Federal Signal Corporation QuadraFlare QL64Z3V-LI User manual

Installation Manual
2562429B
REV. B 1109
Printed in U.S.A.
Qu a d r a Fl a r e ™
Models
QL64Z3V-LI and QL64Z3V-RI

Contents
Safety Message to Installers and Service Personnel.......................... 1
Safety Message to Operators of Warning Light Equipment ............... 4
Product Overview .................................................................................. 6
Unpacking the Product .......................................................................... 6
Mounting the Qu a d r a Fl a r e Lights ......................................................... 6
Making Electrical Connections ............................................................. 7
Completing the Installation ................................................................... 8
Cleaning the Plastic Lenses.................................................................. 8
Getting Service and Parts.................................................................... 10

1
Safety Message to Installers and Service Personnel
of Warning Light Equipment
People’s lives depend on your proper installation and servicing of Fed-
eral Signal products. It is important to read and follow all instructions
shipped with this product. In addition, listed below are some other im-
portant safety instructions and precautions you should follow:
Before Installation or Service
Qualifications
• 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 safe-
ty warning equipment. Always refer to the vehicle’s service manuals
when performing equipment installations on a vehicle.
Light Hazards
• 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 per-
manent 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
safely operate the vehicle.
• Federal Signal power supplies and light heads are designed to work
together as a system. Combining light heads 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 ensure the system works together and meets
federal, state and local standards or guidelines.
Electrical Hazards
• Strobe systems present a shock hazard because they use high voltage
to operate. Do not handle strobe cables, the power supply or bulbs or
remove the lens while the equipment is connected. Strobe systems can
also hold their charge even after they have been turned off. After dis-
connecting power to the unit, wait ve minutes before handling any
parts of the strobe system.

2Qu a d r a Fl a r e Warning Lights
• A light system is a high current system. For the system to function
properly, a separate negative (–) connection and positive (+) connec-
tion 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 ve-
hicle wiring without reviewing a vehicle wiring diagram available from
the vehicle manufacturer. Ensure that your installation will not affect
vehicle operation or mandated safety functions or circuits. Always
check the vehicle for proper operation after installation.
• The lighting system components, especially light bulbs, strobe tubes,
LEDs, and the outer housing, get hot during operation. Be sure to dis-
connect power to the system and allow the system to cool down before
handling any components of the system.
• Halogen light bulbs and strobe tubes are pressurized and if broken, can
burst and result in ying glass. Always wear gloves and eye protection
when handling these components.
• Do not mount a radio antenna within 18 inches (45.7 cm) of the light-
ing 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 any unsealed electrical device while it is con-
nected to its power source.
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.
• DO NOT connect this system to the vehicle battery until ALL other
electrical connections are made, mounting of all components is com-
plete, 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 hazard-
ous 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.

3
Qu a d r a Fl a r e Warning Lights
• If a vehicle seat is temporarily removed, verify with the vehicle manu-
facturer if the seat needs to be recalibrated for proper airbag deploy-
ment.
• 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 com-
partment or other extreme environmental exposure areas.
• The service life of light bulbs and strobes tubes will be shortened if the
glass portion is touched during installation. Use gloves when handling
these components. If the glass portion has been touched, clean the glass
carefully with isopropyl alcohol.
• Before 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 manual packed with the lighting system for proper electri-
cal 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.
On lightbar models other than Legend, tighten the hook adjustment
bolts 10 ft-lb to 11 ft-lb to prevent the lightbar from sliding front-to-
back when pulling on the mounting bracket. On all other models, tight-
en the hook adjustment bolts 6 ft-lb to 7 ft-lb.
• 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.
• Test all vehicle functions, including horn operation, vehicle safety
functions and vehicle light systems, to ensure proper operation. Ensure

4Qu a d r a Fl a r e Warning Lights
that the installation has not affected the vehicle operation or changed
any vehicle safety function or circuit.
• Scratched or dull reectors, mirrors or lenses will reduce the effective-
ness 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 de-activate the light system controls while
driving in a hazardous situation.
• You should frequently inspect the light system to ensure that it is oper-
ating properly and that it is securely attached to the vehicle.
• After installation and testing are complete, provide a copy of these in-
structions to instructional staff and all operating personnel.
• File these instructions in a safe place and refer to them when maintain-
ing and/or re-installing the product.
Failure to follow all safety precautions and instructions may result in
property damage, serious injury, or death to you or others.
RETAIN AND REFER TO THIS MESSAGE
Safety Message to Operators of Warning Light Equipment
People’s lives depend on your safe use of our products. Listed below are
some important safety instructions and precautions you should follow:
• Do not attempt to activate or de-activate the light system control while
driving in a hazardous situation.
• 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.

