2561268B
REV. B 702
Printed in U.S.A.
WIRING AND MAINTENANCE
FOR
FEDERAL STREETHAWK® LIGHT ASSEMBLY
SAFETY MESSAGE TO INSTALLERS
WARNING
People’s lives depend on your safe installation
of our products. It is important to read, understand and follow all instructions shipped with
this product and the related add-on products.
In addition, listed below are some other
important safety instructions and precautions
you should follow:
•
•
•
•
•
When drilling into a vehicle structure, be
sure that both sides of the surface are
clear of anything that could be damaged.
Remove all burrs from drilled holes. To
prevent electrical shorts, grommet all
drilled holes through which wiring passes.
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 is to be
used.
This product may contain high intensity
LED devices. To prevent eye damage, DO
NOT stare into the light beam at close
range.
High voltages are present inside the strobe
light equipped models during and after
operation. Ensure that power is disconnected and wait at least ten minutes before
removing the dome.
Locate light system controls so the VEHICLE and CONTROLS can be operated
safely under all driving conditions.
•
You should frequently inspect the light to
ensure that it is operating properly and
that it is securely attached to the vehicle.
GENERAL.
The Light Assembly comes from the factory with six (6)
stationary light lenses, gaskets and mounting hardware in
kit form. This enables the user to choose and install the color
combination that best suits the application. The Light
Assembly comes from the factory with six (6) black lenses,
gaskets and mounting hardware in kit form which enables
the user to cover the pod openings when optional lighting is
not desired.
To properly install this light: you must
have a good understanding of automotive
electrical procedures and systems, along
with proficiency in the installation and use
of safety warning equipment.
•
•
I.
WARNING
Using a lens colored differently than an LED
will greatly reduce the light output, thereby
reducing the effectiveness of the light for
emergency signaling purposes. Either use a
clear lens or match the color of the lens with
the LED.
Federal recommends that lenses be installed prior to
mounting the light assembly on the vehicle. To install a lens
in any position, proceed as follows (see figure 1):
A. Install gasket on rim of lens.
B. Insert lens and gasket into lens opening. Secure
with two #6 screws. Tighten to 10-15 in./lbs. of torque.
II.
ELECTRICAL WIRING.
A. General.
WARNING
To prevent personal injury and/or damage to
vehicle components, in the event of a shortcircuit in the power cable, install a fuse in
each incoming cable conductor.
LENS
GASKET
BASE
REF.
File these instructions in a safe place and
refer to them when maintaining and/or
reinstalling the product.
Failure to follow all safety precautions and instructions may result in property damage, serious
injury, or death to you or others.
#6 SCREWS
290A2893
Figure 1.
NOTE
FRONT
DRIVER'S SIDE
Any of the light assembly 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.
PASSENGER SIDE
STROBE,
TAKEDOWN
OR
END LAMP
C OF
L
LIGHT BAR
ROTATING
OR
OMNI-DIRECTIONAL
STROBE
1 2 3 4 5 6 7 8 9 10 11
STROBE,
ROTATING
TAKEDOWN
OR
OR END LAMP OMNI-DIRECTIONAL
STROBE
SPEAKER
The Light Assembly is completely wired at the
factory and does not require any additional internal wiring.
(If desired, to allow Intelli-Flash Mode 2, connect the wht/red
Intelli-Flash wire to an unused power cable wire or a usersupplied wire.) The cable connected to the Light Assembly
contains all the conductors necessary for proper control of all
basic and optional functions. Figure 2 illustrates the function
of each conductor in the cable. Be sure to use fuses (current
ratings shown in figure 2), wire and switches with adequate
current capacity for each function.
ROTATING
DYNARAY
DYNARAY
ALLEY
LIGHT
END LAMP
OR
DIRECTIONAL STROBE
END LAMP
OR
DIRECTIONAL STROBE
ROTATING
ALLEY
LIGHT
11 10 9 8 7 6 5 4 3 2 1
CHASSIS
GROUND
SCREW
INTERNAL WIRING
EXTERNAL WIRING
Figure 2 illustrates the external/internal Light
Assembly wiring by function. Using figures 2 and 3 as a
guide, make the appropriate electrical connections. Be sure
to use fuses (current ratings shown in the diagram in figure
2), wire and switches with adequate current capacity for each
function.
ACCESSORY CABLE
GROUND (-)
BLK
15A
DYNARAY
RED/WHT
BLK/WHT
NOT USED
NOTE
DIRECTIONAL STROBES(1 & 2) 10A
DUAL DIRECTIONAL STROBES (4) 20A
When takedown lights or directional strobe lights
are not used in the front and rear secondary light
positions, alternating flash end lamps (35-watt
halogen lamps) will be found in these positions.
