INSTALLATION AND INSTRUCTION MANUAL Aerostar PLITSTR335 REV.
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.
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.
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.
(Direct Wiring Guide 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 screws on the terminal block and remove only those wires that exit the lightbar through the hole in the base.
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.
Remote Strobe Power Supply Connections For Linear Strobe Heads If your lightbar DOES NOT contain linear strobe heads, you can skip to page 10. If your lightbar contains linear strobe heads, follow the instructions on pages 5-9 for proper wiring of the strobe power supply. Please note that any additional lights in your lightbar must also be connected to +12VDC through a switch. This section only discusses the proper wiring of the strobe power supplies.
Lightbars with Two or Four Linear Strobe Heads (cont'd) 4 2 3 1 (Pictured above is one example of a bar with four linear strobe heads) Activating the Front and Rear Strobes Separately If you would like the ability to switch the Front Strobes On and Off separate from the Rear Strobes, connect the White w/Green Stripe wire to the switch that will activate your Front Strobes, and connect the Black w/Green Stripe wire to the switch that will activate your Rear Strobes.
Lightbars with Eight Linear Strobe Heads 2A 4B 3B 2B 1A PACK B 3A PACK A 4A 1B (Pictured above is one example of a bar with 8 linear strobe heads) Three wires in your cable harness control the strobe power supplies and the strobe heads connected to them.
(Remote Strobe Power Supply Connections For Linear Strobe Heads cont’d) Automatic Power Up Head Check Your new power pack comes with a safety feature which checks for proper operation of each individual strobe head each time you turn on the strobe pack. This feature works by quickly flashing each head once separately and determining if any of the heads did not flash.
LED Pattern Programming LEDs in your lightbar are programmed using the Red w/Green stripe wire. If you have LEDs controlled by an external flasher (LDF369 or LDF398), the pattern will be sett by touching the Red w/Green wire to +12VDC. If you have Halo 360º LEDs, you will set the pattern by touching the Red w/Green wire to ground. LED Pattern Selection for Remote LED Flashers 1.
(LED Pattern Programming cont’d) LED Pattern Selection for 360º Halo Heads (touch Red w/Green to ground) 1. Power up the LED heads.. 2. Touch and release the Red w/Green stripe wire to ground to scroll through the patterns listed below. The cycle will repeat itself after the last pattern. 3. Once you find the pattern you wish to select, leave the Pattern Select wire disconnected and turn the LEDs off.
Troubleshooting If a light on your bar fails to work, please refer to this section to help solve your problem. If you still cannot resolve your problem, please contact our Customer Service Department at 585-226-9787. The chart below contains some basic guidelines for troubleshooting any problems you may experience with your bar. The section following the chart will explain in further detail how to perform some of the troubleshooting tasks.
Determining if the bar is properly grounded: 1. While the bar is turned on, using a test meter, measure the voltage from the base of the bar itself to the negative post of the battery or a good chassis ground if the battery can’t be easily reached. You may need to scrape away a bit of anodizing or paint in order to ensure a good connection with the probe of your test meter. 2. If the difference shown is greater than .25 volts, then your ground is not sufficient. 3.
TROUBLESHOOTING GUIDE (cont’d) Checking one non-working strobe or LED head: If a problem exists in only one head, a strobe tube or LED head may have burned out, or there may be an open electrical connection in the wiring harness or strobe head. 1. Check connections at and between the strobe pack and the faulty strobe head or between the flasher unit and LED head, including all wiring. 2. Disconnect both the faulty head and a working head. 3.
TROUBLESHOOTING GUIDE (cont’d) WHITE BLACK RED CONTROL 5. Check that the proper voltage is reaching the necessary CTRL inputs. Check that the proper voltage is reaching the Black wire (across from the Black w/Green stripe wire on the Terminal Block) and White wire (across from the White w/Green stripe wire on the Terminal block) of the CTRL plug on your strobe pack with the vehicle turned off, and while the bar is running.
Domes and Exterior Parts 620-12 3 1 4 3 1 2 4 2 620-22-134* 4 4 2 3 620-22-3* 1 620-22-0* 2 3 1 (Support Baffle) 620-22-234* Full Domes Full 20" Outer Dome 620-21-20-* Full 24" Outer Dome 620-21-24-* Center Shrouds 8" Centerpiece Silver - 2007 Black - 2007B 12" Centerpiece Silver - 2015 Black - 2015B 16" Centerpiece Silver - 2010 Black - 2010B 3-HOLE 4-HOLE 5-HOLE 8" Speaker Centerpiece 12" Speaker Centerpiece Silver -2009 Silver - 2012 Black - 2008 Black - 2013 3-HOLE 4-HOLE -1
Interior Parts Filters and Lenses 2073-795X 920-100-* 50-WATT HALOGEN BULB (Rotators, Work Lights, Takedowns, Flashers, etc.) ST3901-7 COLOR FILTER FOR ROTATORS & STATIONARY LIGHTS LSF4.5-* 360° STROBE HEAD COLOR FILTER FOR 4.5" STROBE HEAD (SH3964) LST129-4 LSF7-* 4.
Interior Parts (cont’d) HR FHR S RSH 920-99 OR 920-99F LH1 80FPM OR 160FPM HALOGEN ROTATOR L8H1 240SFQ 360° STROBE RSH 360° REMOTE STROBE HEAD w/DOME 620-D1AL-* or 620-D1ALV-* Standard or Value M-Tech LED Lighthead w/Left Angle Reflector for Aerostar and Interceptor 2-HEAD LINEAR STROBE KIT w/RP310-SBQ Power Pack, 820-292 Medium Diamond Mirror and two ST3901-7 360 Degree Strobe Heads for Aerostar or Interceptor 620-D1AR-* or 620-D1ARV-* Standard or Value M-Tech LED Lighthead w/Right Angle Reflect
Switches and Switchboxes SP3860-1 SP3860-2 SP3860-3 SP3860-4 ROTATORS SP1515 LEFT ALLEY STROBES RIGHT ALLEY WORK LIGHTS FLASHERS SP3015 SB4020 MODE 1 2 3 SB1515 GRILL LIGHTS HEADLIGHT FLASHER CORNER LIGHTS TAKE DOWN SB3015 ONE YEAR LIMITED WARRANTY LED FIVE YEAR LIMITED WARRANTY The manufacturer warrants each new product, under normal use, against factory defects in material and workmanship for one year after the date of purchase.
