Page 1
INSTALLATION AND INSTRUCTION MANUAL
TM
Aerostar
Aerostar
Aerostar Aerostar
PLITSTR335 REV. G 8/16/12
Page 2
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
Table of Contents
MOUNTING INSTRUCTIONS 2
(For Mounting see Mounting Bracket Manual)
WIRING INSTRUCTIONS 2-9
Wire Harness Replacement 2-3
Electrical Connections 4
Remote Power Supply Connections for Linear Strobe Heads 5-8
STROBE PATTERN PROGRAMMING 8
LED PATTERN PROGRAMMING 9-10
TROUBLESHOOTING 11-14
PARTS 15-17
SWITCHES 18
WARRANTY 18
SERVICE 18
NOTICE
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.
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.
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.
-i-
Page 3
QUICK-INSTALL WIRING GUIDE
All lightbars are shipped with a Wire Harness Assembly Checklist that is unique to your bar and will
define what each wire controls. You can also use the chart below for general reference.
Please note: Depending upon the components in your lightbar, the wire colors used in your
harness may differ slightly from the chart below.
Wire Harness Usage Chart
LIGHT(S) WIRE COLOR AWG
Connect to Negative Side of Battery
-12 VDC /Ground/Neutral Black 10
Connect to +12VDC
Rotating Halogen Lights Orange 14
Secondary Rotator Orange w/Black Stripe 14
360° Strobe, 360° Halo, or Strobe Power Pack* Red 14
Front Strobe Heads On/Off
Rear Strobe Heads On/Off
Pattern Select (Strobe and/or LED)‡ Red w/Green Stripe 22
Alternate Strobe Pack PWR Red w/Black Stripe 14
LED Flasher Power
LED High/Low Control Purple 18
Front Take-Down/Work Lights Green w/Yellow Stripe 14
Rear Floods/Work Lights White w/Orange Stripe 14
Front Alternating Flashers White w/Brown Stripe 16
Rear Alternating Flashers White 16
Driver’s Side Alley Light Blue 16
Passenger Side Alley Light Gray 16
Left Turn Signal Yellow 16
Right Turn Signal Green 16
Tail Lights & ID Marker Lights Brown 18
Intersection Clearing Lights White w/Blue Stripe 18
Alternate Power Red w/White Stripe 14
Traffic Director † †
‡ Please note: If you have a lightbar with a strobe pack or LED flasher, the
(4-Head Packs Only)
(4-Head Packs Only)
(LDF369 or LDF398)
* White w/Green Stripe 22
* Black w/Green Stripe 22
Orange w/Red Stripe 16
* See Remote Strobe Power Supply Connection section on pages 5-8
‡
See Pattern Programming section on page 9-11
†
Separate Bundled 9-Conductor Cable
Red w/Green Stripe wire is only used when programming the flash pattern.
This wire MUST NOT be connected to continuous +12VDC!!! Once the
pattern has been selected, tape the end of this wire off. (See page 10)
)
)
)
)
Minimum
Please find to the right a
sample of the terminal
block, showing the
correct wire colors from
a lightbar using the
271STROBE cable.
)
CTRL Power Plug
PWR Plug Strobe Pack 1
PWR Plug Strobe Pack 2
CTRL Plug
(
White w/Brown
White w/Blue
Blue
Blue
Green w/Yellow
White w/Blue
White w/Brown
Green w/Yellow
Red w/White
Red
Red (
Red (
Red
Red w/Black
Red w/White
Red w/Green
CTRL Power Plug
To Lightbar Components
White (
Black (
From Wire Harness
Black w/Green
White w/Green
)
LED Flasher
White
Orange
Orange
Gray
Black
Red (
White
Orange w/Red
Bare
Bare
Gray
Black
-1-
Page 4
Mounting Instructions
Please review the separate Mounting Bracket manual that
is also enclosed with your bar for mounting instructions.
Wiring Instructions
PLEASE NOTE: If you are using the existing 15-foot cable supplied with the lightbar,
you may skip to the Electrical Connections section on page 4.
Wire Harness Replacement
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.
1. Use the Wire Usage Table shown on page 1 to determine how many wires you will need
to run.
2. After identifying the necessary wires, 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 outer dome to
expose the terminal block.
Step 1 : Remove the
two screws
holding the
endcap to the
lightbar base.
Step 2 : Loosen the two screws that
are holding the dome to the
center divider section.
Step 3 : Slide the dome (with the attached
endcap) off the end of the base,
exposing the interior components.
Step 4 : When all work is completed, reverse the steps to reinstall
the dome, taking care that the gasket is properly aligned.
Step 2
Step 3
-2-
Page 5
(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.
-3-
Page 6
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.
Use the Wire Harness Usage Table on page 1 to identify the wire colors
and connect the appropriate wires to your switches supplying +12VDC.
• For all standard lightbars, 15 feet of cable 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 Wire Harness Replacement section on pages 2-3 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.
