Federal Signal Corporation Navigator Lightbar Manual

Installation, Operation,
and Service Instructions
25500145
Rev. C0 0716
Printed in U.S.A.
Navigator®Lightbar
SLR

3
Navigator Lightbar
Installation, Operation, and Service Instructions
Contents
Safety Messages to Installers Warning Light Equipment..................................................................5
Safety Messages to Operators.............................................................................................................7
Overview of the Lightbar ......................................................................................................................8
Solaris LED Reector Technology.................................................................................................................... 8
LED Rotating Lights ......................................................................................................................................... 8
QuadraFlare LED Stationary Lights ................................................................................................................. 8
Control Options ................................................................................................................................................ 8
Mount Options.................................................................................................................................................. 9
Preparing for the Lightbar Installation ................................................................................................9
Unpacking the Lightbar .................................................................................................................................... 9
Programming the Lightbar .................................................................................................................10
Flashing Modes ............................................................................................................................................. 10
Selecting Flash Patterns.....................................................................................................................10
Selecting a Flash Pattern with the Orange Lead in the Control Cable........................................................... 10
Selecting a Flash Pattern with the Pushbutton............................................................................................... 10
Changing the Features on a 45-inch, 53-inch and 60-inch Navigator ............................................13
Changing the Rotator Functions in an All-Rotator Navigator .........................................................13
Determining the Mounting Location and Wire Routing ...................................................................14
Wiring the Navigator in the Vehicle ...................................................................................................15
Connecting Power to the Lightbar.....................................................................................................16
10-inch All-Stationary Navigator with a 4-Conductor Control Cable............................................................... 17
10-inch or 18-inch All-Rotator Navigator with a 4-Conductor Control Cable ................................................. 17
Navigator with Power, Ground, and 5 Control Leads ..................................................................................... 18
Navigator with Power Ground and 10-Conductor Control Cable.................................................................... 18
Navigator with a 20-Conductor Control Cable................................................................................................ 20
Navigator with Power, Ground Leads, and Serial Cable ................................................................................ 22
Wiring the Navigator Stop/Tail/Turn Lights Option ......................................................................................... 23
Maintaining and Servicing the Navigator..........................................................................................23
Cleaning the Domes....................................................................................................................................... 24
Cleaning the Reectors and Mirrors............................................................................................................... 24
Replacing a Dome or Bulkhead...................................................................................................................... 24
Troubleshooting the Lightbar.......................................................................................................................... 25
Replacing a Rotator Assembly ....................................................................................................................... 26
Conguring How a Rotator Operates ............................................................................................................. 27
Replacing a Mirror.......................................................................................................................................... 28
Replacing a QuadraFlare Stationary Light ..................................................................................................... 28
Replacement Parts ..............................................................................................................................29
Getting Technical Support and Service.............................................................................................32

4
Navigator Lightbar
Installation, Operation, and Service Instructions
Tables
Table 1 Dimensions in inches (less mounting feet ................................................................................................ 9
Table 2 Light Specications .................................................................................................................................. 9
Table 3 Navigator ash patterns: 10-conductor discrete-wired cable .................................................................11
Table 4 Navigator ash patterns: 45 in, 53 in, and 60 in serial-controlled/discrete lightbar ................................ 12
Table 5 Functions of SW4 ................................................................................................................................... 13
Table 6 Cabling based on lightbar length and conguration (see pages referenced)......................................... 16
Table 7 Lightbar functions for 10-conductor cable .............................................................................................. 19
Table 8 Lightbar functions for 20-conductor cable .............................................................................................. 21
Table 9 Lightbar functions for 10-inch Navigator cable ....................................................................................... 22
Table 10 Troubleshooting tips ............................................................................................................................. 26
Table 11 Dip switch settings for rotator operation ............................................................................................... 28
Figures
Figure 1 Flash pattern pushbutton on control board discrete-wired Navigator.................................................... 11
Figure 2 Central control board with switches off (down)..................................................................................... 13
Figure 3 All-rotator power distribution board....................................................................................................... 14
Figure 4 Wire functions for 4-conductor cable (10-inch all stationary)................................................................ 17
Figure 5 Wire functions for 10-conductor cable.................................................................................................. 18
Figure 6 Lightbar functions for 10-conductor cable ............................................................................................ 20
Figure 7 Cable leads for stop/tail/turn lights ....................................................................................................... 23
Figure 8 Navigator (25-inch) with the end dome disassembled.......................................................................... 25
Figure 9 Navigator (25 inch) viewed from the top................................................................................................ 27

