LED Light Bar Model Numbers:
LW1-06S, LW1-12S, LW1-18S, LW1-24S,
LW1-31S, LW1-37S, LW1-43S, LW1-50S
www.lottworx.com
LOTTworx
Las Vegas, NV. 89115 U.S.A
No portion of this manual, including artwork, may be reproduced
without written consent from LOTTworx. Actual product may slightly
differ from the product described herein due to continuing
improvements to product and production processes. LOTTworx and/or
any associates are not responsible in any capacity or form for any
damage or loss caused by the installation or use of the products
described herein.
WARNING
Read, understand, and follow all contents
of this manual before and during
installation and operation this product.
Failure to do so may result in damage to
property, product and/or personal injury.
REV 3.6A
READ NOW AND SAVE THIS
DOCUMENTATION FOR FUTURE REFERENCE
Proudly engineered, designed, tested and
assembled in the United States of America.
Installation Instructions & Owners Manual
Table of Contents
Product Warnings - - - - - - - - - - - - - - - - - - - - - - - - 1
Installation Instructions - - - - - - - - - - - - - - - - - - - 2
Product Features, Details, & Specifications - - - - - 8
Product Maintenance - - - - - - - - - - - - - - - - - - - - 9
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - 11
1
Product Warnings
•Never look directly into the light produced by this product, serious
eye injury can occur.
•Never intentionally direct the light produced by this product at
other living humans or animals, serious eye injury can occur.
•This product is intended as a secondary source of illumination,
never use as a primary source of illumination especially during
navigation.
•This product is NOT Department of Transportation (D.O.T)
approved, NEVER operate this product on public roadways.
•Installation of this product requires connection of electrical wires
and should only be performed by trained personnel.
•Verify electrical voltage has been removed from all wires involved
in the installation of this product prior to installation.
•Remove negative terminal from all batteries of vehicle during
installation of this product.
•Never apply power to this product other than 6-38 Volts of
Direct Current (VDC) electrical power.
•DO NOT CONNECT THIS PRODUCT TO HOUSEHOLD ALTERNATING
CURRENT (AC) ELECTRICAL POWER, SERIOUS INJURY AND DAMAGE
MAY OCCUR.
•Prior to operation, verify all electrical wires and connections
upstream of this product are capable of supporting the amperage
requirements placed on them during operation of this product.
Copyright 2015 LOTTworx Copyright 2015 LOTTworx
2
Installation Instructions
Warning
•Installation of this product requires connection of electrical wires and
should only be performed by trained personnel.
•Verify electrical voltage has been removed from all wires involved in the
installation of this product prior to installation.
•Remove negative terminal from all batteries of vehicle during installation of
this product.
•Installation of this product may require the use of various power tools,
ensure all safety precautions are followed in accordance with the specific
power tool manufacturers safety recommendations
•Ensure ANSI approved Z87+ or better eye protection is worn at all times
during the installation of this product.
•Before performing the following installation steps, read and understand this
manual in its entirety.
1. Mounting
It is acceptable to mount this product in any vertical or horizontal
orientation as shown in Figure 1.3. The unit is supplied from the factory
with stainless steel fasteners installed on the light and the end cap
mounting stud. Corrosion resistant Grade 5 hardware is included to
secure the mounting brackets down to any mounting surface of choice.
The factory brackets can be installed so that the mounting leg of the
bracket faces either inward or outward, the difference is shown in
Figures 1.1 and 1.2 on the following page. It is very important to install
the hardware as shown in the diagrams. It is acceptable to use mounting
brackets other than the factory brackets, however it is very important
that the Nylon Spacer is installed between any mounting bracket and the
housing end cap.
•Verify nylon spacer is installed between
housing end cap and mounting bracket.
Mounting Continued
Figure 1.1: Inward facing
bracket hardware stack-up.
Figure 1.2: Outward facing
bracket hardware stack-up.
Figure 1.3: Examples of acceptable
bracket mounting positions.
3
•If brackets will be utilized in the inward position, (as shown in Figure 1.1)
the bottom mounting bolt and washer must be installed onto mounting
bracket prior to bracket installation onto housing end cap stud.
•After mounting brackets are installed onto housing end cap studs, snug
down the stainless steel end cap stud lock nut and maneuver light onto
final mounting surface.
Copyright 2015 LOTTworx Copyright 2015 LOTTworx
4
Mounting Continued
•If drilling is necessary, mark where mounting holes are required.
•Remove light and brackets from mounting surface and place light
assembly in a safe location.
