Federal Signal Corporation AD Series Manual

256843D
REV. D 1296
Printed in U.S.A.
WIRING AND MAINTENANCE INSTRUCTIONS
FOR
MODEL AD SERIES AND ADL SERIES INDEPENDENT ROTATOR LIGHT ASSEMBLIES
SAFETY MESSAGE TO INSTALLERS
OF
FEDERAL SIGNAL LIGHT SYSTEMS
People’s lives depend on your safe installation of
our products. It is important to read, understand and
follow all instructions shipped with the products. In
addition, listed below are some other important
safety instructions and precautions you should
follow:
• To properly install a light assembly: you
must have a good understanding of
automotive electrical procedures and
systems, along with proficiency in the
installation
and use of safety warning equip-
ment.
• When drilling into a vehicle structure, be
sure that both sides of the surface are
clear of anything that could be damaged.
• A light system is a high current device. In
order for it to function properly, separate
ground (-) and positive (+) connections
must be made. If practical, they should be
connected to the battery terminals. A
suitable fuse should be installed as close
to the battery as practical. At a minimum,
the ground connection may be attached to
a solid metal body or chassis part that
will provide an effective ground path as
long as the light system is to be used.
• Locate light system controls so the
VEHICLE and CONTROLS can be
operated safely under all driving condi-
tions.
• You should frequently inspect the light
system to ensure that it is operating
properly and that it is securely attached
to the vehicle.
• File these instructions in a safe place and
refer to them when maintaining and/or
reinstalling the product.
Failure to follow all safety precautions and
instructions may result in property damage, serious
injury, or death to you or others.
A. UNPACKING.
After unpacking the light bar, inspect it for
damage that may have occurred in transit. If the unit
has been damaged, file a claim immediately with the
carrier, stating the extent of damage. Carefully check
all envelopes, shipping labels and tags before remov-
ing or destroying them.
B. INSTALLATION.
The light bar is completely wired at the factory
and does not require any additional internal wiring.
All the conductors necessary for control of any and all
basic and optional functions are contained in the
cable.
The basic light functions of the unit must be
controlled by a user-supplied control head.
Before proceeding, ensure that the light bar has
been installed on the vehicle roof in accordance with
the instructions packed with the mounting kit. Route
the light bar cable as described below.
WARNING
Ensure that light system controls have been
located so that VEHICLE and CONTROLS
can be operated safely under all driving
conditions.
1. Route the control cable into the vehicle and
under the dash, near the eventual location of the
user-supplied control head.
2. For proper operation, the control cable must
be properly terminated inside the user-supplied
control head. Use figure 1 as a guide and make the
appropriate electrical connections shown in table 1 or
2, as applicable. Ensure that the lines are adequately
fused as shown in figure 1.
NOTE
Any of the light bar functions can be activated
by applying 12VDC to the appropriate control
line. To perform a function check, the heavy
black lead (-) must be connected to vehicle
ground.
3. Connect the black lead (-) to chassis ground.

