Whelen 9M144000 User Manual

ENGINEERING COMPANY INC.

51 Winthrop Road Chester, Connecticut 06412-0684

Installati on Guide:

Edge® 9M Lightbar

Phone: (860) 526-9504 Fax: (860) 526-4078 Internet: www.whelen.com Sales e-mail: autosale@whelen.com Canadian Sales e-mai l: auto can@whelen.com Customer Service e-mail: custserv@whelen.com

Safety First

This document provid es all the nec es sa ry in form at ion to allow your Whelen prod uc t to b e pro perl y a nd s afe ly ins tal le d. Before beginning the installation and/or operation of your new product, the installation technician and operator must read this manual completely. Important information is contained herein that could prevent serious injury or damage.

• Proper installation of this product requires the installer to have a good understanding of automotive electronics, systems and proced ur es.

• If mounting this product requires drilling holes, the installer MUST be sure that no vehicle components or other vital parts could be damaged by the drilling process. Check both sid es of the mo unting sur f ace bef ore drilling begins. Also de-burr any holes and remove any metal shards or remnants. Install grommets into all wire passage holes.

• If this manual states that this product may be mounted with suction cups, magnets, tape or Velcro®, clean the mounting surface with a 50/50 mix of isopropyl alco hol and wa te r and dry thoroughly.

• Do not install this product or route any wires in the deployment area of your air bag. Equipment mounted or located in the air bag deployment area will damage or reduce the effectiveness of the air bag, or become a projectile that could cause serious personal injury or death. Refer to your vehicle owner’s manual for the air bag deployment area. The User/Installer assumes full responsibility to deter m ine pr oper mounting location, based on providing ultimate safet y t o al l passenge rs ins id e the vehicle.

• For this product to operate at optim u m ef f icie ncy, a good electrical connec tion t o chassis ground must be made. The recommended procedure requires the product ground wire to be connected directly to the NEGATIVE (-) battery post.

• If this product uses a rem ote d evice to activate or control th is product, make sure that th is control is located in an area that allows both the vehicl e a nd th e control to be operated safely in any dr i vi ng co ndi tion.

• Do not attempt to activate or con trol this device in a hazardous driving si tu at io n.

• This product contains either strobe light(s), halogen light(s), high-intensity LEDs or a com bination of these lights. Do not stare directly into these lights. Momentary blindness and/or eye damage could result.

• Use only soap and water to clean the outer lens. Use of other chemicals could result in premature lens cracking (crazing) and discoloration. Lenses in this cond ition hav e sign ificantly reduced effectiveness and should be replaced immediately. Inspect and operate this product regularly to confirm its proper operation and mountin g condition. Do not use a pre ss u re w asher to clean this product.

• It is recommended tha t th ese instructions be stored i n a safe place and referred t o w hen performing maintenance and/or reinstallation of this product.

• FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTR UCTIONS COUL D RESULT IN DAMAGE TO THE PRODUCT OR VEHICLE AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!

Automotive: Lightbars

For warranty information regarding this product, visit www.whelen.com/warranty

Page 1

IMPORTANT! The lightbar should be located a minimum of 16" from any radio antennas!

Permanent Mounting:

1. Locate the mounting foot and locking plate included with your lightbar. If not already present, install the locking plate onto the mounting foot. When properly positioned, this plate is centered from side to side on the mounting foot.

2. Flip the lightbar upside-down to expose the bottom of the extrusion and place the mounting foot onto the extrusion.

3. Rotate the mounting foot 90° in a counter-clockwise direction. Make sure that the edges of the mounting foot swing into position under the extrusion mounting lip.

4. Repeat this procedure for the remaining mounting foot and return the lightbar to its right side-up position.

5. Position the lightbar onto the vehicle roof in the desired mounting location. One often selected location is directly above the B-pillars. This area is the strongest part of the roof. Refer to your lightbar manual for cable exit location, to be sure that the lightbar is facing the proper direction.

6. Adjust the two mounting feet outwards so that they are as close to the edge of the roof as possible. Make s ure that both mounting feet are in full contact with the roof. Be sure that there is no less than 1/2” clearance between the roof and the lightbar at their closest point. When the mounting feet are in their proper position, lightly tighten the locking plate allen head set screws.

