Star Headlight & Lantern 9500 Series - 58" Warning Package - Manual (Page 15)

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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 that 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.
Blue
White w/Brown
White w/Blue
Green w/Yellow
Red
Red w/Black
Red w/White
Red w/Green
Black w/Green
White w/Green
Orange
White
Orange w/Red
Gray
Black
Bare
F ro
m
W
ir
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H
a rn
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s
Blue
White w/Brown
White w/Blue
Green w/Yellow
Red ( PWR Plug Strobe Pack 1 )
Red ( PWR Plug Strobe Pack 2 )
Red w/White
Red ( CTRL Plug )
Black ( CTRL Power Plug )
White ( CTRL Power Plug )
Orange
White
Red ( LED Flasher )
Gray
Black
Bare
(271STROBE Cable Shown)
T o
L
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h
tb
a
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C
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n ts
From Wire Harness
To Lightbar Components