• The Wire Harness Usage Table on page 1 lists the different wire colors and lights
controlled by those wires. Your harness may contain unused wires. The “dead” wires in
the harness will be connected to the terminal block inside your lightbar, but there will be
no wires connected to the terminal across from them. These “dead” wires can be used
for additional components that may be added at some point in the future, or they may be
used to separately switch components that are currently wired together.
• 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.
-4-
Page 7
Remote Strobe Power Supply Connections For Linear Strobe Heads
If your lightbar DOES NOT contain linear strobe heads, you can skip to page 10.
If your lightbar contains linear strobe heads, follow the instructions on pages 5-9 for proper
wiring of the strobe power supply. Please note that any additional lights in your lightbar
must also be connected to +12VDC through a switch. This section only discusses the
proper wiring of the strobe power supplies. For each strobe head configuration, you will be
shown two ways to wire the lightbar:
Four wires in your cable harness control the strobe power supply and the strobe heads connected
to it. The functions of those wires are as follows:
Red - Power to the strobe power supply
White w/Green Stripe - On/Off control for Front Linear Strobe Heads
Black w/Green Stripe - On/Off control for Rear Linear Strobe Heads
Red w/Green Stripe - Pattern Select
Activating All Strobe Heads Together
(MOST APPLICATIONS)
To turn on all four heads connected to the power supply together, connect the Red, White w/
Green Stripe, and Black w/Green Stripe wires together through your switch. When the
switch is thrown, all of your strobes will flash. (#1 & #4 will alternate with #2 & #3)
1. All strobe heads turn On and Off together
2. Separate activation of Front and Rear facing strobe heads
Lightbars with Two or Four Linear Strobe Heads
3
(Pictured above is one example of a bar with four linear strobe heads)
Connect to +12VDC
Touch and release to +12VDC
Harness from
Lightbar
24
1
Red
White w/Green
On/Off
SWITCH
CONNECT
TO +12 VDC
Black w/Green
Touch and Release To
Red w/Green
+12VDC to Change Pattern
DO NOT PERMANENTLY
CONNECT Red w/Green
!
Stripe TO +12VDC!!!
Proceed to the Pattern Selection section on page 10 to program the flash pattern of your strobe
pack.
-5-
Page 8
Lightbars with Two or Four Linear Strobe Heads (cont'd)
4
3
Activating the Front and Rear Strobes Separately
If you would like the ability to switch the Front Strobes On and Off separate from the Rear
Strobes, connect the White w/Green Stripe wire to the switch that will activate your Front
Strobes, and connect the Black w/Green Stripe wire to the switch that will activate your Rear
Strobes.
The Red wire must be connected to constant +12VDC.
Please Note:
(Pictured above is one example of a bar with four linear strobe heads)
When the red wire is connected to +12VDC the pack will draw a small
current (50 mA). If your vehicle will be sitting for extended periods of time
(i.e. more than a few days), it is recommended this wire be routed through a
switch.
Harness from
Lightbar
Front Strobes
On/Off Switch
White w/Green
Rear Strobes
On/Off Switch
Black w/Green
2
1
CONNECT
TO +12 VDC
CONNECT
TO +12 VDC
Red
Please Note: When the Red wire is connected to +12VDC the pack will
draw a small current (50 mA). If your vehicle will be sitting for extended
periods of time (i.e. more than a few days), it is recommended the Red wire
be routed through a switch.
CONNECT TO CONSTANT +12 VDC
Touch and Release To
Red w/Green
+12VDC to Change Pattern
DO NOT PERMANENTLY CONNECT Red
!
Note: If you have power to both White w/Green and Black w/Green, #1 & #4 will flash together
alternating with #2 & #3. For two outlet packs, the two heads will alternate.
Proceed to the Pattern Selection section on page 10 to program the flash pattern of your strobe
pack.
w/Green Stripe TO +12VDC!!!
-6-
Page 9
Lightbars with Eight Linear Strobe Heads
4A
3A
2A
1A
PACK A
4B
(Pictured above is one example of a bar with 8 linear strobe heads)
3B
PACK B
2B
1B
Three wires in your cable harness control the strobe power supplies and the strobe heads
connected to them. The functions of those wires are as follows:
Connect to +12VDC
Red - Front Linear Strobe Heads On/Off
Red w/Black Stripe - Rear Linear Strobe Heads On/Off
Red w/Green Stripe - Pattern Select
Note: Heads #1 & #4 will flash together alternating with #2 & #3.
Touch and release to +12VDC
Activating All Strobe Heads Together
(MOST APPLICATIONS)
To turn on all eight heads
connected to both power
supplies together, connect the
Red and Red w/Black Stripe
wires together through your
On/Off switch. When the
switch is thrown, all of your
strobes will flash. (#1 & #4 will
alternate with #2 & #3)
Proceed to the Pattern
Selection section on page 10
to program the flash pattern of
your strobe packs.
Activating Front and Rear Strobes Separately
To turn on your front strobe
Harness from
Lightbar
Red
Red w/Black
Red w/Green
Harness from
Lightbar
20 Amp
On/Off
SWITCH
Touch and Release To
+12VDC to Change Pattern
DO NOT PERMANENTLY
CONNECT Red w/Green
!