GRA
OMNI-DIRECTIONAL STROBES (2) 10A
PRIMARY ROTATING LIGHTS (4) 25A
RED
BRN/WHT
SPEAKER
B. Programming the Intelli-Flash (see figure 3).
BRN
SPEAKER
TAKEDOWN (1) 8A, (2) 15A
To operate the flasher in Mode 1, close SW1. To
operate the flasher in Mode 2, close SW1 and SW2.
15A
FLASHING END LAMPS
(2) 5A, (3) 10A, (4) 15A
Turn on the flasher in Mode 1. Short across the
programming pins until the desired pattern is running.
Allow the pattern to run for at least 15-seconds to program
Mode 1.
15A
BLU
8A
LEFT ALLEY LIGHT
ORN
8A
GRN
CUSTOMER SUPPLIED
SUPPLIED
W/LIGHTBAR
RIGHT ALLEY LIGHT
POWER (+)
Turn on the flasher in Mode 2. Short across the
programming pins until the desired pattern is running.
Allow the pattern to run for at least 15-seconds to program
Mode 2.
YEL
TO POWER/IGNITION
290A2898
Figure 2.
B. Lamp Replacement.
1.
Dome Removal (see figure 4).
III. MAINTENANCE.
a.
A. Cleaning the Plastic Domes and Lenses.
Turn-off power to Light Assembly.
b. Remove three #10 type “B” hex washer
head thread-forming screws which secure the upper speaker
grille to the lower speaker grille. Lift upper grille away from
lower grille.
WARNING
Crazing (cracking of domes or lenses) will
cause reduced effectiveness of the light. Do not
use cleaning agents (which will cause crazing)
such as strong detergents, solvents, or petroleum products. If crazing of domes or lenses
does occur, reliability of light for emergency
signaling purposes may be reduced until
domes or lenses are replaced.
c. Remove the eight (four on each side) #8-32
x 7/8" hex head screws and #8 flat washers from the front
and rear edges of the dome.
d. Carefully remove the domes. Ensure that
the bulkhead gasket remains tucked in its groove.
Ordinary cleaning of the plastic domes and lenses
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,
one-step, automotive paste cleaner/wax and a soft cloth.
e. The domes and upper speaker grille can be
replaced by reversing the procedure. Torque dome screws to
14-18 in./lbs and grille screws to 20-25 in./lbs.
-2-
PRIMARY
ROTATING LIGHTS
DOMESTIC
RED
RED
INCOMING 1 2 3 4 5 6 7 8 9 10 11
CABLE
RED
INCOMING
CABLE
1 2
PRIMARY
ROTATING LIGHTS
INTERNATIONAL
3 4 5 6 7 8 9 10 11
RED
R
M
M
R
BLK
BLK
BLK
PASSENGER SIDE
BLK
RF
BLK
R
-
4
5
R
2 1
BLK
PASSENGER SIDE
INCOMING CABLE
ORN
GRN
BLK
BLK
PASSENGER SIDE
BLU
INCOMING 1 2
CABLE
BLK
Y
D
BLK
11 10 9 8 7 6 5 4 3 2 1
RE
BLK
YEL
ORN
BLK
D
BLU
BLU
BLK
BLK
BLK
BLK
F
RF BLK
BLK
POWER
F
BLU
BLU
11 10 9 8 7 6 5 4 3 2 1
TD
TWO REAR FLASHING
NOTE: 35W LAMPS ONLY
3 4 5 6 7 8 9 10 11
BLK
FE
DRIVER SIDE
FRONT
BLU
BLK
ONE TAKEDOWN
PASSENGER SIDE
1 2 3 4 5 6 7 8 9 10 11
BLK
11 10 9 8 7 6 5 4 3 2 1
INCOMING 1 2
CABLE
BLK RF
PASSENGER SIDE
DRIVER SIDE
FRONT
INTELLI-FLASH
*
*
SW1
INCOMING
CABLE
SW2
1
BLK
4
A
1 2 3 4 5 6 7 8 9 10 11
PASSENGER SIDE
FRONT
YEL
INCOMING
CABLE
B
DRIVER SIDE
1. POWER CABLE WIRE COLOR
(TYP. BLUE OR WHT/RED) AND
LOCATION OF FLASHING LIGHTS
DEPENDENT UPON CONFIGURATIION.