•Use a 9/32” drill bit to drill mounting hole through mounting surface.
• Maneuver light and mounting brackets into mounting position and
install the bottom mounting bolts, washers, and nuts.
•Torque the bottom mounting bolt nuts to 7ft-lbs (84 in-lbs).
•Align fixture to desired axial position and torque the stainless steel end
cap stud nuts to a maximum of 7ft-lbs (84 in-lbs).
CAUTION
•If adjustments to illumination direction are required after electrical
installation is complete, loosen fasteners just enough to make
adjustment and re-torque applicable fasteners to 7ft-lbs (84 in-lbs).
•NEVER install or tighten mounting fasteners in a manner that
create a torsion, compression, or tensile force on the housing
end cap. Permanent damage is possible.
Figure 1.4: Example of
assembled mounting
brackets.(Inward Position)
Figure 1.5: Example of assembled
mounting brackets.(Outward
Position)
•NEVER attempt to remove the Philips screws from the housing
ends. There is delicate circuitry below these end caps that can
be damaged as a result.
Mounting Continued
5
Alternative Mounting Method Example:
•An acceptable alternative mounting method is to utilize the factory
mounting brackets (in either the inward or outward facing position) and
secure them to a mounting surface by the use of common hose clamps;
shown below in Figures 1.6 and 1.7.
•This method is particularly useful when securing mounting brackets to
round tubing without the use of welded brackets or drilled holes.
•If this method of mounting is chosen, it is strongly recommended to
utilize a relatively strong hose clamp, such as a “T-Band Clamp”.
Figure 1.6: Example of
assembled mounting bracket
and use of hose clamp.(Inward
Position)
2. Electrical Installation
•Verify electrical voltage has been removed from all wires involved in the
installation of this product prior to installation.
•Remove negative terminal from all batteries of vehicle during installation of
this product.
Figure 1.7: Example of assembled
mounting bracket and use of hose
clamp.(Outward Position)
Copyright 2015 LOTTworx Copyright 2015 LOTTworx
6
Electrical Installation Continued
•There are several acceptable methods for connection of the electrical wires
to this product, the most common methods are described below and
illustrated in Figure 2.1, Figure 2.2, and Figure 2.3. An electrical pigtail
consisting of an electrical connector and wires are supplied with this unit.
The RED wire is the POSITIVE connection of the unit and the BLACK wire is
the NEGATIVE connection.
WARNING
NEVER ATTEMPT TO CONNECT AN ELECTRICAL POWER SOURCE
OTHER THAN 6-38V DC TO THIS PRODUCT, SERIOUS INJURY OR
DAMAGE CAN OCCUR IF THIS WARNING IS NOT FOLLOWED
•Figure 2.1 shown below is the preferred and recommended method of
electrically connecting this product. This method utilizes a 30 Amp rated
automotive relay and allows the toggle switch to encounter only a fraction of
the overall current requirement.
Figure 2.1: Electrical diagram utilizing automotive relay.
7
Electrical Installation Continued
•The electrical diagram shown below in Figure 2.2 is an acceptable
method for connection of this product; however, SPECIAL ATTENTION
MUST BE TAKEN TO ENSURE THE AMPERAGE RATING OF THE SWITCH
IS GREATER THAN THE MAXIMUM AMPERAGE SPECIFICATIONS OF
THE LIGHT. Amperage specifications of each light unit can be found
in the Specifications section of this manual under the Maximum
Amperage Requirement column in Table 3.1 on Page 9.
Figure 2.2: Electrical diagram utilizing toggle switch and fuse only.
Figure 2.3: Electrical diagram utilizing toggle switch and fuse only.
Copyright 2015 LOTTworx Copyright 2015 LOTTworx
Attribute
Model
Number
Lumen
Output
Voltage
Range
Maximum Amperage
Requirement
Nominal
Operating
Amperage
LW1-06S
1164
6-38 VDC
1.870 A
0.806 A
LW1-12S
2328
6-38 VDC
3.707 A
1.680 A
LW1-18S
3492
6-38 VDC
5.390 A
2.580 A
LW1-24S
4656
6-38 VDC
7.416 A
3.500 A
LW1-31S
5820
6-38 VDC
9.289 A
4.512 A
LW1-37S
6984
6-38 VDC
12.566 A
5.570 A
LW1-43S
8148
6-38 VDC
14.901 A
6.432 A
LW1-50S
9312
6-38 VDC
15.374 A
7.382 A
•Fully ROHS compliant
•6 – 38 Volt Direct Current (DC) operating range.
