Installation and Service Manual LED JETSOLARIS
Contents
1. Color Description Red 12 Vdc Brown Chassis Green Center Out directional pattern White Left arrow directional pattern Black Right arrow directional pattern White Green Not used Operating the Control Head The control head has a power switch and a rocker switch that enables the operator to select SicnaLMaster patterns ON OFF Switch When the control head s power switch is in the ON position the LED in the switch turns on If the LED does not turn on check the ground lead on the control head s mounting bracket properly grounded to the vehicle chassis Rocker Switch The patterns the switch positions display override the turn signal brake option LEFT position Displays a left arrow flashing pattern directing traffic to proceed around the vehicle to the left CENTER position The middle lights alternate with two outer lights on each side RIGHT position Displays right arrow flashing pattern directing traffic to proceed around the vehicle to the right 25 Chapter 5 Installing the Solar Panel Charging System Option In this chapter mM An Overview of the Solar Panel Charging System mM Product Specifications mH Mounting the Charger H Wiring the Solar Panel Charging System An Overview of the Solar Panel Charging System The Solar Panel Charging System comprises a solar panel mounted inside the lightbar and a charger that is mounted near the vehicle battery with installer supplied hardware Th2. s cable White Light Cutoff The option to cut off the standard lightbar s white lights is set at the factory with dip switches on the lightbar s control board The cable s yellow wire controls White Light Cutoff When 12 Vdc is applied to the wire the white lights flash in the same flash pattern as the rest of the lightbar When 12 Vdc is removed from the wire the white lights turn off If white light cutoff is not needed fold and insulate the wire Front or Rear Light Cutoff The lightbar may be equipped to shut off the front of the lightbar or the rear of the lightbar while the rest of the lightbar is still flashing The option is controlled by the green wire in the lightbar control cable When 12 Vdc is applied to the wire the lights flash When 12 Vdc is removed from the wire the lights shut off If front or rear light cutoff is not needed fold and insulate the wire Selecting Flash Patterns for Primary and Secondary Mode Although the standard JetSotaris is shipped with preselected flash patterns for Primary and Secondary Mode you can select new patterns from the lightbar internal library of 40 flash patterns A pattern displayed in Primary Mode is typically more active than the pattern displayed in Secondary Mode It indicates the primary purpose of the vehicle for example the vehicle is on its way to the scene of an emergency or is towing a car A pattern displayed in Secondary Mode is a more relaxed pattern indicating
3. 8 32 Phillips screw securing the black ground wire GND to the control board and remove the wire from the board NOTE The colors of the wires connected to the control board are silkscreened next to their connectors 6 Disconnect wires and harnesses from the control board and remove it from the lightbar 7 Remove the six 6 Phillips screws securing the control board to the end bracket 8 Remove the control board from the end bracket Installing the Control Board NOTICE DO NOT OVERTIGHTEN SCREWS NUTS To avoid damage to the lightbar do not overtighten the screws and nuts 1 Secure the control board to the end bracket with the six 6 Phillips screws 2 Reattach the black ground wire GND to the control board with the 8 32 Phillips screw NOTE The colors of the wires connected to the control board are silkscreened next to their connectors 3 Reconnect the wires and harnesses to the control board and secure them with wires ties 36 Chapter 6 Servicing the Lightbar 4 Secure the end bracket to the aluminum extrusion with the ten 5 16 screws 5 Install the end PCB and end dome as described in Installing an End Board on page 30 6 Reconnect power to the lightbar 5 16 HEX HEAD SCREWS 10 SECURING THE END BRACKET TO THE ALUMINUM EXTRUSION END BRACKET WITHOUT THE END PCB g _ 6 PHILLIPS SCREWS 6 290A6259 SECURING THE CONTROL a BOARD TO THE BRACKET Figure 6 5 Control board remove
4. E ON OFF ON ea S NY SWITCH ON OFF 290A5308 01 Figure 4 1 S1gnatMaster control head Chapter 4 Installing the SignalMaster Option 23 NOTE When selecting a mounting location for the control head it is necessary to keep in mind the SignalMaster s cable length Plan wiring and cable routing before installation 1 Select a mounting location for the control head that allows the vehicle and controls to be operated safely at all times 2 Use the control head as a template and scribe two drill position marks at the selected mounting location DRILLING PRECAUTIONS Before drilling holes check the area into which you plan to drill to ensure you do not damage vehicle components while drilling All drilled holes should be deburred and all sharp edges should be smoothed All wires going through drilled holes should be protected by a grommet or convolute split loom tubing 3 Drilla hole at each drill position mark 4 Secure the control head to the mounting surface with two installer supplied sheet metal screws Wiring the Control Head A WARNING SPARK HAZARD If wires are shorted to the vehicle frame or each other high current conductors can cause hazardous sparks resulting in electrical fires and molten metal Verify that no short circuits exist before connecting to the positive battery terminal 4 CAUTION HIGH CURRENT ARCING Do not connect this system to the vehicle battery until all oth
5. power is removed See Wiring the Controls for White Light and Front Rear Cutoff Except Lightbars with 23 Pin Shell Connectors on page 12 If the wire is not used for white light cutoff other options are takedown lights traffic clearing lights or worklights Driver side alley light driver side stop turn tail light steady burn lights worklights driver traffic clearing light Brown White Passenger side alley light If there is no alley light option the wire is used for SicnaALMaster right directional lights passenger side stop turn tail lights or the passenger side traffic clearing light Table 3 2 11 conductor cable wires 12 AWG Standard JLX Wire Color Function Red PRIMARY MODE 12 Vdc Activates the lightbar in Primary Mode For a description of Primary Mode see page 12 Black GND Connects to a good battery chassis ground Gray Takedown traffic clearing light worklight or StcnaLMaster left directional lights Green Front light cutoff rear light cutoff driver side stop turn tail lights steady burn or SicnatMaster center out directional lights Blue SECONDARY MODE Applying 12 Vdc changes the pattern of the lightbar to the pattern selected for Secondary Mode Only active if the lightbar is normally flashing in Primary Mode For a description of Secondary Mode see page 12 Orange PROGRAM for Primary Mode Applying GND advances the flash pattern to the next patt
6. Custom JLX Lightbars built for UNICOR have wiring that is terminated in a 23 pin shell connector Table 3 3 describes the wires from the connector to the lightbar Table 3 3 23 conductor cable wires 12 AWG UNICOR Number Letter Wire Color Function 1 A Open 2 B Open 3 C Open 4 D Black Chassis ground to the lightbar 5 E Black Chassis ground to the lightbar 6 F Black Chassis ground to the lightbar 7 G Black Chassis ground to the lightbar 8 H Red Red wire to solar panel 9 J Red with white stripe Front of lightbar 10 K Red with black stripe Steady burn 11 L Open 12 M Blue Takedowns 13 N Open 14 P Yellow Yellow wire to solar panel 15 R Open 16 S Orange with black stripe Left alley 17 T Open 18 U Orange Right alley 19 V Green with black stripe Rear of lightbar continues on next page 16 Chapter 3 Installing the JLX JetSolaris Table 3 3 23 conductor cable wires 12 AWG UNICOR continued 20 W Open 21 X Open 22 Y Open 23 Z Black Black wire to solar panel Wiring the Controls for White Light and Front Rear Cutoff Except Lightbars with 23 Pin Shell Connectors The standard lightbar can be configured when ordered from the factory with options that turn off white lights or turn off the front or rear of the lightbar The options are controlled by applying and removing power to the control wire of the function in the lightbar