Stripe TO +12VDC!!!
CONNECT
TO +12 VDC
separately from your rear
strobes, connect the Red and
Red w/Black Stripe wires
through two separate
Red
Front Strobes
On/Off Switch
CONNECT
TO +12 VDC
switches. When one switch is
thrown, only the front strobes
will flash. (#1 & #4 will
alternate with #2 & #3). When
Red w/Black
Rear Strobes
On/Off Switch
CONNECT
TO +12 VDC
the other switch is thrown the
rear strobes will flash.
Proceed to the Pattern Selection
section on page 10 to program
the flash pattern of your strobe
pack.
Red w/Green
!
Touch and Release To
+12VDC to Change Pattern
DO NOT PERMANENTLY
CONNECT Red w/Green
Stripe TO +12VDC!!!
-7-
Page 10
(Remote Strobe Power Supply Connections For Linear Strobe Heads cont’d)
Automatic Power Up Head Check
Your new power pack comes with a safety feature which checks for proper operation of
each individual strobe head each time you turn on the strobe pack. This feature works by
quickly flashing each head once separately and determining if any of the heads did not
flash. If two heads normally flash together and one should fail and does not flash during the
start up test, the strobe pack will automatically reduce the output power to that particular
side so that the “other” remaining head(s) isn’t over powered. The power to that side will be
cut in half until the strobe pack is turned off and on again.
The strobe pack will check all of the heads each time the pack is turned on EVEN if the
head select feature is being used and only two heads are to be activated. After checking all
of the heads, the pack will begin flashing normally. It takes approximately 0.250 sec. to
check all of the heads.
Note:
If you replace the non-working head, it is necessary to cycle power to the pack
before that head and the one that flashes with it will start flashing again at full power.
Strobe Pattern Programming
Linear Strobe Pattern Selection
1. Activate the strobe heads (if they are in your bar) by applying power to the appropriate wire (s)
(usually Red wire).
2. Briefly touch the Red w/Green stripe wire to +12VDC and release it, repeating this to scroll
through the patterns listed below. The cycle will repeat itself after the last pattern.
Five-Flash → Pseudo-Random → Singleflash → Doubleflash → Quadflash
3. Once you find the pattern you wish to select, leave the Pattern Select terminal
disconnected and turn the flasher off. This will store the selected pattern into the
memory.
Please note:
Green Stripe
If you have a lightbar with a strobe pack, the
Red w/
wire is only used when programming the strobe
pack flash pattern. This wire MUST NOT be connected to
continuous +12VDC. Once the pattern has been selected, tape
the end of this wire off.
-8-
Page 11
LED Pattern Programming
LEDs in your lightbar are programmed using the Red w/Green stripe wire. If you have LEDs
controlled by an external flasher (LDF369 or LDF398), the pattern will be sett by touching the Red
w/Green wire to +12VDC. If you have Halo 360º LEDs, you will set the pattern by touching the Red
w/Green wire to ground.
LED Pattern Selection for Remote LED Flashers
1. Power up the LED heads you wish to program by applying power to the appropriate wire (s)
(usually Orange w/Red Stripe for remote flashers).
2. Briefly touch the Red w/Green stripe wire to +12VDC and release it, repeating this to
scroll through the patterns listed below. The cycle will repeat itself after the last pattern.
3. Once you find the pattern you wish to select, leave the Pattern Select wire
disconnected and turn the LEDs off. This will store the selected pattern.
8-Terminal LDF369 Flash Patterns
1. Slow Warn
2. Alt. Doubleflash, Flicker
3. All Double, Alt. Pre-Pop Triple, Slow Warn
4. Alternating Doubleflash, Non-Synch
5. Alt. Triple, Alt. Pre-Pop Triple, Flicker *
6. Alt. Quad, Flicker, Alt. Double, Flicker
7. Alt. Pre-Pop Quint, Alt. Quint, Flicker
8. All Tripleflash
9. Alt. Quadflash w/Post Pop
10. All Quadflash w/Post Pop
11. Alt. Quintflash
12. One Side Steady/Other Side Singleflash †
13. Alt. Pre-Pop Quintflash
14. All Flicker
15. Alt. PSU Flicker
16. One Side Steady/Other Side Short-Long †
17. One Side Rapid Fire, Other Side Pop
* =
Default Pattern
† =
California Title 13 Approved w/Red Steady/Blue Flashing
NOTE: If at any time you would like to reset the pattern to the factory default (Pattern 28), simply
connect the Pattern Select wire to +12VDC for five seconds, then release it, and the default
pattern will be restored.
