INSTALL INSTRUCTIONS CD-QS & CD-QS-KIT ROOF MOUNTED SPOT LIGHT

Transcription

1 INSTALL INSTRUCTIONS CD-QS & CD-QS-KIT ROOF MOUNTED SPOT LIGHT TOOLS REQUIRED: Safety goggles Power drill Phillips head screwdriver 1/8 & 1/4 drill bits 3/4 hole saw 1/2 masking tape Utility knife Wire cutter/ stripper/ Crimping Tool Tin Snips Tarp or cover for seat Measuring tape Round file IMPORTANT INFORMATION REVIEW PRIOR TO INSTALLATION Visual Inspection Many vehicles have a large area in which to mount the Roof Mounted spotlight. In addition to the location specified above, you should be able to find other locations that will allow the mounting of additional optional equipment on the roof. Some headliners have optional overhead storage compartments. Always try to mount the Roof Mounted spotlight in an area where the headliner is on a flat surface and tight to the roof liner. It is necessary to check under the headliner to make sure there are no wire harnesses or other obstructions where the trim grommet is to be installed. Inspect the roof structure to make sure that you will not be cutting a structural roof member. For vehicles not listed in application guide Use the following steps to determine if you can install a Roof Mounted spotlight in a vehicle not listed in this guide. 1. Remove sun visor and/ or any other parts in the way so the headliner can be lowered on at least one side. 2. Look for cross supports and supports running from front to rear that would interfere with the area needed to mount the spotlight. Removal of these supports is not recommended. Use a flashlight or droplight. If necessary, take measurements to determine if space is available. Trim Grommet space requirements are: 4G-TG, for CD-QS-1 & 2: 9 long x 6 wide and 4G-VTB, for CD-QS-3 & 4: 6 round. 3. Choose a mounting location on a flat surface of roof, allowing as much contact as possible for the stabilizer plate on the spotlight. Also be aware of roof corrugations, and double-skin roofs. Note: Spotlight must be mounted through only the outer skin of roof. 4. Once an acceptable location for distance A or B (refer to Application Guide on pg.2) is determined, the headliner may be put back into position and the installation can proceed according to the Installation Guide. Note: Tin snips or air nibblers are needed for double panel steel roofs Note: Vehicles with double-steel roofs: The inner steel roof must be cut out!

2 Roof Mounted Spotlight Application Guide Distance A is to the front of the trim grommet and Distance B is to the center of the trim bowl. Distance A and B are the distances measured from the windshield edge. Mark this distance on centerline of masking tape. Model Years Dist. A Dist. B Application Notes CHEVROLET Colorado/Canyon Note 5, 9 (QS-3 or QS-4 recommended) Impala (Police Pkg.) Impala Note 1 (not recommended) Blazer/Jimmy (full size) Notes 2, 4, 9 S-10 Blazer/S-15 Jimmy Note 2 S-10 Blazer/S-15 Jimmy (4 DR) Note 2 Suburban Notes 2, 4, 9 Suburban/Tahoe Notes 2, 6 GMC Yukon/Yukon XL Notes 2, 6 S-10/S-15 Sonoma (all) Silverado/Sierra Pick-ups (all) Note 2, 6 Suburban/Tahoe/Silverado Notes 2, 6 Yukon/Yukon XL/Sierra Notes 2, 6 G series van Note 7 Astro/Safari van DAIMLER CHRYSLER Durango Effects light bar mounting, note 9 Durango Jeep Cherokee Note 1 (not recommended) Ram Charger Note 2, 4 Dodge Full-Size Pickup Regular & Extended Cab Club Cab Note 4 Dodge Dakota Standard/Club Cab Full size Ram Van 109 W.B./127 W.B Note 1 (not recommended) Caravan/Voyager 112 W.B./119 W.B Note 1, 2 (not recommended) Charger Magnum FORD LTD / Crown Victoria Note 6 Taurus Excursion See Note Notes 2, 9, 10 (CD-QS-3 or CD-QS-4 recommended) Expedition Note 2 Explorer Sport Trac F Regular Cab Note 8 Super Cab F-150 (Excluding Heritage) Notes 1, 2 (not recommended) F-250, 350, 450, 550 (all) See Note 10, Notes 2, 5, 9, 10, 11 (CD-QS-3 or CD-QS-4 recommended) F-250, 350, 450, 550 (all) See Note 12, Notes 1, 12,13 F (Chassis cab) See Note 10, Notes 2, 5, 9, 10, 11 (CD-QS-3 or CD-QS-4 recommended) Ranger Pick-up Econoline E-Series Van Note 2 Windstar Application Notes 2