7. Turn the lightbar upside down and firmly tighten all of the set screws from step 6 (2 or 4 per side).

8. On the adjustable foot, use the hole in the pad as a guide to drill the two holes into the mounting foot at the locations shown.

Standard Mounting

Bolt

Locking Plate

Foot

Mounting Foot Base

Nut

Washer

Mounting

Pad

9. Place the lightbar in its final mounting position on the vehicle, mark the mounting hole locations off onto the mounting surface, remove the lightbar and drill the mounting holes.

10. Place the lightbar back onto the vehicle lined up with the mounting holes and secure the mounting feet to the vehicle with the supplied hardware.

Mounting

Pad

Washer

Nut

Adjustable Mounting Foot

Strap Mounting:

1. Locate the mounting foot, anchor plate and locking plate included with your lightbar. If not already present, install the locking plate onto the mounting foot. When properly positioned, this plate is centered from sideto-side on the mounting foot.

2. Flip the lightbar upside-down to expose the bottom of the extrusion and place the mounting foot onto the extrusion.

3. Rotate the mounting foot 90° in a counter-clockwise direction. Make sure that the edges of t he mounting f oot s wing int o p ositi on u nde r t he ex tru sion mounting lip. Install an anchor plate onto the extrusion in the same manner.

4. Repeat this procedure for the remaining mounting foot and anchor plate and return the lightbar to its right side-up position.

5. Position the lig htbar ont o the v eh icle ro of in the d esi red mou nt ing locat ion . One often selected location is directly above the B-pillars. This area is the

Insert foot into extrusion with locking plate attached.

ANCHOR PLATE

Twist mounting foot into position

strongest part of the roof. Refer to your lightbar manual for cable exit location, to be sure that the lightbar is facing the proper direction.

6. Adjust the two mounting feet outwards so that they are as close to the edge of the roof as possible. Both mounting feet must be in full contact with the roof. Be sure that there is no less than 1/2” clearance between roof and lightbar at their closest poin t. When the mounti ng feet are in the ir proper position, lightly tighten the locking plate allen head set screws.

7. Return the lightbar to an upside-down position. Slide each anchor plate outwards until it is fully engaged with its corresponding mounting foot. With the mounting feet and anchor plates in their proper positions firmly tighten all of the s et screws (2 or 4 per side). Flip the lightba r right side-up and return it to its mounting position.

8. Open both drivers side doors. In the area directly below the mounting foot, pull the weatherstrip away from the vehicle so the area where the mounting strap will be secured is expos ed. Repeat for the other side.

9. Insert the mounting strap through the mounting foot. Be sure that the strap fits flush against the area where it will be secured onto the vehicle.

Loosely secure foot and locking plate.

Page 2

Insert the tension bolt through the mounting strap and anchor plate, into the tinnerman nut. Tighten slightly with a long-shafted, Phillips screwdriver. Repeat procedure for passenger side.

10. If your mounting strap has mounting holes in the end of the strap, use these holes as a template to drill appropriately sized pilot holes through the strap and into the vehicle. Repeat for passenger side of the vehicle.

11. Firmly tighten the tension bolts to secure the lightbar to the vehicle.

NOTE: Model MKAJ is an adjustable mounting foot. On this model you may loosen the screws on the rear of the foo t and adjust the angle of the lightbar. This feature can be used if the angle of the roof is not level with the road. IMPORTANT: To adjust the leveling screws you must use a torque wrench set at 35 to 40in./lbs.