(touch Red w/Green to +12VDC)
18. Comet 1
19. Alt Long Singleflash (Medium W arn)
20. Alt. Short - Alt. Long
21. Slow Warn, Alt. Tripleflash
22. Slow Warn, Super Fast Warn
23. All Doubleflash, Alt. Doubleflash
24. All Double, Alt. Double, Flicker
25. Fast Warn
26. Superfast Warn
27. Warn Fade
28. Pre-Pop Warn
29. All Singleflash
30. Alt. Tripleflash
31. All Quintflash
32. One Side Pop, Other Side Rapid Fire
33. Comet 2
34. Delta Omega
35. Cycle All Patterns
20-Terminal LDF398 Flash Patterns
1 Pursuit Mode
2 Alternating Slow Single (1-5 vs 6-10)
3 Alternate Pursuit Mode
4 Alternating Quad Flash (1-5 vs 6-10)
5 Alternating Triple (1,2,6,7,8 vs 3,4,5,9,10)
6 Alternating Quint (1,2,6,7,8 vs 3,4,5,9,10)
7 Simultaneous Slow Single (All Modules)
8 Simultaneous Fast Single (All Modules)
9 Simultaneous Triple Flash (All Modules)
10 Simultaneous Quad Flash (All Modules)
11 Simultaneous Quint Flash (All Modules)
12 Simultaneous Fast Triple Flash (All Modules)
13 Simultaneous Fast Quint Flash (All Modules)
14 In/Out Single (1,2,9,10 vs 3-8)
15 In/Out Triple (1,2,9,10 vs 3-8)
(Default)
(touch Red w/Green to +12VDC)
16 In/Out Quint (1,2,9,10 vs 3-8)
17 In/Out Single (1,2,3,8,9,10 vs 4-7)
18 In/Out Triple (1,2,3,8,9,10 vs 4-7)
19 In/Out Quint (1,2,3,8,9,10 vs 4-7)
20 1-5 Steady; 6-10 Single Flash
21 1-5 Steady; 6-10 Slow Single Flash
22 6-10 Steady; 1-5 Single Flash
23 6-10 Steady; 1-5 Slow Single Flash
24 Sequential Back And Forth
25 Sequential In/Out
26 Burst All w/ Alternating Burst
27 Alternating Burst w/ Sim. Double Then Quint
28 Simultaneous Burst w/ Alt. Double Then Quint
29 Hyper-Random
30 Demo
(Cycle Through Patterns 1-4,6-9,13-20,25-29)
Please Note: At any time during the programming sequence, you can reset the flash pattern back to the
default mode (Pattern 1 – Pursuit) by holding the red w/green Pattern Select wire to
+12VDC for 5 seconds, then releasing it.
-9-
Page 12
(LED Pattern Programming cont’d)
LED Pattern Selection for 360º Halo Heads
1. Power up the LED heads..
(touch Red w/Green to ground)
2. Touch and release the Red w/Green stripe wire to ground to scroll through the patterns
listed below. The cycle will repeat itself after the last pattern.
3. Once you find the pattern you wish to select, leave the Pattern Select wire disconnected
and turn the LEDs off.
360º Halo™ Flash Patterns
(touch Red w/Green to ground)
Flash
Pattern #
Type
1 K Flicker † 1
2 L Fast Doubleflash 3.3
3 M Tripleflash † 2.5
N
4
A5
O
5
A6
6 F
7 G
8 H
9 I
10 J Variable AKA Delta-Omega 0.3
11 C Post pop 1.4CPS † 1.4
12 E Random 0.4CPS 0.4
NA Steady NA
† - Approved patterns for SAE J845
‡ - California Title 13
Pattern
Pattern Description CPS
PSU Flicker (Non-Rotating Models)
CCW Rotation 1 (Rotating Models) †
PSU Random (Non-Rotating Models)
CCW Rotation 2 (Rotating Models)
Quadflash †‡
Quadflash w/Post-Pop †‡
Singleflash †‡
Doubleflash †‡
Shortcuts
(Hold Red w/Green
wire to ground for:)
3 Sec
0.7
(Rotating Only)
1.3
0.6
2.7
1
1
1
1
(Non-Rot ating Only)
3 Sec
6 Sec
9 Sec
-10-
Page 13
Troubleshooting
If a light on your bar fails to work, please refer to this section to help solve your problem.
If you still cannot resolve your problem, please contact our
Department
The chart below contains some basic guidelines for troubleshooting any problems you may
experience with your bar. The section following the chart will explain in further detail how to
perform some of the troubleshooting tasks.
at 585-226-9787.
Customer Service
Symptom:
One rotator spins but won't
light up
One rotator does not spin and
does not light up
More than one rotator does
not spin and does not light up
One single LED light is Out LED Head needs to be replaced
One LED head does not flash Check wiring between LED head and flasher unit
Multiple LED heads not
flashing
One flashing light out
Multiple flashing lights out
One remote strobe head out Check the strobe head
Multiple strobe heads out
Check bulb
Check the power wire running between the rotator and the terminal
block
Check the ground wire on the rotator
Check power to terminal block
Check the ground
Possible Solutions
Check LED head
Check power to terminal block
Check that the bar is properly grounded
Check power from terminal block to LED flasher unit
Check that the LED flasher unit is grounded properly
Check bulb
Check power wire from flasher unit to bulb
Check that the bulb is grounded
Check power to terminal block
Check that the bar is properly grounded
Check power from terminal block to flasher unit
Check that the flasher unit is grounded properly
Check the cable from the remote pack to the strobe head
Check power to terminal block
Check power to strobe pack Power Outlet (PWR)
Check power to strobe pack Control wires (CTRL)
Check that the pack is properly grounded
Check that the Red w/Green stripe wire IS NOT connected to +12VDC.
