(WESTERN PA) ATTACHMENT E, Txt Only Sup Vehic Instl Serv Man (1).docx

Attachment E, Warden/Supervisor Vehicle Installation & Service Manual

Section 1.0 Pre-Installation

· Check in vehicle before work starts, record year, make, model, equipment #, VIN, registration, and plate number. Inspection of interior/exterior vehicle components for any scratches or damage to vehicle.

· Disconnect the ground from the battery.

· Strip vehicle of all trim panels and place trim panels in a safe area away from the vehicle while working. Any small pieces of trim and hardware that are removed are stored in a zip lock bag and placed in the glove box until all prep work and harnesses are run in the vehicle.

· Continuing preparation of vehicle, remove center front seat (if provided), cutting out center carpet, vent duct, place foam into vent to prevent air condition/heat flow into soon to be installed console. Find the key fob antenna module placing double sided 3M adhesive pad onto it.

· Cutting out rear carpet under rear seat so main power, console, triggers, antenna cables can be laid smoothly out going to equipment box.

2.0 Interior Installation Guide

· Vehicle’s BCM plugs need to be individually wired for headlight and taillight with reverse flashing lights. As well as surveillance mode for blackout factory interior dash and headliner lights. Violet plug has headlight and taillight flasher that requires two (2) wires spliced into one (1) wire connected to 12ft, 18G green wire designated to 30AMP negative ground relay. 12ft, 18G dark blue has surveillance mode that requires one (1) wire connected to 12ft, 18G violet designated to 30AMP negative ground relay. All wires will be connected to relays inside equipment box.

Disconnect purple BCM module to add taillight flasher with reverse and front head light flashers. Disconnect dark blue BCM modular plug connect surveillance mode wire to blackout interior/exterior lights. Vehicle’s BCM plugs need to be individually wired for headlight and taillight with reverse flashing lights. As well as surveillance mode for blackout factory interior dash and headliner lights. Violet plug has headlight and taillight flasher that requires 2 wires into 1 wire connected to 18g green designated to 30AMP negative ground relay. Dark blue has surveillance mode that requires 1 wire connected to 18G violet designated to 30AMP negative ground relay. Each relay is inside equipment box labeled for quick identification. 12ft lengths.

· Front Visor Light Bar / Rear Signal Master Mounting front visor light bar in front windshield, mounting rear signal master in rear window if DiamondBack is installed, or rear window of LEER cap. Remounting headliner after cables ran to back seat area.

Section 3.0 – Exterior Installation Guide

· Mounting five (5) antennas on roof top: one (1) 800mhz, one (1) VHF, one (1) radio GPS, (2) two CAD antennae on either side of GPS antenna; or one (1) radio GPS, one (1) 800mhz, one (1) VHF, one (1) shark fin CAD antenna for Rocket.

Section 4.0 – Front-End Installation Guide

· Under hood, passenger-side: Mount a 150-amp breaker at the battery upper trim panel, running 18-gauge white wire to fuse panel to reliable ignition source to connect to 30-amp ignition relay.

· Drill three (3) holes in front of vehicle: one (1) 1 ¾” hole through carpet, one (1) 1” hole through the firewall on driver and passenger-side, and one (1) under dash panel with 1” snap grommet.

· Feed front driver-side wires for triggers for grill, wheel well lights, siren, and Rumbler speakers, and tie down with zip-ties, sealing with duct-sealant to prevent moisture in vehicle.

· Feed into passenger-side: one (1) 4G red battery lead and one (1) 18G white wire from battery to ignition, fed through 1” snap grommet and seal with duct-sealant.

· All cables run from equipment box to individual areas with true lengths and colors

· Installation of front bumper guards to be determined.

Section 5.0 – Rear Installation Guide

· Passenger-side Rear Wiring trough, led through ¾” finger grommets for rear trigger bumper lights for DiamondBack lights, or signal master in rear LEER cap. Loomed, duct sealed to prevent moisture inside vehicle.

· Mounting diamond back on top of pickup takes a day on each mounting back rack. Mounting 2 red/blue LED lights inside cover.

