Star Headlight & Lantern Optimax-DH RP242 - Manual (Page 10)

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4.
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. 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 pak, the problem
is most likely internal to the pak. Call Star to obtain an R.G.A. number to return the pak for
service.
5.
If sufficient voltage is not reaching the pak perform the following tests: With the vehicle
turned off and while the pak 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
pak 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 second step. If there is an
excessive difference then continue on to the next step.
6.
Move to the ON/OFF switch in the cab and gain access to the rear of the switch panel.
NOTE: Excessive voltage drop may be occurring in the connections on the switch panel.
For the Star switch, you can increase the contact pressure by removing the FASTON
terminal from the tab on the switch. Using long nose pliers, gently squeeze the FASTON
terminal together in the area which slides on to the tab of the switch. This will increase the
pressure applied between the tabs and the connector and reduce voltage drop. With the
vehicle not running and the pak on at the high power setting, 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.
7.
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 pak,
while the pak 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.
8.
This same procedure can be used to check the wires between the switch panel and the
pak. Place one probe on the terminal at the switch and the other probe into the terminal
with the corresponding wire color in the PWR connector on the pak. Once again if any
of the readings exceed 0.25 volts then you should check those wires and their
connections.
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