-11-
Page 14
Determining if the bar is properly grounded:
1. While the bar is turned on, using a test meter, measure the voltage from the base of the bar
itself to the negative post of the battery or a good chassis ground if the battery can’t be easily
reached. You may need to scrape away a bit of anodizing or paint in order to ensure a good
connection with the probe of your test meter.
2. If the difference shown is greater than .25 volts, then your ground is not sufficient.
3. If the ground is insufficient, locate the ground wire connection in your lightbar by removing the
dome over the section where the wires enter the bar. Please follow the appropriate dome
removal instructions listed earlier in this manual when removing this dome. The ground wire is
the large (10AWG) black wire attached to the inside of the lightbar base with a ring terminal.
Check the integrity of the connection of the ground wire to both the lightbar base and at the
other end to a good chassis ground.
4. While inspecting the ground wire connections you should also check that the wire itself is not
damaged. Carefully inspect the wire along its entire length, paying special attention to those
areas where the wire passes through any holes that may have sharp edges that can damage
the wire and the areas where the wire makes any sharp bends.
Checking the power to the terminal block
(Determining if the proper voltage is reaching your bar):
1. Locate the terminal block in your lightbar
by removing the dome over the section
To Lightbar Components
where the wires enter the bar. Please
follow the appropriate dome removal
instructions listed earlier in this manual
when removing this dome. After entering
the bar, the wires will be connected to the
terminal block with a number of small
Phillips head screws.
2. With the bar turned on, use a test meter to test
From Wire Harness
the voltage at the terminal block. A nominal
12.5 volts should be present. Low voltage can
cause erratic flashing in strobe heads or even
complete failure of the heads. A minimum of
10.5 volts should be present for the pack to
Blue
White w/Brown
White w/Blue
Green w/Yellow
Red
Red w/Black
Red w/White
Red w/Green
Harness
Blue
White w/Brown
White w/Blue
Green w/Yellow
Red (
PWR Plug Strobe Pack 1
Red (
PWR Plug Strobe Pack 2
Red w/White
Red (
CTRL Plug
Components
From
Wire
Lightbar
)
To
operate properly. Low voltage in strobe lights,
flashing lights, or LEDs can result in lowered
intensity or even complete failure.
3. Be sure to test each wire that comes into the
terminal block for proper voltage.
4. Carefully inspect each wire in the terminal
block. Check that the ends of the wires
have not frayed and shorted against one
another or against the base. This may
Black w/Green
White w/Green
Orange
White
Orange w/Red
Gray
Black
Bare
Black (
White (
Orange
White
Red (
Gray
Black
Bare
CTRL Power Plug
CTRL Power Plug
LED Flasher
)
)
)
cause lights to operate inadvertently or
may result in the failure of lights.
(271STROBE Cable Shown)
)
)
-12-
Page 15
TROUBLESHOOTING GUIDE (cont’d)
Checking one non-working strobe or LED head:
If a problem exists in only one head
there may be an open electrical connection in the wiring harness or strobe head.
, a strobe tube or LED head may have burned out, or
1. Check connections at and between the strobe pack and the faulty strobe head or between
the flasher unit and LED head, including all wiring.
2. Disconnect both the faulty head and a working head.
3. Check the faulty head by connecting it into the side you just unplugged the working head
from. If the faulty head still does not work, then the head is bad and will need to be replaced.
4. If the head that was not flashing works when connected to the other side, the problem
probably lies in the power pack or flasher unit. Verify this by plugging the other head (the
original working head you just unplugged) into the side that previously had the non-working
head.
Checking multiple non-working strobe heads:
If the problem exists in only your strobe heads, and none of your strobe heads are
flashing, follow these steps to determine the problem:
1. Check all fuses, including those at the battery, at the switch panel, in the dash, and
on the pack (if applicable). The strobe power supplies all have automotive “blade”
type fuses. Remove these fuses, and check them to confirm they have not blown.
Replace any blown fuses with only fuses of identical values. Replacing the fuse with
the wrong rating may damage your pack and/or vehicle, and will void your warranty.
2. Check the power and ground wires to your pack. With the vehicle turned off and
while the pack is running, measure the voltage across the red wire (pin 1) and the
black wire (pin 2) of the
PWR
connector on the power pack (the one with the Black,
Black, and Purple wires). Push the probes of the test meter down into the connector
at the wire entry points to contact the terminals for the measurement. A nominal 12.5
volts should be present. Low voltage to the pack can cause erratic flashing or even
complete failure of the heads. A minimum of 10.5 volts should be present for the
pack to operate properly. If you do not have proper voltage present, your power or
ground is bad. Continue to step 3. If your pack is receiving sufficient voltage then
skip to step 5.