3 Note #1. Extended cab trucks and vans. This roof may have a center rib running front to rear on the outer roof skin. Check the outer roof prior to installing. This will necessitate off-center mounting. Note #2. Overhead consoles If your vehicle has a full-length over-head console, the Roof Mounted spotlight will have to be mounted off to one side of the console, or the console will have to be modified by the equipment installer. Electronic controls mounted in consoles have wires that run from front to rear that must be relocated prior to installing the spotlight. Note #3. The Chevy G-Series Van with a cardboard headliner has a sheet metal screw in the center of the headliner that holds it to a small support bracket underneath. Remove the screw and headliner; the support bracket must be removed by using tin snips, or a similar cutting tool. Reinstall the headliner and install Roof Mounted Spotlight. When the light is installed, it will support the headliner. Note #4. Double steel roof Pickup trucks with double steel roofs require the inner metal roof to be cut out after the material headliner is cut out. After cutting the material headliner, mark the metal panel, and remove, or pull down the headliner. Prior to cutting the metal, redraw the hole opening 1/4 larger. The inner metal may be cut with a small Air Nibbler, or tin snips. If you use an Air Nibbler, make sure that there is enough clearance between the inner and outer roofs so the anvil, or punch doesn t hit the outer roof panel. Note #5. Cross members There are several cross members in the roof. The Roof Mounted Spotlight trim bezel must be mounted in the exact location listed on the application guide. Note #6. If vehicle does not have an overhead console, it most likely will have the steel mount bracket between the roof and headliner for mounting the optional overhead console. (bracket goes from windshield frame rearward to cross support). This bracket must be removed in order to mount the Questar spotlight. Some police vehicles are equipped with optional dome lights, which may have to be relocated to install the Roof Mounted Spotlight. Note #7. Full-size G-Series van- Measure on centerline over the storage compartment. Note #8. Ford F-Series- After you cut the headliner out, trim grommet gaskets (included - part # 4G-TG-GASK) will need to be used. Note #9. Smaller trim Grommet Recommended CD-QS-3 or CD-QS-4: We recommend the smaller optional trim grommet for this application. This trim grommet does not have a built-in on/off switch. Using this trim grommet requires hard wiring a switch on the dash or other location, if standard CD-QS-1 or CD-QS-2 grommet is used. Note #10. Special install instructions: These vehicles have a roof support member which mounts across the cab. When mounting a Roof Mounted Spotlight on this vehicle, with or without OEM marker lights, the measurement for the mounting holes should be marked on the truck exterior (12 1/8 ), and must be exact. See special instructions on following page. Note #11. Installation of the CD-QS-1 and CD-QS-2 can be done on the Ford F trucks, but it is a very close fit. The CD-QS-3 or CD-QS-4 is recommended. The measurement provided for distance B is for the CD-QS-3 and CD-QS-4. If using a CD-QS-1 or CD-QS-2, the Installer must determine distance A. It should be approximately (11 5/8 ), but the installer must confirm exact location prior to drilling holes. Note # Ford F-250 F-550 s have a overhead forward console or headliner that drops down 3 ½ from the sheet metal roof. The CD-QS-1, CD-QS-2, CD-QS-3 and CD-QS-4 can be mounted, but installation distance A or B must be 24 inches reward of the windshield. (rearward of headliner drop down) This may interfere with roof lighting or other roof mounted equipment. Note #13. Will NOT work on Ford F-250 F-550 s Standard Length Cab because there is not enough space between cross support beam and rear dome light. Will work on Extended or Crew Cab. 3

4 NOTE #10 VEHCLE SPECIFIC INSTALLATION INSTRUCTIONS CD-QS-3 & CD-QS-4 MOUNTED ON: FORD F PICK-UPS F CHASIS CAB FORD EXCURSION These vehicles have a roof support member* which mounts across the cab. Please note that when mounting a Roof Mounted Spotlight on this vehicle with or without OEM marker lights, the measurement for the mounting holes should be marked on the truck EXTERIOR, and MUST BE EXACT, (especially with marker lights). Please contact our customer service department prior to installation if you have questions:

5 INSTALLATION NOTE #10: 1. Mark location of hole to be drilled 12 1/8 rear of windshield rubber (as shown in photo). (Distance B ) 2. Use 1/8 drill bit and drill pilot hole from the outside of the vehicle through metal outer skin and inner headliner. 3. With the 1/8 hole in the headliner as a center reference inside the vehicle, hold the plastic stabilizer up to headliner and align the 3/4 hole in the stabilizer with 1/8 center hole that was drilled through the headliner. 4. Use Stabilizer as a template and mark outline to be cut in headliner. Check the hole size with template provided to make sure hole is sized properly (copper tabs and switch go to rear of vehicle). 5. Cut headliner for trim ring. 6. Place stabilizer into the headliner cut-out and against metal inner roof with the existing 3/4 hole, in stabilizer, align with the original 1/8 center hole. 7. Mark for the additional (2) outside mounting holes. 8. Drill center hole out to 3/4 and (2) outer holes to ¼ (Note: these holes should be perpendicular to the front/rear center line on the vehicle). Follow the standard installation instructions starting with step 10 in the CD-QS-3 & CD-QS-4 Roof Mounted Spotlight installation guide. Note: Installation of the CD-QS-1 and CD-QS-2 can be done on the Ford F trucks, but it is a very close fit. The CD-QS-3 or CD-QS-4 is recommended. The measurement provided for distance B is for the CD-QS-3 and CD-QS-4. If using a CD-QS-1 or CD-QS-2, the Installer must determine distance A. It should be approximately (11 5/8 ), but the installer must confirm exact location prior to drilling holes. 5

6 CD-QS-1 & CD-QS-2 CD-QS-3 & CD-QS-4 INSTALLATION: INSTALLATION: 1. DISASSEMBLE SPOTLIGHT: 1. DISASSEMBLE SPOTLIGHT: Roof Mounted Spotlight is fully assembled and tested before shipping Disassemble the product by removing the center socket head screw in the Handle with the Allen key provided. Separate the Handle from the Light head by pulling downward on the handle. Remove Light head from Upper Hemisphere by pulling straight up Roof Mounted Spotlight is fully assembled and tested before shipping Disassemble the product by removing the center socket head screw in the Handle with the Allen key provided. Separate the Handle from the Light head by pulling downward on the handle. Remove Light head from Upper Hemisphere by pulling straight up 2. DISASSEMBLE (cont.): 2. DISASSEMBLE (cont.): The Lower Hemisphere is friction pin mounted and can be easily separated from the Stabilizer. Remove the two exposed wing nuts and Upper Hemisphere assembly. The Lower Hemisphere is friction pin mounted and can be easily separated from the trim bowl assembly. Remove the two exposed wing nuts and Upper Hemisphere assembly. 6

7 3. VISUAL INSPECTION: 3. VISUAL INSPECTION: Some vehicles are equipped with inner roof supports or cross members that may interfere with Spotlight installation. To avoid conflict, be certain to consult the Roof Mounted Spotlight Application Guide (pages 2-3) for the recommended mounting location for your vehicle. Some vehicles are equipped with inner roof supports or cross members that may interfere with Questar installation. To avoid conflict, be certain to consult the Roof Mounted Spotlight Application Guide (pages 2-3) for the recommended mounting location for your vehicle. 4. CREATE CENTERLINE: 4. CREATE CENTERLINE: Apply masking tape to the headliner between the rearview mirror and the dome light to indicate the centerline of the roof. Apply masking tape to the headliner between the rearview mirror and the dome light to indicate the centerline of the roof. 7