5
Navigator Lightbar
Installation, Operation, and Service Instructions
Safety Messages to Installers Warning Light Equipment
People’s lives depend on your proper installation and servicing of Federal Signal products. It is important to
read and follow all instructions shipped with this product and the original product. Listed below are some other
important safety instructions and precautions you should follow:
Before Installation or Service
Qualications
• To properly install or service this equipment, you must have a good understanding of automotive mechanical
and electrical procedures and systems, along with prociency in the installation and service of safety warning
equipment. Always refer to the vehicle’s service manuals when performing equipment installations on a vehicle.
Light Hazards
• In order to be an effective warning device, this product produces bright light that can be hazardous to your
eyesight when viewed at a close range. Do not stare directly into this lighting product at a close range or
permanent damage to your eyesight may occur.
• Do not install the light system in an area that would block, impair or blind the driver’s vision. Ensure that the
light system is mounted in a position that is outside of the driver’s eld of vision, so the driver can maintain
safe vehicle operation.
• Federal Signal power supplies and lightheads are designed to work together as a system. Combining
lightheads and a power supply from different manufacturers may reduce the warning effectiveness of the
lighting system and may damage the components. You should verify or test your combination to make sure
the system works together and meets federal, state and local standards or guidelines.
Electrical Hazards
• A light system is a high current system. In order for the system to function properly, a separate negative (-)
connection and positive (+) connection must be made. All negative connections should be connected to the
negative battery terminal and a suitable fuse should be installed on the positive battery terminal connection as
close to the battery as possible. Ensure that all wires and fuses are rated correctly to handle the device and system
amperage requirements.
• Never attempt to install aftermarket equipment that connects to the vehicle wiring, without reviewing a
vehicle wiring diagram available from the vehicle manufacturer. Ensure that your installation will not effect
vehicle operation or mandated safety functions or circuits. Always check the vehicle for proper operation
after installation.
• The lighting system components, especially LEDs and the outer housing, get hot during operation. Be sure
to disconnect power to the system and allow the system to cool down before handling any components of the
system.
• Do not mount a radio antenna within 18 inches of the lighting system. Placing the antenna too close to
the lighting system could cause the lighting system to malfunction or be damaged by strong radio elds.
Mounting the antenna too close to the lighting system may also cause the radio noise emitted from the
lighting system to interfere with the reception of the radio transmitter and reduce radio reception.
• Do not attempt to wash this or any other electrical device while it is connected to its power source. Exposure
to liquid while the product is connected to the power source may result in an electrical shock and personal
injury and may short circuit and damage the product.