7. Ends 80 Double FPM Pattern 16 Wraparound Inside to Outside Pattern 17 Wraparound Inside to Outside to Inside Followed by Wig Wag Alt Flash Pattern 18 Wig Wag Driver Side Front Alt with Passenger Side Front Pattern 19 In Tow Mode Pattern 1 Mode 2 Pattern 1 continues on next page 20 Chapter 3 Installing the JLX JetSolaris Table 3 4 Lightbar Flash Patterns for Standard JLX ROC Lightbars continued Pattern 20 In Tow Mode Pattern 2 Mode 2 Pattern 2 Pattern 21 In Tow Mode Pattern 3 Mode 2 Pattern 3 Pattern 22 Flash Mode 2 Pattern 4 Pattern 23 Quad Wraparound In Out Full Quad Pattern 24 Wraparound In Out 40 mS Per Lighthead Pattern 25 Wig Wag Driver Side Front Alt with Passenger Side Front Followed by Alt Flash Pattern 26 Quad Flash Pattern 27 Wraparound Inside to Outside to Inside Followed by Wig Wag Alt Flash Followed by Full Quad Flash Pattern 28 Wraparound Inside to Outside to Inside Followed by a Quad Flash Pattern 29 Double Flash of Pairs Followed by a Quad Flash of Pairs and End Caps Pattern 30 Quadrant Flash Followed by Wraparound Inside to Outside Followed by a Triple Full Flash Pattern 31 Increasing Rate Alt Flash Followed by a Triple Full Flash Pattern 32 Alternate Triple Flash of Entire Lightbar Pattern 33 Double Flash Driver and P
8. Establishing a regular maintenance schedule for the LED JLX extends the life of the lightbar and ensures safety Periodically check that the lightbar operates properly and that all mounting hardware is securely fastened to the vehicle Also inspect the domes and reflectors for cracks crazing hairline cracks discoloration and other defects This chapter has information for replacing components such as lamps printed circuit boards PCBs and fuses For service support or replacement parts contact the Federal Signal Service Department at 1 800 433 9132 7 am to 5 pm Monday through Friday CT Cleaning the Plastic Domes A WARNING CRAZING CHEMICALS Crazing cracking of domes 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 does occur the reliability of light for emergency signaling purposes may be reduced until domes are replaced Chapter 6 Servicing the Lightbar 29 Failure to follow this warning can damage the domes and may result in bodily injury or death to you or others 1 Rinse the domes with lukewarm water to loosen dirt and debris 2 Use a mild soap lukewarm water and a soft cloth to gently clean the domes To avoid dam aging the lens do not use heavy pressure or caustic abrasive or petroleum based cleaners 3 Rinse then dry the domes with a soft cloth to prevent water
9. S E EG 28 Cleaning the Refl ctorS h cssetisrsieccsasieentiesa ienna AAEE AEEA AEA E 29 Replacing the Halogen LamMPSiiiriissnani tinia ter AEEA ANEA AAEREN 29 Aiming the Halogen Lamps iecccecccitiedvencstecscid hansie a e aaa OERA brace tii ES 32 R pl cing an End BOard o neniraeniann eina a AEA E da A TAES 33 Replacing the Control Boardi cirean oniani a EAEE EEEE AA 35 Replacing a FUSS iss cassecancesactacavanpacavede AOE EA A ENE AEE AEE NENEA 36 Replacing a Center Board tscneiiinsiaisneiweitaveinedsmaeuiwid ees E EAE 37 Replacing the Solar Panel isetecistcsaesieiw ea E E E 38 Chapter 7 Ordering Parts and ServiCe c cccceeeeeeeeeeeeeeeeeeeeeeeeaeeeeaeeauaesaseoueseouaeeouageanaes 39 Getting Technical Support and ServiCe cece eee eee EEN ANETE NENA 39 Ordering Replacement Parts ei ciasca dees ninina ana ENAA Sens Giaesiiaedaheetdsausdacnedeeedanetane 39 Returning a Product to Federal Sighaless guirean nans a a a a a E ene 39 Contents Table 3 1 Table 3 2 Table 3 3 Table 3 3 Table 3 4 Table 4 1 Figure 3 1 Figure 3 2 Figure 4 1 Figure 4 2 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Tables 9 conductor cable wires 12 AWG Standard JLX csccececceceeceeeeeeeeee teense eeeetenteees 14 11 conductor cable wires 12 AWG Standard JLX s sssssssssssssssssrrrrssrrrrrssrrrrnes 14 23 conductor cable wires 12 AWG UNICOR ssessessssssrssssssnsannersnrrensanrse
10. be the sole responsibility of the user To avoid denting the roof of the vehicle place the lightbar mounting feet as close to the outer edge of the roof as possible Roof damage can occur if the hook adjustment bolts are over tightened Tighten adjustment bolts 10 to 11 ft lb to prevent the lightbar from sliding front to back when pulling on the mounting bracket Locate the light system controls so the VEHICLE and CONTROLS can be operated safely under all driving conditions After Installation or Service After installation test the light system to ensure that it is operating properly Test all vehicle functions including horn operation vehicle safety functions and vehicle light systems to ensure proper operation Ensure that the installation has not affected the vehicle operation or changed any vehicle safety function or circuit Scratched or dull reflectors mirrors or domes will reduce the effectiveness of the lighting system Avoid heavy pressure and use of caustic or petroleum based products when cleaning the lighting system Replace any optical components that may have been scratched or crazed during system installation Do not attempt to activate or de activate the light system control while driving in a hazardous situation You should frequently inspect the light system to ensure that it is operating properly and that it is securely attached to the vehicle After installation and testing are complete provide a copy of
11. resulting in electrical fires or flying molten metal DO NOT install equipment or route wiring or the plug in cord in the deployment path of an airbag Before mounting any components check the manual to be sure that the component you are installing is suitable for use in that area of the vehicle Many components are not suitable for use in the engine compartment or other extreme environmental exposure areas Service life of light bulbs and strobes tubes will be shortened if the glass portion is touched during installation Use gloves when handling these components If the glass portion has been touched clean the glass carefully with isopropyl alcohol Chapter 1 Safety Message to Installers and Service Personnel 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 Also ensure that the mounting screws do not cause electrical or mechanical damage to the vehicle Refer to the manual packed with the lighting system for proper electrical connections additional precautions and information Because vehicle roof construction and driving conditions vary do not drive a vehicle with a magnetically mounted warning light installed The light could fly off the vehicle causing injury or damage Repair of damage incurred because of ignoring this warning shall
12. spotting 4 To remove fine scratches and haze use a specialty plastic cleaner polish and a soft cloth You can also use a high quality automotive paste cleaner wax that is non abrasive The most effective product you can use for cleaning protecting and polishing clear and colored plastics is Plexus Plastic Cleaner Protectant amp Polish Over time exposure to heat sunlight and smog causes plastic to fade discolor scratch or become brittle Plexus seals the pores of the plastic making the plastic easier to clean improving scratch resistance and increasing product longevity Plexus is available in cases of twelve 13 ounce cans PX13 from Federal Signal Corporation Cleaning the Reflectors 1 Use a large flat head screwdriver to remove the two 1 4 20 screws that secure the end dome to the aluminum extrusion Figure 3 1 on page 14 and remove the nameplate 2 Slide the end dome off the aluminum extrusion along with any additional domes to access the PCB containing the reflectors 3 Use a soft tissue to clean the reflectors Avoid heavy pressure and the use of caustic or pe troleum base solvents which will scratch or dull the surface Replacing the Halogen Lamps A WARNING CAREFULLY HANDLE THE HALOGEN LAMP Halogen lamps get hot enough to burn you Always allow these devices to cool before handling them Halogen lamps are also pressurized and if broken can result in flying glass Always wear gloves and eye protection wh
