Star Headlight & Lantern 5600 User Manual

INSTALLATION AND INSTRUCTION MANUAL

SABRE

SABRE

SABRESABRE

LIGHTBARS

LIGHTBARS

LIGHTBARSLIGHTBARS

Owner's Manual & Installation Instructions

Owner's Manual & Installation Instructions

Owner's Manual & Installation InstructionsOwner's Manual & Installation Instructions

PLITSTR325 REV F 8/4/11

!

When mounting your lightbar, please be sure to keep any radio frequency
sensitive equipment at least 20” from the bar and power cable(s). This is
especially critical in lightbars utilizing strobes. Our strobe power supplies
have been designed to limit RFI emissions, but certain very sensitive
equipment may still be affected. Symptoms may include, but are not
limited to, sporadic operation and degraded performance. Star Headlight
& Lantern Co., Inc. cannot assume any responsibility for any radio
frequency induced malfunction or damage to any radios, sirens, lightbars,
or any other equipment mounted within 20” of a strobe lightbar. Any
antennae mounted in the proximity of the lightbar may cause your radio to
suffer the aforementioned results.

PLEASE NOTE: THE DIRECT MOUNT IS THE
STANDARD MOUNT INCLUDED WITH THE LIGHTBAR.
THE HOOK MOUNTS MUST BE USED ON ALL POLICE
AND/OR OTHER EMERGENCY VEHICLES!!!
THE HOOK MOUNTS ARE SOLD SEPARATELY. THEY
ARE NOT INCLUDED WITH EACH LIGHTBAR. THEY
MUST BE ORDERED SEPARATELY. SEE THE
ACCOMPANYING HOOK MOUNT MANUAL FOR A
COMPLETE LIST OF AVAILABLE MOUNTS AND
KNOWN VEHICLE APPLICATIONS.

I

t is the sole responsibility of the owner to ensure the lightbar is
mounted securely. Check your light every time you enter the
vehicle to ensure that it is mounted securely. The manufacturer
assumes no responsibility for the secure mounting of this light.

-i-

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.

WARNINGS i

QUICK-INSTALL WIRING GUIDE 1-2

Table of Contents

MOUNTING INSTRUCTIONS 3

(For Mounting see Mounting Bracket Manual)

WIRING INSTRUCTIONS 3-10

Direct Wiring Guide 3-4
Electrical Connections 5
Wire Functions 6
Strobe Power Supply Connections 7-10

PATTERN PROGRAMMING 11-14

Strobe Pack Flash Patterns 11
LED Flash Patterns 12-14

PARTS 15-17

SWITCHES 17

TROUBLESHOOTING 18-20

WARRANTY 21

SERVICE 21

Due to continuous product improvements, we must reserve the right to change any specifications and information,
contained in this manual at any time without notice. Star Headlight & Lantern Co., Inc. makes no warranty of any
kind with regard to this manual, including, but not limited to, the implied warranties of merchantability and fitness
for a particular purpose. Star Headlight & Lantern Co., Inc. shall not be liable for errors contained herein or for
incidental or consequential damages in connection with the furnishing, performance, or use of this manual.

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NOTICE

Terminal

Terminal

Terminal

Terminal

Terminal Terminal

Block

Block

BlockB lock

A

P271-RAZOR

B

CONNECTED

Wire Harness for Bars Without Stop/Tail/Turn Lights

P271-TOWBAR Layout 1

CONNECTED

Terminal

Terminal

Terminal Terminal

Wire Harness for Bars with Incandescent STT Lights

Block

Block

BlockBlock

QUICK-INSTALL WIRING GUIDE

P271-TOWBAR Layout 2

Wire Harness for Bars With LED STT Lights

Please Note: If your lightbar has an LED or incandescent traffic director in it, there will also be a separate bundled 9-conductor cable specifically for that function.

CONNECTED

TerminalTerminal

TO BASE

Terminal

Terminal

TerminalTerminal

Block

Block

BlockB lock

1

2

3

4

5

6

7

8

9

10

11

12

13

14

TO BASE

Terminal

Terminal

TerminalTerminal

A

B

TO BASE

Color AWG Function

1

Blue 18 Driver side Alley

2

White w/Blue 18 Intersection Clearing Lights

3

White w/Yellow 18 Front Corner

4

Orange w/Yellow 18 Front Outboard

5

Brown w/Yellow 22 Front Inboard and Ends

6

Red 14 Power

7

Red w/Green 22 Pattern Select

8

Purple 22 High/Low Power (Ground for Low)

9

Green w/Yellow 18 Lower Level Takedowns

10

Red w/Black 18 Upper Level Takedowns or AUX

11

White w/Brown 18 Front Pursuit

12

Green w/Red 18 Rear Center or TD Warn

13

Brown w/Red 22 Rear Inboard or TD Left

12

Orange w/Red 22 Rear Outboard or TD Right

1

White w/Red 18 Rear Corner (rear ICL)