Section 6.0 – Custom Equipment Box

· Passenger side rear “B” Pillar lower, grind off paint to smooth metallic shiny finish to attach 4-gauge black ground with 1 ¼”-20, 2- ¼” star washer with 1 ¼” K Nut and 1 ¼” Nylon insert nut for security of ground.

· Secure jack to equipment box on driver side end cap and the inside at the gun rack.

· Begin wiring equipment box; starting on passenger-side, connect radio GPS to jumper then 7/800 blue tape, VHF green tape to jumper off then multiplexer. Using 4-3/8” P clips and as much cable up without extra antenna cable. Running 2 sets of orange (driver side) and red (passenger side) antenna cables running to rocket case in equipment box. Then moving to connecting 12G green/black zip to timer fuse pane for docking station, separating grounds from other colored wiring making appropriate connection to battery/ignition/grounds. Connecting 4G red battery to red stud, 4G black ground to black stud. Silicone battery and ignition studs so nothing arcs off them. Duct seal and silicone 4G red stud.

· Wiring up switch panel with expansion module, running Cat 5 for expansion module, front/rear visor and signal master to 3-way splitter RJ-45 connector. Wiring up head/taillight surveillance mode input/outputs to relays. Running program cable to driver side end cap to program lights/siren/Rumbler.

Section 7.0 - Console

· Console main power harness: run under the driver side from the center console back to equipment box with the following wire designation, amperage, battery, ignition and timer.

· 18G: Violet/Black- USB Port, Ignition 5AMP

· 18G: Pink- Switch Box turn on

· 16g: Yellow/Black- APX8500 control head, Battery, 5AMP

· 14G: Orange/Black_ Siren/switch box, Battery, 10AMP

· 14G: Blue/Black- Extra

· 12G: White/Black- Extra

· 12G: Blue/Black- Radio switch, Battery, 20AMP

· 12G: Green/Black- 20AMP Timer

· All of these are 18ft. Mounting equipment box under the rear flip up beach seat, running APX remote cables, rocket body cam remote cable, Cat 5 control head cable, radio ignition, body cam, printer power/ground cables down passenger side wiring trough under passenger seat carpet to center console.

· Console preparation before mounting center underneath electrical panel, mounted Motorola speaker to template, mount computer dock power supply with industrial strength Velcro and super glue. Mount side plates to electrical panel and place assembly into vehicle under dash panel.

· Remove printer holder and install printer power cable with Velcro x2 with super glue. Insert 8 ¼”-20 black nuts on each side of side of console. Driver side gets mic clip bracket to of console with hex head ½” black hardware. Side mount armrest. Passenger side mic clip. Telescoping small mount inside console. Mount the side mounts on side of center seat removed using existing hardware. Then slide console onto side mounts, sliding console into electrical panel assembly mounting console together. Then using wire brush grinding off paint in console driver lower top hole for grounding console to scan when mic hangs up on mic clip. Start mounting console to side mounts with 8 carriage 1” bolts, fender washer and speed nuts. Except ground, use 2- ¼” star washers tighten into place and level console.

· Working up the console, install radio bracket, 2 auxiliary switches (blacked out), Pathfinder siren/lighting controller, cup holder, locking lid accessory pocket, file folder, and printer case. Mounting body cam charger with Velcro on horseshoe bracket for gun rack. Mount tilt swivel motion computer dock onto telescoping mount, running power cable to docking station securing cable to docking station.

Section 8.0 – Wire Color Reference Guide

· All wiring has its own gauge, color and designation to identify so installers and customers can service equipment easier.

· Front grill triggers driver side firewall from equipment box Pathfinder of 18ft of red, blue, light green, light blue, tan, pink, brown, violet. Black lamp cord for siren and Rumbler speakers. Gray-black for individual lights in grill and wheel wells.

· Driver-side rear window 15ft of 18-gauge red/black zip, violet, yellow through rear driver door boot to equipment box.

· Passenger side rear door window 18ft of 18-gauge blue/black zip, dark blue, orange through rear passenger side rear door boot to equipment box.

· Rear bumper LED lights and Diamond back to rear equipment box.