Adjustable Foot Model MKAJ

Tension

Bolt

Mounting

Screw

Adjustment

screws

Lock

Washer

5" Mounting Foot

METAL SCREW

SHEET METAL SCREWS

NOTE: The mounting straps are made to fit the contours of individual

NOTE: NOTE: NOTE: NOTE: NOTE: NOTE:

Mounting Strap

Locking

Plate

Tinnerman

Nut

Anchor Plate

Nut

Mounting Foot

Mounting Pad

MOUNTING FOOT

EXTENSION

BOLT

SPLIT LOCK

STRAP

vehicles. The strap for your vehicle mounting foot, it will assemble differently than the standard mounting foot. It also uses an extension to compensate for the extra height. Follow these illustrations for assembly. Mounting to the lightbar is the same.

shown here is for example only. The strap

may look different. If your lightbar has a 5"

WASHER

NUT

Model MKAJ

Tighten screws

with torque wrench

set at 35 to 40 in/lbs

Mounting

Screw

TINNERMAN

NUT

FOOT

ANCHOR

PLATE

VEHICLE ROOF

Mounting

Strap

Tension

Bolt

Plate slides into lightbar extrusion

SET SCREW

Locking

Plate

Anchor Plate

Standard Foot

Model MKEZ

Tinnerman Nut

Mounting Foot

NOTE: Unless otherwise specified, the

lightbar mounting feet must be sitting as

1/2" Minimum Clearance at Closest Point

close to the edge of the roof as possible. Mounting feet must also be in full contact with the roof and not be hanging off

IMPORTANT: For strap mounted bars, be sure you have the right

the edge. sized lightbar for your vehicle. The lightbar should be about the same width as the vehicle roof. If the lightbar is too large or small it will not mount properly to the vehicle and may shift or come loose during driving.

Page 3

Routing your Edge® Lightbar Cable(s)

1. To protect the headliner from damage caused by drilling the cable access hole through the vehicle roof, allow a 5” to 7” distance between roof and headliner by lowering the headliner before drilling.

2. Using a 1” hole saw, drill the cable access hole.

DRILLING THE CABLE ACCESS HOLE

FRONT OF LIGHTBAR

For

lightbars

cables exiting

with

the Driver-side

of the extrusion

Drill cable access hole in appropriate area

for your lightbar (see note)

For

lightbars

cables exiting

with

the Passenger-side

of the extrusion

NOTE:There may be a roof support member that spans the distance between the dr i ver’s and passenger’s side. DO N OT DRILL THROUGH THIS MEMBER! Adjust the location until the hole can be drilled without contacting this support member.

3. Use a round file to smooth and de-burr the edges of the hole.

4. Insert a 1” grommet (user supplied) into the cable access hole.

5. Insert the cable(s) through the cable access hole into the vehicle. Use RTV silicone to weatherproof the access hole after the cable(s) are pulled completely into the vehicle.

6. Route the cable(s) one at a time to their respective destinations (power cable to vehicle battery; control cable to customer switch panel). It is left to the ins tallati on tech nicia n's discretion to select a path for these cables that will both protect the cables from possible damage and not interfere with the operation of any other vehicle components or equipment. Refer to the instructions included with your switches for switch wiring information.

NOTE: The outer surfaces of this product may be cleaned with mild soap and water. Use of any other chemicals may void product warranty. Do not use a pressure washer.

Connecting the Cables

WARNING! All customer supplied wires that connect to the positive terminal of the battery must be sized to supply at least 125% of the maximum operating current and FUSED

at the battery to carry that load. DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT!

Power Cable:

1. Follow the factory wiring harness through the firewall. It may

be necessary to drill a hole in the firewall. If so, be absolutely sure that there are no components that could be damaged by drilling. After the hole has been drilled, insert a grommet to protect the cable.

2. Route the cable along the factory wiring harness towards the battery. Install a 40 amp fuse block (customer supplied) on the end of the RED wire in the power cab le. Rem ove th e fus e from the fuse block before connecting any wires to the battery.

3. Connect the fuse block to the POSITIVE (+) terminal on the battery. There can not be more than two (2) feet of wire between the fuse block and the battery. The wire between the fuse block and the battery is “unprotected”, do not allow this wire to come into contact with any other wires.

4. Connect the BLACK wire to the factory chassis ground adjacent to the battery.

Control Cable:

Extend the control cable to your switch panel and make the appropriate connections, using the information provided on pages 4 or 5, depending on which lightbar you have. When you apply +12 VDC to a Control Cable wire, you activate its func tion. The control cable connects to your control head or switch box and is fused there. Typical fusing is 5 Amps.