2

Yellow w/Black 18 Cruise

3

White w/Black 18 Alley w/Flash

4

Gray 18 Passenger Alley

Black 10 Ground (Battery Negative)

Bare 18 Shield/Drain (Battery Negative)

Color AWG Function

Light Blue 16 Driver Side Alley Light

Orange 14 Rotators

Yellow 16 Left Stop Light

Green 16 Right Stop Light

White/Orange 14 Work Lights

Brown

Red 14 Strobe Power

Red/White 14 Power for Optional Components

Red/Green 22 Strobe Pattern Select

Black/Green 22 Strobe Head Select 1

White/Green 22 Strobe Head Select 2

Gray 16 Passenger Side Alley Light

Black 10

Bare 18

Color AWG Function

1 OPEN OPEN

2 OPEN OPEN

3 OPEN OPEN

4 Blue OPEN or Driver Alley or Steady Burn Alley

5 Orange 16 Front LEDs

6 W hite w/Orange 14 Rear Work Lights

7 Red 14 Power

8 Red w/White 14 Rear LEDs

9 Red w/Green 22 Pattern Select

10 Black w/Green 22 Strobe Control 1 or OPEN

11 W hite w/Green 22 Strobe Control 2 or OPEN

12 Gray 16 OPEN or Passenger Alley

1 Yellow 16 Left ( Driver) Turn Signal

2 Di ode Red 6” Wire

3 OPEN OPEN

4 Green 16 Right (Passenger) Turn Signal

5 Di ode Red 6” Wire

6 OPEN OPEN

7 Brown 18 Tail Lights

8 Diode Red 6” Wire/Power

BLACK 10 Ground (Battery Negative)

BARE 18 Shield/Drain (Battery Negative)

18 Tail Lights/I.D. Lights

OPEN

Ground (Battery Negative)

Shield/Drain (Battery Negative)

-1-

Wire Harness for Bars With Rotators

Wire Harness for Bars with Strobe Lights

P271-ROTATOR

CONNECTED

P271-STROBE

CONNECTED

Terminal

Terminal

TerminalTerminal

1

2

3

4

5

6

7

8

9

10

11

12

TO BASE

Terminal

Terminal

TerminalTerminal

Block

Block

BlockBlock

1

2

3

4

5

6

7

8

9

10

11

12

13

14

TO BASE

COLOR

COLOR AWG

COLORCOLOR

Blue 16 Driver Side Alley

White w/Brown 16 Front Flashers

White w/Blue 18 Intersection Clearing Lights

Green w/Yellow 14 Front Takedown/Worklights

Red w/Green 22 Pattern Select or OPEN

Orange 14 Rotators

Red w/White 14 Alternate Power

Orange w/Black 14 Alternate Rotators

White 16 Rear Flashers

Orange w/Red 16 Alternate Rear Flasher

Gray 16 Passenger Side Alley

Black 10 Ground (Battery Negative)

Bare 18 Shield/Drain (Battery Negative)

Color AWG Function

Light Blue 16 Driver Side Alley Light

White w/Brown 16 Pursuit

White w/Blue 18 Intersection Clearing

Green w/Yellow 14 Takedowns

Red 14 LED Power

Red w/Black 14 Driver Side or Lower Front Pattern

Red/White 14 Synchronization

Red/Green 22 Passenger Side or Lower Front Pattern

Black/Green 22 Rear Enable

White/Green 22 F ront Enable

Orange 14 OPEN

White 16 Rear Flasher

Orange w/Red 16 High/Low Power

Gray 16 Passenger Side Alley Light

Black 10

Bare 18

AWG

AWGAWG

FUNCTION

FUNCTION

FUNCTIONFUNCTION

Ground (Battery Negative)

Shield/Drain (Battery Negative)

QUICK-INSTALL WIRING GUIDE

Please Note: If your lightbar has an LED or incandescent traffic director in it, there will also be a separate bundled 9-conductor cable specifically for that function.

-2-

Mounting Instructions

Please review the separate Mounting Bracket manual that
is also enclosed with your bar for mounting instructions.

Wiring Instructions

All standard lightbar models are designed for 12VDC negative ground vehicles
only. Reverse polarity will cause serious damage to the lightbar and/or vehicle.

Contact the automotive dealer if there are any doubts about the polarity of your vehicle.

Direct Wiring Guide

PLEASE NOTE: If you are using the existing 15-foot cable supplied with the lightbar,

If the wire supplied is too short, Star recommends direct wiring to the terminal block on

the inside of the lightbar, rather than making connections to the end of the wire that is
supplied. This lightbar is designed so that no wire connectors are needed and only a few
common tools are necessary in order to do this. Direct wiring allows the wire connections
to the lightbar to be made in a clean and dry environment, avoiding any problems that may
arise due to weathering on external connections. There is also an increase in voltage loss
with the addition of each connection. Wiring directly inside the lightbar reduces the number
of connections. However, making connections to the wires already provided is an
acceptable alternative, as long as these connections are good electrical connections and
are resistant from weathering effects. For direct wiring into the lightbar, follow the
instructions listed below.

you may skip to the Electrical Connections section on page 4.