6
Navigator Lightbar
Installation, Operation, and Service Instructions
During Installation and Service
• DO NOT get metal shavings inside the product. Metal shavings in the product can cause the system to fail.
If drilling must be done near the unit, place an ESD approved cover over the unit. Inspect the unit after
mounting to be sure there are no shavings present in or near the unit.
• To avoid a battery explosion, always disconnect the negative battery cable rst and reconnect it last. Avoid
causing a spark when connecting near or to the battery. The gases produced by a battery can cause a battery
explosion that could result in vehicle damage and serious injury.
• DO NOT connect this system to the vehicle battery until ALL other electrical connections are made,
mounting of all components is complete, and you have veried that no shorts exist. If the wiring is shorted to
the vehicle body or frame, high current conductors can cause hazardous sparks resulting in electrical res or
ying molten metal.
• DO NOT install equipment or route wiring (or the plug in cord) in the deployment path of an airbag.
• If a vehicle seat is temporarily removed, verify with the vehicle manufacturer if the seat needs to be
recalibrated for proper airbag deployment.
• Before mounting any components, check the manual to be sure that the component you are installing is suitable
for use in that area of the vehicle. Many components are not suitable for use in the engine compartment or other
extreme environmental exposure areas.
• When drilling into a vehicle structure, be sure that both sides of the surface are clear of anything that could be
damaged. Remove all burrs from drilled holes. To prevent electrical shorts, grommet all drilled holes through
which wiring passes. Also, ensure that the mounting screws do not cause electrical or mechanical damage to
the vehicle.
• Refer to the instruction sheet packed with the lighting system for proper electrical connections, additional
precautions and information.
• Because vehicle roof construction and driving conditions vary, do not drive a vehicle with a magnetically
mounted warning light installed. The light could y off the vehicle causing injury or damage. Repair of
damage incurred because of ignoring this warning shall be the sole responsibility of the user.
• To avoid denting the roof of the vehicle, place the lightbar mounting feet as close to outer edge of the roof as
possible.
•Roof damage can occur if the hook adjustment bolts are over-tightened. Torque the hook adjustment bolts 6
ft-lb to 7 ft-lb. Install keeper plates.
• Locate the light system controls so the VEHICLE and CONTROLS can be operated safely under all driving
conditions.
After Installation or Service
• After installation, test the light system to ensure that it is operating properly.
• If a seat is temporarily removed, verify with the vehicle manufacturer if the seat needs to be recalibrated for
proper airbag deployment.
• Test all vehicle functions, including horn operation, vehicle safety functions and vehicle light systems, to
ensure proper operation. Ensure that the installation has not affected the vehicle operation or changed any
vehicle safety function or circuit.

7
Navigator Lightbar
Installation, Operation, and Service Instructions
• Scratched or dull reectors, mirrors or lenses will reduce the effectiveness of the lighting system. Avoid
heavy pressure and use of caustic or petroleum based products when cleaning the lighting system. Replace
any optical components that may have been scratched or crazed during system installation.
• Do not attempt to activate or deactivate the light system control while driving in a hazardous situation.
• You should frequently inspect the light system to ensure that it is operating properly and that it is securely
attached to the vehicle.
• After installation and testing are complete, provide a copy of these instructions to instructional staff and all
operating personnel.
• File these instructions in a safe place and refer to them when maintaining and/or re-installing the product.
Failure to follow all safety precautions and instructions may result in property damage, serious injury, or death.
Safety Messages to Operators
Peoples’ lives depend on your safe use of our products. Listed below are some important safety instructions and
precautions you should follow:
• Although your warning system is operating properly, it may not be completely effective. People may not see
or heed your warning signal. You must recognize this fact and continue driving cautiously.
• Also, situations may occur which obstruct your warning signal when natural and man-made objects are
between your vehicle and others, such as raising your hood or trunk lid. If these situations occur, be
especially careful.
• All effective sirens and horns produce loud sounds which may cause, in certain situations permanent hearing
loss. You and your passengers should consider taking appropriate safety precautions such as wearing hearing
protection.
• To be an effective warning device, this product produces bright light that can be hazardous to your eyesight
when viewed at a close range. Do not stare directly into this lighting product at a close range or permanent
damage to your eyesight may occur.
• It is important that you fully understand how to safely operate this warning system before use.
• You should only operate your vehicle and its light/sound system in accordance with your department’s
Standard Operating Procedure.
• If a selected function does not perform properly or if any of the LEDs remain illuminated when the control is
off, disconnect the power connector from the control unit and contact the nearest service center.
• At the start of your shift, you should ensure that the entire warning light system and the siren system is
securely attached and operating properly.
Failure to follow all safety precautions and instructions may result in property damage, serious injury, or death.
RETAIN AND REFER TO THESE MESSAGES

