Star Headlight & Lantern 8600 User Manual

INSTALLATION AND INSTRUCTION MANUAL

®

LIGHTBARS

LIGHTBARS

LIGHTBARSLIGHTBARS

Owner's Manual & Installation

Owner's Manual & Installation

Owner's Manual & Installation Owner's Manual & Installation

Instructions

Instructions

InstructionsInstructions

PLITSTR328 REV D 5/22/12

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.

Due to continuous product improvements, we must reserve the right to change any specifications and information,

NOTICE

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.

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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
Wire Functions 5
Remote Power Supply Connections for Linear Strobe Heads 6-9

PATTERN PROGRAMMING 10-14

Strobe Pack Patterns 10
LED Patterns 11-14

PARTS 15-16

TROUBLESHOOTING 17-20

SERVICE

(Warranty)

21

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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 7-10

‡

See Pattern Programming section on page 11-13

†

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 11)

Minimum

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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 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 Harness Assembly Checklist that was shipped with your lightbar or 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 dome lens at this end of the lightbar:

Step 1 : Loosen the four screws

holding each dome on.

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.

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(Wire Harness Replacement 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

From Lightbar Components

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

From Wire Harness

These

Remove

optional.

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. When all work is completed, reverse Steps A-C in #4 to reinstall the dome, taking care

that the gasket is properly aligned.

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

the Electrical Connections section.

-3-

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.

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Wire Functions

PLEASE NOTE: There are three different harnesses that could be installed on your lightbar.
Please review the Quick-Install Wiring Guide on page 1 for proper connection of your wires.
Your harness will contain all of the colored wires, the drain wire, and the foil shield, but
most applications will not use every wire. 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.

Black: (GROUND) - The black wire is the ground wire and MUST be connected

on EVERY lightbar.

Red: (Power/+12VDC) - The red wire provides the main power to the LED

flashers and/or strobe packs. Connect the red wire directly to continuous
+12VDC through a high-current fuse.

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 or ignition switched relay.

Bare Wire: (Drain/GROUND) - This wire will help eliminate RFI. We recommend that it

be connected to ground.

Purple: (High/Low Power) - The purple wire is optional and can be used to switch

LED applications to low power. Connect the purple wire to ground to
operate the bar under low power.

Red w/Green: (Pattern Select/Touch and Release to +12VDC) - The red w/green stripe

wire is used to select the flash pattern of your LEDs or strobes. It will

normally be left unconnected. (For more detailed instructions, see
Pattern Programming on pages 8-10).

Please note: If you have a lightbar with a strobe pack or LED

flasher, the 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 pages 8-10)

All Other Colors: The remaining wires are typically On/Off controls for the lights shown in the

corresponding Quick-Install Wiring Guide on the page 1. Most applications
will not use every color wire.

Connect the wires that your lightbar utilizes to +12VDC through your switches
(not included). The “dead” wires (not needed) will be connected to the terminal
block inside your lightbar, but there will be no wires connected to the terminal
across from them. These wires do not need to be connected at the other end
of the harness.

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