256817B
REV. B 797
Printed in U.S.A.
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FOR
MODEL JSL6000 & JSL5400
LIGHT BARS
SAFETY MESSAGE TO INSTALLERS
OF
FEDERAL SIGNAL LIGHT SYSTEMS
I.
After unpacking the light bar, inspect it for
damage that may have occurred in transit. If the unit
has been damaged, file a claim immediately with the
carrier, stating the extent of damage. Carefully check
all envelopes, shipping labels and tags before removing or destroying them.
People’s lives depend on your safe installation of
our products. It is important to read, understand and
follow all instructions shipped with the products. In
addition, listed below are some other important
safety instructions and precautions you should
follow:
•
To properly install a light assembly: you
must have a good understanding of automotive electrical procedures and systems,
along with proficiency in the installation
and use of safety warning equipment.
•
When drilling into a vehicle structure,
be sure that both sides of the surface are
clear of anything that could be damaged.
•
A light system is a high current device.
In order for it to function properly, a
separate ground connection must be
made. If practical, it should be connected
to the negative battery terminal. At a
minimum, it may be attached to a solid
metal body or chassis part that will provide an effective ground path as long as
the light system is to be used.
•
II. INSTALLATION.
The basic light bar is completely wired at the
factory and does not require any additional internal
wiring. All the conductors necessary for control of
any and all basic and optional functions are contained in the cable. Installation of options will
require additional wiring in the light bar.
The basic light functions of the unit must be
controlled by a user supplied control head.
Before proceeding, ensure that the light bar has
been installed on the vehicle roof in accordance with
the instructions packed with the mounting kit. Route
the light bar cable as described below.
WARNING
Light system controls must be located so that
VEHICLE and CONTROLS can be operated
safely under all driving conditions.
A. Route the control cable into the vehicle and
under the dash, near the eventual location of the
user-supplied control head.
Locate light system controls so the
VEHICLE and CONTROLS can be
operated safely under all driving
conditions.
•
You should frequently inspect the light
system to ensure that it is operating
properly and that it is securely attached
to the vehicle.
•
File these instructions in a safe place
and refer to them when maintaining
and/or re-installing the product.
UNPACKING.
B. For proper light operation, the control cable
must be properly terminated inside the user-supplied
control head. Table 1 shows the recommended control
cable wire colors for various light bar functions.
Using figure 1 as a guide, make the applicable
electrical connections for the functions installed in
your light bar as shown in Table 1. Switch current
capacities should be at least 15 amps. Ensure that
the lines are adequately fused as shown in figure 1.
NOTE
Any of the light bar functions can be activated
by applying 12VDC to the appropriate control
line. The heavy black lead (-) must be connected to vehicle ground, to perform a function
check.
Failure to follow all safety precautions and
instructions may result in property damage, serious
injury, or death to you or others.
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-2-
RED
RF
WHT/GRN
RF
RED
RED
TB
1
2
RF
RF
BLU
FLASHER
POWER
TB
TB
WORK LIGHT OPTION
R
RF
F
F
F
5
F
WHT/RED
F
F
WHT/RED
WHT/RED
RF
ORN
TB
WHT/BRN
W
BLK/WHT
TB
WHT/RED
T.L.C.
RF
RF
RF
(TAIL LIGHT)
R
290A2453-14
R
290A2453-13B
WHT
RF
RF
RF
RF
RED
RF
2
1
J22
WORK (W)
STROBE (S)
LEFT BRAKE/TURN
ORN
GRA
YEL
15A
15A
8A
(+) POWER/IGN.
BRN/WHT N.C. (SPARE)
FUSE AND SWITCH TO
BE ADDED WHEN USED
BLK/WHT
15A
RF
R
S
RED
RF
R
290A2453-19
4
6
5
7
6
7
290A2453-21
SUPPLIED WITH
LIGHTBAR
(-) TO GROUND
290A2453-22B
NOTE: JSL5400
HAS
10 SELECTIONS
JSL5400
&
JSL6000
TM
JETSTREAM
WITH
INDEPENDENT
ROTATING
LIGHTS
EXTERNAL
WIRING
(SPARE)
N.C.
INTERNAL WIRING
(SHOWN ABOVE)
SELECT NEXT OPEN POSITION
3
5
CUSTOMER
SUPPLIED
2
4
RED
ONE TERMINAL BOARD (7 POS.)
SUPPLIED WITH LIGHT BAR
R
290A2453-20
TWO STROBES PER J22 POWER SUPPLY
WHT/BLK
SELECT NEXT OPEN POSITION
S
R
TWO STROBES PER J22 POWER SUPPLY
SELECT NEXT OPEN POSITION
WHT/BLK
RF
290A2453-18
RED
TWO STROBES PER J22 POWER SUPPLY
WHT/BLK
SELECT NEXT OPEN POSITION
S
RED
3
J22
J22
TRAFFIC CLEARING (T.C.L.)
FLASHING (F)
RIGHT BRAKE/TURN
BLU
GRN
8A
TAIL LIGHT
BRN
8A
15A
END ROTATING (R)
15A
RED/WHT
1
TB
S
TB
CENTER ROTATING (RF)
GROUND
RED
15A
BLK
TB
RED/WHT
TB
GRA
BLK
RED
GRA
BLK
S
GRA
S
RED
BLK
RED
ACCESSORY CABLE
GND.