LowPower / VIOLET :

The type of switch used is dependant on how the operator wishes the Hi/Low feature to function:

Latching Mode: By applying +12 VDC voltage to the Violet wire for less than 1 sec., the power supply is “latched” into low power operation. The unit must be turn ed off and then back on to restore normal, Hi power operation. (A Momentary Switch is Preferred)

Level Mode: Applying +12 VDC voltage to the Violet wire for more than 1 sec. holds the power supply in low power mode until voltage is removed. (A Toggle Switch is Preferred)

NOTE: The wire functions listed in this ma nual are the factory default settings for a fully loaded lightbar. To find the correct wire functions for the lightbar you ordered, refer to the switch operations sheet included with your lightbar.

Troubleshooting:

Your lightbar should now be fully opera tion al . If yo ur li ghtbar is not functioning properly, check the following:

• The positive wire (RED) is properly connected to the battery, by way of the user supplied fuse block.

• A working fuse of the correct amperage (40 amp) is installed in the fuse block.

• The ground wire (BLACK) is properly connected to the factory ground.

If these connections are good, contact your Whelen representative for further assistance.

Page 4

S:C

Changing Flash Patterns Without a Scan-Lock™ Cable:

The 9M lightbar is cap able of displaying a variet y of fl ash patt erns. Th ese patte rns can be chan ged using one of two methods. The first is th rough the option al Scan-Lock™ pattern cable. This allows you to change patterns from within the vehicle and is preferred by customers who want to be able to easily change their flash patterns if need arises.

For users who rarely or infrequently change patterns and do not require a Scan-Lock cable, you must partially disassemble the lightbar and change patterns manually.

WARNING: The strobe light power supply is a high voltage device. Do not remove strobe tubes or dismantle strobe light head assemblies in the system while it is in operation. Wait 10 minutes after turning off power before starting work or any trouble shooting.

WARNING! THIS PROCEDURE REQUIRES THE LIGHTBAR TO BE ACTIVE WHILE IN A PARTIALLY DISASSEMBLED STATE. DO NOT TOUCH ANY LIGHT BAR

1. Notice where the cable ente rs the bottom of th e extrusion. If it enters on th e driver side, the Po wer Distribution Board will facethe rear of th e vehicle . If it ent ers on the

2. Rem ove the endc ap nearest to the cable entr y. On the appropriate side ( front or rea r) of the lig htbar, remove lenses and mov e lighthea ds away fro m the extrus ion until

3. Changing Strobe Lighth ead Pa tt er ns - Locate the 3-position connector. Each of the 3 sockets control pattern selection for each of the lightbar’s 3 strobe power supplies

4. Changing Halogen Lighthead Patterns - Locate the 4-position connector on the ap propria te halog en fl asher ( A or B). The socket loca ted i n position 4 contro ls pat tern

Mounting Lightheads to Extrusion

COMPONENTS EXCEPT FOR THOSE REFERENCED IN THIS PROCEDURE.

passenger side, it will be facing the front of the vehicle.

clear access to the Power Distribution Board has been gained. Be sure to record the exact position of each component to ensure proper re-assembly.

(PS:A, PS:B and PS:C). In the default configuration, the corner strobes use PS: A, the inboard strobes use PS: B and the end strobes use PS: C. Activate the strobe lights that are to receive the new flash pattern. Momentarily ap plying +12VDC to the appropriate socket will cycle that power supply’s current flash patt ern to the next flas h pattern. Repeat this procedure until the desired pattern is displayed. Allowing this pattern to flash for a minimum of 5 seconds will make this pattern the default pattern.

selection for the halogen lightheads connected to that flasher. Momentarily applying +12VDC to this socket will cycle that halogen flasher’s current flash pattern to the next one. Repeat this procedure until the desired pattern is displayed. Allowing this pattern to flash for a minimum of 5 seconds will make this pattern the default pattern.

Restoring the Factory Default Pattern - To restore the factory d efault

flash pattern, make sure that the lightheads to be restore d are off. For strobe lightheads, apply +12VDC to the appropriate socket (see strobe lighthead procedure above) while powering up the corresponding lightheads. Allow pattern to be displayed for a minimum of 5 seconds to make this the default pattern. For halogen lightheads, use the same procedure as outlined for strobe lightheads, substituting the halogen selection socket(s) where the strobe socket is referenced.

owerDistributionBoar

Lighthead mounting holes snap into the raised bosses on the lighthead bracket.

