
Figure 3-5. Control Head and Bracket Installation.
3-4
2.
Use the mounting bracket as a tem-
plate and scribe two drill positioning marks at the
selected mounting location.
CAUTION
Before drilling holes in ANY part of a vehicle,
be sure that both sides of the mounting sur-
face are clear of parts that could be damaged;
such as brake lines, fuel lines, electrical wiring
or other vital parts.
3.
Drill two mounting holes at the posi-
tion marks.
4.
Secure the mounting bracket to the
mounting surface with the #10 thread-forming
screws as shown in figure 3-5.
B.
If the control head/bracket assembly cannot
be secured to the firm mounting surface with screws,
remove the brackets and use the supplied adhesive-
backed velcro hook-and-loop pads to attach the unit
to a
firm, flat surface
.
3-7. ELECTRICAL INSTALLATION.
WARNING
Failure to observe this WARNING may result
in fire, burns or blindness.
If shorted to vehicle frame, high current con-
ductors can cause hazardous sparks resulting
in electrical fires or molten metal.
DO NOT connect this system to vehicle bat-
tery until ALL other electrical connections
are made and mounting of all components is
complete.
Verify that no short circuits exist, before con-
necting to the Positive (+) battery terminal.
To complete this portion of the installation, refer
to the block wiring diagram (figure 3-2) and figure 3-
6. Proceed as follows:
A.
Lightbar Connections.
The lightbar is completely wired at the
factory and does not require any additional internal
wiring. All the conductors necessary for control of all
functions are contained in the cables.
1.
Route the lightbar power cable and the
control cable into the vehicle.
2.
Route the control cable near the
location of the previously installed Interface/Relay
Unit and secure the cable with user-supplied clamps
and hold-downs as required.
3.
Plug the control cable’s connector into
the mating connector on the Interface/Relay Unit.
CAUTION
Before drilling holes in ANY part of a vehicle,
be sure that both sides of the mounting sur-
face are clear of parts that could be damaged;
such as brake lines, fuel lines, electrical wiring
or other vital parts.
4.
If necessary, drill a hole in the vehicle
firewall. Place a grommet or similar device in the
hole to protect the wires against damage from rough
edges. Route the power cable into the engine com-
partment.
To protect the wire, a separate circuit
breaker must be connected as close as practical to the
positive (+) battery terminal. FUSES ARE NOT
ACCEPTABLE. See figures 3-2 and 3-6. Install the
supplied two 50-ampere circuit breakers (Federal
Part No. 8474176). DO NOT remove the jumper on
the battery side of the circuit breakers. Connect the
red wire to one of the 50-ampere circuit breakers.
Do NOT make any connections to the
battery until all other wiring is complete.
B.
Interface/Relay Unit Power Cable
Connections.
The Interface/Relay Unit power cable,
included in the carton, is equipped with a six-pin
plug that mates with the connector on the rear of the
Interface/Relay Unit (see figures 3-7 and 3-8). Addi-
tional wire (the same gauge or heavier) may be
spliced to the leads as required. The various wires on
the connector must be connected as follows:
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