Help Our Rescue!

philyumpshus

Member
Jun 20, 2010
1,273
Malone, NY
We have a 2000 Hackney heavy rescue with all halogen lighting. There are 2 main flashers, one does the upper lighting and the other the lower, which is eight 600s and two 900s. The problem is that they have been working for a few minutes, then they cut out, then they work again. I got to the whole board where everything is wired; the problem is that the relay (40A) and breaker (20A) are getting extremely hot, which causes them to overheat and cut out. What I can't figure out is why they are doing this, especially because they're mounted in a Class 1 circuit board, so all the connections seem good.


Does anyone have any ideas? I'd rather not have the rescue burn down.
 

Shawn L

Member
May 21, 2010
2,474
Corbett, Oregon
whats the wattage on the bulbs, and how many and what light heads are on each flasher? do both flasher wire into the 40 amp relay and 2o amp breaker?
 

tnems7

Member
May 21, 2010
407
USA Nashville Tennessee
That's probably a lot of lighting wiring on a heavy rescue truck. Check the wiring size (gauge)and also see if there is corrosion on the terminals into the lightheads, flashers, and relays. Are there extra wire splices or multiple connections that could increase resistance. As to the breaker, could that be the problem?


I am also not a fan of circuit breakers. Have you replaced the breaker or tried using a fuse instead?
 

JohnMarcson

Administrator
May 7, 2010
10,613
Northwest Ohio
If this just now became a problem, what changed? If you haven't added any lights to those circuits the either a connect, wire or breaker is bad.
 

philyumpshus

Member
Jun 20, 2010
1,273
Malone, NY
The breaker and relay are good because I've tried different ones and the same thing happened. There are 2 flashers on separate relays/breakers. I can't really change anything because everything is mounted on a circuit board and it's factory from Hackney.


John, apparently it's always done this but no one had the ambition to figure it out. This is a squad I joined at school, so I've been kept busy fixing stuff like this. I think the truck is around a 1998; it's an International 4700.


My opinion is that the wire going to the flasher isn't a big enough gauge. The other flasher is set up the same way but it only flashes 6 lights, not 10. Keep in mind these flashers are rated for 50 amps per output pole.
 

JohnMarcson

Administrator
May 7, 2010
10,613
Northwest Ohio
philyumpshus said:
The breaker and relay are good because I've tried different ones and the same thing happened. There are 2 flashers on separate relays/breakers. I can't really change anything because everything is mounted on a circuit board and it's factory from Hackney.

John, apparently it's always done this but no one had the ambition to figure it out. This is a squad I joined at school, so I've been kept busy fixing stuff like this. I think the truck is around a 1998; it's an International 4700.


My opinion is that the wire going to the flasher isn't a big enough gauge. The other flasher is set up the same way but it only flashes 6 lights, not 10. Keep in mind these flashers are rated for 50 amps per output pole.

You are most likely right... insufficient gauge would cause that
 

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