Star Headlight & Lantern 9500 Series - 58" Warning Package - Manual (Page 17)

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TROUBLESHOOTING GUIDE (cont’d)
5. Check that the proper voltage is reaching the necessary CTRL inputs. Check
that the proper voltage is reaching the Black wire (across from the Black w/Green
stripe wire on the Terminal Block) and White wire (across from the White w/Green
stripe wire on the Terminal block) of the
CTRL plug on your strobe pack with the
vehicle turned off, and while the bar is running. Measure the voltage across the Black
wire (pin 2) on the CTRL plug
(NOT THE POWER PLUG) and the negative terminal
of your battery. Push the probes of the test meter down into the connector at the wire
entry points on the pack side of the connectors to contact the terminals for the
measurement. Note this reading. A nominal 12.5 volts should be present. A
minimum of 10.5 volts should be present for the pack to operate properly. Also,
check the voltage on the White wire. If your pack is receiving sufficient voltage to
both wires then continue to step 6. If you do not have proper voltage present on
either wire, check the wiring to the connector.
6. Check the CTRL connector to be sure that +12VDC is not applied the Red wire.
The Red wire on the CTRL connector of the strobe pack is used for pattern select.
The patterns are changed by touching AND RELEASING this wire to +12VDC. A
constant voltage applied to the Red wire on the CTRL connector will prevent the
strobe pack from flashing.
7. Check each strobe head. If the leads in one of the heads have shorted out, the
output voltage of the other heads may be held down as well. To test for this, unplug
all of the heads and plug them in individually, one at a time. If your problem is a result
of a shorted head, then the other heads should function properly if the faulty head is
no longer connected. Note: A burned out strobe tube does not cause a short and will
not affect the operation of the remaining heads. If the problem is not with a shorted
head and if proper voltage is reaching the pack, the problem is most likely internal to
the pack.
8. If sufficient voltage is not reaching the pack perform the following tests: With the
vehicle turned off and while the pack is running, measure the battery voltage at the
battery. A nominal 12.5 volts should exist. Note this voltage. If this voltage is below
10.0 volts the pack will not function properly and the problem is with the battery. This
reading should not be more than 1-1.25 volts higher than the reading in the 4
th step. If
there is an excessive difference then continue on to the next step.
9. With the vehicle not running and the lightbar on, measure the voltage in the red wire
by taking a reading from the positive side of the battery to pin 1 of your switch. If this
reading exceeds 0.25 volts then there is a poor connection between the switch and
the battery in the red wire and it should be checked.
10. If you still have not located the problem, troubleshoot the connections between the
good chassis ground and pin 2 (black or blue wire) of the PWR connector on the
power pack, while the lightbar is running. If this reading exceeds 0.25 volts then there
is a poor connection between the switch and the ground in the black wire and it should
be checked.
11. This same procedure can be used to check the wires between the terminal block and
the pack. Place one probe on the terminal at the terminal block and the other probe
into the terminal with the corresponding wire color in the connector on the pack. Once
again if any of the readings exceed 0.25 volts then you should check those wires and
their connections.
BLACK
RED
WHITE (Heads 2 & 4)
RED (Pattern Select)
BLACK (Heads 1 & 3)
C
O
N
T
R
O
L
WHITE