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.

11
Navigator Lightbar
Installation, Operation, and Service Instructions
Figure 1 Flash pattern pushbutton on control board discrete-wired Navigator
Pattern selection button
Power leads connector
Table 3 Navigator ash patterns: 10-conductor discrete-wired cable
No. Description Rotators
Channel A*
Rotators
Channel B*
11Solid-head alternating quad ashes 90 RPM 90 RPM
22Split-head shufe/triple ash 90 RPM 90 RPM
3Rotate heads clockwise around 90 RPM 90 RPM
4 Top-bottom alternate ash 120 RPM 90 RPM
5 Criss-cross shufe followed by a solid ash – 53 cycles per minute 120 RPM 90 RPM
6 Split alternate single ash – 120 FPM 120 RPM 90 RPM
7Split alternate single ash – variable rate 120 RPM 90 RPM
8Solid heads alternating 120 FPM 120 RPM 90 RPM
9Split alternate single ash 75 FPM 90 RPM 90 RPM
10 FedPulse 75 – Solid Heads – Alternating 75 QFPM 90 RPM 90 RPM
11 Split head alternating quad ashes – 75 QFPM 120 RPM 90 RPM
12 Solid-head 120 triple FPM 120 RPM 120 RPM
13 Split-head 120 triple FPM 120 RPM 90 RPM
14 Solid head/split head alternating quad ashes 90 RPM 90 RPM
15 Solid head/split head quad ashes 120 RPM 90 RPM
16 Solid quad pulse/solid all on 120 RPM 90 RPM
17 Bottom top shufe-solid pulse 120 RPM 90 RPM
18 FedPulse 75 followed by 120 triple ash 90 RPM 90 RPM
19 Bottom top shufe – 75 single FPM 90 RPM 90 RPM
20 Split head shufe – 75 single FPM 90 RPM 90 RPM
21 Bottom top shufe – criss-cross shufe – 75 patterns per minute 90 RPM 90 RPM
22 Top/bottom alternate single ash – variable rate 120 RPM 90 RPM
23 Split alternate – top/bottom alternate single ash 120 RPM 90 RPM
24 FedPulse 75 – split heads –alternating – 75 QFM 90 RPM 90 RPM
25 Split head shufe/triple ash/alternating shufe 90 RPM 90 RPM
26 Triple solid head ashes/alternating ash 90 RPM 90 RPM
27 Triple solid head ashes/alternating triple ash 90 RPM 90 RPM
28 Fast bottom top shufe – criss-cross shufe 90 RPM 120 RPM
29 FedPulse 75 – solid heads – split heads 90 RPM 90 RPM
30 Random pattern - - - -
*Channel A rotors are located
in the outer positions of the
lightbar. Channel B rotators are
located in the inner positions.
1Denotes default ash pattern
for Mode 1.
2Denotes default ash pattern
for Mode 2.

12
Navigator Lightbar
Installation, Operation, and Service Instructions
Table 4 Navigator ash patterns: 45 in, 53 in, and 60 in serial-controlled/discrete lightbar
No. Description Rotator
1Solid head alternating quad ashes 90 RPM
2 Split-head shufe/triple ash 90 RPM
3Rotate heads clockwise around 90 RPM
4 Alternating solid-head quad ash – amber 90 RPM
5 Decelerating solid-head ash – amber 90 RPM
6 Seven-head solid-head ash – amber 90 RPM
7Quad -ash fast and solid-head ash – amber 90 RPM
8Double-ash and quad ash solid-head ash – amber 90 RPM
9Single-ash alternating solid head ash – amber 90 RPM
10 Quad-ash alternating solid head ash – amber 90 RPM
11 Split head alternating quad ashes – 75 QFPM 90 RPM
12 Alternating triple solid-head ash – amber 90 RPM
13 Single-ash all solid head ash – amber 90 RPM
14 Double-ash all solid head ash – amber 90 RPM
15 SCDOT double-ash all solid head ash – amber 90 RPM
16 Alternating sides ashing – police 90 RPM
17 2 quadrant chase – police 90 RPM
18 Alternate-end crisscross – police 90 RPM
19 Double criss cross, double half ash 90 RPM
20 Alternate side-split ash – police 90 RPM
21 Double-ash wig wag – police 90 RPM
22 Alternating solid-head quad ash and rotate – police 90 RPM
23 Variable ash left-right – police 90 RPM
24 Scroll center-out – police 90 RPM
25 Split-side wigwag and alternate-end criss cross ash – police 90 RPM
26 Alternate sides ashing and split-side wigwag 90 RPM
27 Amber random patterns 90 RPM
28 Police random patterns 90 RPM

