Federal Signal Corporation AD Series Handbuch

256843D

REV. D 1296

Printed in U.S.A.

WIRING AND MAINTENANCE INSTRUCTIONS

FOR

MODEL AD SERIES AND ADL SERIES INDEPENDENT ROTATOR LIGHT ASSEMBLIES

SAFETY MESSAGE TO INSTALLERS

FEDERAL SIGNAL LIGHT SYSTEMS

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 equip-

ment.

• 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, separate

ground (-) and positive (+) connections

must be made. If practical, they should be

connected to the battery terminals. A

suitable fuse should be installed as close

to the battery as practical. At a minimum,

the ground connection 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.

• Locate light system controls so the

VEHICLE and CONTROLS can be

operated safely under all driving condi-

tions.

• 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

reinstalling the product.

Failure to follow all safety precautions and

instructions may result in property damage, serious

injury, or death to you or others.

A. UNPACKING.

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 remov-

ing or destroying them.

B. INSTALLATION.

The 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.

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

Ensure that light system controls have been

located so that VEHICLE and CONTROLS

can be operated safely under all driving

conditions.

1. Route the control cable into the vehicle and

under the dash, near the eventual location of the

user-supplied control head.

2. For proper operation, the control cable must

be properly terminated inside the user-supplied

control head. Use figure 1 as a guide and make the

appropriate electrical connections shown in table 1 or

2, as applicable. 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. To perform a function check, the heavy

black lead (-) must be connected to vehicle

ground.

3. Connect the black lead (-) to chassis ground.

-2-

Table 1. AD Electrical Connections.

Control Cable

Wire Color Functions

RED Rotating Lights & Middle Rotating Lights

BLK Power (-)

BRN Speaker

BRN/WHT Speaker

GRY Traffic Clearing Light

GREEN Left Alley

ORANGE Right Alley

GRY (BLUE if GRY Takedown

is used.)

BLUE Front Flashing Lights

YEL Rear Flashing Lights

Table 2. ADL Electrical Connections.

Control Cable

Wire Color Functions

RED Rotating Lights & Middle Rotating Lights

BLK Power (-)

BRN Traffic Clearing Light

GREEN Left Alley

ORANGE Right Alley

GRY Inner Rotating Lights

BRN/WHT Takedown

BLUE Front Flashing Lights

YEL Rear Flashing Lights

Figure 1.

INTERNAL WIRING

EXTERNAL WIRING

SPEAKER

TO POWER/IGNITION (+)

ROTATINGROTATING

RED

SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED

CABLE

STANDARD

290A2545-01B

REDRED

BRN

SPEAKER

BRN

RED10A ROTATING

SPEAKER

BRN/WHT SPEAKER

BRN/WHT

INTERNAL WIRING

EXTERNAL WIRING

TO POWER/IGNITION (+)

MIDDLE

ROTATING MIDDLE

ROTATING

INNER

ROTATING

SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED

CABLE

ROTATING

OPTION

290A2545-05D

WHT/BLU

WHT/BLU WHT/BLU

RED

GRAY15A INNER ROTATING

MIDDLE ROTATING

15A

M MM M

INTERNAL WIRING

EXTERNAL WIRING

TO POWER/IGNITION (+)

FRONT

REAR

FLASHING

SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED

CABLE

FLASHING

OPTION

290A2545-04C

WHT/RED

WHT/RED FLASHER

YEL

BLU

15A

REAR

FRONT

INTERNAL WIRING

EXTERNAL WIRING

TO POWER/IGNITION (+)

ALLEY LIGHT ALLEY LIGHT

SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED

CABLE

ALLEY

LIGHT

OPTION

290A2545-03

WHT/GRNWHT/GRN WHT/ORN

ORN8A R. ALLEY

GRN8A L. ALLEY

INTERNAL WIRING

EXTERNAL WIRING

TO POWER/IGNITION (+)

ROTATINGROTATING

RED

SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED

CABLE

ADL

STANDARD

290A2545-02C

REDRED

RED10A ROTATING

INTERNAL WIRING

EXTERNAL WIRING

TO POWER/IGNITION (+)

DUAL

CENTER

TAKEDOWN

SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED

CABLE

TAKEDOWN

OPTION

290A2545-06B

WHT/BRN

WHT/BRN TB

BRN/WHT

OR GRAY

15A TAKEDOWN

TAKEDOWN TAKEDOWN

INTERNAL WIRING

EXTERNAL WIRING

TO POWER/IGNITION (+)

DUAL

TRAFFIC

CLEARING

LIGHT

(T.C.L.)

SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED

CABLE

TCL ORTCLF

OPTION

290A2545-07C

WHT/YEL

WHT/YEL TB

GRAY OR BRN

15A T.C.L.

T.C.L. T.C.L.

INTERNAL WIRING

EXTERNAL WIRING

TO POWER/IGNITION (+)

ROTATING ROTATING

INNER

FAST

ROTATING

SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED

CABLE

ADL-FAST

290A2545-08B

RED

175175 9090

RED

RED RED

RED

GRAY10A

ROTATING

INNER FAST ROTATING

10A

M MM M

INTERNAL WIRING

EXTERNAL WIRING

TO POWER/IGNITION (+)

ROTATING ROTATING

SUPPLIED WITH LIGHTBAR

CUSTOMER SUPPLIED

CABLE

ADL-NFPA

290A3168

RED

12345678

BRN

YEL

BRN/WHT

RED

10A

INNER ROTATING

OUTER ROTATING

10A

MM M

WHT/BLU WHT/BLU WHT/BLU WHT/BLU

MM M

INTERNAL WIRING

EXTERNAL WIRING

TO POWER/IGNITION (+)

ROTATING ROTATING

INNER

ROTATING

SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED

CABLE

AD-24V

290A2545-09B

RED

RED RED

RED

GRAY

RED10A

INNER ROTATING

ROTATING

10A

M MM M

-3-

FRONT OF TRUCK FRONT OF BAR

RED

95/17595/175 TCL/175TCL/175

BROWN

BROWN/WHITE

YEL

CALLING/BLOCKING

CALL FOR

RIGHT OF WAY

MAY BE LOAD

MANAGED

MAY BE LOAD

MANAGED

,,



290A316

Figure 2.

4. 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.

C. NFPA INSTALLATION.

MESSAGE TO NFPA INSTALLERS

For mounting, color configuration, and

mounting considerations, refer to the latest

edition of the NFPA standard for automotive

fire apparatus.

For Models ADL5202 and ADL5256, use figure 2

and table 3 as a guide (for mounting and wiring)

when installing this light assembly as part of an

NFPA certified system.

D. MAINTENANCE.

1. Cleaning the Plastic Domes.

WARNING

Crazing (cracking) of domes will cause re-

duced effectiveness of light system. Do not

use cleaning agents (which will cause crazing)

such as strong detergents, solvents, or petro-

leum products. If crazing of domes does occur,

reliability of light for emergency purposes

may be reduced until domes are replaced.

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 domes,

they can ordinarily be removed with a non-abrasive,

high quality, one-step, automotive paste cleaner/wax

and a soft cloth.

2. Lamp Replacement.

CAUTION

Service life of lamp will be shortened if glass

portion is touched. If glass has been handled,

clean carefully with a grease solvent.

Table 3. ADL Electrical Connections for NFPA Models.

Term. Block Control Cable

Position Wire Color Functions

BLK Power (-)

1 RED Outboard Rotating Lights

2 GRY Front/Rear Work Lights

3 BLUE Front/Rear Flashers

4 BRN Call for Right of Way

5 YEL Load Managed Inboard Rotators

6 ORANGE Right Work Light

7 GREEN Left Work Light

8 BRN/WHT Load Managed Call for Right of Way

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.

To replace the halogen lamp, proceed as

follows (see figure 3):

CAUTION

Forced rotation of the light mechanism will

cause damage to the worm gear. ALWAYS

rotate the light mechanism by rotating the

motor shaft.

a. Rotate the reflector until the lamp clip

(located at the base of the lamp) can be removed, and

remove the clip by sliding it away from the reflector.

b. Note the lamp’s orientation and pull the

defective lamp and connector out of the socket.

CAUTION

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 (Federal 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.

3. Cleaning Reflectors and Mirrors.

WARNING

Scratched or dulled reflectors or mirrors will

cause reduced effectiveness of light system.

Avoid heavy pressure and use of caustic or

petroleum based products when cleaning. If

crazing of reflectors or mirrors does occur,

reliability of light for emergency warning

purposes may be reduced until reflectors or

mirrors are replaced.

Use a soft tissue to clean the reflector and

mirrors.

Figure 3.

290A2600-01

H-I HALOGEN LAMP

LAMP BASE

LAMP SOCKET

CONNECTOR

GROOVES(2)

GEAR AND REFLECTOR

ASSEMBLY

ORIENTED PARALLEL

TO GROVES IN

LAMP SOCKET

SLIDE CLIP OVER

LAMP BASE INTO

GROOVES ON

LAMP SOCKET

DO NOT TOUCH

GLASS PORTION

OF LAMP

-4-

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