BLACK (GROUND)
RED (+12 VDC)
POWER
PURPLE (High/Low)
BLACK (GROUND)
BLACK (Power)
3. Test the Power to the power supply from the terminal block. If sufficient voltage
is not reaching the pack, and you have already determined that proper voltage is
reaching your terminal block, perform the following tests: With the vehicle turned off
and while the pack is running, measure the voltage drop in the red wire by taking a
reading from pin 1 of your Power connector (Red wire) and the corresponding wire on
the terminal block. If this reading exceeds 0.25 volts then there is a poor connection
between the terminal block and your power supply in the red wire and it should be
checked.
4. Check the Ground wire on the pack. If you still have not located the problem,
troubleshoot the connections between pin 2 (black wire) of the
PWR
connector on the
power pack and the lightbar base, while the lightbar is running. If this reading
exceeds 0.25 volts then there is a poor connection between the pack and the lightbar
base in the black wire and it should be checked.
-13-
Page 16
TROUBLESHOOTING GUIDE (cont’d)
5. Check that the proper voltage is reaching the necessary CTRL inputs. Check
that the proper voltage is reaching the Black wire (across from the Black w/Green
stripe wire on the Terminal Block) and White wire (across from the White w/Green
stripe wire on the Terminal block) of the
CTRL
plug on your strobe pack with the
vehicle turned off, and while the bar is running. Measure the voltage across the Black
wire (pin 2) on the CTRL plug
(NOT THE POWER PLUG)
and the negative terminal
of your battery. Push the probes of the test meter down into the connector at the wire
entry points on the pack side of the connectors to contact the terminals for the
measurement. Note this reading. A nominal 12.5 volts should be present. A
minimum of 10.5 volts should be present for the pack to operate properly. Also,
check the voltage on the White wire. If your pack is receiving sufficient voltage to
both wires then continue to step 6. If you do not have proper voltage present on
either wire, check the wiring to the connector.
WHITE
BLACK
RED
CONTROL
WHITE (Heads 2 & 4)
BLACK (Heads 1 & 3)
RED (Pattern Select)
6. Check the CTRL connector to be sure that +12VDC is not applied the Red wire.
The Red wire on the CTRL connector of the strobe pack is used for pattern select.
The patterns are changed by touching AND RELEASING this wire to +12VDC. A
constant voltage applied to the Red wire on the CTRL connector will prevent the
strobe pack from flashing.
7. Check each strobe head. If the leads in one of the heads have shorted out, the
output voltage of the other heads may be held down as well. To test for this, unplug
all of the heads and plug them in individually, one at a time. If your problem is a result
of a shorted head, then the other heads should function properly if the faulty head is
no longer connected. Note: A burned out strobe tube does not cause a short and will
not affect the operation of the remaining heads. If the problem is not with a shorted
head and if proper voltage is reaching the pack, the problem is most likely internal to
the pack.
8. If sufficient voltage is not reaching the pack perform the following tests: With the
vehicle turned off and while the pack is running, measure the battery voltage
battery
. A nominal 12.5 volts should exist. Note this voltage. If this voltage is below
at the
10.0 volts the pack will not function properly and the problem is with the battery. This
reading should not be more than 1-1.25 volts higher than the reading in the 4th step. If
there is an excessive difference then continue on to the next step.
9. With the vehicle not running and the lightbar on, measure the voltage in the red wire
by taking a reading from the positive side of the battery to pin 1 of your switch. If this
reading exceeds 0.25 volts then there is a poor connection between the switch and
the battery in the red wire and it should be checked.
10. If you still have not located the problem, troubleshoot the connections between the
good chassis ground and pin 2 (black or blue wire) of the
PWR
connector on the
power pack, while the lightbar is running. If this reading exceeds 0.25 volts then there
is a poor connection between the switch and the ground in the black wire and it should
be checked.
11. This same procedure can be used to check the wires between the terminal block and
the pack. Place one probe on the terminal at the terminal block and the other probe
into the terminal with the corresponding wire color in the connector on the pack. Once
again if any of the readings exceed 0.25 volts then you should check those wires and
their connections.
-14-
Page 17
Domes and Exterior Parts
620-12
(Support Baffle)
3
1
4
2
620-22-0*
31
2 4
620-22-134*
Full Domes
Full 20" Outer Dome
620-21-20-*
Full 24" Outer Dome
620-21-24-*
1 3
2 4
620-22-3*
11 33
2 42 4
620-22-234*
Center Shrouds
8" Centerpiece
Silver - 2007
Black - 2007B
3-HOLE
8" Speaker Centerpiece
Silver -2009
Black - 2008
3-HOLE 4-HOLE 2-HOLE5-HOLE
12" Centerpiece
Silver - 2015
Black - 2015B
4-HOLE
12" Speaker Centerpiece
Silver - 2012
Black - 2013
16" Centerpiece
Silver - 2010
Black - 2010B
5-HOLE
16" Speaker Centerpiece
Silver - 2016
Black - 2017
2-3/8" Centerpiece
Silver - 2003
Black - 2004
2-HOLE
48" AND 56"
LIGHT BARS
4" Centerpiece
Silver - 2011
Black - 2014
-15-
Page 18
Interior Parts
2073-795X
50-WATT HALOGEN BULB
(Rotators, Work Lights, Takedowns, Flashers, etc.)