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Table 1. AD Electrical Connections.
Control Cable
Wire Color Functions
RED Rotating Lights & Middle Rotating Lights
BLK Power (-)
BRN Speaker
BRN/WHT Speaker
GRY Traffic Clearing Light
GREEN Left Alley
ORANGE Right Alley
GRY (BLUE if GRY Takedown
is used.)
BLUE Front Flashing Lights
YEL Rear Flashing Lights
Table 2. ADL Electrical Connections.
Control Cable
Wire Color Functions
RED Rotating Lights & Middle Rotating Lights
BLK Power (-)
BRN Traffic Clearing Light
GREEN Left Alley
ORANGE Right Alley
GRY Inner Rotating Lights
BRN/WHT Takedown
BLUE Front Flashing Lights
YEL Rear Flashing Lights
Figure 1.
INTERNAL WIRING
EXTERNAL WIRING
SPEAKER
TO POWER/IGNITION (+)
ROTATINGROTATING
RED
M
SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED
CABLE
AD
STANDARD
290A2545-01B
REDRED
TB
BRN
SPEAKER
BRN
RED10A ROTATING
SPEAKER
BRN/WHT SPEAKER
BRN/WHT
M
INTERNAL WIRING
EXTERNAL WIRING
TO POWER/IGNITION (+)
MIDDLE
ROTATING MIDDLE ROTATING
INNER
ROTATING
SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED
CABLE
ROTATING
OPTION
290A2545-05D
WHT/BLU
WHT/BLU
WHT/BLU WHT/BLU
TB
RED
GRAY15A INNER ROTATING
MIDDLE ROTATING
15A
M MM M
INTERNAL WIRING
EXTERNAL WIRING
TO POWER/IGNITION (+)
FRONT
OR
REAR
FLASHING
SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED
CABLE
FLASHING
FLASHING
OPTION
290A2545-04C
WHT/RED
WHT/RED
WHT/RED
WHT/RED FLASHER
TB
YEL
BLU
15A
REAR
FRONT
X
L
L
INTERNAL WIRING
EXTERNAL WIRING
TO POWER/IGNITION (+)
ALLEY LIGHT ALLEY LIGHT
SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED
CABLE
ALLEY
LIGHT
OPTION
290A2545-03
WHT/GRNWHT/GRN WHT/ORN
TB
ORN8A R. ALLEY
GRN8A L. ALLEY
INTERNAL WIRING
EXTERNAL WIRING
TO POWER/IGNITION (+)
ROTATINGROTATING
RED
M
SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED
CABLE
ADL
STANDARD
290A2545-02C
REDRED
TB
RED10A ROTATING
M
INTERNAL WIRING
EXTERNAL WIRING
TO POWER/IGNITION (+)
DUAL
CENTER
TAKEDOWN
SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED
CABLE
TAKEDOWN
OPTION
290A2545-06B
WHT/BRN
WHT/BRN TB
BRN/WHT
OR GRAY
15A TAKEDOWN
TAKEDOWN TAKEDOWN
INTERNAL WIRING
EXTERNAL WIRING
TO POWER/IGNITION (+)
DUAL
TRAFFIC
CLEARING
LIGHT
(T.C.L.)
SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED
CABLE
TCL ORTCLF
OPTION
290A2545-07C
WHT/YEL
WHT/YEL TB
GRAY OR BRN
15A T.C.L.
T.C.L. T.C.L.
INTERNAL WIRING
EXTERNAL WIRING
TO POWER/IGNITION (+)
ROTATING ROTATING
INNER
FAST
ROTATING
SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED
CABLE
ADL-FAST
290A2545-08B
RED
175175 9090
RED
RED RED
TB
RED
GRAY10A
ROTATING
INNER FAST ROTATING
10A
M MM M
INTERNAL WIRING
EXTERNAL WIRING
TO POWER/IGNITION (+)
ROTATING ROTATING
SUPPLIED WITH LIGHTBAR
CUSTOMER SUPPLIED
CABLE
ADL-NFPA
290A3168
RED
RED
TB
12345678
BRN
YEL
BRN/WHT
RED
10A
INNER ROTATING
INNER ROTATING
INNER ROTATING
OUTER ROTATING
10A
10A
10A
MM M
WHT/BLU WHT/BLU WHT/BLU WHT/BLU
MM M
INTERNAL WIRING
EXTERNAL WIRING
TO POWER/IGNITION (+)
ROTATING ROTATING
INNER
ROTATING
SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED
CABLE
AD-24V
290A2545-09B
RED
RED RED
RED
RED
TB
GRAY
RED10A
INNER ROTATING
ROTATING
10A
M MM M

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FRONT OF TRUCK FRONT OF BAR
RED
95
95
95/17595/175 TCL/175TCL/175
BROWN
BROWN/WHITE
YEL
CALLING/BLOCKING
CALL FOR
RIGHT OF WAY
MAY BE LOAD
MANAGED
MAY BE LOAD
MANAGED
,,