ABAUX

Installing a Corner Strobe

CENTER OF LIGHTBAR

Ears on lighthead bracket

P PS:B PS:A

POS.4 POS.4

POWER SUPPLY

HALOGEN

FLASHER

HALOGEN

FLASHER

Tabs slide into base

slide inton channels in extrusion (base).

CORNER STROBE

LIG

Before working on your strobe lights, disconnect the lightbar from power and remove the endcap. WARNING: The strobe light power supply is a high voltage device. Do not remove the strobe tubes or dismantle the strobe lightheads in the system while the unit is in operation. Wait 10 minutes after turning off power before working on the system. To

BASE

EXTRUSION

remove the lighthead, unsnap it from the mounting bracket, unplug it, and slide it out of the side of the lightbar base. If you

are replacing the lighthead, snap off the bottom bead on the new lighthead as shown. Plug the new lighthead int the lightbar,

slide it into the base and snap it into the mounting bracket.

Endcap, Gasket , Lens & Spacer Installation

Remove the screws (A) that hold the endcap on and pull the endcap and gasket (C) off. the extrusion. When reinstalling the lenses and spacers, install the cord seal (NFPA ). When reinstalling the endcap, place the endcap gasket into it's position on the endcap and line up all the tabs and holes. Spacers (not shown) mount the same as lenses.

4 (B)

Slide lenses (D) out of the lightbar, to gain access to

Halogen Lighthead

snaps into extrusion

BOSS

BARB

Align the lighthead reflector with the 4 bosses in the endcap. Press the reflector into place.

Snap lighthead into bracket.

Seal Cord Installation / NFPA Only:

123-

33-

44-

5555-

REAR OF LIGHTBAR

(Drivers Side - Top View)

Cut the seal cord approx. 1-1/2" longer than the extrusion on each side. Rub silicone over the cord seal leaving 3 to 4 inches on one end dry. Begining with 1 corner lens, start the lens into the bottom lens track. Place the cord seal onto the groove in the top of the lens eav 1 to 2 inches Hold onto the left end of the seal hanging out and slide the corner lens into position. From the opposite end of the lightbar, pull the seal cord tight and install the remaining lenses and divider.

TAB

Snap lighthead

into bracket

. L e free.

Snap off bottom

bead of reflector

Insert cord seal into track in lens

Inspect seal cord for any areas that have wrinkled.

Especially in the areas around the dividers.

Push the lenses together tight and trim excess seal cord at each end.

END VIEW OF BASE

Page 5

Slide Spacer in here

NOTE: Lens dividers must be installed as each lens is put into position

EDGE® 9M SERIES LIGHTBAR for MODELS EQUIPPED with STROBE TRAFFIC ADVISOR™

MAIN FUSE CHART

To use the chart below: After determining which function wires you will use, add up the amp rating of each function wire. You must then multiply this by 1.25 (see warning) and fuse the RED power wire at this rating.

WIRE

GRN

BLU

GRN/WHT TRACE

BLU/WHT TRACE

WHT/GRN TRACE

WHT/BLU

YEL

WHT

WHT/BLK

WHT/BRN

GRN/BLK

WHT/ORG

WHT/YEL

BLU/BLK

EXAMPLE: Using the WHITE/BLACK, WHITE, & WHITE/ ORANGE function wires, the total amp draw isou17.5 amps. Multiply this by 1.25 which comes out to 21.87 amps. Y must fuse the RED power wire at 25 amps.

