Code 3 XL 5000 - Manual (Page 4)

WARNING!
Larger wires and tight connections will provide longer service life for components. For high
current wires it is highly recommended that terminal blocks or soldered connections be used
with shrink tubing to protect the connections. Do not use insulation displacement
connectors (e.g. 3M
® Scotchlock type connectors). Route wiring using grommets and
sealant when passing through compartment walls. Minimize the number of splices to reduce
voltage drop. High ambient temperatures (e.g. under hood) will significantly reduce the
current carrying capacity of wires, fuses, and circuit breakers. Use "SXL" type wire in engine
compartment. All wiring should conform to the minimum wire size and other
recommendations of the manufacturer and be protected from moving parts and hot surfaces.
Looms, grommets, cable ties, and similar installation hardware should be used to anchor and
protect all wiring.
Fuses or circuit breakers should be located as close to the power takeoff points as possible
and properly sized to protect the wiring and devices.
Particular attention should be paid to the location and method of making electrical
connections and splices to protect these points from corrosion and loss of conductivity.
Ground terminations should only be made to substantial chassis components, preferably
directly to the vehicle battery.
The user should install a fuse sized to approximately 125% of the maximum Amp capacity in
the supply line to protect against short circuits. For example, a 30 Amp fuse should carry a
maximum of 24 Amps. DO NOT USE 1/4" DIAMETER GLASS FUSES AS THEY ARE NOT
SUITABLE FOR CONTINUOUS DUTY IN SIZES ABOVE 15 AMPS. Circuit breakers are
very sensitive to high temperatures and will "false trip" when mounted in hot environments or
operated close to their capacity.
35 Watt Lamp = 3 Amp Load
50 Watt Lamp = 4 Amp Load
100 Watt Lamp = 8 Amp Load
Motors and Electronics Boxes = Negligible Load
Total watts in light bar divided by 13 volts equals amperage draw or:
Watts / 13 Volts = Amp Draw
If the light bar has a speaker section, the blue wires go to the siren amplifier and are to be connected in
accordance with the siren manufacturer's instructions. Test the unit for proper operation.
Route the wiring cable into the engine or passenger compartment, taking care to use grommets and to
apply sealant around openings to keep water out. It is advisable to leave an extra loop of cable when
installing the light bar to allow for future changes or reinstallations. Connect the black lead to a solid
frame ground (earth), preferably, the (-) or ground (earth) side of the battery and bring the other wires to the
control head or switches. Connect the wires to the control head or switch (as directed by the wiring
instructions on the cable). Caution - Operating a siren with a live speaker can inflict hearing
damage--always use hearing protection.
Maintenance
Lens Removal
Force 4 TM XL 5000 TM series light bars are assembled with 1/4" Hex Head Screws. A 1/4" Socket or Nut
Driver is ideal, but a phillips screwdriver may be used.
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