8 5. MARK DISTANCE A : 5. MARK DISTANCE B : Measure backward, from the windshield edge, the distance A referenced in Roof Mounted Spotlight Application Guide (pages 2 and 3) Mark this distance on centerline of masking tape. Measure backward, from the windshield edge, the distance B referenced in Roof Mounted Spotlight Application Guide (pages 2 and 3) Mark this distance on centerline of masking tape. Center of Trim Bowl Distance B 6. MARK HEADLINER CUTOUT: 6. MARK HEADLINER CUTOUT: Position the supplied Spotlight template with the front edge on the marked center point. Align the centerlines and mark the headliner around the edges of the template. Note: Prior to working on cutout area, place protective cover over seats. Position the supplied Spotlight template with the center hole on the marked center point. Align the centerlines and mark the headliner around the edges of the template. Note: Prior to working on cutout area, place protective cover over seats. Center of Trim Bowl Distance B 8

9 7. CUT HEADLINER: 7. CUT HEADLINER: Cut away the marked section of the soft headliner. If the vehicle has a metal inner roof, this has to be cut away. Drill 1/8 pilot hole through the center point. Make sure you wear safety goggles when cutting the inner roof. Do not remove beyond the inner roof skin! Cut away the marked section of the soft headliner. If the vehicle has a metal inner roof, this has to be cut away using a 5 1/2 hole saw or other metal cutter. Drill 1/8 pilot hole through the center point. Make sure you wear safety goggles when cutting the inner roof. Do not remove beyond the inner roof skin! 8. MARK INNER ROOF: 8. MARK INNER ROOF: Fit the Trim Grommet Assembly into the cutout area of the headliner with the switch towards the rear of the vehicle. Mark center points of the three holes in the assembly The three marks should be in a line perpendicular to the centerline spaced 1 1/8 apart. Fit the Trim Bowl Assembly into the cutout area of the headliner with the terminals facing towards the rear of the vehicle. Mark center points of the three holes in the assembly The three marks should be in a line perpendicular to the centerline spaced 1 1/8 apart. 9

10 9. DRILL ROOF: 9. DRILL ROOF: Drill three pilot holes with a 1/8 bit at the points marked. Drill the two outboard holes with a 1/4 bit. Drill the center hole with a 3/4 hole saw or arbor cutter File the holes. Be sure to wear safety goggles when drilling and filing. Drill three pilot holes with a 1/8 bit at the points marked. Drill the two outboard holes with a 1/4 bit. Drill the center hole with a 3/4 hole saw or arbor cutter File the holes with a filing tool or file. Be sure to wear safety goggles when drilling and filing. 10. CHECK FOR FIT: 10. CHECK FOR FIT: Verify the fit of the Trim Grommet assembly so that the stabilizer rests firmly against the underside of the outer roof and the Trim Grommet flange is flush with the headliner surface Use the supplied black neoprene rings to fill any gap left between the headliner and the trim grommet assembly. Verify the fit of the Trim Bowl Assembly so that the stabilizer rests firmly against the underside of the outer roof and the Trim Bowl flange is flush with the headliner surface Use the supplied black neoprene rings to fill any gap left between the headliner and the trim bowl assembly. 10

11 11. MEASURE GAP: 11. ROUTE POWER AND GROUND If Trim Grommet assembly does not fit flush with headliner, measure gap between Trim Grommet flange and headliner (be sure to measure front and rear to meet the contour of the roof). You will need to shorten Trim Grommet equal to this amount. Using 14-gauge wire, run both a hot and ground lead up the A Pillar and under the headliner to the rear of the cutout. The hot lead should have an inline fuse removed) near the power source. 12. REMOVE STABILIZER: 12. PLACE UPPER HEMISPHERE: To shorten Trim Grommet, loosen four screws in the side and separate trim grommet from Stabilizer. Remove rocker switch from Trim Grommet. Wipe off the outer roof, where the holes were drilled, with alcohol. Fit upper hemisphere into the drilled holes on the outer roof. Press firmly against roof surface. Align the Internal Slip Ring assembly so that the two holes of the Internal Slip Ring are positioned toward the rear of the vehicle. 11

12 13. MARK AND CUT TRIM GROMMET: SKIP TO STEP 13 Mark a cut line on the Trim Grommet and cut with tin snips. Notch Trim Grommet for wire terminal clearance. Reassemble Trim Grommet and Stabilizer. Reinstall rocker switch. Recheck fit. If there is still a small gap between headliner and trim grommet use supplied trim grommet gasket to fill gap. (4G-TG-GASK-1 or 2) 14. ROUTE POWER AND GROUND: Using 14-gauge wire, run both a hot and ground lead up the A Pillar and under the headliner to the rear of the cutout. The hot lead should have an inline fuse removed) near the power source. 12