ST3901-7
360° STROBE HEAD
LST129-4
4.5" LINEAR STROBE TUBE
LST129-7
7" LINEAR STROBE TUBE
2073-795S
65-WATT HALOGEN BULB w/Black Top
(for Metal Alley Lights)
2073-H27
27-WATT HALOGEN BULB
(for Plastic Alley Lights)
2073-1157
STOP-TURN-TAIL BULB
Power Supplies/Flashers
620-181-MPQ
2-HEAD WALL MIRROR/POWER PACK
ASSEMBLY FOR 6020S and 6222S
RP310-SBQ
2-HEAD REPLACEMENT STROBE
POWER SUPPLY w/MOUNTING PLATE
RP248A
2-OUTLET STROBE PACK FOR LINEAR
STROBE HEADS
RP248
4-OUTLET STROBE PACK FOR LINEAR
STROBE HEADS
Filters and Lenses
920-100-*
COLOR FILTER FOR ROTATORS
& STATIONARY LIGHTS
LSF4.5-*
COLOR FILTER FOR 4.5" STROBE HEA D
(SH3964)
LSF7-*
COLOR FILTER FOR 7" STROBE HEA D
(SH3967)
330-1-*
330-* DOME w/P30165-5 DOME RING
FOR ST3901-7 360 DEGREE
STROBE HEADS
620-7-*
END DOME WINDOW FOR
ALLEY LIGHTS
Mirrors
620-30
WALL MIRROR FOR AEROSTAR
(*=L or R)
820-29
MEDIUM V-MIRROR FOR AEROSTAR,
INTERCEPTOR, & STROBE MINBARS
820-292
MEDIUM DOUBLE V-MIRROR FOR
AEROSTAR, INTERCEPTOR,
& STROBE MINBARS
Mounts
920-39
DIRECT MOUNT KIT
177-BK-1
MAGNETIC MOUNT
FOR 20" BARS ONLY
FM3661
1.9 FPS HALOGEN FLASHER
FM3662
2.9 FPS HALOGEN FLASHER
LDF369
2-OUTPUT LED FLASHER
(8 OUTPUT TERMINALS)
-16-
920-39T
LOW PROFILE TOW MOUNT
HOOK MOUNTS
THESE ARE PICTURED IN THE
HOOK MOUNT MANUAL ALSO
ENCLOSED WITH YOUR LIGHTBAR
AND WORK IN CONJUNCTION
WITH THE 820-39P*
* = COLOR (White, Black, Clear, o r Gray)
Page 19
Interior Parts (cont’d)
RSH
RP248
DHF DHF
HR
920-99 OR 920-99F
FHR
80FPM OR 160FPM HALOGEN ROTATOR
240SFQ
S
360° STROBE
ST3901-7 and 333-* DOME
RSH
360° REMOTE STROBE HEAD w/DOME
RSK620-SBQ
2-HEAD LINEAR STROBE KIT w/RP310-SBQ
RSH
Power Pack, 820-292 Medium Diamond Mirror
and two ST3901-7 360 Degree Strobe Heads for
Aerostar or Interceptor
SH3964
4.5" LINEAR STROBE HEAD
RSK248A-4K
4.5" 2-HEAD LINEAR STROBE KIT W/RP248A
RP248A
POWER SUPPLY FOR AEROSTAR
RSK248-4K
4.5" 4-HEAD LINEAR STROBE KIT W/RP248
POWER SUPPLY FOR AEROSTAR
SH3967
7" LINEAR STROBE HEAD
RSK248A-7K
7" 2-HEAD LINEAR STROBE KIT W/RP248A
POWER SUPPLY FOR AEROSTARS
RSK248-7K
7" 4-HEAD LINEAR STROBE KIT W/RP248
POWER SUPPLY FOR AEROSTARS
DH
920-51
DIRECTIONAL HALOGEN
FLOOD/TAKEDOWN LIGHT
DHF
920-51F
DIRECTIONAL HALOGEN
FLASHING LIGHT
920-51FK*
2-LIGHT HALOGEN FLASHER KIT
w/FM3662 FLASHER
FRONT or REAR (*=F or R)
DHP
920-51HP
DIRECTIONAL HALOGEN
TAKEDOWN/PURSUIT LIGHT
620-36
TRIPLE MARKER LIGHT BRACKET
STRIP FOR AEROSTAR EXTRUSION
920-37
SINGLE ID LIGHT FOR TRIPLE
EXTRUSION BRACKET
620-38-1
620-36 w/3 (920-37) ID LIGHTS
S920HL-1-*
LH1
360° 4-LED HALO HEAD
S920H8L-1-*
L8H1
360° 8-LED HALO HEAD
620-D1-* or 620-D1V-*
Standard or Value M-Tech LED Lighthead
w/No Endcaps for Aerostar and Interceptor
620-D1AL-* or 620-D1ALV-*
Standard or Value M-Tech LED Lighthead w/Left
Angle Reflector for Aerostar and Interceptor
620-D1AR-* or 620-D1ARV-*
Standard or Value M-Tech LED Lighthead w/Right
Angle Reflector for Aerostar and Interceptor
620-D1LEC-* or 620-D1LECV-*
Standard or Value M-Tech LED Lighthead
w/Left Endcap for Aerostar and Interceptor
620-D1REC-* or 620-D1RECV-*
Standard or Value M-Tech LED Lighthead
w/Right Endcap for Aerostar and Interceptor
620-D1EC-* or 620-D1ECV-*
Standard or Value M-Tech LED Lighthead
w/Endcaps for Aerostar and Interceptor
620-D3-* or 620-D3V-*
Standard or Value M-Tech LED 3-Lighthead
End Assembly for Aerostar and Interceptor
620-D2-* or 620-D2V-*
Standard or Value M-Tech LED 2-Lighthead
End Assembly for Aerostar and Interceptor
620-D2EC-* or 620-D2ECV-*
Standard or Value M-Tech LED 2-Lighthead End
Assembly w/Endcaps for Aerostar and Interceptor