13
Navigator Lightbar
Installation, Operation, and Service Instructions
Changing the Features on a 45-inch, 53-inch and 60-inch Navigator
The central control board of the 45-inch, 53-inch, and 60-inch lightbars have factory-set DIP switches that
affect the operation of the lightbar. SW2 and SW3 are nine-position switches numbered 1 to 18. These switches
determine if the corresponding stationary lightheads respond to functions and commands that use white light.
If the corresponding lighthead has white LEDs, the switch is turned on (up), the lighthead ashes white when
WHITE ENABLE is activated or responds to the FLOOD, TAKEDOWN, or ALLEY.
The third dip switch (SW4) affects additional features, which are described in Table 5. The switches are set at the
factory based on the conguration of the lightbar.
Figure 2 Central control board with switches off (down)
SW2
ON
SW3
SW4
U19 U20 U21
VBAT/SW
DIS/CON
SM
AUX
WK SB 45 53
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
ON
1 2 3 4 5 6 7 8 9
ON
10 11 12 13 14 15 16 17 18
1 2 3 4 5 6 7 8 9
Table 5 Functions of SW4
VBAT/SW If the Navigator lightbar is controlled by a Convergence Network control head,
the lightbar can power the control head through the CAT5 cable. To enable
this feature set the switch to ON.
DIS/CON If the Navigator lightbar is controlled by a Convergence Network control head,
the lightbar can power the control head. Turn on this feature by setting the
switch to ON.
FL SM The rear facing amber lightheads do not ash in Modes 1, 2, 3 and only
respond to SignalMaster commands. To enable ashing, set the switch to ON.
AUX No function
WK If the lightbar is congured with work lights, the switch is set to ON.
SB If the lightbar is congured with steady burn lights on the passenger and
driver side, the switch is set to ON.
45 This switch is set to ON for 45-inch lightbars.
53 This switch is set to ON for 53-inch lightbars.
Changing the Rotator Functions in an All-Rotator Navigator
STATIC SENSITIVE DEVICE: This circuitry of the lightbar can be damaged by electrostatic discharge
(ESD). Follow anti-static procedures while changing the rotator functions.
An all-rotator Navigator has a power distribution board instead of a control board. The board accepts up to 7
rotators. Each rotator has a 2 x 4 header on the board. Two positions on the header determine the operation of the
rotator when power is applied. Two additional positions on the header determine if the rotator is to operate in Flood
Mode, which is white light to the front or rear of the lightbar. You can select how a rotator operates by placing a
jumper across a pair of pins (Figure 1 on page 11).

14
Navigator Lightbar
Installation, Operation, and Service Instructions
Figure 3 All-rotator power distribution board
J13
J3
J1
J5
J7
J6 J2
J8
J14
J9
J10J11
MINUS BLACK
20000160
J15
UNIVERSITY
FEDERAL SIGNAL
J16
PMTH2
FF
FR
90
120
J4
J12
FF FR
90
120
FF
FR
90
120
FF
FR
90
120
FF
FR
90
120
FF
120
1
2
3
4
5
6
7
FF
FR
90
120
FR
90
3
14
123
2
CORPORATION
PARK, IL
GREEN
LEFT ALLEY
ORANGE
RIGHT ALLEY
WHITE
REAR CUT
YELLOW
WHITE LIGHT
GRAY
FLOOD
VBAT+
RED
PMTH1
LEGENDS FOR LIGHTHEAD JUMPERS J8 TO J14
120 = ROTATE AT 120 RPM
90 = ROTATE AT 90 RPM
FF = FLOOD FORWARD (FACTORY CONFIGURED)
FR= FLOOD REARWARD (FACTORY CONFIGURED)
J15 CONNECTOR:
ALLEY LIGHTS
REAR LIGHT CUTOFF
WHITE LIGHT
J16 CONNECTOR:
+12 Vdc POWER
FLOOD LIGHTS
The selectable options are:
Rotation speed
When power is applied to the lightbar, the rotator lights rotate at either 90 RPM or 120 RPM. These functions are xed
while power is supplied to the lightbar. To select a rotation angle, move the jumper on the power distribution board
across the pairs of pins labeled 90 or 120.
White light ood
When +12 Vdc is applied to the GRAY ood wire in the lightbar, the rotator stops and the reector faces either
forward or rearward with the LEDs changing to white. The determination and conguration of whether a rotator
should ood is made at the factory when the lightbar is assembled. For a rotator to ood when the ood wire is
activated, the jumper must be placed in the FF (Flood Forward) or FR (Flood Rearward) position on the power
distribution board.
Determining the Mounting Location and Wire Routing
LOCATING OPERATOR CONTROLS: The controls for the light system must be located so that the
VEHICLE and CONTROLS can be operated safely under all driving conditions.
AIRBAG DEPLOYMENT: Do not install equipment or route wiring in the deployment path of an airbag.
Failure to observe this warning will reduce the effectiveness of the airbag or potentially dislodge the
equipment, causing serious injury or death.
SEAT REMOVAL PRECAUTION: If a vehicle seat is temporarily removed, verify with the vehicle manufacturer
if the seat needs to be recalibrated for proper airbag deployment. Failure to follow this warning cause
serious injury or death.

15
Navigator Lightbar
Installation, Operation, and Service Instructions
INSTALLATION PRECAUTIONS: The warning system and/or two-way radio system may operate improperly
if a two-way radio antenna installed on or within 18 inches of the lightbar. Before permanently installing
the lightbar or a two-way radio antenna, test the warning system and two-way radio system. DO NOT
install a two-way radio antenna on the lightbar. Some installations may require the relocation of the two-
way radio antenna to a trunk or fender location. DO NOT drill holes in the lightbar or install auxiliary
devices on the lightbar or the warning system may fail.
To prepare for installing the Navigator:
• Ensure that the battery voltage is the same as the voltage rating of the lightbar.
• Verify that the lightbar and mounting hardware t the vehicle.
• Determine where to mount the lightbar on the vehicle.
• Decide where to route wiring around airbag areas.
• Decide where to route the power and ground wires from the lightbar.
• To make wiring easier, remove the seats, spare tire, and pull down the headliner where needed.
• Separate all electronic equipment wiring from two-way radio equipment wiring.
• To avoid interference, keep two-way radio antennas a minimum of 18 inches (45.7 cm) away from warning
equipment.
• Whenever possible, run full wire lengths. DO NOT splice the wires.
• Do not coil excess wire. Leave a drain loop for servicing the lightbar.
• After drilling holes for wires, deburr them, smooth sharp edges, and insert grommets to protect the wires
from chang.
• When you frame-ground the equipment, use the manufacturer-supplied ground locations in the vehicle.
IMPORTANT: After the installation, frequently inspect the lightbar and mounting feet to ensure that all
fasteners and brackets are tight.
Wiring the Navigator in the Vehicle
Before wiring the Navigator in the vehicle, ensure that the lightbar has been installed on the vehicle roof in accordance
with the instructions included with the mounting kit. Installation of options such as an Opticom®require additional
wiring to the warning light system and vehicle battery not covered in this manual. Review the electrical requirements
of the lightbar and use an installer-supplied switch or relay properly rated for the connection between the red power
lead of the lightbar and the fused power source. If additional wire length is needed, splice wire of the same gauge or
heavier to the leads.
All of the lightbar controls are integrated into the Navigator central control board. The Navigator has one of 5 different
wiring types depending on its length and how it was congured. Table 6 on page 16 shows on the wiring/cabling
for each length/conguration of Navigator. Refer to the page number listed for details on the proper wiring of your
particular Navigator.

16
Navigator Lightbar
Installation, Operation, and Service Instructions
Table 6 Cabling based on lightbar length and conguration (see pages referenced)
10 inch 18 inch 25 inch 45 inch
Stationary/
Mixed
Rotator Stationary/
Mixed
Rotator Stationary/
Mixed
Stationary/
Mixed
Rotator
4-Conductor Cable page 17 page 17 page 17
Power, Ground, and
10-Conductor Cable page 18 page 18
Power, Ground, and
20-Conductor Cable page 20
Power, Ground, and
Serial Cable page 22
Power, Ground, and
5 Control Leads page 18 page 18
53 inch 60 inch 73 inch 87 inch
Stationary/
Mixed Rotator Stationary/ Mixed Rotator Stationary/ Mixed Rotator Stationary/ Mixed Rotator
4-Conductor Cable
Power, Ground, and
10-Conductor Cable page 18 page 18
Power, Ground, and
20-Conductor Cable page 20 page 18
Power, Ground, and
Serial Cable page 22 page 22
Power, Ground, and
5 Control Leads page 18 page 18 page 18 page 18
Connecting Power to the Lightbar
BATTERY EXPLOSION: To avoid a battery explosion, always disconnect the negative 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 an electrical explosion that could result in vehicle damage and serious injury.
PROPER GROUNDING: The lightbar WILL NOT light up or ash if it is improperly grounded. Be sure
that the lightbar is connected to a good vehicle ground. Failure to observe this warning can lead to
equipment failure and may result in serious injury or death.
SPARK HAZARD: If wires are shorted to the vehicle frame or each other, high-current conductors can
cause hazardous sparks resulting in electrical res and molten metal. Verify that no short circuits exist
before connecting to the positive (+) battery terminal.
CURRENT CAPABILITY: For safe operation of the lightbar, the power control switch and wiring must be
capable of handling the rated current of the fuse at the source.

17
Navigator Lightbar
Installation, Operation, and Service Instructions
10-inch All-Stationary Navigator with a 4-Conductor Control Cable
The 10-inch all stationary Navigator has a 4-conductor cable exiting the lightbar. Each wire has the following
function:
BLACK WIRE: Attach this wire to a known good vehicle ground.
MODE 1: Applying +12 Vdc to the RED wire activates ashing mode. This wire must be on a switched feed that is
fused at 10 A.
WHITE LIGHT: Applying + 12 Vdc to the WHITE wire while the lightbar is ashing activates the white LEDs in the
lightheads, if installed (White Light Enable). If used, this wire must be on a switched feed that is fused at 10 A.
WORK LIGHT: Apply + Vdc to the GREEN wire activates ashing.
Figure 4 Wire functions for 4-conductor cable (10-inch all stationary)
WORKLIGHT
WHITE LIGHT ENABLE
GREEN
WHITE
+POWER RED
–GROUND BLACK
HIGH-SIDE (12 V dc ) SWITCHED OUTPUTS
4-CONDUCTOR CABLE
FROM LIGHTBAR
INSTALLER SUPPLIED SUPPLIED WITH LIGHTBAR
FUSE RATINGS ARE BASED ON A
STANDARD OPTION INSTALLATION.
IF MULTIPLES OF ANY OPTION ARE
INSTALLED, ADJUST THE FUSE
SIZE AS REQUIRED.
40 A
40 A
(EXTEND LEADS WITH
16 AWG OR THICKER)
10-inch or 18-inch All-Rotator Navigator with a 4-Conductor Control Cable
A 10-inch or 18-inch all-rotator Navigator has a 4-conductor cable exiting the lightbar. Each wire has the
following function:
BLACK WIRE: Attach this wire to a known good vehicle ground.
90 RPM: Applying +12 Vdc to the RED wire turns on the rotators, which spin at 90 RPM. This wire must be on a
switched feed that is fused at 10 A
WHITE LIGHT: Applying + 12 Vdc to the WHITE wire while the while the rotators are active activates the white in
the rotators congured with white light. The rotator LEDs are white to the front and a primary color to the rear. If
used, this wire must be on a switched feed that is fused at 10 A.
120 RPM: Applying +12 Vdc to the GREEN wire turns on the rotators, which spin at 120 RPM. This wire must be
on a switched feed that is fused at 10 A.

18
Navigator Lightbar
Installation, Operation, and Service Instructions
Navigator with Power, Ground, and 5 Control Leads
Navigators with this wiring have 10 AWG RED and BLACK power leads along with WHITE, YELLOW, GREEN,
and ORANGE leads.
BLACK WIRE: Attach this wire to a known good vehicle ground.
90 RPM: Applying +12 Vdc to the RED lead activates the rotators.
WHITE LIGHT: Applying +12 Vdc to the YELLOW lead powers the white light in the rotators congured for white
light. The rotator LEDs are white to the front and red to rear. This wire must be on a switched feed
FLOOD: Applying +12 Vdc to the GRAY lead enables White Light Flood in the rotators congured for Flood. The
lightheads ood forward or rearward depending on the jumper setting on the power distribution board (Figure 3
on page 14).
REAR LIGHT CUTOFF: Applying +12 Vdc to the WHITE lead enables rear light cutoff in the rotators.
DRIVER-SIDE ALLEY: Applying +12 Vdc to the GREEN lead powers the driver-side alley light.
PASSENGER-SIDE ALLEY: Applying +12 Vdc to the ORANGE lead powers the passenger-side alley light.
Navigator with Power Ground and 10-Conductor Control Cable
A Navigator with full-function control has RED and BLACK 10 AWG power leads. There is a separate
10-conductor control cable, the functions of which are dened in Figure 5 below and in the tables on page 19.
All inputs are high-side activated, which means that applying +12 Vdc activates the input. For instructions on
wiring lights congured as stop/tail/turn, see page 23.
BLACK Power Lead: Attach this lead to a known good vehicle ground.
RED Power Lead: Attach this lead to a known good vehicle ground.
Figure 5 Wire functions for 10-conductor cable
1A MODE 1 BRN
MODE 2
STEADY BURN
WHITE LIGHT ENABLE
FRONT FLOOD
PATTERN SELECT
FRONT LIGHT CUTOFF
DIM (LOW POWER)
REAR LIGHT CUTOFF
WORKLIGHTS
BLU
RED
YEL
GRY
ORG
BLK
GRN
WHT
VIO
(-) TO GROUND
1A
1A
1A
1A
1A
1A
1A
1A
1A
SUPPLIED WITH LIGHTBAR
CUSTOMER SUPPLIED
40A RED (10 AWG)
BLK (10 AWG)
MAIN POWER
PASSENGER SIDE ALLEY
(+) POWER
ACTIVATED BY IGNITION WITH
USE OF A RELAY
(OPTION: TO +12 VDC BATTERY
IF USING IGNITION TIMERS)
10-CONDUCTOR CABLE
FROM LIGHTBAR

19
Navigator Lightbar
Installation, Operation, and Service Instructions
Table 7 Lightbar functions for 10-conductor cable
Wires Function Description
Brown Mode 1
Applying +12 Vdc activates the lightbar in Mode 1 (Primary
Mode) has priority over Mode 2 (Secondary Mode). The
lightbar can be programmed to have one of 30 ash patterns in
this mode.
Blue Mode 2
Applying +12 Vdc activates the lightbar in Secondary Mode.
The lightbar can be programmed to have one of 30 ash
patterns in this mode.
Red Steady Burn Red Applying +12 Vdc activates any steady burn modules in the
lightbar. The lightbar is congured upon request for this option.
Yellow White Light Enable
When calling for the right of way, a vehicle responding to an
emergency is permitted to have white light. Applying +12 Vdc
activates the white ashing LED heads and may turn the
rotators white depending on the lightbar conguration.
Gray Flood Mode Applying +12 Vdc activates Flood Mode, which turns on lights
that are congured for Steady White.
Orange Pattern Selection Touching the wire to +12 Vdc changes the pattern and stores it
in memory.
Black Front Light Cutoff Applying +12 Vdc cuts off forward ashing lights.
Green Dim Applying +12 Vdc dims the lightbar 50 percent. Dimming has
no effect on the rotating lightheads.
White Rear Light Cutoff Applying +12 Vdc cuts off light to the rear.
Violet Work lights Applying +12 Vdc activates the work lights if congured for this
option when the lightbar is ordered.

20
Navigator Lightbar
Installation, Operation, and Service Instructions
Navigator with a 20-Conductor Control Cable
A Navigator with full-function control has RED and BLACK 10 AWG power leads. There is a separate
20-conductor control cable, the functions of which are dened in Figure 6 below and in Table 8 on page 21.
All inputs are high-side activated, which means that applying +12 Vdc activates the input. For instructions on
wiring lights congured as stop/tail/turn, see page 23.
BLACK Power Lead: Attach this lead to a known good vehicle ground.
RED Power Lead: Attach this lead to a known good vehicle ground.
Figure 6 Lightbar functions for 10-conductor cable
1A TAKEDOWNS WHT/BLK
DIM (LOW POWER)
REAR FLOOD
WORKLIGHTS
CRUISE
PATTERN SELECT
WARN 1
SIGNALMASTER, LEFT
SIGNALMASTER, RIGHT
SIGNALMASTER, CENTER-OUT
MODE 1
MODE 2
MODE 3
FRONT LIGHT CUTOFF
STEADY BURN
REAR LIGHT CUTOFF
GRN
RED/BLK
WHT/BLK
BLK
ORG
RED/GRN
RED
WHT/RED
BLU/RED
BLU
BLU/WHT
BLK/RED
GRN/WHT
RED/WHT
BLU/BLK
WHT
GRN/BLK
ORG/RED
ORG/BLK
FRONT FLOOD
WHITE LIGHT ENABLE
DRIVER SIDE ALLEY
PASSENGER SIDE ALLEY
(-) TO GROUND
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
1A
SUPPLIED WITH LIGHTBARCUSTOMER SUPPLIED
40A RED (10 AWG)
BLK (10 AWG)
MAIN POWER
PASSENGER SIDE ALLEY
(+) POWER
ACTIVATED BY IGNITION WITH
USE OF A RELAY
(OPTION: TO +12 VDC BATTERY
IF USING IGNITION TIMERS)
20-CONDUCTOR CABLE
FROM LIGHTBAR