Star Headlight & Lantern 7400 Star Lase - Manual (Page 8)

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Wire Harness Replacement
Standard Laser lightbars come with two 15-foot wiring harnesses: a 2-conductor harness
for Power and Ground, and a 19-conductor harness for the control wires. Laser lightbars
with a traffic director (arrowstick) will have three harnesses. If any of the harnesses
supplied with the lightbar is not long enough for your application, Star recommends
ordering the proper cable of the desired length from the factory. Completely remove the
pre-installed wire harness(es) and replace it (them) with one that is the correct length.
• Star recommends direct wiring to the terminal block(s) on the inside of the
lightbar, rather than making connections to the end of the wire that is supplied.
• This lightbar is designed so that when replacing the wire harness(es), no wire
connectors are needed and only a few common tools are necessary.
• Direct wiring allows the wire connections to the lightbar to be made in a clean
and dry environment, avoiding any problems that may arise due to weathering on
external connections.
• Wiring directly inside the lightbar reduces the number of connections. There is
an increase in voltage loss with the addition of each connection.
• Making connections to the wires already provided is an acceptable alternative, as
long as these connections are good electrical connections and are resistant from
weathering effects.
1.
To replace the wire harness(es) you will need to access the inside of the lightbar.
Remove the endcaps by removing the four screws from each end and the screws
that hold the top extrusion on the lightbar (ex. 6 screws on a 46” lightbar), and
carefully lift the top off of the lightbar (as shown below).
If you are using the existing 15-foot harnesses supplied with the lightbar,
you may skip to the LED Head Programming section on page 7.