· Driver side bumper 18G Red/Black, 18G Green 20ft

· Passenger side bumper 18G Blue/Black, 18G White 18ft

· Main battery power and ground connections with ignition wire ran from equipment box to battery/passenger side “B” pillar/fuse panel on passenger side under hood.

· 4G red battery cable ran from 150Amp breaker mounted under hood high and dry area ran through passenger side firewall, down wiring trough to equipment box ran to red battery stud. 23ft length.

· 18G white wire ran from passenger side under hood through firewall with 4G red battery cable down wiring trough to equipment box to 30Amp relay marked designated to its own. 23ft length.

· 4G black ground passenger lower “B” pillar to a Motorola ground. Clean off all paint of lower “B’ pillar ground using ¼”-20 x 1” stainless steel hex head bolt with 2 locking star washers with copper ¼” eye lid between star locking washers screwed with ¼”-20 K Nut and ¼” nylon insert nut to secure it. Run to equipment box ground stud. 10ft length.

· All harness throughout vehicle secured by 18” zip ties in a X pattern to main vehicle harness under trim panels. All wiring harnesses going through steel have a grommet and are duct sealed to prevent moisture in vehicles.

· Each wire to equipment is fused to equipment required amperage usage.

· Each fuse panel designated battery/ignition timer lid has its own fuse chart secured under seat with Velcro or within the vicinity of the fuse panel.

· Radio remote cable, bodycam charger run white radio ignition, printer powers.

· 18G Orange: Radio ignition 4Amp

· 18G Red/Black: Body camera cradle 4Amp

· 18G: Printer/Portable charger 4Amp

Section 9.0 – Gunrack

· Mounting lower plates for partition to driver/passenger seats and mounting “horseshoe bracket” between inner seat bolts for gun rack.

· Driver side flip up set, mount vehicle jack tools under rear seat with wood under carpet with bracket fastened framework.

· Installing gun base to the horseshoe base, drilling 3/8” holes through floor to secure and tighten 3/8” bolt and nuts to vehicle. Mounting gun base into base plate securing both together, wiring up to switch box in equipment box.

Section 10.00 – Prisoner Cage

· Cut lower plastic “B” pillar on passenger/driver side panel to prep for partition to be installed.

· Insert partition into vehicle, start mounting feet to brackets and center foot to floor, mount side lower panel and upper plexiglass to partition fasten and tighten down. Slide in full sheet of plexiglass, mounting in place to partition 4 areas, 2- top, 1-mid, 1-lower using ¼”-20 hardware and fender washers. Fabrication rear window bracket to fit plexiglass in rear and lower bracket to fit plexiglass in top and lower bracket center seat. Securing everything down tightly.

Section 11.00 – Light Placement

· Installation of lights, siren speaker, Rumbler on Chevy 1500

· Grill lights mount to front of grill with stainless steel 6/32” nylon insert nuts with brackets.

· Wheel well lights mounted directly to wheel well with stainless steel 6/32” hardware nylon insert nuts.

· AS124 100-watt siren speaker mount to Havis 4” bail steel bracket cut in having mounted to hood release latch.

· Rumbler speakers mounted under seat of vehicle on Federal Signal Chevy frame brackets wire to triggers on driver side through firewall.

· Driver/passenger doors, mounted to fabricated brackets with shrouds. Stainless steel hardware 10/32” with nylon insert nuts, wired through door boot.

· Driver/passenger side rear bumper with 6/32” hardware with nylon nuts, wired into diamond back lights using 3-way trailer plug connections.

Section 12.0 – Post-Installation

· Return all trim panels and hardware to vehicle.

· Clean up/check out

· Clean up areas worked in, vacuuming, wiping down vehicle, checking out all trim and rubber door gaskets in place. Operation of all lighting, siren, gun rack, signal master, front visor, head/taillights, turn signals, brakes and reverse.

· Radio check out, watt meter checking out wattage on VHF and 7/800MHz, RSSI reading and site location, radio test with central.

· Check body cam power.

Attachment E, Warden/Supervisor Vehicle Installation & Service Manual 23 BLE W Vehicle Upfit Project