8
Navigator Lightbar
Installation, Operation, and Service Instructions
Overview of the Lightbar
The Navigator lightbar is a linear, high prole LED lightbar that offers First Responders a unique choice of
using stationary LED heads and LED rotators in one platform. Designed to t the needs of multiple agencies, the
Navigator’s options and overall exibility can be used on re apparatus and command/eet vehicles.
A Navigator lightbar can be congured to have all stationary LED heads, all rotating heads, or a mix of both
stationary LED heads with rotating heads. The Navigator lightbar comes in multiple lengths from 10 inches to
87 inches for a consistent look across an entire eet of vehicles. Dome color options include red, amber, blue
and clear while bulkhead options can be black or clear. Mirrors are used with rotating heads to give the effect of
multiple ashes from a single rotating source.
Along with ashing stationary and rotating heads, the Navigator can be congured with work lights, stop/tail/
turn lights, and steady-burn heads. White Light enable, Flood, Front and Rear Light Cutoff are standard features.
The Navigator lightbar is designed to ash one of 28 or 30 patterns in each mode of operation. The Navigator
can also be congured to meet NFPA, SAE, and California Title 13 requirements.
For the Navigator to respond to SignalMaster commands, the rear facing heads must be red/amber, blue amber,
or amber. SignalMaster functionality is limited to Navigators that are 45, 53, or 60-inches long. Only the amber
channels perform SignalMaster functions.
The Flood/Scene feature of the Navigator illuminates the area around the vehicle. The Flood/Scene commands/
inputs steady-burn the corresponding white lights and turn off any other LED in the activated lighthead.
Solaris LED Reector Technology
Federal Signal’s exclusive Solaris LED rotating reectors (SLR) and QuadraFlare reectors are engineered
to signicantly increase off-axis warning and maximize the LED light source to eliminate dark spots for true
360-degree light coverage.
LED Rotating Lights
The LED rotating lights are designed to be individually controlled single color or two-color lights. The lights
rotate 90 RPM or 120 RPM depending on the Navigator ash pattern. Thepattern of the LED warning lights is
controlled by the central control board inside the lightbar. The lights are rotated by quiet, smooth, precise, and
efcient positioning stepper motors that control the Solaris S2 reectors. The stepper motors have a longer life
than conventional DC motors. The lights change to white when White Light is enabled, ood forward when
Flood is enabled and be cut off to the rear.
Mirrors inside the lightbar give the rotating head the effect of multiple ashes. The default direction of rotation is
clockwise. Counter-clockwise rotation is selectable by changing a setting on a DIP switch on the rotator PCB. In
addition, each reector enables two LEDs to shine upward for the aerial location of the vehicle.
QuadraFlare LED Stationary Lights
The QuadraFlare LED stationary lights are designed to be single-color or two-color discreet, two-tier warning
lights. The lights are ashed by a central control board inside the lightbar. Lightheads can be congured with large
6 x 4 heads mounted in the center of the lightbar and smaller 7 x 3and 4 x 3 heads mounted on the ends of the
lightbar. The central control board controls all ashing of the lightheads.
Control Options
The Navigator is completely wired at the factory and does not require any additional internal wiring. There are RED
and BLACK 10 AWG power leads which supply power to the lightbar. There are separate +12 Vdc activated control
leads that initiate the functions of the lightbar or Convergence Network cable. If the lightbar is congured from the
factory with stop/tail/turn lights, there is a separate cable for splicing into the vehicle harness.