LDH3966-*
STARBLAST™ LINEAR LED HEAD
(*=A,B,C,R)
LDH3966K2-*
2-HEAD LINEAR LED KIT W/
LDF399 FLASHER
(*=A,B,C,R,BR)
LDH3966K4-*
4-HEAD LINEAR LED KIT W/
LDF399 FLASHER (*=A,B,C,R,BR)
920-32*
STOP/TAIL/TURN LIGHT
STT
(Specify R or L)
620-50
OLD STYLE METAL ALLEY LIGHT FOR
AEROSTAR LIGHTBARS
620-14
LDH
NEW STYLE PLASTIC ALLEY LIGHT
FOR AEROSTAR LIGHTBARS
620-SPKK
AEROSTAR SPEAKER KIT
-17-
Page 20
Switches and Switchboxes
SP3860-1 SP3860-2 SP3860-3 SP3860-4
LEFT
WORK
RIGHT
STROBES
ROTATORS
ALLEY
LIGHTS
ALLEY
FLASHERS
SP1515
SP3015
SB4020
MODE
GRILL
CORNER
1 2 3
HEADLIGHT
LIGHTS
FLASHER
TAKE
LIGHTS
DOWN
SB1515 SB3015
ONE YEAR LIMITED WARRANTY
The manufacturer warrants each new product, under normal use, against factory defects in material and
workmanship for one year after the date of purchase. The manufacturer warrants the LED components in this
light against factory defects in material and workmanship for five years after the date of purchase. The
owner will be responsible for returning to the Service Center any defective item(s) with the transportation
costs prepaid. The manufacturer will, without charge, repair or replace at its option, products, or part(s),
which its inspection determines to be defective. Repaired or replacement item(s) will be returned to the
purchaser with transportation costs prepaid from the service point. A copy of the purchaser's receipt must be
returned with the defective item(s) in order to qualify for the warranty coverage. If a copy of the receipt is
not provided, the warranty period shall cover five years from the date of manufacture.
Exclusions from this warranty include, but are not limited to, bulbs, strobe tubes, domes, and/or the finish. This
warranty shall not apply to any light, which has been altered, such that in the manufacturer's judgment, the
performance or reliability has been affected, or if any damage has resulted from abnormal use or service.
This warranty does not apply to defect or damage occurring as a result of disaster, accident, abuse, misuse,
lightning, power surges, or failure to follow instructions in any enclosed manuals. Any damage or defects
occurring as a result of any unauthorized service or repairs by unauthorized persons shall be excluded from
this warranty.
There are no warranties expressed or implied (including any warranty of merchantability or fitness), which
extend these warranty period. The loss of use of the product, loss of time, inconvenience, commercial loss or
consequential damages, including costs of any labor, are not covered. The manufacturer reserves the right
to change the design of the product without assuming any obligation to modify any product previously
manufactured.
This warranty gives you specific legal rights. You might also have additional rights that may vary from state to
state. Some states do not allow limitations on how long an implied warranty lasts. Some states do not allow
the exclusion or limitation of incidental or consequential damages. Therefore, the above limitation(s) or
exclusion(s) may not apply to you.
LED FIVE YEAR LIMITED WARRANTY
If you have any questions concerning this or any other product, please contact our
Customer Service Department
at (585) 226-9787.
If a product must be returned for any reason, please contact our Customer Service
Department to obtain a Returned Materials Authorization number (RMA #) before you ship
the product back. Please write the RMA # clearly on the package near the mailing label.
-18-
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