SCREW
STANDARD (2 ROTATORS)
LIGHT BAR
R
360° STROBE OPTION
R
STROBE OPTION (FRONT)
R
STROBE OPTION (BACK OR REAR)
R
Figure 1. Wiring Diagram.
290A2453-17
R
290A2453-16
R
290A2453-15
TWO LIGHTS PER
FLASHER
FLASHER, SECOND
POWER
TERMINAL BOARD
TB
MAY BE REQUIRED.
YEL
RF
SELECT NEXT OPEN POSITION
WHT/BRN
W
R
WHT/YEL
B/T
290A2453-12
(LEFT BRAKE/TURN)
RF
SELECT NEXT OPEN POSITION
WHT/RED
T.L.C.
R
ONE TERMINAL BOARD (7 POS.)
SUPPLIED WITH LIGHT BAR
RED
TWO LIGHTS PER FLASHER
YEL
BRN
7
RED
RF
SELECT NEXT OPEN POSITIONS
WHT/RED
RF
BRN
6
SELECT NEXT OPEN POSITIONS
WHT/RED
TRAFIC CLEARING LIGHT (T.C.L.) OPTION
R
BLU
RF
FLASHING LIGHT
OPTION (FRONT & BACK)
R
RF
FLASHER
POWER
FLASHING LIGHT
OPTION (LEFT & RIGHT)
R
4
RED/WHT
3
WHT/BLU
RF
WHT
SELECT NEXT OPEN POSITIONS
BRAKE/TAIL OPTION & D.O.T. LIGHT
TB
GRN
(RIGHT BRAKE/TURN)
R
B/T
STANDARD (5 ROTATORS)
LIGHT BAR
R
Table 1. Electrical Connections.
Control Cable
Wire Color
RED/WHT
BRN/WHT
BRN
BLU
ORN
YEL
GRN
GRY
RED
BLK
BLK/WHT
III. BASIC MAINTENANCE.
WARNING
Functions
Center Rotating Lights
No Connection
Tail Light and D.O.T. Light
Flashing
Work
Left Turn/Brake
Right Turn/Brake
Strobe
Rotating Lights
Power (-)
Traffic Clearing Light
High voltages are present inside the light bar,
when the strobe light option is installed. Wait
at least ten (10) minutes, after shutting off
power, before servicing this unit. Failure to do
so may result in property damage, serious
injury, or death to you or others.
A. Cleaning the Plastic Domes.
Ordinary cleaning of the plastic domes can be
accomplished by using mild soap and a soft rag.
Should fine scratches or a haze appear on the domes,
they can ordinarily be removed with a non-abrasive,
high quality, automotive paste wax.
C. Connect the black lead to chassis ground.
D. Connect the light bar's red power lead to a
fuse or circuit breaker rated at 50 amperes. Connect
the other side of the fuse /circuit breaker to the
+12VDC supply.
CAUTION
The use of other materials such as strong detergents, solvents, petroleum products, etc. can
cause crazing (cracking) of the plastic domes.
E. The recommended optional function locations
are shown in figure 2. Refer to the instructions
provided in the option kit for installation details.
POSITIONS
1
2
3
4
5
RF
6
7
8
RF
9
10
11
RF
R
R
FRONT
POSITIONS
STANDARD
OPTIONS
1
2
3
4
5
ROTATOR, 90FPM
V-MIRROR
ROTATOR, 175FPM
V-MIRROR
V-MIRROR
BRAKE/TAIL
6
7
ROTATOR, 175 FPM
V-MIRROR
8
9
10
11
V-MIRROR
ROTATOR, 175FPM
V-MIRROR
ROTATOR, 90FPM
TCL, WORK, FLASHING, DIRECTIONAL STROBE, OR
360 STROBE
TCL, WORK, FLASHING, DIRECTIONAL STROBE, OR
360 STROBE
BRAKE/TAIL
NOTE: JSL5400 HAS 10 SECTIONS.
Figure 2. Recommended Option Locations.
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290A2452
B. Lamp Replacement.
The strobe light power supply does not
contain any user serviceable parts. Should a breakdown in the power supply occur, it should be returned to Federal for repair and replaced. To remove
the power supply, proceed as follows:
WARNING
A serious injury may result if lamp is touched
when hot. Always allow lamp to cool before
removing. Halogen lamps are pressurized and
if broken can result in flying glass. Always
wear gloves and eye protection when handling
the lamps.
1. Unplug the connector from the power
supply.
2. Remove the two #10 screws which secure
the power supply.
CAUTION
Service life of lamp will be shortened if glass
portion is touched. If glass has been handled,
clean carefully with a grease solvent.
3. Install the new power supply by performing the previous steps in reverse order.
See figure 3. To replace the lamp, Twist to
unlock and then pull the defective lamp out of the
socket. Install a new lamp of the same type in the
socket.
DO NOT TOUCH
THE GLASS PORTION
OF LAMP
C. Cleaning Reflectors and Mirrors.
Use a soft tissue to clean the reflector and
mirrors. Avoid heavy pressure and the use of caustic
or petroleum base solvents which will scratch or dull
the surface.
795
D. Strobe Power Supply Replacement.
LAMP
SOCKET
WARNING
High voltages are present inside the light bar,
when the strobe light option is installed. Wait
at least ten (10) minutes, after shutting off
power, before servicing this unit. Failure to do
so may result in property damage, serious
injury, or death to you or others.
290A2399
Figure 3. Lamp Replacement Diagram.
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