13. tabs on the housing The hardware to install the charger is installer supplied 1 3 Select a permanent mounting location for the charger near the battery that is protected from the elements and is undisturbed by mechanics or other devices The location also must be close enough to the battery so that the 18 AWG 33 red and black power leads from the charger can be connected to the battery without splicing 4 WARNING DO NOT MOUNT Charger ON BATTERY Do not mount or fasten the charger directly to the surface of the battery Failure to heed this warning may damage the equipment or cause personal injury 4 WARNING DRILLING PRECAUTIONS Before drilling holes check the area into which you plan to drill to ensure you do not damage vehicle components while drilling All drilled holes should be deburred and all sharp edges should be smoothed All wires going through drilled holes should be protected by a grommet or convolute split loom tubing To mount the charger use the tabs as a template and mark two drill position marks at the mounting location Use the installer supplied hardware to secure the charger box to the mounting location Wiring the Solar Panel Charging System 4 WARNING AIRBAG DEPLOYMENT Do not install equipment or route wiring in the deployment path of an airbag Failure to observe this warning will reduce the effectiveness of the airbag or potentially dislodge the equipment c
14. that the vehicle is returning from the scene The default pattern in Primary Mode is Pattern 1 Alternating Quad Flash 76 QFPM In Secondary Mode it is Pattern 2 Overlapping Penta Flash 87 FPM Table 3 4 on page 15 lists the flash patterns in the lightbar pattern library We recommended that you select flash patterns for both Primary and Secondary Mode during the installation of the lightbar There are two methods of selecting a flash pattern for Primary and Secondary Mode One method enables you to directly apply ground or 12 Vdc power to wires in the lightbar control cable This method is best suited for a lightbar not yet connected to a control head The other method enables you to press a mode button on the control head and select a pattern using a programming button inside the lightbar The two methods are described in the next sections For descriptions of the control wires see Tables 3 1 and 3 2 on page 10 Chapter 3 Installing the JLX JetSolaris 17 NOTE To return to the default flash pattern while programming Primary or Secondary Mode using the control wire method apply GND to the orange wire for 5 seconds Programming Primary Mode Table 3 4 on page 15 lists the flash patterns in the lightbar library 1 2 4 Apply 12 Vdc to the Primary red wire in the lightbar cable Apply GND to the orange wire in the lightbar cable A WARNING LIGHT HAZARDS To be an effective warning device this product
15. 4 WARNING People s lives depend on your proper installation and servicing of Federal Signal products It is important to read and follow all instructions shipped with this product In addition listed below are some other important safety instructions and precautions you should follow Before Installation or Service Qualifications To properly install or service this equipment you must have a good understanding of automotive mechanical and electrical procedures and systems along with proficiency in the installation and service of safety warning equipment Always refer to the vehicle service manuals when performing equipment installations on a vehicle Light Hazards To be an effective warning device this product produces bright light that can be hazardous to your eyesight when viewed at a close range Do not stare directly into this lighting product at a close range or permanent damage to your eyesight may occur Do not install the light system in an area that would block impair or blind the driver s vision Ensure that the light system is mounted in a position that is outside of the driver s field of vision so the driver can safely operate the vehicle Federal Signal power supplies and light heads are designed to work together as a system Combining light heads and a power supply from different manufacturers may reduce the warning effectiveness of the lighting system and may damage the components You should verify o
16. ALL other electrical connections are completed mounting of all components are complete and you have verified that no shorts exist High current shorts can cause hazardous sparks or burning wire resulting in an electrical fire FUSE ELECTRICAL SOURCES Always fuse the current voltage sources with a fuse connected near the power source Be sure that the fuse is properly rated to protect the electrical load the wiring and the connectors in the circuit Failure to follow this notice could result in vehicle or equipment damage 4 Connect the red 10 AWG power lead from the lightbar to an installer supplied switch or re lay rated at 30 A 5 Connect the other side of the fuse circuit breaker to the 12 Vdc supply NOTE The driver and passenger sides of the lightbar are individually and internally fused with a 15 A fuse located on the lightbar control board at F3 and F4 See Replacing a Fuse on page 32 Control Wires For the Standard JLX Lightbar All of the lightbar controls are integrated in the ROC PC board Lightbars are manufactured with either a 9 conductor control cable or a 11 conductor control cable See Tables 3 1 and 3 2 on page 10 for the functions of the control wires You can activate any of the lightbar functions by applying 12 Vdc to the wire that controls the function 14 Chapter 3 Installing the JLX JetSolaris For information on the option to enable the lightbar to cut off certain lights see Wirin
17. F FEDERAL SIGNAL LED JetSoLar s Lightbar with ROC Technology JLX 48 54 60 and 72 Series AN iN ij RET wee AAEE pE a C Sovaris LQ RELIABLE ONBOARD CIRCUITRY Installation and Service Manual 2562335C REV C 512 Printed in U S A Contents Chapter 1 Safety MCSSAGES u csscsecseceseeeeeneeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeaeeaaeaaeaaensaeaaeuneaaenaennenaes 5 Safety Messages to Installers and Service Personnel of Warning Light Equipment 5 Safety Message to Operators of Warning Light Equipment ceeceeeeee eee eee teeta e eee ee 8 Chapter 2 An Overview of the JLX JETSOLARIS ccceceeeeeeeeeeeeeaueeeauaeeauaeeaseauaseauaeeauaneauaneaes 10 Product OVEIVICW sisictiutes siiri t anant inna AEEA AER ANNEE AEEA ADE AARNA E N EAAS 10 Lightbar Specification Snir erenaam a e a aaa ANETAR ENTENT 10 Unpacking the PrOduUctictt cteacietisideiventhtaneted aan a a AEA a A TA biased aliens 11 Before YOU BEGIMcasctasiavadsesacthwavaipacavicaaanctunenunedawe dean Ccnteraan dae elencdaterteden dant oustaeereras eke 11 Chapter 3 Installing the JLX JETSOLARIS ccececeeeeeeeeeeeeeeeeeaeaeeauaeeaeaeeaeaeeageauaseaueseauageanags 12 Connecting the Power Leads for the Standard JLX c ceceeceee eee eect eee e eens eee eee eae 12 Control Wires For the Standard JLX Lightbar eccecceeee eect e eee erates teeta eee ena 13 Control Wires for the UNICOR JLX Lightbar ec cece e
18. aged by an electrostatic discharge ESD Follow anti static procedures while servicing the PCB Use a 1 4 nutdriver to remove the eight hex head screws securing the end board to the end bracket Turn the endboard over noting the placement of the ground lead on the aluminum extrusion 34 Chapter 6 Servicing the Lightbar 1 4 HEX HEAD SCREWS 4 SECURING THE CENTER BOARD 1 4 HEX HEAD SCREWS 8 5 16 HEX HEAD SCREWS 4 SECURING THE CENTER 9 ALUMINUM EXTRUSION TO THE BRACKET SECURING THE END BOARD TO THE BRACKET ENTER BOARD Q END BOARD 5 16 HEX HEAD SCREWS 10 SECURING THE END BRACKET TO THE ALUMINUM EXTRUSION BRACKET TO THE ALUMINUM EXTRUSION ae CENTER aaa 1 k Pa 290A6262 END BRACKET Figure 6 4 Center board and end board exploded view Use a 5 16 nutdriver to remove the nut securing the ground connection to the aluminum extrusion Remove the ring terminal from the ground stud Remove the 8 32 Phillips screw securing the ground wire GND to the end PCB and remove the wire from the board Cut any wire ties that group the wire connections to the end board NOTE The colors of the wires connected to the end board are silkscreened next to their connectors Disconnect wires and harnesses from the end board and remove it from the lightbar Installing an End Board 1 2 Reconnect the wires and harnes