290A316
0
Figure 2.
4. Connect the light bar’s red power lead to a
fuse or circuit breaker rated at 50 amperes. Connect
the other side of the fuse/circuit breaker to the
+12VDC supply.
C. NFPA INSTALLATION.
MESSAGE TO NFPA INSTALLERS
For mounting, color configuration, and
mounting considerations, refer to the latest
edition of the NFPA standard for automotive
fire apparatus.
For Models ADL5202 and ADL5256, use figure 2
and table 3 as a guide (for mounting and wiring)
when installing this light assembly as part of an
NFPA certified system.
D. MAINTENANCE.
1. Cleaning the Plastic Domes.
WARNING
Crazing (cracking) of domes will cause re-
duced effectiveness of light system. Do not
use cleaning agents (which will cause crazing)
such as strong detergents, solvents, or petro-
leum products. If crazing of domes does occur,
reliability of light for emergency purposes
may be reduced until domes are replaced.
Ordinary cleaning of the plastic domes can be
accomplished by using mild soap and a soft rag.
Should fine scratches or a haze appear on domes,
they can ordinarily be removed with a non-abrasive,
high quality, one-step, automotive paste cleaner/wax
and a soft cloth.
2. Lamp Replacement.
CAUTION
Service life of lamp will be shortened if glass
portion is touched. If glass has been handled,
clean carefully with a grease solvent.
Table 3. ADL Electrical Connections for NFPA Models.
Term. Block Control Cable
Position Wire Color Functions
BLK Power (-)
1 RED Outboard Rotating Lights
2 GRY Front/Rear Work Lights
3 BLUE Front/Rear Flashers
4 BRN Call for Right of Way
5 YEL Load Managed Inboard Rotators
6 ORANGE Right Work Light
7 GREEN Left Work Light
8 BRN/WHT Load Managed Call for Right of Way
WARNING
A serious injury may result if lamp is touched
when hot. Always allow lamp to cool before
removing. Halogen lamps are pressurized and
if broken can result in flying glass. Always
wear gloves and eye protection when handling
the lamps.
To replace the halogen lamp, proceed as
follows (see figure 3):
CAUTION
Forced rotation of the light mechanism will
cause damage to the worm gear. ALWAYS
rotate the light mechanism by rotating the
motor shaft.
a. Rotate the reflector until the lamp clip
(located at the base of the lamp) can be removed, and
remove the clip by sliding it away from the reflector.
b. Note the lamp’s orientation and pull the
defective lamp and connector out of the socket.
CAUTION
When installing a new lamp, do not touch the
glass portion. If the glass has been touched,
shortened lamp life will result. If the glass
end has been handled, it should be carefully
cleaned with a grease solvent.
c. Replace the defective lamp with a new
H-1 halogen lamp (Federal Part No. 8440A265A).

When reassembling, ensure that the lamp is secured
to the connector and that the clip is properly seated
in the grooves on the lamp socket.
3. Cleaning Reflectors and Mirrors.
WARNING
Scratched or dulled reflectors or mirrors will
cause reduced effectiveness of light system.
Avoid heavy pressure and use of caustic or
petroleum based products when cleaning. If
crazing of reflectors or mirrors does occur,
reliability of light for emergency warning
purposes may be reduced until reflectors or
mirrors are replaced.
Use a soft tissue to clean the reflector and
mirrors.
Figure 3.
290A2600-01
H-I HALOGEN LAMP
LAMP BASE
LAMP SOCKET
CONNECTOR
GROOVES(2)
GEAR AND REFLECTOR
ASSEMBLY
ORIENTED PARALLEL
TO GROVES IN
LAMP SOCKET
SLIDE CLIP OVER
LAMP BASE INTO
GROOVES ON
LAMP SOCKET
DO NOT TOUCH
GLASS PORTION
OF LAMP
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