Volt VSAL-9007-BBZ Installation Instructions Manual

The Volt VSAL-9007-BBZ is a high-performance LED light bar designed for off-road and utility vehicle applications. It features a durable aluminum housing, polycarbonate lens, IP68 waterproof rating, and high-intensity LED chips. This manual provides essential information for safe unpacking, mounting, wiring, and operation. Below are key sections covering safety, components, installation steps, wiring, operation, maintenance, and troubleshooting.

1. Package Contents & Inspection 2. Safety Precautions 3. Mounting & Positioning 4. Electrical Wiring 5. Specifications 6. Operation & Controls 7. Maintenance & Cleaning 8. Regulatory & Warranty 9. Troubleshooting

Package Contents & Inspection

Before installation, carefully unpack and verify all components are present and undamaged.

ComponentQuantityDescription
VSAL-9007-BBZ Light Bar1Main LED light bar unit
Mounting Brackets2Heavy-duty steel brackets with hardware
Wiring Harness1Complete harness with relay, fuse, switch, and connectors
Hardware Kit1Bolts, nuts, washers, and zip ties
User Manual1This installation guide

NOTE: Inspect for shipping damage. Contact supplier if any parts are missing or damaged.

Safety Precautions

Read all instructions before proceeding. Failure to follow safety guidelines may result in injury or damage.

  1. Disconnect Vehicle Battery: Always disconnect negative (-) terminal before wiring.
  2. Secure Mounting: Ensure mounting surface is solid and brackets are tightened to specification.
  3. Wiring Protection: Route wiring away from hot surfaces, sharp edges, and moving parts.
  4. Legal Compliance: Check local regulations regarding auxiliary light use on public roads.
  5. Eye Protection: Do not look directly at illuminated LEDs at close range.

WARNING! This product is not intended for use as primary road-illumination. Use off-road or in accordance with local laws.

Mounting & Positioning

Choose a suitable location on your vehicle (roof, bumper, grille). Ensure the bar will not obstruct license plates, sensors, or airflow.

  1. Test Fit: Hold light bar and brackets in desired position. Mark drill holes if necessary.
  2. Drill Holes: Using appropriate drill bit, create holes for mounting bolts. Deburr edges.
  3. Attach Brackets: Secure brackets to vehicle using provided hardware. Do not overtighten.
  4. Mount Light Bar: Place light bar onto brackets. Insert bolts and tighten evenly.
  5. Final Check: Ensure bar is level and secure. There should be no excessive vibration.

Tip: For roof mounting, ensure the vehicle's structure can support the weight and wind load.

Electrical Wiring

Connect the included wiring harness to the vehicle's battery and a switched ignition source for control.

  1. Route Wires: Run the harness from the light bar to the engine bay, securing with zip ties.
  2. Connect to Battery: Attach RED wire to positive (+) terminal. Attach BLACK wire to negative (-) terminal or chassis ground.
  3. Connect Switch Wire: Connect the BLUE wire to a switched +12V source (e.g., accessory circuit).
  4. Connect Light Bar: Plug the waterproof connector from the harness into the light bar's input port.
  5. Secure Relay & Fuse: Mount the relay in a dry location. Ensure the fuse (included) is installed in the holder on the RED wire.

CAUTION! Always use the provided fuse. Do not bypass it. Ensure all connections are waterproofed.

Specifications

Operation & Controls

The light bar is controlled by the provided rocker switch. The wiring harness includes a relay for high-current switching.

Switch Operation: - OFF: Switch is in the out (0) position. Light bar is off. - ON: Press switch in (I). The indicator LED on the switch will illuminate, and the light bar will turn on.

Using with Vehicle: For best practice, only operate the light bar when the vehicle's engine is running to avoid battery drain. Turn off when not in use.

Maintenance & Cleaning

Regular inspection ensures optimal performance and longevity.

  1. Cleaning Lens: Use a soft, damp cloth with mild soap. Do not use abrasive cleaners or high-pressure sprays directly on seals.
  2. Inspect Mounts: Periodically check bracket bolts for tightness, especially after off-road use.
  3. Check Wiring: Look for frayed wires, loose connections, or corrosion. Address immediately.
  4. Seal Inspection: Ensure the rubber seal around the lens and connector is intact and clean.

CAUTION! Do not open the light bar housing. This will void the warranty and compromise the waterproof seal.

Regulatory & Warranty

This device complies with FCC Part 15B for unintentional radiators. It is intended for off-road/auxiliary use only.

Warranty: Volt Lighting provides a limited 2-year warranty against defects in materials and workmanship under normal use. Warranty is void if product is modified, misused, or installed incorrectly.

Support: For technical assistance or warranty claims, contact Volt Customer Service at 1-800-555-9876 or visit www.voltlighting.com/support.

Troubleshooting

SymptomPossible CauseCorrective Action
Light bar does not turn onNo power, blown fuse, bad connectionCheck battery connections. Inspect and replace fuse if blown. Verify switch wire has +12V.
Light bar flickers or is dimPoor ground, low voltage, loose wireEnsure ground connection is clean and tight. Check vehicle alternator output. Secure all connectors.
Water inside lensDamaged seal, improper installationInspect and clean seal. Ensure drain holes (if present) are clear. Contact support if seal is faulty.
Switch LED on but light bar offFaulty relay or harnessTest relay by swapping with a known good one. Check for continuity in harness wires.
Only some LEDs workInternal LED or driver failureContact Volt Customer Service for warranty evaluation. Do not attempt internal repair.

Reset: Disconnect from power for 60 seconds and reconnect.

Service: 1-800-555-9876; www.voltlighting.com/support

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