19. and the outer housing get hot during operation Be sure to disconnect power to the system and allow the system to cool down before handling any components of the system Halogen light bulbs and strobe tubes are pressurized and if broken can burst and result in flying glass Always wear gloves and eye protection when handling these components Do not mount a radio antenna within 18 inches 45 7 cm of the lighting system Placing the antenna too close to the lighting system could cause the lighting system to malfunction or be damaged by strong radio fields Mounting the antenna too close to the lighting system may also cause the radio noise emitted from the lighting system to interfere with the reception of the radio transmitter and reduce radio reception Do not attempt to wash any unsealed electrical device while it is connected to its power source During Installation and Service DO NOT get metal shavings inside the product Metal shavings in the product can cause the system to fail If drilling must be done near the unit place an ESD approved cover over the unit Inspect the unit after mounting to be sure there are no shavings present in or near the unit DO NOT connect this system to the vehicle battery until ALL other electrical connections are made mounting of all components is complete and you have verified that no shorts exist If the wiring is shorted to the vehicle body or frame high current conductors can cause hazardous sparks
20. aris 19 TOP OF PASSENGER SIDE END PCB PROGRAM BOTTOM OF f PASSENGER SIDE IS Figure 3 2 Location circle of S1 PROGRAM button 5 To see the next pattern in the library press the PROGRAM button until the lightbar again changes patterns 6 To select a pattern allow it to run for at least 15 seconds to save it in memory Table 3 4 Lightbar Flash Patterns for Standard JLX ROC Lightbars Pattern Description Pattern 1 175 Alternating Single Pattern 2 Overlapping Penta Flash 87 FPM Pattern 3 Overlapping Alternating 95 FPM Pattern 4 Alternate Quad Flash 76 QFPM Pattern 5 Simultaneous Overlapping Triple Nine Pattern 6 Alternating Single Pattern 7 640 FPM Overlapping With Overlap 5 2 Pattern 8 2 at 60 FPM 4 Pulse Alternating then 2 at 60 FPM 2 Pulse Simultaneous Pattern 9 Driver Side End Rear Alt with Passenger Side End Rear 1i20 Single FPM Pattern 10 Driver Side End Rear Alt with Passenger Side End Rear 90 Single FPM Pattern 11 Driver Side End Rear Alt with Passenger Side End Rear Alternate with Center Rear 80 Double FPM Pattern 12 Driver Side Passenger Side Center Rear Alternate with Center Rear Driver and Passenger Ends 80 Double FPM Pattern 13 Lightheads Oscillate In Out Pattern 14 Driver and Passenger Front Ends Alt with Center Front Pattern 15 Driver and Passenger Front Ends Alt with Center Front Followed by Center Front Alt with Driver and Passenger Front
21. assenger Front with Driver and Passenger Rear Pattern 34 Double Flash Driver and Passenger Front with Driver and Passenger Rear Followed by Wraparound Inside to Outside Pattern 35 Double Flash Driver and Passenger Front Wraparound In Out Followed by Double Flash of Driver and Passenger Rear Wraparound Out In Pattern 36 Wraparound In Out Alt Double Flash Wraparound Out In Full Quad Flash Pattern 37 Full Quad Flash Wraparound Out In Alt Double Flash Wraparound In Out Pattern 38 Alternate Triple Flash Entire Lightbar Twice Wraparound In Out Alt Double Flash Wraparound In Out Pattern 39 Alternating 90 FPM Pattern 40 Test Pattern Rotate Entire Lightbar 750 mS Per Head Denotes that the pattern is SAE compliant Testing the System 4 WARNING SOUND HAZARD All effective sirens and horns produce loud sounds 120 dB that may cause permanent hearing loss Always minimize your exposure to siren sound and wear hearing protection Do not sound the siren indoors or in enclosed areas where you and others will be exposed to the sound After the installation test the emergency warning system to ensure that it is operating properly Also test all vehicle functions including horn operation vehicle safety functions and vehicle lighting systems to ensure proper operation Ensure that the installation has not affected the vehicle operation or changed any vehicle safety functions or circuits After testing is complet
22. at prevent good surface contact Jv Ensure that mounting surface is flat Chapter 1 Safety Message to Installers and Service Personnel 9 J A magnet mounting system should not be used on vehicles with vinyl tops J To prevent sliding of light assembly on mounting surface quick acceleration and hard stops should be avoided Failure to follow these precautions may result in property damage serious injury or death to you to passengers and to others RETAIN AND REFER TO THIS MESSAGE 10 Chapter 2 An Overview of the JLX JetSo aris In this chapter E Product Overview E Lightbar Specifications mM Unpacking the Product E Before You Begin Product Overview The JetSotaris is an LED lightbar that can be used in a variety of applications for Fire Rescue Police DOT and Tow Recovery The JetSotaris features the latest in SoLaris LED and ROC Reliable Onboard Circuitry technology ROC substantially reduces wiring and connections with its consolidated design of printed circuit boards and the So aris LED reflectors provide maximum LED performance Sotarts LED and ROC technology improves the performance and virtually eliminates any maintenance while being supported by a five year warranty on the LED components The standard JetSo aris comes with 40 selectable flash patterns including a test pattern The LEDs are available in amber blue red white and green Dome colors are available in amber blue red and clear Hal
23. ausing serious injury to you or others Installer supplied connectors are required for splicing wires from the solar panel to the charger l Route the solar panel 28 ft cable through the vehicle toward the charger Apply sealant to all drilled holes 4 CAUTION SHOCK HAZARD DO NOT hold the positive and negative ends of the terminal wires at the same time if the solar panel is in sunlight as it can inflict an electric charge to the body Chapter 5 Installing the Solar Panel Charging System Option 27 NOTICE SHORT CIRCUIT HAZARD DO NOT hold the ends of the solar panel wires together while the panel is in sunlight Failure to heed this notice will short out the output of the solar panel and can cause the panel to fail ee ae DO NOT SPLICE LEADS TO BATTERY Do not splice the leads between the charger and the battery Increasing the lead length will decrease the effectiveness of the charger Remove excess cable and splice the 18 AWG red yellow and black wires from the lightbar cable to wires of the same gauge and color in the charger cable 4 CAUTION HIGH CURRENT ARCING DO NOT connect this system to the vehicle battery until ALL other electrical connections are completed mounting of the components is complete and you have verified that no shorts exit High current shorts can cause hazardous sparks or burning wire resulting in an electrical fire DO NOT SPLICE CHARGER WIRES Do not splice t
24. b Slide the end dome off the aluminum extrusion c Usea 1 4 nutdriver to remove the eight hex head screws that secure the lamp PCB to the bracket and turn the PCB over d Use a 1 16 hex key to remove the lamp s retaining screws and clamps Figure 6 2 on page 28 3 Replace the lamp a Slide the lamp and socket from the housing just far enough to grasp the socket You may need to unplug the connector to gain adequate slack in leads b Hold the socket firmly and unplug lamp c Insert a new lamp and reinstall the clamps and retaining screws Do not overtighten screws 4 Turn the PCB over and secure it to the bracket with the eight 1 4 screws 5 Secure the end dome and nameplate with the two 1 4 20 screws 6 Reconnect power to the lightbar 32 Chapter 6 Servicing the Lightbar SOCKET RETAINING CLAMP 2 RETAINING SCREW 2 1 pa By N 290A5759B Figure 6 2 Alley lamp replacement PN 8107241 Aiming the Halogen Lamps You can adjust the aim of the halogen lamps horizontally 8 degrees and vertically 2 degrees 5 degrees NOTICE STATIC SENSITIVE DEVICE The PCBs can be damaged by an electrostatic discharge ESD Follow anti static procedures while servicing the PCB 1 Disconnect power to the lightbar 2 Remove the appropriate end dome NOTICE DO NOT OVERTIGHTEN SCREWS NUTS To avoid damage to the lightbar do not overtighten the screws and nuts 3 Adjust the horizonta
25. d from bracket Replacing a Fuse The control board which is beneath the passenger side PCB has two 15 A automotive mini blade fuses to protect the lightbar The fuse in position F3 is for the passenger side of the lightbar and the fuse at F4 is for the driver side if available in your model and the driver side of the lightbar Before replacing a fuse investigate the cause of the circuit failure __NOTICE STATIC SENSITIVE DEVICE The PCBs can be damaged by an electrostatic discharge ESD Follow anti static procedures while servicing the PCB 1 2 Disconnect power to the lightbar Use a flat head screwdriver to remove the two 1 4 20 screws that secure the passenger side end dome to the aluminum extrusion and remove the nameplate Figure 3 1 on page 14 Slide the dome off the aluminum extrusion Use a 5 16 nutdriver to remove the ten hex head screws securing the end bracket to the aluminum extrusion Turn the bracket over to expose the control board Chapter 6 Servicing the Lightbar 37 6 Use needle nose pliers to pull the fuse straight out off the board 7 Insert a new fuse of the same type and amperage into the slots and ensure that it is prop erly seated NOTICE DO NOT OVERTIGHTEN SCREWS NUTS To avoid damage to the lightbar do not overtighten the screws and nuts 8 Secure the end bracket to the aluminum extrusion with the ten 5 16 hex head screws 9 Reinstall the dome 10 Reconnect power to
26. e provide a copy of these instructions to the instructional staff and all operating personnel Chapter 3 Installing the JLX JetSolaris 21 Do not test the sound and light system of the vehicle while driving Operating the vehicle warning systems may pose a hazard to the operator and other drivers if the systems do not function as expected Test the vehicle only in a controlled environment 22 Chapter 4 Installing the S1icnaLMaster Option In this chapter m Assembling and Mounting the Control Head Wiring the Control Head MH Operating the Control Head Assembling and Mounting the Control Head A WARNING AIRBAG DEPLOYMENT Do not install equipment or route wiring in the deployment path of an airbag Failure to observe this warning will reduce the effectiveness of the airbag damage the airbag or potentially dislodge the equipment causing serious injury to you or others The SicnaLMaster option includes a control head with a cable that has five 22 AWG leads and one 18 AWG jumper wire If additional wire length is need splice wire of the same gauge or heavier to the leads 1 Assemble the control head as shown in Figure 4 1 The switches must be installed as shown for the control head to operate properly Two installer supplied sheet metal screws are re quired for mounting the control head 22 AWG CHASSIS GROUND LEAD FROM SIGNALMASTER SWITCH BRACKET NOTE GOLD NO 3 i TERMINAL gt s Swie ONETOR
27. e system has two functions It provides a charge to the battery to offset parasitic loads on the lead acid vehicle battery such as a radio computer or alarm These key off loads drain the battery even when the ignition is turned off It provides a constant electronic direct current pulse that removes lead sulfates on the lead acid vehicle battery Cleaning the battery plates of sulfates helps batteries maintain maximum power and extends battery life IMPORTANT For the Solar Panel Charging System to be effective the vehicle must be parked in an area exposed to DIRECT SUNLIGHT Although the Solar Panel Charging System is inside the lightbar it is not electrically connected to the lightbar electronics Instead it has a 28 ft 3 conductor cable exiting the bottom of the lightbar that you splice to the same color leads from the charger during the lightbar installation The charger also has 33 inch power leads with ring terminals that you will connect to the vehicle battery Product Specifications Battery Type Lead acid flooded AGM gel cell Poise Frequency 22 28 kHz Extends battery life by cleaning battery plates of large damaging lead sulfates Max Charging DC Voltage 16 5 V 365 mA Charger Dimensions 3 25 in x 2 25 in x 1 5 in HxLxW 82 6 mm x 57 2 mm x 38 1 mm Reverse polarity protected 26 Chapter 5 Installing the Solar Panel Charging System Option Mounting the Charger The charger has two mounting
28. ee eee eee e eee teeta eiia 15 Wiring the Controls for White Light and Front Rear Cutoff Except Lightbars with 23 Pin Shell Connectors c cece cece e ee eee EAEN na neat 16 Selecting Flash Patterns for Primary and Secondary MOde ccccesceeeeeeeeee tees eeeeeneeeeeeneenaees 16 Testing the SYStEM evi ciscrsseccetiaeeeerrseesdQacitea a Eee A a aA a a Aaa 20 Chapter 4 Installing the SIGNALMASTER Option ssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 22 Assembling and Mounting the Control Head cccccece eee ee eee e ee eee eee eee eaten aa a 22 Wiring the Control H ad ienser cease riii ienaa EE EAA ANETE E EEEE 23 Operating the Control H ad srsisissciriroini eneas anaE EAEAN EEEE 24 Chapter 5 Installing the Solar Panel Charging System Option c ccseeeeseeeeeeeeeeenees 25 An Overview of the Solar Panel Charging SySteM ccciceeeeeeee eee e eee eee eats teeta tetas 25 Product Specifications esre ess ocevetidinnteae cas een tierendign DE dsaetiaa died cee conta didveukds 25 Mounting the Charger sciiscceisticted ieir a Aaa a a AEE alee EA a E 26 Wiring the Solar Panel Charging SyStem sessrstsiririiosrieo ieii iE AAE AAAA 26 Chapter 6 Servicing the Lightbar ccscccceeeeceeueeeeeeeeeueeeeauaeeauaeeauaeeauaseausauageauaseauageanags 28 Establishing a Maintenance Schedule cee cce cece eee eee a a eae eee eee a E 28 Cleaning the Plastic DOMES viicirssetescctsaweisereeane stan ekeuetia a a a A
29. en handling these devices Failure to follow this caution may result in personal injury AWARNING LAMP WATTAGE This device is designed to use a halogen lamp of 50 watts only Use of a lamp of more than 50 watts can result in damage to the lens property damage or injury to you or others 4 CAUTION HANDLE STROBE AND HALOGEN LAMPS CAREFULLY Strobe and halogen lamps get hot enough to burn you Always allow the lamps to cool before handling these devices Halogen and strobe lamps are also pressurized 30 Chapter 6 Servicing the Lightbar and if broken can result in flying glass Always wear gloves and eye protection when handling these devices Failure to follow this caution may result in personal injury NOTICE _ DO NOT TOUCH LAMPS WITH BARE HANDS Oil deposits on the glass portion of a halogen lamp can cause the glass to facture during use If you are unsure whether the glass portion has been handled without gloves clean the glass using a soft cloth and isopropyl alcohol before installing the lamp NOTICE DO NOT OVERTIGHTEN SCREWS NUTS To avoid damage to the lightbar do not overtighten the screws and nuts NOTICE _ STATIC SENSITIVE DEVICE The PCBs can be damaged by an electrostatic discharge ESD Follow anti static procedures while servicing the PCB Replacing the Worklight and Takedown Halogen Lamps Depending on your lightbar configuration the lightbar may be equipped
30. er electrical connections are completed mounting of all components is complete and you have verified that no shorts exist High current shorts can cause hazardous sparks or burning wire resulting in an electrical fire 1 Wrap the control cable s stripped wire ends with tape and route the cable to the control head mounting location 2 Crimp the 1 4 inch FASTON terminals on the ends of the cable leads 3 Connect the terminals on the switch as shown in Figure 4 2 on page 20 4 Ensure that there are no loose wire strands or other bare wires that may cause a short circuit All wires must be protected from any sharp edges that could eventually cut through the insulation 24 Chapter 4 Installing the SignalMaster Option SWITCH BRACKET HAZARD REAR VIEW N SWITCH CHASSIS GROUND SWITCH WHITE p GOLD 112i RED TERMINAL BLACK RED GREEN JUMPER WIRE FROM NOTE TWO WIRES ARE INSTALLATION KIT CONTROL CABLE CRIMPED IN ONE TERMINAL ASSEMBLY NOTE MATING FEMALE TERMINALS ARE CRIMPED ON WIRES BEFORE CONNECTING TO SWITCHES CAUTION IMPROPER WIRING OF THE ILLUMINATED SWITCH FEATURE WILL RESULT IN P C B DAMAGE ENSURE THAT THE CHASSIS GROUND LEAD 22 AWG BROWN IS CONNECTED TO THE GOLD PIN 3 TERMINAL 290A5309 01 Figure 4 2 Connections for SicnatMaster control head Table 4 1 SignatMaster control cable wires
31. ern in the library and stores it in memory For a description of the flash patterns see Table 3 4 on page 15 continues on next page Chapter 3 Installing the JLX JetSolaris 15 Table 3 2 11 conductor cable wires 12 AWG Standard JLX continued Yellow WHITE LIGHT CUTOFF Used only in lightbars that have white light in the front three positions White lights flash with the rest of the lightbar when 12 Vdc is applied to the yellow wire White lights are cut off when disconnected or power is removed See Wiring the Controls for White Light and Front Rear Cutoff Except for Lightbars with 23 Pin Shell Connectors on page 12 If the wire is not used for white light cutoff other options are takedown lights traffic clearing lights or worklights Brown Driver side brake turn or alley lights Brown White Passenger side brake turn alley light or passenger side traffic clearing light Black White Tail lights takedown lights traffic clearing lights or worklights Red White SicnaLMaster right directional lights passenger side stop turn tail lights or both alleys simultaneously The red and blue wires also serve as programming wires for Secondary Mode See Programming Secondary Mode on page 13 The wire color for a function with the exceptions of the red blue and orange wires may vary depending on the configured options in the lightbar Control Wires for the UNICOR JLX Lightbar
32. g the Controls for White Light and Front Rear Cutoff Except Lightbars with 23 Pin Shell Connectors on page 12 Table 3 1 9 conductor cable wires 12 AWG Standard JLX Wire Color Function Red PRIMARY MODE 12 Vdc Activates the lightbar in Primary Mode For a description of Primary Mode see page Selecting Flash Patterns for Primary and Secondary Mode on page 12 Black GND Connects to a good battery chassis ground Gray Takedown lights traffic clearing light worklights or StcnaLMaster left directional lights Green Front light cutoff rear light cutoff or StcnaLMaster center out directional lights Blue SECONDARY MODE Applying 12 Vdc changes the pattern of the lightbar to the pattern selected for Secondary Mode The function is only active if the lightbar is flashing in Primary Mode For a description of Secondary Mode see page Selecting Flash Patterns for Primary and Secondary Mode on page 12 Orange PROGRAM for Primary Mode Applying GND advances the flash pattern to the next pattern in the library and stores it in memory For a description of the flash patterns see Table 3 4 on page 15 for the flash patterns Yellow Brown WHITE LIGHT CUTOFF Used only in lightbars that have white light in the front positions White lights flash with the rest of the lightbar when 12 Vdc is applied to the yellow wire White lights are cut off when disconnected or
33. hapter 7 Ordering Parts and Service In this chapter MH Getting Technical Support and Service mM Ordering Replacement Parts E Returning a Product to Federal Signal Getting Technical Support and Service For technical assistance and service for your Federal Signal product please contact Federal Signal Corporation Mobile Systems Service Department Phone 1 800 433 9132 Fax 1 800 343 9706 Email empserviceinfo fedsig com Ordering Replacement Parts To order replacement parts please contact your local dealer distributor or Mobile Systems Customer Support Federal Signal Corporation Phone 1 800 264 3578 Returning a Product to Federal Signal Before returning a product to Federal Signal call 800 264 3578 800 433 9132 or 800 824 0254 to obtain a Returned Merchandise Authorization number RMA number To expedite the process please be prepared with the following information e Your Federal Signal customer or account number e The purchase order number under which the items were purchased e The shipping method e The model or part number of the product being returned e The quantity of products being returned e Drop ship information as needed e Any estimate required 40 Chapter 7 Ordering Parts and Service When you receive your RMA Number e Write the RMA number on the outside of the box of returned items e Reference the RMA number on your paperwork inside of the box e Write the RMA number down so tha
34. he leads between the charger and the battery increasing the distance from the charger to the battery Increasing the lead length will decrease the effectiveness of the charging module NOTICE REVERSE POLARITY The red positive wire must be connected to the red positive battery terminal and the black negative wire to the black battery terminal Reversing connections could drain the battery Remove the nut securing the battery clamp to the positive battery terminal Slip the ring terminal on the red positive wire from the charger on the battery clamp and securely tighten the nut onto the clamp Remove the nut securing the battery clamp to the negative battery terminal Slip the ring terminal on the black negative 18 AWG wire from the charger on the bat tery clamp and securely tighten the nut onto the clamp 28 Chapter 6 Servicing the Lightbar In this chapter Establishing a Maintenance Schedule Cleaning the Plastic Domes Cleaning the Reflectors Replacing the Halogen Lamps Aiming the Halogen Lamps Replacing an End Board Replacing the Control Board Replacing a Fuse Replacing a Center Board Replacing the Solar Panel Establishing a Maintenance Schedule A WARNING QUALIFICATIONS To properly service a lightbar you must have a good understanding of automotive electrical procedures and systems along with proficiency in the installation and use of safety warning equipment
35. he lightbar 38 Chapter 6 Servicing the Lightbar Installing a Center Board 1 Reconnect the wires and harness to the center board and secure them with plastic ties NOTICE DO NOT OVERTIGHTEN SCREWS NUTS To avoid damage to the lightbar do not overtighten the screws and nuts 2 Secure the ground wire to the ground connection GND on the center board with the 8 32 Phillips screw 3 Secure the center board to the bracket with the four 1 4 hex head screws 4 Reinstall the domes 5 Reconnect power to the lightbar Replacing the Solar Panel The solar panel is attached to the driver side end board with Velcro It is connected to the charger cable with a red yellow and black wire Figure 6 6 7 290A6258 Figure 6 6 Solar panel 1 Disconnect power to the lightbar 2 Use a flat head screwdriver to remove the two 1 4 20 screws that secure the driver side end dome to the aluminum extrusion and remove the nameplate Figure 3 1 on page 14 3 Slide the end dome off the aluminum extrusion 4 Disconnect the three wires to the solar panel by grasping the connectors and pulling them apart 5 Grasp the solar panel by the edges and pull it from the Velcro 6 Press the new solar panel onto the Velco and ensure that the panel is securely attached 7 Reconnect the wires from the solar panel to the wires of the same color from the charger cable 8 Reinstall the dome 9 Reconnect power to the lightbar 39 C
36. l or vertical aim of the lamp Figure 6 4 on page 30 a Horizontal adjustment Loosen the lock nut with a 3 8 wrench while holding the adjusting screw with a small screwdriver Aim the lamp then carefully tighten the locknut with the wrench while holding the adjusting screw with screwdriver b Vertical adjustment Loosen the lock nut with a 3 8 wrench while holding the adjusting screw with a small screwdriver Turn the screw clockwise to lower the aim or counter clockwise to raise the aim Carefully tighten locknut with wrench while holding adjusting screw with screwdriver Chapter 6 Servicing the Lightbar 33 ADJUSTING SCREW LOCK NUT 290A5760B Figure 6 3 Adjustment screw for aiming the halogen lamp Replacing an End Board If the LEDs and halogen lamps on the end board do not light the fuse at F3 or F3 on the control board is intact and you have replaced the lamps the problem may lie with the end board or the control board For additional information see Replacing the Halogen Lamps on page 25 Replacing the Control Board on page 31 and Replacing a Fuse on page 32 Removing an End Board 1 2 Disconnect power to the lightbar Use a flat head screwdriver to remove the two 1 4 20 screws that secure the passenger side end dome to the aluminum extrusion and remove the nameplate Figure 3 1 on page 14 Slide the end dome off the aluminum extrusion STATIC SENSITIVE DEVICE The PCBs can be dam
37. nsennes 15 23 conductor cable wires 12 AWG UNICOR continued ssssssssssssssssssrsssssssss 16 Lightbar Flash Patterns for Standard JLX ROC LiQhtbasrs csccseceeeeeeneeseeseneenenes 19 SIGNALMASTER CONFON cable WIPES creirias kriinte de deen sh tend EREA EEEE sen gncse paves denn REEE 24 Figures Location circles of screws securing end COME s sssessesssrssrssnrssnssnserrerrsnrsersan 18 Location circle of S1 PROGRAM utton cscsistcscesnecncencceceenceeceeneeeeneneeennenaenaneas 19 SIGNALMASTER CONTFOL Nead serraria e inini EAEE Ove Deven E EE EEEE E 22 Connections for SIGNALMASTER CONtIO heades sisisvisnmisiiiiirantisti rennan LAE Eaa E RA 24 Halogen worklight and takedown replacement types ssssssssssssssssnssnnssrerrrrrrnrn 31 Alley lamp replacement PN 8107241 cccccccccacscccunennnennenneenneeneenn eee eeneeneenneensennaenen 32 Adjustment screw for aiming the halogen lamp 1ccscceceecee cette eee eeeeneeaenaeeetneeneee 33 Center board and end board exploded ViCW cctccececeeeeeeeneee eee enee nena ena teeenetaeee 34 Control board removed from bracket sssusa irnar iea A EREE E LERA 36 Solar paneli piren rennen a O a a A R E E Oii 38 Chapter 1 Safety Messages In this chapter mM Safety Messages to Installers and Service Personnel of Warning Light Equipment mM Safety Message to Operators of Warning Light Equipment Safety Messages to Installers and Service Personnel of Warning Light Equipment
38. ogen worklight options are also available Lightbar Specifications Dimensions H x L x W JLX 48 4 7 in x 47 5 in x 11 2 in 119 mm x 1207 mm x 284 mm JLX 54 4 7 in x 54 in x 11 2 in 119 mm x 1372 mm x 284 mm JLX 60 4 7 in x 60 in x 11 2 in 119 mm x 1524 mm x 284 mm JLX 72 4 7 in x 72 in x 11 2 in 119 mm x 1829 mm x 284 mm Current Draw Three button Solaris LED 0 5 A reflector any color Six button Solaris LED 1 0 A reflector any color Traffic Clearing Light 4 3 A Halogen Worklight 4 0 A Stop Tail Turn Light 0 32 A Voltage 12 Vdc Cable Length 15 ft 457 2 cm Chapter 2 An Overview of the JLX JetSolaris 11 Shipping Weight JLX 48 32 0 Ib 14 5 kg JLX 54 33 5 Ib 14 2 kg JLX 60 35 0 Ib 16 3 kg JLX 72 38 0 Ib 17 2 kg Approvals NFPA 1901 compliant models are available SAE J1318 J595 and J845 Class 1 Unpacking the Product After unpacking the product examine it for damage that may have occurred in transit If the product 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 Before You Begin 4 WARNING AIRBAG DEPLOYMENT Locate the controls for the light system so that the vehicle and control can be operated safely under all driving conditions Failure to heed this precaution could result in driver distraction or driver error while opera
39. passenger side end PCB directly below the label PROGRAM silkscreened on the top of the board Figure 3 2 on page 15 Table 3 4 on page 15 lists the flash patterns in the lightbar s library NOTICE STATIC SENSITIVE DEVICE This product s circuitry can be damaged by electrostatic discharge ESD Follow anti static procedures while installing this product NOTE To return to the default flash pattern while programming Primary or Secondary Mode using the pushbutton method apply GND to the orange wire for 5 seconds 1 Use a large flat head screwdriver to remove the two 1 4 20 screws that secure the passenger side end dome to the aluminum extrusion Figure 3 1 and remove the nameplate JetSola ris FEDERAL SIGNAL C ORPORATION Figure 3 1 Location circles of screws securing end dome 2 Slide the end dome off the aluminum extrusion 3 Apply power to flash the lightbar in Primary Mode A WARNING LIGHT HAZARDS To be an effective warning device this product produces bright light that can be hazardous to your eyesight when viewed at a close range Do not stare directly into this lighting product at a close range or permanent damage to your eyesight may occur 4 Press the Si PROGRAM button on the underside of the passenger side end PCB Figure 3 2 on page 15 The lightbar turns off momentarily and flashes the next pattern When the pattern changes observe the pattern Chapter 3 Installing the JLX JetSol
40. produces bright light that can be hazardous to your eyesight when viewed at a close range Do not stare directly into this lighting product at a close range or permanent damage to your eyesight may occur When the pattern changes disconnect the orange wire for a few seconds and observe the pattern To display the next pattern in the library apply and remove GND to the orange wire To select the pattern allow it to run for at least 15 seconds to set it in memory Programming Secondary Mode Table 3 4 on page 15 lists the flash patterns in the lightbar library 1 Apply 12 Vdc to both the Primary red and Secondary blue Mode wires to turn on the lightbar in Secondary Mode Apply GND to the orange wire in the lightbar cable A WARNING LIGHT HAZARDS To be an effective warning device this product produces bright light that can be hazardous to your eyesight when viewed at a close range Do not stare directly into this lighting product at a close range or permanent damage to your eyesight may occur When the pattern changes disconnect the orange wire for a few seconds and observe the pattern To display the next pattern in the library apply and remove GND to the orange wire To select a pattern allow it to run for at least 15 seconds to save it in memory 18 Chapter 3 Installing the JLX JetSolaris Programming with the PROGRAM Pushbutton The S1 PROGRAM pushbutton is on the underside of the
41. r test your combination to ensure the system works together and meets federal state and local standards or guidelines Electrical Hazards e Strobe systems present a shock hazard because they use high voltage to operate Do not handle strobe cables the power supply or bulbs or remove the lens while the equipment is connected Strobe systems can also hold their charge even after they have been turned Chapter 1 Safety Message to Installers and Service Personnel off After disconnecting power to the unit wait five minutes before handling any parts of the strobe system A light system is a high current system In order for the system to function properly a separate negative connection and positive connection must be made All negative connections should be connected to the negative battery terminal and a suitable fuse should be installed on the positive battery terminal connection as close to the battery as possible Ensure that all wires and fuses are rated correctly to handle the device and system amperage requirements Never attempt to install aftermarket equipment that connects to the vehicle wiring without reviewing a vehicle wiring diagram available from the vehicle manufacturer Ensure that your installation will not affect vehicle operation or mandated safety functions or circuits Always check the vehicle for proper operation after installation The lighting system components especially light bulbs strobe tubes LEDs
42. s injury to you or others 1 Route the control cable into the vehicle and under the dash near the eventual location of the installer supplied control head Apply sealant to all drilled holes 2 For proper lightbar operation the control cable must be properly terminated inside the install er supplied control head The current capacities of the switch for the control head should be at least 15 A See Tables 3 1 and 3 2 on page 10 for the wire colors and functions 4 WARNING PROPER GROUNDING The lightbar WILL NOT light up or flash if it is improperly grounded Be sure that the lightbar is connected to a good vehicle ground Failure to observe this warning can lead to equipment failure and may result in serious injury or death to you or others Chapter 3 Installing the JLX JetSolaris 13 3 Connect the black 10 AWG ground lead to a good battery or chassis ground 4 WARNING SPARK HAZARD If wires are shorted to the vehicle frame or each other high current conductors can cause hazardous sparks resulting in electrical fires and molten metal Verify that no short circuits exist before connecting to the positive battery terminal A WARNING CURRENT CAPABILITY To provide safe operation of the lightbar the power control switch and wiring must be capable of handling the rated current of the fuse at the source 4 CAUTION HIGH CURRENT ARCING Do not connect this system to the vehicle battery until
43. s to the end board and secure them with plastic ties Reconnect the black ground wire GND to the end board with the 8 32 Phillips screw DO NOT OVERTIGHTEN SCREWS NUTS To avoid damage to the lightbar do not overtighten the screws and nuts Reconnect the ground wire to the aluminum extrusion with the 5 16 nut Secure the end board to the end bracket with the eight 1 4 hex head screws Slide the end dome onto the aluminum extrusion Secure the nameplate and end dome with the two 1 4 20 screws Chapter 6 Servicing the Lightbar 35 Replacing the Control Board The control board generates and receives the signals that control the lightbar s flash patterns If the lightbar fails the problem may lie with the board The board is underneath the passenger side end PCB The board also has two 15 A fuses that protect the lightbar To replace them see Replacing a Fuse on page 32 NOTICE STATIC SENSITIVE DEVICE The PCBs can be damaged by an electrostatic discharge ESD Follow anti static procedures while servicing the PCB Removing the Control Board 1 Disconnect power to the lightbar 2 Remove the end dome and end board from the passenger side of the lightbar as described in Removing an End board on page 29 3 Use a 5 16 nutdriver to remove the ten hex head screws securing the end bracket to the aluminum extrusion Figure 6 4 on page 30 4 Turn the bracket over to expose the control board 5 Remove the
44. t you can easily check on status of the returned equipment Send all material with the issued RMA Number to Federal Signal Corporation 2645 Federal Signal Drive University Park IL 60466 Attn Service Department RMA EF FEDERAL SIGNAL www fedsig com 2009 Federal Signal Corporation
45. the lightbar Replacing a Center Board The center board is approximately one third the size of an end board The 54 JLX has one center board the 60 JLX has three and the 72 JLX has four If the LEDs and halogen lamps on the center board do not light the fuse at F3 or F3 on the control board is intact and you have replaced the lamps the problem may lie with the center board For additional information see Replacing the Halogen Lamps on page 25 Replacing the Control Board on page 31 and Replacing a Fuse on page 32 __ NOTICE _ STATIC SENSITIVE DEVICE The PCBs can be damaged by an electrostatic discharge ESD Follow anti static procedures while servicing the PCBs Removing a Center Board 1 Disconnect power to the lightbar 2 Use a flat head screwdriver to remove the two 1 4 20 screws that secure the passenger side or driver side end dome to the aluminum extrusion and remove the nameplate Figure 3 1 on page 14 3 Slide the dome off the aluminum extrusion 4 Slide domes off the lightbar to expose the appropriate center board 5 Use a 1 4 hex wrench to remove the four hex head screws securing the board to the end bracket 6 Remove the 8 32 screw securing the ground wire GND to the center board and remove the wire from the board NOTE The colors of the wires connected to the center board are silkscreened next to their connectors 7 Disconnect wires and harnesses from the center board and remove it from t
46. these instructions to instructional staff and all operating personnel File these instructions in a safe place and refer to them when maintaining or re installing the product Failure to follow all safety precautions and instructions may result in property damage serious injury or death to you or others RETAIN AND REFER TO THIS MESSAGE 7 Chapter 1 Safety Message to Installers and Service Personnel Safety Message to Operators of Warning Light Equipment 4 WARNING People s lives depend on your safe use of our products Listed below are some important safety instructions and precautions you should follow Do not attempt to activate or de activate the light system control while driving in a hazard ous situation Although your warning system is operating properly it may not be completely effective People may not see or heed your warning signal You must recognize this fact and continue driving cautiously Also situations may occur which obstruct your warning signal when natural and man made objects are between your vehicle and others such as raising your hood or trunk lid If these situations occur be especially careful All effective sirens and horns produce loud sounds that may cause in certain situations permanent hearing loss You and your passengers should consider taking appropriate safety precautions such as wearing hearing protection In order to be an effective warning device this product prod
47. ting the vehicle Before you begin ensure that the lightbar has been installed on the vehicle roof according to the instructions included with the mounting kit An installer supplied control head controls the basic functions of the lightbar 12 Chapter 3 Installing the JLX JetSo aris In this chapter Connecting the Power Leads for the Standard JLX Control Wires for the Standard JLX Control Wires for the UNICOR JLX Lightbar Wiring the Controls for Front and Rear Light Cutoff Except Lightbars with 23 Pin Shell Connectors Selecting Flash Patterns for Primary and Secondary Mode Testing the System Connecting the Power Leads for the Standard JLX The lightbar is completely wired at the factory and does not require any additional internal wiring All the conductors necessary to control the lightbar s functions are contained in the cable Installation of options requires additional wiring to the warning light system and vehicle battery An installer supplied switch or relay rated at 30 A is required for the connection between the JLX red power lead and the fused power source If additional wire length is needed splice wire of the same gauge or heavier to the leads 4 WARNING AIRBAG DEPLOYMENT Do not install equipment or route wiring in the deployment path of an airbag Failure to observe this warning will reduce the effectiveness of the airbag damage the airbag or potentially dislodge the equipment causing seriou
48. uces bright light that can be hazardous to your eyesight when viewed at a close range Do not stare directly into this lighting product at a close range or permanent damage to your eyesight may occur It is important that you fully understand how to safely operate this warning system before use You should only operate your vehicle and its light sound system in accordance with your department s Standard Operating Procedures If a selected function does not perform properly or if any of the lamps remain illuminated when the control is off disconnect the power connector from the control unit and contact the nearest service center At the start of your shift you should ensure that the entire warning light system and the siren system is securely attached and operating properly Suction cup mounting is for temporary applications only The unit should be removed from the window and stored securely when not in use Temperature changes and sunlight can cause suction cups to lose holding power Periodically check the unit to be sure the suction cups have a firm grip on the mounting surface An improperly secured light could fall off of the vehicle causing injury and damage Holding power of magnetic mounting systems is dependent upon surface finish surface flat ness and thickness of the steel mounting surface Therefore to promote proper magnetic mounting J Mounting surface and magnets must be kept clean dry and free of foreign particles th
49. with either type of lamp shown in Figure 6 1 on page 27 1 Disconnect power to the lightbar 2 Usea large flat head screwdriver to remove the two 1 4 20 screws that secure the end dome to the aluminum extrusion Figure 3 1 on page 14 and remove the nameplate 3 Slide the end dome off the aluminum extrusion along with any additional domes to access the PCB containing the lamp 4 Replace the lamp If the lamp is P N 810A119 Figure 6 1 left Twist the lamp counterclockwise to unlock it then pull it out of the socket Insert a lamp that is an exact replacement and gently twist it clockwise into the socket until it locks If the lamp is P N 8107169 Figure 6 2 right pull it straight out of the socket Align the two pins of the new lamp with the pin holes in the socket and gently push the lamp into the socket until the lamp is properly seated 5 Reinstall the domes and secure the end dome and nameplate with the two 1 4 20 screws 6 Reconnect power to the lightbar Chapter 6 Servicing the Lightbar 31 PART NO 810A119 PART NO 8107169 A m SOCKET i 290A5758B Figure 6 1 Halogen worklight and takedown replacement types Replacing the Alley Lamps 1 Disconnect power to the lightbar 2 Access the PCB containing the alley lamp a Use a large flat head screwdriver to remove the two 1 4 20 screws that secure the end dome to the aluminum extrusion and remove the nameplate Figure 3 1 on page 14
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