DUAL TAKEDOWN
(NON-FLASHING)
1 2 3 4 5 6 7 8 9 10 11
*
BLK
RED
BLK
RED
11 10 9 8 7 6 5 4 3 2 1
G
A
DRIVER SIDE
FRONT
YEL
BLK
PASSENGER SIDE
BLK
BLK
YEL
YEL
BLK
PASSENGER SIDE
INCOMING
CABLE
BLK
E
ORN
WHT/RED
BLK
BLK
BLK
ALLEY LIGHTS
AND/OR DYNARAY
RE BLK
BLK
POWER
F
3
11 10 9 8 7 6 5 4 3 2 1
THREE FLASHING END LAMPS
(TWO REAR AND ONE FRONT)
3 4 5 6 7 8 9 10 11
2 1RED
DRIVER SIDE
FRONT
FF
DRIVER SIDE
FRONT
BLK
BLK
+
4
-
BLK
A
BLK
BLK
C
BLK
11 10 9 8 7 6
1 2 3 4 5 6 7 8 9 10 11
BLK
FF
+
RED
BLK
RF BLK
BLU
BLK
M
BLK
5
B
FRONT AND REAR
FLASHING LIGHTS
NOTE: 35W LAMPS ONLY
BLU
BLK
R
3
BLK
BLK
+
-
-
DRIVER SIDE
FRONT
BLK
-
M
+
M
M
-
BLK
BLK
R
+
+ RED
BLK
POWER
F
BLK
BLK
+
BLK
11 10 9 8 7 6
BLU
INCOMING 1 2 3 4 5 6 7 8 9 10 11
CABLE
M
+
RED
RED
A
+
-
+
-
-
M
+
+
R
RED
+ BLK
D
Y
RED
+
BLK
RED
R
+ BLK
RED/GREEN
LED
GRN
RED
ORN
RED
BLK
PROGRAMMING
PINS
2. UNUSED POWER CABLE WIRE OR
USER-SUPPLIED WIRE TO BE
CONNECTED TO MODE 2.
YEL
YEL
BLK
TD
H
RED/WHT (MODE 2)
RED (MODE 1)
1110 9 8 7 6 5 4 3 2 1
TD
PASSENGER SIDE
FRONT
BRN/WHT
INCOMING
CABLE
BLK
11 10 9 8 7 6 5 4 3 2 1
BLK
3. SOLID GREEN LED INDICATES SAE
APPROVED PATTERN. SOLID OR
INTERMITTENT RED LED INDICATES
UNAPPROVED SAE PATTERN.
BLK
DRIVER SIDE
4
SPEAKER
58 OR 100 WATT
1 2 3 4 5 6 7 8 9 10 11
1
PASSENGER SIDE
FRONT
DRIVER SIDE
BRN
BRN
PATTERN
BRN
OUTSIDE
ALL
WIRE NUTS
PASSENGER SIDE
FRONT
PATTERN 1
PATTERN 2
PATTERN 3
PATTERN 4
PATTERN 5
PATTERN 6
PATTERN 7
PATTERN 8
11 10 9 8 7 6 5 4 3 2 1
L
POSITION
1 2 3 4
A A A B
A A A A
75 FPM ALTERNATING
95 FPM ALTERNATING
115 FPM ALTERNATING
4 @ 120 FPM ALTERNATING THEN
4 @ 120 FPM SIMULTANEOUS
180 FPM ALTERNATING
ALTERNATING 260 FPM DOUBLE
ALTERNATING 300 FPM TRIPLE
300 FPM TRIPLE/60 FPM SINGLE
290A2899B
DRIVER SIDE
Figure 3.
-3-
DOME
#10 TYPE "B" HEX HEAD
SCREW, THD. FORMING (3)
UPPER GRILLE
DOME
8-32 x 7/8" HEX HD. SCREWS(8)
(4 ON EACH DOME SECTION)
LOWER GRILLE
BULKHEAD GASKET
290A2892
Figure 4.
CAUTION
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.
2.
When installing a new lamp, do not touch the glass
portion. If the glass has been touched, shortened
lamp life will result. If the glass end has been
handled, it should be carefully cleaned with a grease
solvent.
c. Replace the defective lamp with a new H-1
halogen lamp (Part No. 8440A265A). When reassembling,
ensure that the lamp is secured to the connector and that the
clip is properly seated in the grooves on the lamp socket.
Primary Rotating Lamps.
To replace the halogen lamp, proceed as follows
(see figure 5):
3.
CAUTION
Omni-Directional Strobe Tube.
Remove fresnel lens from base. Pull defective
flash tube from mounting socket. Replace with Part No.
8422A420 flash tube.
Forced rotation of the light mechansim will cause
damage to the worm gear. ALWAYS rotate the light
mechansim by rotating the motor shaft.
4.
a. Rotate the reflector unitl the lamp clip
(located at the base of the lamp) can be removed, and remove
the clip by sliding it away from the reflector.
Secondary Lamps.
To replace lamps in the secondary light positions (six locations), proceed as follows (see figure 1):
b. Note the lamp’s orientation and pull the
defective lamp and connector out of the socket.
a.
