Installation And Mounting - Code 3 45 Series Installation And Operation Instructions Manual

Installation and Mounting:

There are three mounting options for the LED base unit:
1. Attaching the LED base unit with high strength double-sided foam tape (customer supplied). This option minimizes the
piercing of the vehicle by requiring only a center wire hole.
2. Attaching the LED base unit with four #10 x ¾" sheet metal screws.
3. Attaching the LED base unit and lens together using four #6 x 1-½" sheet metal screws.
NOTE: Options 1 and 2 allow removal of the outer lens without removing the base from the vehicle. Option 3 allows
removal of the entire unit from the vehicle with the removal of only four screws.
Step 1. Determine the mounting options to be used. Select the desired mounting location for the light head assembly. The installation must
accommodate the base gaskets. Note: The gaskets are flexible. Do not use them for drill templates.
Step 2. Verify free clearance behind the mounting surface for wiring and fasteners.
Step 3. Using the appropriate template (Figures 2-4) cut the center opening for the wiring and install a grommet (customer supplied). Use a
drill bit sized for the appropriate thickness of the mounting surface and a #10 sheet metal screw for drilling the screw holes. For example: for
aluminum alloy sheet metal .125" thick, a #23 (.154") drill size is recommended. Note: If the unit is to be attached with very high bond
tape instead of screws then the screw holes need not be drilled. Clean the mounting surfaces of the vehicle and the light head with
isopropyl alcohol and dry thoroughly prior to attaching tape.
Step 4. Route the vehicle power wires and allow a minimum of 3 inches of slack to protrude from the center opening at each light head
location. Use 18 AWG for wires up to 40 feet length, 16 AWG for wires up to 70 feet length.
Step 5. Place the light head gasket (and bezel if used) over the light head location and run the vehicle power wire slack through the center
opening of the gasket. Refer to Figures 2 & 3.
Step 6. For Perimeter Lights refer to the section Flash Pattern Selection prior to finalizing the electrical connections. Prepare the vehicle
power wires and the light head's wires with terminations of the customer's choice (not supplied). Waterproof connectors are recommended.
Refer to the following table for appropriate wiring connections.
Step 7. At the power source end of the cable determine if the cable length is acceptable. If a shorter length is required, coil the cable and tie
with an electrical tie.
Step 8. Verify proper light head operation by supplying electrical power to the system wires at the power source end of the cable.
Step 9. Verify that the O-ring is properly seated onto the LED base unit.
Step 10. Push the assembled electrical connectors through the center opening and into the vehicle.
Step 11. Push the LED base unit (and bezel if used) into the gasket. The LED base unit is symmetric and does not have a preferred top or
bottom. Verify that the gasket (and bezel if used) is properly oriented. These parts are labeled with "TOP" and their part numbers at the top
and have a drain slot at the bottom.
Step 12. Mount the LED base unit and gasket (and bezel if used) using four #10 x ¾" screws. Optionally the unit may be mounted with very
high bond tape (customer supplied). If tape is used it should be attached to the base unit and the vehicle. Do not use tape to secure the
gasket to either the LED base unit or the vehicle chassis. Follow the tape manufacturer's instructions to ensure proper adhesion.
Step 13. Verify the "TOP" lens marking is on the top and install the lens using four screws. Two screw options are supplied: four #10 x ¾"
screws or four #6 x 1-½" screws. The #10 screws attach the lens to the LED base unit. The optional longer #6 screws go through the LED
base unit and tap into the vehicle body. If the longer #6 screws are used then first drill an appropriate pilot hole into the vehicle body.
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