Star Headlight & Lantern 5600 Series 66" Warning Packages - Manual (Page 22)

-19-
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. If the ground is insufficient, locate the ground wire connection in your lightbar by removing the
dome over the section where the wires enter the bar. Please follow the appropriate dome
removal instructions listed earlier in this manual when removing this dome. The ground wire is
the large (10AWG) black wire attached to the inside of the lightbar base with a ring terminal.
Check the integrity of the connection of the ground wire to both the lightbar base and at the
other end to a good chassis ground.
4. While inspecting the ground wire connections you should also check that the wire itself is not
damaged. Carefully inspect the wire along its entire length, paying special attention to those
areas where the wire passes through any holes that may have sharp edges, which can
damage the wire, and the areas where the wire makes any sharp bends.
Checking the power to the terminal block
(Determining if the proper voltage is reaching your bar):
1. Locate the terminal block in your lightbar by removing the dome over the section where the
wires enter the bar. Please follow the appropriate dome removal instructions listed earlier in
this manual when removing this dome. After entering the bar, the wires will be connected to
the terminal block with a number of small Phillips head screws.
2. With the bar turned on, use a test meter to test the voltage at the terminal block. A nominal
12.5 volts should be present. Low voltage can cause erratic flashing in strobe heads or even
complete failure of the heads. A minimum of 10.5 volts should be present for the pack to
operate properly. Low voltage in strobe lights, flashing lights, or LEDs can result in lowered
intensity or even complete failure.
3. Be sure to test each wire that comes into the terminal block for proper voltage.
4. Carefully inspect each wire in the terminal block. Check that the ends of the wires have not
frayed and shorted against one another or against the base. This may cause lights to operate
inadvertently or may result in the failure of lights.
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. Check the faulty head by connecting it into the side you just unplugged the working head from.
If the faulty head still does not work, then the head is bad and will need to be replaced.
4. If the head that was not flashing works when connected to the other side, the problem
probably lies in the power pack or flasher unit. Verify this by plugging the other head
(the original working head you just unplugged) into the side that previously had the non-
working head.