FUNCTION CURRENT

Front Corner Strobes

Rear Corner Strobes

Front Inboard Strobes

Rear Inboard Strobes

T.A. / 2 Strobe Flash

T.A. / 4 Strobe Flash

Passenger Alley Light

Driver Alley Light

Take-Down Lights

Flasher "A"

Right TrafficAdvisor

Auxiliary Option

Flashing Take-Downs

Left TrafficAdvisor

DRAW

3 amps

6 amps

2.5 amps

5 amps

6 amps

5 amps

2.5 amps

6 amps

In the factory default configuration, this wire activates

GREEN -

In factory default configuration, this wire activates

BLUE -

GREEN/WHITE TRACE -

BLUE/WHITE TRACE -

WHITE/GREEN TRACE -

WHITE/BLUE -

This will initiate low power operation of all strobes

VIOLET -

In factory default configuration, this activates

YELLOW -

In factory default configuration, this activates

WHITE -

WHITE/ORANGE -

WHITE/BLACK -

WHITE/BROWN - *

GREEN/BLACK -

WHITE/YELLOW -

BLUE/BLACK -

RFI shield drain wire; connect to Ground

NONE -

WHITE/RED -

RED - +12 VDC/8 AWG BLACK - Ground/8 AWG

NONE - RFI Shield Drain

In factory default configuration, this activates

Not Used

See for fuse valueMain Fuse Chart

Front Corner Strobes

Rear Corner Strobes

Front Inboard Strobes

Rear Inboard Strobes

2 Strobe T.A. Flash

4 Strobe T.A. Flash

See: Low Power Violet

Passenger Alley Light *

Driver Alley Light *

9MTD2 Take-Down Lights *

or Aux. Lights

9MH2 Take-Down Lights * not used if 9MTD2 is present

Flasher "A"

Right Traffic Advisor *

not used if 9MTD2 is present

Flashing Take-Downs *

Left Traffic Advisor *

Optional Equipment:

May not be present on all Lightbars

CONTROL CABLE

POWER CABLE

MAIN FUSE CHART

WIRE

GRN

BLU

GRN/WHT TRACE

BLU/WHT TRACE

GRN/BLK

BLU/BLK

YEL

WHT

WHIT/BLK

WHT/BRN

WHT/GRN

WHT/ORG

WHT/YEL

WHT/BLU

WHT/VIO

EXAMPLE: Using the WHITE/BLACK, WHITE,

& WHITE/ ORANGE function wires, the total amp draw isou17.5 amps. Multiply this by 1.25 which comes out to 21.87 amps. Y must fuse the RED power wire at 25 amps.

FUNCTION

Front Corner Strobes

Rear Corner Strobes

Front Inboard Strobes

Rear Inboard Strobes

Front Outboard Strobe

Rear

Outboard Strobe

Passenger Alley Light

Driver Alley Light

Take-Down Lights

Flasher "A"

Flashers "B"

Auxiliary Option

Flashing Take-Downs

Work Lights

Flashing Work Lights

CURRENT

DRAW

3 amps

2.5 amps

5 amps

2.5 amps

5 amps

2.5 amps

EDGE® 9M SERIES LIGHTBAR

GREEN -

In the factory default configuration, this wire activates

BLUE -

In factory default configuration, this wire activates

GREEN/WHITE TRACE -

BLUE/WHITE TRACE -

GREEN/BLACK

BLUE/BLACK

VIOLET -

his will initiate low power operation of all strobes

YELLOW -

In factory default configuration, this activates

WHITE -

In factory default configuration, this activates

WHITE/ORANGE -

WHITE/BLACK -

WHITE/BROWN -

WHITE/GREEN

WHITE/YELLOW -

WHITE/BLUE -

NONE -

RFI shield drain wire; connect to Ground

WHITE/VIOLET -

WHITE/RED -

RED - +12 VDC/8 AWG

BLACK - Ground/8 AWG

NONE - RFI Shield Drain

Not Used

In factory default configuration, this activates

See for fuse valueMain Fuse Chart

Page 6

Front Corner Strobes

Rear Corner Strobes

Front Inboard Strobes

Rear Inboard Strobes

Front Outboard Strobes

Rear Outboard Strobes

(See: Low Power Violet)

Passenger Alley Light

Driver Alley Light

9MTD2 Take-Down Lights* or Aux. Lights

9MH2 Take-Down Lights*

not used if 9MTD2 is present

Flasher "A" *

Flasher "B"

Flashing Take-Downs*

not used if 9MTD2 is present

Work Lights*

Flashing Work Lights

Optional Equipment:

May not be present on all Lightbars

CONTROL CABLE

POWER CABLE

Whelen 9M144000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual