13704: LFL LC Model LL274FHP Service Manual
Contents
1. 3n18 DECK DCK DECK DECK DECK 3n18 LY Fit 38081sg Ng ri i D AGOYLS sais yt Wt E qt V zm SH3ON3SSVd I T a L I SMH3AIHG Co pesf imn I 1 1 Lo CI S JON bh LYS dib OI h Se ta 8Sd i1 o je im H EH Ge V ATdd 1S YAMOd 8 ATddN S YIMOd E Ke A3TW 1 Deg S Ts esst BEE E CI 1 1 1 1 1 4 G L ZER Lgs cas 0 G L WH AgOULS j3dOULS 28081s WH ZV i i i eva 3godis AGOYLS ania GEN ania GEN ania GEN ania 1NOYA uoneoimnuop juduodwo9 z Du Page 4 NMOHS LON N3901VH NI dWNS dINa ZINSLZH v 6D u3gWv aa1sani3s 00s A ssv vi sezeovoo e b GV3HLH91T NI dVNS DNISNOH ooo vesesr lL o 2 GUVOE 0 1147 Leen 00 91 6920 10 ED T TYHSAMAS 005 NFdVNS 510193143 oo reseseo 20 v 38OMISZIg Tl AlddNS N3MOd 0096069204400 Z Ep UVINIT H3NM02 38031S oo zecegeo 20 v 059 6 saamoN 3nB avoaNa ez99scevo i0 z Op Lou S ANTA eng grrerogLgn zo Y dyana LIANSYO 00 225e8z088 z Qn L t c uv319 SN31 102tttc96 89 8 solLdO M uva312 SNIT 0t 2 96H09 7 O LaMSV9 M SN31 YAGIAIA mi izrenzn a AGOULS ND SAINAS 005 oo zeze2. FRONT 3 BLUE CLEAR BLUE CLEAR BLUE CLEAR BLUE N 5 11 16 5 116 5 1 16 5 1116 5 1 16 5 1 16 5 11 16 X eer NA CZ KO LUE BLUE wICLEAR S WICLEAR LLEY ALLEY X TJ N BLUE CLEAR CLEAR CLEAR CLEAR CLEAR BLUE Natal 5 11 16 5 1 16 5 1 16 5 1 16 5 1 16 5 1 16 5 11 16 DY REAR Fig 1 Top View of Lightbar page 3 shows lens length and location Refer to Fig 2 Component Identification page 4 for an overall view of the lightbar with individual lighthead designations Refer to Fig 3 Exploded View page 5 for an exploded view along with each components corresponding part number Page 3
3. is suspect present Inspect repair or replace Check the fuses amp ground at power supply A and replace if necessary d Bar operating y operates properly properly Swap the two Power Supplies Are outboard Power Supply strobes still is suspect bad Y Disconnect strobes one at a time no more than 1 strobe unplugged at any one time Did remaining Y strobes start working Inspect the wires between strobe lightheads and Power Supply A Repair any breaks or damage Did this Bar N solve Y operates problem properly Contact Whelen Engineering Technical Support Page 12 Inboard Strobe Failure Perform these procedures with BLUE control wire active for the duration of this test Open lightbar as outlined previously New fuse blows Bad Power Supply Bar operates properly Y Did all strobes start working N Disconnected strobe is suspect Replace with known good strobe Wires were intact Confirm BLU control wire has 12VDC at switch output Is 12VDC N present Confirm 12VDC BLU wire in input control connector Switch output is suspect Inspect repair or replace Input harness is suspect present Inspect repair or replace Check the fuses amp ground at power supply B and replace if necessary d Bar operating y operates properly properly
4. Page 9 High Voltage is present within the lightbar The diagnostic procedures outlined herein should not be attempted by anyone other than trained and experienced All Lamp Failure dead bar Perform these procedures with BLUE control wire active for the duration of this test IO board is suspect Inspect repair or replace Bar operates properly New fuse blows Main power cable is suspect Inspect repair or replace GE Probl operates Y roblem yN GE Solved Open lightbar as outlined previously New fuses blow Disconnect TD Alley amp LED harnesses from IO Board and replace blown fuses Harness wires are suspect Inspect repair or replace Is bar Y operating properly Contact Whelen Engineering Technical Support Page 10 Check master fuse at battery and replace if necessary Check power and ground wires at battery Confirm good electrical connections Confirm BLU control wire has 12VDC at switch output present Confirm 12VDC BLU wire in input control connector present Check both fuses on I O board and replace if necessary Confirm 12VDC amp Ground at I O Card main voltage inputs present I O board is malfunctioning and must be replaced Is bar N operating properly Bar operates properly Bar operates properly Switch output is suspect Inspect repair or replace Input
5. 15 Take down failure nA a erri a ane a naa na ing uan na page 16 IR ne EU D page 17 Traffic Advisor Failure Lima a RANG ata ais CRn co kau sadi ANAKAN page 18 Illustrations Fig 1 Top viow of Iilghtbar iiit desea tera are Senden eege dE page 3 Fig 2 Component Identification seen page 4 Fig 3 Exploded View of complete lightbar esee nnne page 5 Fig 45 Main Power MEI uiii iier rre tinc ENEE Eege pde dna oak Pru gus page 6 Fig 5 Endcap Removal View 0 0000 22 aa aaanassassananasasanasasosassanssssssssensoss000xa page 8 Fig 6 O Board Connections ciscccisccedecccssssesctersaniscetscusnssssecedntcrsesunestednsnnsrecedesessteduccesensua page 9 Page 2 Lightbar Components The model LL274FHP lightbar is comprised of the following components Designation B1 B2 B3 A1 A2 HAS A4 L1 L2 L3 L4 L5 Qty Description 3 500 series Linear Strobe Module 4 Corner Strobe Assemblies 5 8 500 series Amber LED Lightheads 4 500 series Halogen Snap in Reflectors w 27 watt Halogen Lamps x N A 0 GG RTGOTO GG Ki Strobe Power Supplies N Endcap Gaskets A Blue Lens 5 11 16 Lens Dividers w gaskets Clear Lens 5 1 16 Blue Lens 5 1 16 co N Fig 1 Top View of Lightbar LFL LC Input Output 1 0 Board 500 series Snap in Reflector Housings Blue Endcaps w Clear Alley Light Lens
6. Swap the two Power Supplies Are inboard Power Supply strobes still is suspect bad Y Disconnect strobes one at a time no more than 1 strobe unplugged at any one time Did remaining Y strobes start working Inspect the wires between strobe lightheads and Power Supply B Repair any breaks or damage Did this Bar N solve Y operates problem properly Contact Whelen Engineering Technical Support Page 13 All Halogen Failure Perform these procedures with BLUE control wire active for the duration of this test Confirm BLU control wire has 12VDC at switch output Is 12VDC N present Switch output is suspect Inspect repair or replace Open lightbar as outlined previously Confirm 12VDC BLU wire in input control connector Input harness Is 412VDC is suspect resent N Inspect repair P S or replace Check Halogen fuse on UO board and replace if necessary New fuse blows Disconnect TD amp Bar Alley harnesses operates from IO Board and properly properly replace blown fuse IO board a is suspect I O board is malfunctioning Inspect repair and must be replaced or replace Harness wires isibar are suspect oparatin Bar Inspect repair Sc 3 operates or replace properly properly Bar I var Contact Whelen Engineerin operates Y operating N Technical S 9 rt g properly properly echnical Support Page 14 Alley Light Failure Confirm WH
7. T amp YEL Perform these procedures with the control wires have 12VDC WHITE amp YELLOW control wires at switch output active for the duration of this test Is 12VDC N present Open lightbar as outlined previously Confirm 12VDC WHT amp YEL wires in input control connector Is 12VDC N present Check Halogen fuse on I O board and replace if necessary Is bar N Operating y properly Driver Passenger Side Side Locate the alley light connector Locate the alley light connector on the I O board Insert the on the I O board Insert the lead of voltmeter into Pos 1 lead of voltmeter into Pos 3 and the lead into Pos 2 and the lead into Pos 4 UO board is malfunctioning and must be replaced present present Wiring to lighthead is suspect Inspect repair or replace properly Contact Whelen Engineering Technical Support Page 15 Switch output is suspect Inspect repair or replace Input harness is suspect Inspect repair or replace Bar operates properly Bar operates properly Take Down Light Failure RENE Perform these procedures with the control wire has 12VDC WHITE BLACK control wire active at switch output for the duration of this test Is 12VDC N present Switch output is suspect Inspect repair or replace Open lightbar as outlined previously Confirm 12VDC WHT BLK wire in i
8. eplace if necessary Is bar properly Measure voltage at the appropriate wire colors on the I O board s LED connector for a failed lighthead Is pulsing N voltage present Wiring to lighthead is suspect Inspect repair or replace Is bar operating y properly Contact Whelen Engineering Technical Support Page 18 Switch output is suspect Inspect repair or replace Input harness is suspect Inspect repair or replace Bar operates properly Note and record the LED wire colors at the harness side of the lighthead connector For example the Orange wire connects to the Red lighthead wire while the White Orange wire connects to the Black wire for the same lighthead Measurements will be taken at the rear LED connector on the I O board at the corresponding colors for each failed lighthead Important Solid colors are always POSITIVE UO board is malfunctioning and must be replaced Bar operates properly
9. f voltmeter into Pos 1 and the lead into Pos 2 LED Lighthead has failed and must be replaced Steady Voltage is present Note and record the LED wire colors at the harness side of the lighthead connector For Measure voltage at the appropriate example the Orange wire connects to the 7 g pp p Red lighthead wire while the White Orange wire colors on the I O board s LED wire connects to the Black wire for the same connector for the failed lighthead lighthead Measurements will be taken at the rear LED connector on the I O board at the corresponding colors for each failed lighthead Important Solid colors are always POSITIVE Is pulsing voltage present UO board is malfunctioning and must be replaced N Wiring to lighthead is suspect Inspect repair or replace Is bar a Bar operating y operates properly properly Contact Whelen Engineering Technical Support Page 17 LED Traffic Advisor Failure Perform these procedures with the appropriate control wire active for the duration of this test WHITE YELLOW sequence to LEFT WHITE GREEN sequence to RIGHT Both active Split Confirm the appropriate control wires have 12VDC at switch output Is 12VDC N present Open lightbar as outlined previously Confirm 12VDC the appropriate wire in input control connector Is 12VDC N present Check LED fuse on I O board and r
10. geo zo 8 94M gl mg SN31 ogereroggn v CO NondiMos3d N3HAnNINVd XO WALI Nondi2sad N38WnNINVd AIO Wall ji 2 jo a n IJL IJL dals SYAONASSVWd o EI SH3AlNd IP Main pepojdx3 e 614 Page 5 Wiring Power Cable The Power Cable contains a 8 AWG Black wire and a 8 AWG Red wire Connect the BLACK wire directly to chassis ground typically adjacent to the vehicle battery Connect the RED wire fused 40 amps customer supplied to the POSITIVE battery terminal IMPORTANT There should not be more than 2 two feet of wire between the fuse and battery WARNING AII customer supplied wires that connect to the positive terminal of the battery must be sized to supply at least 125 of the maxi
11. harness is suspect Inspect repair or replace Bar operates properly Main wiring is suspect Inspect repair or replace Bar operates properly All Strobe Failure Confirm GRN amp GRY control wires Perform these procedures with GREEN amp GREY control wire have 12VDC at switch output active for the duration of this test Is P i 12VDC N Switch output is suspect Inspect repair or replace present P P P Open lightbar as outlined previously Confirm 12VDC GREEN wire in input control connector Is Input harness 12VDC N is suspect resent Inspect repair P S or replace Check the fuses amp ground at both power supplies and replace if necessary Is bar Bar operating y operates properly properly I O card is malfunctioning and must be replaced Page 11 Outboard Strobe Failure Perform these procedures with WHITE ORANGE control wire active for the duration of this test Open lightbar as outlined previously New fuse blows Bad Power Supply Bar operates properly Y Did all strobes start working N Disconnected strobe is suspect Replace with known good strobe Wires were intact Confirm WHT ORN control wire has 12VDC at switch output Is 12VDC N present Switch output is suspect Inspect repair or replace Confirm 12VDC WHT ORN wire in input control connector Input harness
12. lack 12VDC Driver side Ground Driver side 12VDC Passenger side Ground Passenger side Remnants of insulating material may remain on the mounting plate after the board has been removed These remnants must be completely removed from the mounting plate prior to Negative Not Rear Not Wire Contact Used LED s Used e sess qeocep oop Liu e Black 1234 1234 20A 2 e 1 f ra Halogen Fuse 20A 4 S 3 Red mE pa 20A 16 position pa Oba 5 L__ LED Fuse 20A i Personanty Input 49 5 s H e odule os eB elle U e Connectors _ Connector 12 o 11 eLelleLe d 14 9 e 43 M ka db S T lag sha e 16 6 e 145 dk ya ire Contact er e p elki e p e e amp Power Power Supply Supply A p Control Wires 1 Violet 9 Green 2 White Green 10 White Brown 3 Brown 11 Grey 4 White Yellow 12 Yellow 5 White Blue 13 Blue 6 White Orange 14 White 7 White Violet 15 Shield 8 White Red 16 White Black Diagnosis The following section will present diagnostic flow charts designed to allow service personnel to isolate the probable cause for specific lightbar failures WARNING Note When measuring voltages within the lightbar clip the Negative lead from your volt meter to service technicians the BLACK 8 AWG wire contact at the I O board see Fig 6
13. mum operating current and FUSED at the battery to carry that load DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT Fig 4 Main Power Wiring C BLACK Ox RED 40 Amp Fuse Customer Supplied JI Chassis Battery Ground Control Wire Functions The control wires 22 AWG are used to activate specific lightbar functions These wires should be connected to a customer supplied control head or switched output Any control wire that requires 12VDC for activation must be fused using a 1 Amp fuse customer supplied Please note that the current draw values shown represent the amount the lightbar will draw through the main power cable with the corresponding control wire active These values are cumulative Yellow Green 14 Amps Current Draw Color Activates Current Draw Function Green Strobe 9 Amps Applying 12VDC to this wire activates Corner Strobes A2 amp A3 Inboard Strobes B2 amp B3 Grey Strobe LED 5 Amps Applying 12VDC to this wire activates Corner Strobes A1 amp A4 LED L2 amp L4 Blue Strobe LED Halogen 26 Amps Applying 12VDC to this wire activates Corner Strobes A1 A2 A3 amp A4 Inboard Strobes B1 B2 amp B3 LED L2 amp L4 Both Take Down Lights flashing Both Alley Lights flashing Page 6 Yellow White White Black White Brown White Red White Orange White Yellow White Green White Blue Whi
14. nd discoloration Lenses in this condition have significantly reduced effectiveness and should be replaced immediately Inspect and operate this product regularly to confirm its proper operation and mounting condition Do not use a pressure washer to clean this product itis recommended that these instructions be stored in a safe place and referred to when performing maintenance and or reinstallation of this product e FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTRUCTIONS COULD RESULT IN DAMAGE TO THE PRODUCT OR VEHICLE AND OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS For warranty information regarding this product visit www whelen com warranty 2002 Whelen Engineering Company Inc Form No 13704B 053007 Table of Contents Lightbar comiporients ua rtasa Ee ecu dai nai ramis va lA RANA NA Ere Dr a page 3 Electrical wiring Power Cable cR page 6 Control WIFGS sies iro aoc iir id KE ando e ETE KR EEst page 6 Troubleshooting Opening the Eightbar eicit iba page 8 Replacing the Strobe Power Supply eene page 8 Replacing the VO Board aaa KAANAK page 9 Diagnostic Flow Charts All lamp failure dead bar eren page 10 All strobe TallUrG succi nn mien crx n chc rir cedendo page 11 Comer strobe fallUFQ iuis inde irai kenn ann i ra Gg page 12 Inboard Strobe failure NAKAKA Rain da cix arva gas EES page 13 All halogen UE page 14 Aleylight failure nse eegen Eeer page
15. nput control connector Input harness Is 12VDC N i is suspect resent nspect repair P or replace Check Halogen fuse on UO board and replace if necessary Is bar Bar N Operating y operates properly properly Driver Passenger Side Side Locate the Take Down light Locate the Take Down light connector on the I O board Insert connector on the I O board Insert the lead of voltmeter into Pos 1 the lead of voltmeter into Pos 3 and the lead into Pos 2 and the lead into Pos 4 UO board is malfunctioning present and must be replaced present Wiring to lighthead is suspect Inspect repair or replace Bar operates properly properly Contact Whelen Engineering Technical Support Page 16 LED Lighthead Failure Perform these procedures with the WHITE BROWN control wire active for the duration of this test Is lighthead S Steady on or Dead Confirm WHT BRN control wire has 12VDC at switch output Is 12VDC N present Switch output is suspect Inspect repair or replace Open lightbar as outlined eviously pP Confirm 12VDC WHT BRN wire in input control connector Input harness Is 12VDC N i is suspect nspect repair present or replace Check LED fuse on UO board and replace if necessary Is bar Bar operating Y operates properly properly At the failed lighthead insert the lead o
16. r determining the probable cause for component failure within your lightbar Disassembly of the lightbar may be required in order to perform specific diagnostic tests and for component removal and or replacement Although the process is not difficult it does require focused attention to ensure proper re assembly It is a good idea to keep careful notes documenting the procedure All components MUST be returned to their original mounting location WITH THEIR ORIGINAL ELECTRICAL CONNECTIONS IN TACT before reassembly WARNING THIS PRODUCT CONTAINS HIGH VOLTAGE DISCONNECT THE LIGHTBAR FROM POWER AND WAIT 10 MINUTES BEFORE PERFORMING ANY DISASSEMBLY PROCEDURES Opening the Lightbar Tools Required 20 Torx head screwdriver 25 Torx head screwdriver 1 Using the 25 Torx head Fig 5 Endcap Removal screwdriver remove the 4 g s endcap screws from each t endcap 2 Remove the endcaps and endcap gasket from the extrusion If the alley light is not being tested it may be unplugged and the endcap assembly may be moved away from the work area 3 Remove all lenses and dividers It is important to note the location of each lens and divider so that each may be returned to their original Halogen Lighthead location Plasti Loc 10 24 x 1 4 Slide the 4 corner strobes out of Screw 25 Torx the extrusion Pan Head Screw 5 Using the 20 Torx head screwdriver remove the 4 screws located on the top of the lightba