5
Qu a d r a Fl a r e Warning Lights
• 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 per-
manent 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 ac-
cordance with your department’s Standard Operating Procedures.
• If a selected function does not perform properly or if any of the lamps
remain illuminated when the control is off, disconnect the power con-
nector 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.
• Suction cup mounting is for temporary applications only. The unit
should be removed from the window and stored securely when not in
use. Temperature changes and sunlight can cause suction cups to lose
holding power. Periodically check the unit to be sure the suction cups
have a rm grip on the mounting surface. An improperly secured light
could fall off of the vehicle causing injury and damage.
• Holding power of magnetic mounting systems is dependent upon sur-
face nish, surface atness, and thickness of the steel mounting sur-
face. Therefore, to promote proper magnetic mounting:
✓ Mounting surface and magnets must be kept clean, dry, and free of
foreign particles that prevent good surface contact.
✓ Ensure that mounting surface is at.
✓ A magnet mounting system should not be used on vehicles with
vinyl tops.
✓ To prevent sliding of light assembly on mounting surface, quick
acceleration and hard stops should be avoided.
Failure to follow these safety instructions and precautions may result
in property damage, serious injury, or death to you, to passengers, and
to others.
RETAIN AND REFER TO THIS MESSAGE

6Qu a d r a Fl a r e Warning Lights
Product Overview
Models QL64Z3V-L1 and QL64Z3V-R1 are three-head Qu a d r a Fl a r e light
assemblies designed to operate on 12 Vdc. They are intended for mounting
on the rear exterior of a vehicle. Both models have a BTT (Brake, Turn, Tail),
TURN or ARROW, and BACKUP Qu a d r a Fl a r e light assembly.
Unpacking the Product
After unpacking the product, inspect it for damage that may have occurred in
transit. If the product has been damaged, do not attempt to install or operate
it. File a claim immediately with the carrier, describing the extent of damage.
Carefully check all envelopes, shipping labels, and tags before removing or
destroying them.
NOTE: There is one preinstalled female Packard connector for every Qu a d r a -
Fl a r e light. The male Packard connectors are user-supplied.
Table 1: Mounting hardware
Qty. Description Part No.
4 #10 x 3/4" Screw, S.S. 7011182-12
Mounting the Qu a d r a Fl a r e Lights
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 to you or
others.
Before installing the lights, read all instructions and plan all wiring and cable
routing. Use grommets, wire ties, looms, and cable mounts (installer supplied)
as needed to secure and protect the wiring.
NOTE: For maximum coverage and effectiveness, each light assembly must
be mounted in the vertical or horizontal orientation shown in Figure 1. Make
sure that the drain hole in each bezel is orientated on the bottom before you
mounting the light assembly.

7
Qu a d r a Fl a r e Warning Lights
LOCATING OPERATOR CONTROLS
Locate the light system controls so the VEHICLE and CONTROLS can
be operates safely under all driving conditions.
Failure to heed this warning could result in driver distraction or driver
error while operating the vehicle.
Before proceeding with the installation, determine the approximate location
of the light assembly and plan all mating connections.
1. Position the Qu a d r a Fl a r e warning light assembly on the mounting sur-
face. Ensure that the assembly is level side to side.
2. Using the Qu a d r a Fl a r e warning light assembly as a guide and the di-
mensions in Figure 1 on page 9, scribe the locations of the four mount-
ing-holes and three wire-routing holes.
DRILLING PRECAUTIONS
Before drilling holes, check the area into which you plan to drill
to ensure you do not damage vehicle components while drilling.
All drilled holes should be deburred and all sharp edges should be
smoothed. All wires going through drilled holes should be protected
by a grommet or convolute/split-loom tubing.
3. Drill four 9/64" (0.140") mounting holes.
Before completing the installation, make connect the for each Qu a d r a Fl a r e
as described in “Making Electrical Connections” on page 8.
Making Electrical Connections
The Qu a d r a Fl a r e lights have Packard female connectors that exit from back
for mating with a user-supplied male Packard connector. The Qu a d r a Fl a r e
warning lights are designed to operate on 12 Vdc
Model Brake Turn Tail (BTT)
To complete the wiring connections:
1. Assemble the male three-pin Packard connector and place it on the
back of the vehicle with the spacing shown in Figure 1 on page 9.
2. Using 18 AWG wire on the male Packard connector, connect the
female and male connectors.

