Page 6
GASKET
LIGHTHEAD
BARB
BOSS
Lighthead Mounting Bracket
Ears on mounting
bracket slide into
the channels in
the extrusion.
Remove the four screws (A) that hold the endcap
on and pull the endcap and gasket (C) off.
(B)
Slide the lenses (D) out of the lightbar, to gain access to the extrusion. When reinstalling the
lenses and spacers, install the cord seal (see below). When reinstalling the endcap,
place the endcap gasket into its position on the endcap and line up all the tabs
and holes. Spacers (not shown) mount the same as lenses.
Removing the Endcap and Lenses
D
D
C
TO
P VIEW
O
F EX
TR
U
S
I
ON
END VIEW OF EXTRUSION
Installing a Corner LED
Slide Spacer in here
Snap lighthead into bracket here
BALLAST
Extrusion
CENTER OF EXTRUSION
LIGHTHEAD
EXTRUSION
Front
Passenger
Front
Passenger
Lighthead Tabs
slide into extrusion
The edge of the lighthead snaps into the
clips on the mounting bracket.
Lighthead mounting
holes snap into the
raised bosses on
mounting bracket.
CORN
E
R
LE
D
Insert
cord
seal
into
track
in
lens
A
B
Seal Cord Installation:
Cut the seal cord approx. 1-1/2" longer than the extrusion on each side.
Rub silicone over the cord seal leaving 3 to 4 inches on one end dry.
Begining with 1 corner lens, start the lens into the bottom
lens track. Place the cord seal onto the groove in the
top of the lens
eav 1 to 2 inches
Hold onto the left end of the seal hanging
out and slide the corner lens into
position.
1 -
2 -
3 -
4 -
3 -
3 -
4 -
4 -
. L
e
free.
Inspect the seal cord for any areas that have wrinkled.
Especially in the areas around the dividers.
Push the lenses together tight and trim excess seal
cord at each end.
6 -
7 -
6 -
7 -
From the opposite end of the
lightbar, pull the seal
cord tight and install
the remaining lenses
and divider.
5 -
5 -
5 -
5 -
5 -
NOTE: Lens dividers must be installed
as each lens is put into position
The lightbar owner should be familiar with the following component replacement procedures to
assure proproper assembly and reassembly of this product
Installing the Endcap Gasket & Alley Light
Place the endcap gasket into position on the endcap, locating all tabs and holes. Align the reflector assembly of the
alley light with the 4 bosses in the endcap. Press the reflector in place until the 4 barbs are engaged around the
reflector.
