Star Headlight & Lantern 400B - Manual (Page 2)

PERMANENT MOUNT INSTALLATION INSTRUCTIONS
IMPORTANT: Please read all of the following instructions before installing your new light.
1. CAUTION: All of our DC powered warning lights are polarity sensitive. These lights are
polarity protected only if the appropriate fuse is used. All wires connected to the positive
terminal of the battery should be fused at the battery for their rated load. Testing the light
before this fuse is properly installed will void the warranty on the light.
2. Your new warning light comes complete with a foam mounting gasket, mounting screws, lock
washers, and well nuts.
3. For any models utilizing a flange mount base, please skip to Step 6.
4. The 20 Series, 200 Series, and the 240 Series Star warning lights come equipped with a
combination base, allowing the light to be either mounted on a 1/2" NPT conduit pipe or
permanently mounted. For NPT pipe, mount the light using the threaded entrance hole in the
base of the light, then skip to Step 11. For the permanent mount, proceed to Step 5.
5. Carefully remove either the clamp ring or the three or four screws near the base of the lens
and lift off the lens. Examine the inside of the base and use a punch or drill to remove the
knock-outs present.
200B and 400B: If you wish to mount the 200B or 400B through the base, you will need to
drill the three 3/8” mounting holes in the base. Use the gasket as a template to mark the
locations in the base, then drill the holes.
6. Next, you will need to drill the holes in your mounting surface. Place the gasket in the exact
position the light is to be mounted, and mark the holes on the mounting surface. (NOTE: You
might have to stretch the gasket slightly to find the location of the holes in the gasket.) Take
care to ensure that the gasket does not move while you are marking each of the holes. Be
sure to mark the center hole if you will be running your wires through the mounting surface.
7. Remove the gasket and drill your holes using an appropriate 3/8" drill bit.
CAUTION: If you are mounting the light on a vehicle, and plan to wire it through the roof of
the vehicle, remove the headliner from the inside of the vehicle. If you do not remove the
headliner, take care so that you do not drill through it.
8. After the holes have been drilled, push the enclosed rubber well nuts through the outer holes
until the bottom side of the wider lip rests on the surface of the vehicle.
9. Place the light on the surface of the vehicle, routing the wires through the center hole, if
applicable.
10. To secure the light to your mounting surface, align the holes with the well nuts. Install the
screws through the base, into the well nuts, and tighten until snug.
11. The black or white wire is the ground lead and should be connected to a good chassis ground.
12. Connect the red wire to the positive side of the power through either a s ingle-pole, t w o-
position switch for normal operation, or a two-switch switch-panel for High/Low operation
(High/Low option available only on models with three wires). Use a 5 amp fuse for all models
except for the 400B, which will use a 10 amp fuse. Check the label on the warning light for
proper voltage. If your light has only two wires then you are finished and may skip the
remaining steps.
13. If your light has three wires (red, black, and purple) you need to decide how you would like
the light to operate:
To utilize the High/Low option: Skip to Step 14.
For low power only: Leave the purple wire unconnected and place a wirenut
over the end. Skip the remaining step.
For high power only: Connect the purple wire to the good chassis ground.
Skip the remaining step.
14. If you intend to make use of the High/Low option through a switch, refer to the wiring
diagram on the following page for proper connections using a two-switch switch panel
available from Star.