8Qu a d r a Fl a r e Warning Lights
3. Energize the supply circuit and test the Qu a d r a Fl a r e warning lights
for proper operation.
Models TURN, ARROW, and BACKUP.
1. Assemble the male two-pin Packard connector (with the appropriate
contact pins) and place it on the back of the vehicle.
2. Using 18 to 20 AWG wire with the contact pins, connect the female
and male Packard connectors.
3. Energize the supply circuit and test the Qu a d r a Fl a r e warning lights
for proper operation.
Completing the Installation
1. See Figure 1 on page 9. Align the mounting gasket and QuadraFlare
warning light assembly over the drilled 9/64" (0.140") holes.
2. Carefully place any connectors into the recessed area in the back of the
aluminum bezel. Secure the assembly with the #10 x 3/4" screws.
Cleaning the Plastic Lenses
CRAZING/CHEMICALS
Crazing (cracking) of lenses will cause reduced effectiveness of the light.
Do not use cleaning agents (which will cause crazing) such as strong de-
tergents, solvents, or petroleum products. If crazing of lenses does occur,
the reliability of light for emergency signaling purposes may be reduced
until lenses are replaced.
Failure to follow this warning can damage the domes and reflectors and
may result in bodily injury or death to you or others.
Clean the plastic lenses with a solution of water and mild soap and a soft rag.
To remove ne scratches and haze, use a specialty plastic cleaner/polish such
as Plexus® and a soft cloth. You can also use a high quality automotive paste
cleaner/wax that is non-abrasive.
NOTE: The most effective product you can use for cleaning, protecting, and
polishing clear and colored plastics is Plexus. Plexus is available in cases of
12 aerosol cans from Federal Signal Corporation, Emergency Products, in
either 7-ounce cans (PX7) or 13-ounce cans (PX13). Over time, exposure to
heat, sunlight, and smog causes plastic to fade, discolor, scratch, or become
brittle. Plexus seals the pores of the plastic, making the domes easier to clean,
improving scratch resistance, and increasing product longevity.

9
Qu a d r a Fl a r e Warning Lights
5.75"
14.38"
4.50"
Ø.21" (4 PLACES)
MOUNTING
GASKET
VEHICLE
BODY
Ø1.50"
(3 PLACES)
#10 X 3/4"
SCREW(4)
290A6150
3.0"
#10 X 3/4"
SCREW(4)
21.6"
6.9"
MOUNTING
GASKET
VEHICLE
BODY
Figure 1: Vertical and horizontal mounting

10
Qu a d r a Fl a r e Warning Lights
Obtaining Service and Parts
Federal Signal provides technical assistance with any problems that cannot be
handled locally.
Any units returned to Federal Signal for service, inspection, or repair must be
accompanied by a Return Material Authorization. The R.M.A. can be obtained
from a local Distributor or Manufacturer’s Representative. Please provide a
brief explanation of the service requested or the nature of the malfunction.
Address all communications and shipments to:
Service Department
Federal Signal Corporation
Phone: [phone]
Fax: [phone]
Email: [email protected]
(7 a m to 5 p m , Monday through Friday, Central Time)
Table 1: Replacement parts
Description Part No.
Qu a d r a Fl a r e Mounting Screws, #6 x 1-1/2" 7011205-20
Screw Grommet 7065073
Lens, Fluted, Red 8012013
Lens, Fluted, Amber 8012013-01
Lens, Fluted, Clear 8012013-02
Lens, Smooth, Red 8012018
Lens, Smooth, Amber 8012018-01
Lens, Smooth, Clear 8012018-02
Bezel Mounting Screws 7011182-12
BTT Lamp 8012049-01
Turn Lamp 8012050-01
Arrow 8012051-01
Backup Lamp 8012052-01
Seal, Packard Connector 139383
2-Position Connector, Packard 139392
3-Position Connector, Packard 139393
Contact Pins 233255

2645 Federal Signal Drive, University Park, IL 60484-3167
Tel.: [phone] • Fax: [phone]
www.fedsig.com ©2009 Federal Signal Corporation