Remove the two #6 pan head screws.
b. Remove lens by pulling straight out.
Remove lens gasket.
H-I HALOGEN LAMP
c. Replace defective lamp with proper lamp
only. Refer to Table 1, Secondary Lamp Replacement Guide.
DO NOT TOUCH
GLASS PORTION
OF LAMP
LAMP BASE
d. Reinstall lens and gasket . Secure with two
#6 screws removed in step a.
ORIENTED PARALLEL
TO GROVES IN
LAMP SOCKET
5.
SLIDE CLIP OVER
LAMP BASE INTO
GROOVES ON
LAMP SOCKET
CONNECTOR
LAMP SOCKET
Gen III PCB Assembly Replacement.
a.
Remove the domes.
GROOVES(2)
b. See figure 6. Disconnect the electrical
connector from the PCB assembly.
GEAR AND REFLECTOR
ASSEMBLY
c. Gently pry the PCB assembly from the
snap-top standoffs on the backplane.
d. Remove the two heat sink retaining screws
and the heat sink.
290A2600-01
Figure 5.
-4-
Table 1. Secondary Lamp Replacement Guide.
RIVSCREWS
FUNCTION
DESCRIPTION
Part No.
Alley Light
(right and
left)
50W Halogen,
Sylvania #795
8107A119
End Lamps
(right and
left,front
and rear)
35W Halogen,
Sylvania #796
8548A028A
Takedown
Lights
(front only)
SEE NOTE
50W Halogen,
Sylvania #795
8107A119
Directional
Strobe
(front and
rear)
Flash Tube Assy.
8107A127
Brake/Tail
Light
(rear only)
Incandescent Lamp
#1157
BACKPLANE
ASSEMBLY
LED MODULE
FRESNEL LENS
290A4532
Figure 7.
Gen III PC Board PCB Assembly
Red/Amber
Blue
e. Assembly is the reverse of disassembly.
Prior to installation of the PCB assembly, ensure that the
LED connector pins on the PCB are not bent or damaged.
8107A095
6.
Z2005175-N
Z2005175-02N
Gen III LED Module Replacement.
a.
Remove the domes.
Gen III LED
Module
LED Module Assy.
Amber
Blue
Red
Z8625106-AS
Z8625106-BS
Z8625106-RS
b. See figure 6. Disconnect the electrical
connector from the PCB assembly.
Gen III Lens
Lens, Fresnel
8625101
c. Gently pry the PCB assembly from the
snap-top standoffs on the backplane.
NOTE: If the alternating flash feature is desired, the flasher
supplied with the Alternating Flasher Kit is required.
d.
e. See figure 7. Remove and discard the
Rivscrews retaining the LED module to the backplane.
Remove the LED module.
HEAT SINK
RETAINING SCREWS
HEAT SINK
Remove the device from the light bar.
f.
Unlatch the Fresnel lens from the LED
module.
PCB ASSEMBLY
g. Snap the Fresnel lens onto the new module.
Make sure the rectangular recess in the lens aligns with the
black connector on the new LED module.
h. Position the LED module on the backplane,
aligning the black connector on the LED with the large
clearance hole in the backplane. Secure the module with the
2 #6-32 screws provided.
i.
ELECTRICAL
CONNECTOR
7.
BACKPLANE ASSEMBLY
Remainder is the reverse of disassembly.
Fresnel Lens Replacement.
Same as LED Module Replacement above,
except that the Rivscrews must be retained for reuse if a new
LED module is not being installed.
290A4531
Figure 6.
-5-
C. Worm Gear and Bearing.
GEAR AND REFLECTOR
ASSEMBLY
H-1
HALOGEN
LAMP
All gears should be greased at least twice a year.
Use medium consistency Dow Corning DC33 or equivalent
type grease. Proceed as follows (see figure 8):
CLIP
1.
Remove lamp and clip from rotating light.
LAMP SOCKET
2. Lift-off reflector and worm gear. Lubricate with
grease as shown in figure 8.
3. Replace parts by performing the above procedure in reverse order.
GROOVE
APPLY GREASE
HERE (3 PLACES)
NOTE
When reassembling, ensure that the lamp is secured
to the connector and that the clip is properly seated
in the grooves on the lamp socket.
MOTOR
D. Motor.
290A2600-03B
1. Before attempting to service the motor, ensure
that the worm gear and worm are free of binding.
Figure 8.
2. There should be a small amount of gear backlash for proper motor operation.
3. Replace motor if operation is sluggish or
intermittent, after it has been determined that there is no
binding and that all electrical connections are correct.
E. Service Parts Kits.
Service Parts Kits and Instructions are available for
these lights. Contact your local Distributor for more information.
-6-