purple wire unconnected and place a wirenut

IMPORTANT: Please read all of the following instructions before installing your new light.

1. 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.

2.
washers, and well nuts.

3. For any models utilizing a flange mount base, please skip to Step 6.

4. The 20 Series, 200 Series, and the 240 Series Star warning lights come equipped with a
combination base, allowing the light to be either mounted on a 1/2" NPT conduit pipe or
permanently mounted. For NPT pipe, mount the light using the threaded entrance hole in the
base of the light, then skip to Step 11. For the permanent mount, proceed to Step 5.

5. Carefully remove either the clamp ring or the three or four screws near the base of the lens
and lift off the lens. Examine the inside of the base and use a punch or drill to remove the
knock-outs present.

200B and 400B: If you wish to mount the 200B or 400B through the base, you will need to

drill the three 3/8” mounting holes in the base. Use the gasket as a template to mark the
locations in the base, then drill the holes.

6. Next, you will need to drill the holes in your mounting surface. Place the gasket in the exact
position the light is to be mounted, and mark the holes on the mounting surface. (NOTE: You
might have to stretch the gasket slightly to find the location of the holes in the gasket.)
care to ensure that the gasket does not move while you are marking each of the holes. Be
sure to mark the center hole if you will be running your wires through the mounting surface.

7. Remove the gasket and drill your holes using an appropriate 3/8" drill bit.

CAUTION: If you are mounting the light on a vehicle, and plan to wire it through the roof of

the vehicle, remove the headliner from the inside of the vehicle. If you do not remove the
headliner, take care so that you do not drill through it.

8. After the holes have been drilled, push the enclosed rubber well nuts through the
until the bottom side of the wider lip rests on the surface of the vehicle.

9. Place the light on the surface of the vehicle, routing the wires through the center hole, if
applicable.

10. To secure the light to your mounting surface, align the holes with the well nuts. Install the
screws through the base, into the well nuts, and tighten until snug.

11.

12. Connect the red wire to the positive side of the power through either a single-pole, two­position switch for normal operation, or a two-switch switch-panel for High/Low operation
(High/Low option available only on models with three wires). Use a 5 amp fuse
except for the 400B, which will use a 10 amp fuse. Check the label on the warning light for
proper voltage. If your light has only two wires then you are finished and may skip the
remaining steps.

13. If your light has three wires (red, black, and purple) you need to decide how you would like
the light to operate:
To utilize the High/Low option: Skip to Step 14.

For low power only:

over the end. Skip the remaining step.

For high power only: Connect the purple wire to the good chassis ground.

Skip the remaining step.

14. If you intend to make use of the High/Low option through a switch, refer to the wiring
diagram on the following page for proper connections using a two-switch switch panel
available from Star.