13 15. PLACE UPPER HEMISPERE: SKIP TO STEP 13 Wipe off the outer roof, where the holes were drilled, with alcohol. Fit upper hemisphere into the drilled holes on the outer roof. Press firmly against roof surface. Align the Internal Slip Ring assembly so that the two holes of the Internal Slip Ring are positioned toward the rear of the vehicle. 16. CONNECT POWER AND GROUND: 13. CONNECT POWER AND GROUND: Inside the vehicle, connect the two electrical leads to those of the Trim Grommet assembly with insulated butt connectors or quick connect terminals. Polarity is not critical. Peel protective masking from grommet assembly. Be sure inner roof surface is free and clean of dirt and oil to allow for proper bonding. Inside the vehicle, connect the two electrical leads to those of the Trim Bowl assembly with insulated butt connectors or quick connect terminals. Polarity is not critical. 13

14 17. ATTACH TRIM GROMMET: 14. ATTACH TRIM BOWL: Raise Trim Grommet into position so the studs from the Upper Hemisphere extend through the matching holes in the Trim Grommet assembly. Secure with the two wing nuts. Press the entire surface of the stabilizer firmly against the roof surface. Raise Trim Bowl into position so the studs from the Upper Hemisphere extend through the matching holes in the Trim Bowl assembly. Secure with the two wing nuts. Press the entire surface of the stabilizer firmly against the roof surface. If there is still a small gap between headliner of trim bowl use supplied trim bowl gasket to fill gap. (4G-TB-GASK-1 or 2) 18. ATTACH LOWER HEMISHERE: 15. ATTACH LOWER HEMISHERE: Tighten the wing nuts so they align with the center of the vehicle and fit the Lower Hemisphere into place. The two plastic studs near the 3/4 center hole mate with holes in the Hemisphere and hold the part in place for assembly. Tighten the wing nuts so they align with the center of the vehicle and fit the Lower Hemisphere into place. The two plastic studs near the 3/4 center hole mate with holes in the Hemisphere and hold the part in place for assembly. 14

15 19. POSITION LIGHT HEAD: 16. POSITION LIGHT HEAD: Install the Light head assembly onto the Upper Hemisphere with the shaft through the 3/4 hole. Make sure the two contact pins are fully seated in the two holes of the slip ring inside the Hemisphere. Install the Light head assembly onto the Upper Hemisphere with the shaft through the 3/4 hole. Make sure the two contact pins are fully seated in the two holes of the slip ring inside the Hemisphere. 20. ATTACH HANDLE: 17. ATTACH HANDLE: Inside the vehicle, fit the handle receiver over the shaft from the Light head, being careful not to unseat the Light head from the Upper Hemisphere Assembly. Secure it with the socket head tension screw. Tighten the screw until the desired handle resistance is reached. Inside the vehicle, fit the handle receiver over the shaft from the Light head, being careful not to unseat the Light head from the Upper Hemisphere Assembly. Secure it with the socket head tension screw. Tighten the screw until the desired handle resistance is reached. 15

16 CLUTCH OPERATION & ADJUSTMENT (Model CD-QS-1 & CD-QS-3 Only) Clutch Operation: 1. After unit is installed, squeeze the lever to engage the clutch, and release. Repeat this operation times to allow all of the components to seat themselves. 2. Handle should stay in position and resist movement. If handle can be easily moved when clutch is engaged, turn tension adjustment screw clockwise with Allen key supplied until desired resistance is reached. 3. After several weeks of operation and the components have worn in, the tension screw may need to be tightened. Squeeze lever to engage clutch Press here to release Release adjustment Tension adjustment CD-QS-1 2. Engage clutch CD-QS-3 2. Engage clutch 1. Push handle completely up 1. Push handle completely up Clutch Adjustment: 1. The clutch is preset at the factory. Should you need to adjust it, use the following steps: Press release to disengage clutch. 2. Adjust pressure needed to release clutch by turning release adjustment set screw with Allen key provided (turn clockwise to decrease pressure; counter clockwise to increase pressure). Setscrew adjustment should not be more than one turn in either direction. 3. When clutch is adjusted properly applying pressure to release the clutch should smoothly disengage it. The clutch handle should not slam out. Note: Keep handle lever in the locked position when not in use. Note: This will eliminate the chance of water getting past the outer seal. 16

