Star Headlight & Lantern 7400 User Manual

INSTALLATION AND INSTRUCTION MANUAL

Ultra Low Profile Modular Mini Lightbar

PLIT441 REV. A 7/2/13

It 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” a strobe lightbar. Any
antennae mounted in the proximity of the lightbar may cause your radio to
suffer the aforementioned results.

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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.

Table of Contents

WARNINGS i

MOUNTING INSTRUCTIONS 1

WIRING INSTRUCTIONS 1-4

Wire Connections 2
Wire Harness Replacement 3-4

LED HEAD PROGRAMMING 5-6

Phase Selection 5
LED Flash Patterns 6

PARTS 7

SWITCHES 8

TROUBLESHOOTING 9-11

WARRANTY 12

SERVICE 12

NOTICE

Please Note: These instructions are provided as a general guideline only. Some

vehicles may require special mounting, wiring, and/or weather-sealing. This is 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.

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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 need a cable longer than the existing 15-foot harnesses

supplied with the lightbar, it is recommended that you completely
replace the harness, rather than adding on to it. Please see the
Wire Harness Replacement section on pages 3-4.

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.

•

All standard Mini Laser lightbars have a 15’ harness. It has 10-conductors (plus a drain wire and a
foil shield). All wires are color coded and sized at the correct gauge. If this length is not sufficient,
it is recommended that the wire harnesses be completely replaced, with the only connections to be
made directly at the terminal blocks 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 the page 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, the red power wire should be connected to the positive terminal of the

battery and fused at the battery for 125% of its rated load. The current for each component is
shown on the Parts list on page 7. Do not use a 1/4" diameter glass fuse, as it is not suitable for
continuous duty above 20 amps. If you are unsure of the current draw, please contact our
Customer Service Department.

•

TESTING THE LIGHTBAR BEFORE IT IS PROPERLY FUSED 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 #14 AW G 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 Connection section and diagram on the next page lists the different wire colors and the
lights controlled by those wires. Your harness WILL contain all 10 of the colored wires, the drain
wire, and a foil shield, although they will not all be utilized.

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(Wiring Instructions CONT’D)

Wire Connections

Harness Wire Colors

Feature Apply +12VDC to:

Main Power Red
Pattern Select Red w/Green (TEMP)

Feature Connect to Ground:
Low Power Purple

Lightbar
Location Apply +12VDC to:

Front Orange
Rear Brown

Connect the appropriate wires from the Wire
Harness to your switchbox (user provided).
Whenever +12VDC is applied to the Orange
or Brown wires, the corresponding heads will
be activated (as long the red wire is

Note: The bare “drain” wire should be
connected to a good chassis ground.

Black Wire: Connect to the negative side of the battery.

connected to +12VDC and the black wire is
connected to the negative side of the battery).

Red Wire: Connect to the positive terminal of the battery through a fuse at the

battery for 125% of the rated load of all your components. The current
for each component is shown on the Parts list on page 7. Do not use
1/4" diameter glass fuses, as they are not suitable for continuous duty
above 20 amps.

Please Note: When the red wire is connected to +12VDC the lightbar will draw a small

current (~100 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 or ignition switched relay.

Red w/Green Wire: Pattern Select wire - see the LED Flash Pattern Selection section on

Purple Wire: Used if you need the ability to switch your lightbar to low power at

page 6.

night. Leave this wire disconnected to run on constant high power.
Connect it to ground through a switch to allow switching to low power
(low when purple connected to ground).

6c

6a

Orange Wire

1

5

Brown Wire

2

3a

3c

4

Note: The low power setting decreases the light output of emergency warning lights,
thus reducing their effectiveness. Star does not recommend the use of low power
mode in brightly lit areas (including daylight). Lightbars running on low power may
not comply with applicable emergency warning light standards and/or specifications.

+12 VDC

User Supplied Switchbox

All Front Warning

All Rear Warning

Red w/ Green

change Flash Patterns)

Black

Red

Drain

2

0

U

F

Orange Wire

Brown Wire

Purple High/Low Power

P

M

A

E

S

(Touch and Release to +12VDC to

+

BATTERY

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