17. r extrusion Remove the top of the extrusion from the lightbar Replacing the Strobe Power Supply 1 Locate and disconnect the 8 position and 12 position power supply connectors 2 Slide the power supply out of the extrusion 3 Slide the replacement power supply into the extrusion using the same extrusion guide tracks as the original Caution It is very important to visually confirm that no wires are being pinched between the power supply and the extrusion 4 Reconnect the two connectors disconnected in step 1 Page 8 Replacing the LFL LC I O Board Remove the main power fuse installed at the vehicle battery This will remove all voltage from the Record the location of where each connector plugs into the I O board Beginning with the main voltage cables unplug each connector from the UO board Locate and remove the 5 Phillips head screws used to secure the I O board to its mounting plate Carefully lift the I O board up and away from the mounting plate 1 lightbar 2 3 4 Note installation of the new I O board 5 Install the new I O board onto the mounting plate using the original mounting hardware 6 Return all the connectors to their original location Fig 6 I O Board Connections Take Down Lights White Black 12VDC Driver side Ground Driver side White Black Black Ground Passenger side 12VDC Passenger side Alley Lights White Black Yellow B
18. rvice Manual Se WHELEN ENGINEERING COMPANY INC HA Lightbar Service Manual ester Connecticu Phone 860 526 9504 Model LL274FHP Fax 860 526 4078 Internet www whelen com Sales e mail autosale whelen com Canadian Sales e mail autocan whelen com Customer Service e mail custserv whelen com Safety First This service manual is for model LL274FHP Lightbar It has been designed to enable a qualified field technician to diagnose and troubleshoot specific problems that may occur over the life of this product It is important to understand that the design of this lightbar precludes the field repair of any electrical assembly Failed components must either be replaced or returned to the factory for repair The installation technician must read this manual completely prior to performing any service on this lightbar Important information is contained herein that could prevent serious injury or damage For this product to operate at optimum efficiency a good electrical connection to chassis ground must be made The recommended procedure requires the product ground wire to be connected directly to the NEGATIVE battery post This product contains strobe lights halogen lights and high intensity LEDs Do not stare directly into these lights Momentary blindness and or eye damage could result e Use only soap and water to clean the outer lens Use of other chemicals could result in premature lens cracking crazing a
19. te Violet Violet No Color Brown Halogen Halogen Halogen LED Strobe LED Strobes LED LED Strobe Flash Pattern Strobe Flash Pattern Low Power RF Drain No Function 2 5 Amps 2 5 Amps 5 Amps 75 Amps 3A Peak 19 Amps 9 Amps 1 1 Amps 3A Peak 1 1 Amps 3A Peak N A N A N A N A N A Page 7 Applying 12VDC to this wire activates Passenger side Alley Light steady on Applying 12VDC to this wire activates Driver side Alley Light steady on Applying 12VDC to this wire activates Both Take Down Lights steady on Applying 12VDC to this wire activates LED L1 L2 L3 L4 amp L5 Applying 12VDC to this wire activates Corner Strobes A1 A2 A3 amp A4 Inboard Strobes B2 amp B3 LED L1 L2 LA amp L5 Applying 12VDC to this wire activates Corner Strobes A1 A2 A3 amp A4 Applying 12VDC to this wire activates Sequence Left Pattern LED s Applying 12VDC to this wire activates Sequence Right Pattern LED s Note White Yellow White Green Split pattern Applying 12VDC to this wire changes the active strobe s pattern to Action Flash Applying 12VDC to this wire changes the active strobe s pattern to Longburst Applying 12VDC to this wire places the bar into Low Power operation mode Connect to chassis ground Troubleshooting This section will outline the necessary diagnostic procedures fo
Download Pdf Manuals
Related Search