17 Changing Bulbs: 1. Pull control handle fully down and engage clutch. 2. Remove the 3 lamp closure screws on upper rear of light head. 3. Carefully pry open lamp body with small screwdriver. 4. Grasp bulb flange with needle nose pliers and pull bulb from carrier. 5. Grasp bulb wire lead terminal with needle nose pliers and pull wire from P.C.B. 6. Replace bulbs with 55 Watt H-3 base only. 7. Be sure bulbs are fully seated in their carrier. 8. Carefully close the lamp body making sure not to pinch wire leads in lower corners. 9. Reinstall lamp closure screws (do not over tighten) Tighten until lamp body is fully closed. Caution: Do not touch bulbs with your fingers. For best results use needle-nose pliers on bulb flange. 17

18 WIRING DIAGRAM FOR ROOF MOUNTED SPOTLIGHT ROOF MOUNTED SPOTLIGHT 12volt-15amp 24volt-7.5amp Fuse or circuit breaker Troubleshooting Procedures LIGHT DOES NOT ILLUMINATE: Pilot light on switch does not light when in ON position: 1. Check fuse; replace if defective 2. Check ground wire for good contact 3. Carefully pry switch out of Trim Grommet If there is voltage on power side of switch but not on accessory side when switch is in ON position, replace switch. If there is no voltage at power side of switch, check all wire connections from fuse to switch. Pilot light on switch is lit when in ON position: 1. Check halogen lamps. If defective, replace lamps. (See page 17). If lamps are good, go to next step. 2. Pull handle down putting light in the up position, and lock clutch. With switch in the ON position, locate the two brass nuts in front of the glass lens. Place test light clip on one nut and probe on the other nut. There should be voltage at this point. If there is NO voltage, go to #4. If there is voltage, go to next step. 3. Check wiring and terminal connections from brass nuts to power input screws located at base of the lamp body. Any damaged or defective parts, or wiring, will require the return of the assembly to the factory for repair. 18

19 4. Remove handle tension screw. Remove handle and lower hemisphere exposing two brass wing nuts. With the switch in ON position, place test light clip on one wing nut and probe on the other wing nut. There should be voltage at this point. If there is no voltage, check wiring and connections between wing nut and switch. If there is voltage, go on to next step. 5. Remove Light head Assembly from Upper Hemisphere by lifting straight up. There are two small round contact points located inside Upper Hemisphere. With switch in the ON position, place clip of test light on one contact (You will need to place a small probe on clip to reach contact point) and place probe of test light on the other contact point. There should be voltage at this point. If there is no voltage, remove the Upper Hemisphere from vehicle, and replace. If there is voltage, the light should work. To check Light head operation: 1. On each side of the square shaft are brass contact studs: one short, and one long. Check Light head by touching one of the brass contacts with 12 volts and grounding the other contact. 2. If Light head doesn t illuminate: Trace power between contacts and lamps, looking for faulty connection. 3. If Light head Does illuminate: Reinstall Light head and handle, making sure tension screw is sufficiently tight. If unit does not illuminate after reassembly, remove and return assembly to factory for repair. If you need installation assistance, call our toll-free number, WATER IS LEAKING THROUGH LIGHT: A. Inspect o-ring by: 1. Remove the handle. 2. Lift lighthead assembly off upper hemishpere. 3. Check for o-ring damage. Yes damaged: If o-ring is damaged, remove damaged o-ring and super glue a replacement o-ring in place. No damage: If o-ring is NOT damaged; a. Apply a coat of white grease to the o-ring surface and reinstall the lighthead and handle. b. Adjust the tension of the handle. Handle should have slight drag when the clutch is disengaged. c. Keep the clutch locked when not in use to keep pressure on the o-ring for a better seal. B. If light continues to leak after following step A, replace upper hemishpere. 19

20 The Roof Mounted Spotlight CD-QS-1 & CD-QS-2 Spotlight Assembly Breakdown 20

21 The Roof Mounted Spotlight CD-QS-3 & CD-QS-4 Spotlight Assembly Breakdown 21