1. Determine the number of wires that you will need to run. This can be done by counting
the number of wires coming out of your lightbar.

2. Using the Wire Usage Table on page 10, identify your wires and select appropriate wire
sizes and colors.

3. Locate the end of the lightbar that has
the external wires entering the base of
the lightbar. The black terminal block
(s), which you will be making your
wire terminations to, should also be
located at this same end.

4. Remove the dome lens at this
end of the lightbar:

Step 1 : Loosen the four screws

holding each dome on.

Step 1

Step

2

Step 2 : Lift the dome off of the base,

exposing the interior
components.

Step 3 : When all work is completed,

reverse the steps to reinstall
the dome, taking care that
the gasket is properly
aligned.

-3-

(Direct Wiring Guide CONT’D)

5. All of the wires coming from outside of the lightbar are terminated on the same side of
the terminal block and the wires leading to the internal components terminate on the
opposite side of the terminal block. Loosen the screws on the terminal block and
remove only those wires that exit the lightbar through the hole in the base. There
may be “dead” wires from the harness connected to the terminal block inside your
lightbar, but there will be no wires connected to the terminal across from them. These
are extra wires in the harness that are not used. Replacing these wires in your new
harness is not necessary.

From Lightbar Components

From Wire Harness

These

Remove

6. Run the new external wires up through the wire bushing into the base and into the
terminal block(s). The function of each of the colored wires in the original wiring harness
is listed in the Wire Harness Usage Table on page 1. There should also be a label next
to the terminal block indicating which color wire should be connected to each terminal.

7. Strip each wire 1/4". Connect the external wires to the proper poles of the terminal
block by inserting the stripped portion of the wire under the rising clamp screw and
tightening down the screw. No wire terminals are needed for connecting wires to this
terminal block.

Be sure to check that no strands of wire are loose and shorting to the
adjacent terminal or to the base of the lightbar.

The correct wire size and color listed in the table on page 1 corresponds directly with the
wiring of the lightbar. All switches used should be rated for at least 125% of their rated load.

8. Once your new wire harness has been connected to the lightbar, you may continue to

the Electrical Connections section.

-4-

Electrical Connections

All standard lightbar models are designed for 12VDC negative ground vehicles
only. Reverse polarity will cause serious damage to the lightbar and/or vehicle.

Contact the automotive dealer if there are any doubts about the polarity of your vehicle.

RF INTERFERENCE

Please take the following steps to help eliminate any Radio Frequency Interference (RFI)
with your two-way radio.

• DO NOT run the power wire for the lightbar along same path as any antenna wires.

• DO NOT run the power wire for the lightbar along same path as any radio power wires.

• DO NOT tap power for the lightbar off of the radio power wires.

• DO NOT mount the lightbar within 20” of any antennae. Sometimes mounting the

lightbar or antenna over by just one foot can make a large difference in the interference.

• Ensure the black wire from the lightbar has a good connection to the negative side of
the battery.

• For all standard lightbars, 15 feet of cable (usually including a drain wire and a foil shield)
is supplied with the bar. All wires are color coded and sized at the correct gauge. If this
length is not sufficient, it is recommended that the wire harness be completely replaced
with the only connections to be made directly at the terminal block inside the lightbar.
This will reduce the number of wire connections and help prevent any weathering
problems on these connections. Refer to the Direct Wiring Guide on pages 3-4 for further
instructions on this.

• CAUTION: All wires and switches should be rated for at least 125% of their
maximum current load. In addition, all wires connected to the positive terminal of the

battery should be fused at the battery for 125% of their rated load. The load can be
calculated by adding all lamp wattages and dividing by 13. (Load <Amps> = Total
Watts / 13 volts) Do not use 1/4" diameter glass fuses, as they are not suitable for
continuous duty above 20 amps. A table of recommended wire colors and wire sizes is
provided on page 1. If you are unsure of the current draw, please contact our Customer
Service Department.

• TESTING THE LIGHTBAR BEFORE IT IS PROPERLY FUSED & INSTALLED WILL
VOID THE WARRANTY!!

• The black ground wire should be connected to the negative terminal of your vehicle’s
battery. This wire should be at least #10 AWG wire and be as short as possible in order
to minimize the voltage loss in this wire and reduce any chance of overheating.

• Since many of the lightbars we build have custom components, occasionally wire colors
may slightly vary. If you are unsure of the function of a particular wire, you may test the
function by grounding the black wire and applying +12VDC to the wire in question. Be
sure to use a 20-amp fuse when testing.

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