•Deutsch electrical connection and pigtail included for ease of unit
installation and removal as needed.
•Highly efficient polycarbonate optic.
Product Description Continued
Electrical Current Requirements Per Unit
•The following table provides performance characteristics of each model.
The column labeled “Maximum Amperage Requirement” is of particular
importance and should be used to determine the correct switch
amperage rating discussed in section 2, Figure 2.2 and Figure 2.3.
Table 3.1: Performance characteristics of the LW1 product family
4. Product Maintenance
•It is imperative that dirt, mud, and debris be kept out of the cooling
geometry around the housing of this unit. Failure to do so can greatly
reduce the operational life of the LED modules.
•Verify on a regular basis that there is no dirt, mud, or debris that has
collected in the cooling geometry of the housing.
9 8
Product Description
3. General Features
The figure above displays the location of the main external features of each
LOTTworx LW1 series light. The other main features of this product series
include:
•CNC milled billet 6061-T6511 aluminum end caps.
•Heat sink/housing extruded from 6063-T5 aluminum.
•Stainless steel external fasteners.
•Extremely strong cold rolled steel mounting brackets.
•Durable powder coated housing, end caps, and brackets
•Nanotechnology conversion coating applied under the durable powder
coating.
•Fully sealed housing that is water resistant and dust proof.
•Pressure equalization vent
•Polycarbonate lens with abrasion resistant hard coat applied to external
surface.
•This product utilizes the super powerful CREE Xlamp XM-L2 LED’s.
•Greater than 92% efficient inductive step down LED driver circuitry.
•Thermal shutdown protection
•Reverse polarity protection.
Copyright 2015 LOTTworx Copyright 2015 LOTTworx
Troubleshooting
Problem
Possible Solution
Light will not turn on
Verify 6-38 VDC electrical potential is
supplied to the positive (RED) wire of
pigtail connector and capable of
handing the required amperage load
of unit.
Verify negative wire is properly
grounded.
Verify all fuses in the system are in
good working order.
If relay circuit is used, verify relay is
working properly.
Check all wires for scrapes, cuts, and
other abnormalities that could cause
the system to short.
Light will not turn off
Remove electrical power from unit.
Low level of light emitted from unit
Clean polycarbonate lens in
accordance with the maintenance
section of this manual.
Emitted light not pointed in desired
direction
Change alignment of light in
accordance with the maintenance
section of this manual.
Product Maintenance Continued
4.3 Mechanical Maintenance Continued
axial adjustment and re-torque the stainless steel end cap nuts to 7ft-lbs
(84 in-lbs).
•It is good practice to routinely verify mounting hardware is secure and
free of corrosion.
5. Troubleshooting
If any other problems or questions are encountered please contact
LOTTworx Technical Support at lottworx.custserv@gmail.com
11
Product Maintenance Continued
Product Maintenance Continued
•The polycarbonate lens on the optical side of the product has a scratch
resistant hard coat applied to the external surface; however, care must be
taken while removing wet/dried mud, dirt, dust, or other debris from the
optical side of the light to not scratch the polycarbonate surface.
NEVER USE ABRASIVES, GRITY CLEANERS, OR HARD
CLEANING IMPLEMENTS (BRUSHES, SQUEEGEES,
SCRAPERS) TO CLEAN THE POLYCARBONATE SURFACE.
AVOID THE USE OF PRESSURE WASHERS ON OR NEAR
THE SEALING SEAMS OF THIS PRODUCT.
4.1 General cleaning of polycarbonate surface and housing
•Thoroughly pre-rinse with warm water to loosen and wash away large
solid deposits.
•Use a moist non-abrasive sponge or microfiber cloth to gently wash with
a diluted solution of mild soap or detergent.
•Rinse thoroughly with clean warm water
•Dry with a soft clean cloth to prevent water spots.
4.2 Electrical Maintenance
•Periodically check all external electrical wires and connections for
abrasions, cuts, exposures, indications of burning, or any other
abnormalities.
•If any abnormalities are found with the external electrical system to this
product, do not attempt to operate the unit before the abnormality is
corrected. If any portion of the wiring of the is found to be exposed,
immediately replace or repair the exposed section as required.
4.3 Mechanical Maintenance
•It may periodically be desired to change the alignment of the light
emission. To make an axial adjustment, turn the mounting nuts secured
to the end cap stud in a counter clockwise direction to loosen. Make
10
Copyright 2015 LOTTworx Copyright 2015 LOTTworx
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Lottworx LW1-37S Installation Instructions & Owner's Manual
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