9
Navigator Lightbar
Installation, Operation, and Service Instructions
Mount Options
Hook Mount Kit: Z8653134
Permanent Mount Kit: Z8653134-01
Flat Surface Mount Kit:* Z8653178-1, Z8653178-2, Z8653178-3
4-inch Riser Mount:* Z806501522-2, Z806501522-4
Vehicle Specic Mounting Options: HKB-(model). Contact the factory for updated vehicle hook-mount options
*Kit options depend on the length of the lightbar.
Table 1 Dimensions in inches (less mounting feet
Models Length Height* Width
NVG10 10.00 in 4.43 in 12.36 in
NVG18 17.60 in 4.44 in 12.37 in
NVG25 24.80 in 4.44 in 12.37 in
NVG45 45.30 in 4.44 in 12.37 in
NVG53 52.50 in 4.44 in 12.37 in
NVG60 59.15 in 4.44 in 12.37 in
NVG73 73.00 in 4.44 in 12.37 in
NVG87 86.85 in 4.44 in 12.37 in
Table 2 Light Specications
Light Source Options LED (All Heads)
Current draw: LED Rotator 2.5 A per rotator
Current draw: 4 x 3 warning head 1.5 A maximum per head—Steady Burn
Current draw: 6 x 4 warning head 1.5 A maximum per head—Steady Burn
Current draw: 7 x 3 warning head 1.5 A maximum per head—Steady Burn
Operating Temperature -40 degrees F to 176 degrees F (-40 degrees C to 80 degrees C)
Reector Style: Offset, compound curve, vacuum metalized reectors
Preparing for the Lightbar Installation
Taking the preparatory steps in this section before mounting and wiring the lightbar to a vehicle will help ensure
that your installation is fast, easy, and error free.
Unpacking the Lightbar
HEAVY OBJECT: Use lifting aids and proper lifting techniques when removing or replacing this product.
Failure to follow this warning may cause personal injury.
Carefully unpack the lightbar assembly and any other products included in the shipment. Inspect them for damage
that may have occurred during shipping. If a product has been damaged, do not install or operate it. Immediately le a
claim with the carrier describing the damage.
Check all envelopes, shipping labels, and tags before removing or destroying them. If you are missing any parts,
contact Customer Support at 1-800-264-3578, 7 a.m. to 5 p.m., Monday through Friday (CT). Disposal of all
shipping materials must be carried out in accordance with national and local codes and standards.

10
Navigator Lightbar
Installation, Operation, and Service Instructions
Programming the Lightbar
Although the Navigator lightbar is congured and programmed at the factory, you may want to change the
default ash patterns before you install the lightbar.
Flashing Modes
The number of ashing modes varies by bar length. You can select a ash pattern for each available mode from the
lightbar’s internal library of ash patterns For a list of patterns, refer to Table 3 and Table 4 starting on page 11.
The INTERSECTION ashing mode is available in lightbars controlled through the Convergence Network The
INTERSECTION Mode is typically a high-activity pattern that attracts attention to the vehicle as it approaches an
intersection. The INTERSECTION mode overrides any of the ashing modes.
NOTE: If a SignalMaster function is activated, it overrides any ashing mode.
Selecting Flash Patterns
LIGHT HAZARD: To be an effective warning device, this product produces bright light that can be
hazardous to your eyesight when viewed at a close range. Do not stare directly into this lighting product
at a close range or permanent damage to your eyesight may occur.
To supply power to the lightbar, use a fully charged 12-volt automotive battery and follow these steps:
1. Place the lightbar on a sturdy at surface.
2. Connect the 10 AWG BLACK wire to the negative battery (-GND) terminal.
3. Connect the 10 AWG RED through a 40 A Maxi fuse to the positive battery (+BAT) terminal.
There are two methods of selecting a ash pattern in the Navigator depending on the cabling of the lightbar:
• by momentarily applying +12 Vdc to the ORANGE lead on certain models of discrete-wire lightbars.
• by pressing the WHITE pushbutton on the control board in the lightbar. The pushbutton is located next
to the connector for the power leads. This method is available in all Navigator lightbars with a central
control board.
Selecting a Flash Pattern with the Orange Lead in the Control Cable
On lightbars with a 10- or 20-conductor control cable, the ORANGE lead is the pattern selection wire.
Momentarily applying +12 Vdc to the ORANGE lead advances the displayed pattern to the next one.
Selecting a Flash Pattern with the Pushbutton
STATIC-SENSITIVE DEVICE: The lightbar circuitry can be damaged by electrostatic discharge (ESD).
Follow anti-static procedures while installing the lightbar.
See Figure 1 on page 11. The pattern selection button is located on the control board inside the lightbar
near the connector foe the power leads. For instructions on removing the domes to access the pushbutton, see
“Replacing a Dome or Bulkhead” on page 24.
With a ashing mode active, momentarily pressing the button advances the pattern to the next one.