Whelen Engineering Company Delta Independence (10/14 Function) Installation Manual

Page 1

ENGINEERING COMPANY INC.

51 Winthrop Road Chester, Connecticut 06412-0684 Phone: (860) 526-9504 Internet: www.whelen.com Sales e-mail: [email protected] Customer Service e-mail: [email protected]

Installation Guide:

Delta™ Independence™ Lightbar

(10/14 Function)

Whelen’s emergency vehicle warning devices must be properly mounted and wired in order to be effective and safe. Read and follow all of Whelen’s written instructions when installing or using this device. Emergency vehicles are often operated under high speed stressful conditions which must be accounted for when installing all emergency warning devices. Controls should be placed within convenient reach of the operator so that they can operate the system without taking their eyes off the roadway. Emergency warning devices can require high electrical voltages and/or currents. Properly protect and use caution around live electrical connections.Grounding or shorting of electrical connections can cause high current arcing, which can cause personal injury and/or vehicle damage, including fire. Many electronic devices used in emergency vehicles can create or be affected by electromagnetic interference. Therefore, after installation of any electronic device it is necessary to test all electronic equipment simultaneously to insure that they operate free of interference from other components within the vehicle. Never power emergency warning equipment from the same circuit or share the same grounding circuit with radio communication equipment. All devices should be mounted in accordance with the manufacturer’s instructions and securely fastened to vehicle elements of sufficient strength to withstand the forces applied to the device. Driver and/or passenger air bags (SRS) will affect the way equipment should be mounted. This device should be mounted by permanent installation and within the zones specified by the vehicle manufacturer, if any. Any device mounted in the deployment area of an air bag will damage or reduce the effectiveness of the air bag and may damage or dislodge the device. Installer must be sure that this device, its mounting hardware and electrical supply wiring does not interfere with the air bag or the SRS wiring or sensors. Mounting the unit inside the vehicle by a method other than permanent installation is not recommended as unit may become dislodged during swerving; sudden braking or collision. Failure to follow instructions can result in personal injury. Whelen assumes no liability for any loss resulting from the use of this warning device. PROPER INSTALLATION COMBINED WITH OPERATOR TRAINING IN THE PROPER USE OF EMERGENCY WARNING DEVICES IS ESSENTIAL TO INSURE THE SAFETY OF EMERGENCY PERSONNEL AND THE PUBLIC.

Warnings to Users

Warnings to Installers

Whelen’s emergency vehicle warning devices are intended to alert other operators and pedestrians to the presence and operation of emergency vehicles and personnel. However, the use of this or any other Whelen emergency warning device does not guarantee that you will have the right-of-way or that other drivers and pedestrians will properly heed an emergency warning signal. Never assume you have the right-of-way. It is your responsibility to proceed safely before entering an intersection, driving against traffic, responding at a high rate of speed, or walking on or around traffic lanes. Emergency vehicle warning devices should be tested on a daily basis to ensure that they operate properly. When in actual use, the operator must ensure that both visual and audible warnings are not blocked by vehicle components (i.e.: open trunks or compartment doors), people, vehicles, or other obstructions. It is the user’s responsibility to understand and obey all laws regarding emergency warning devices. The user should be familiar with all applicable laws and regulations prior to the use of any emergency vehicle warning device. Whelen’s audible warning devices are designed to project sound in a forward direction away from the vehicle occupants. However, because sustained periodic exposure to loud sounds can cause hearing loss, all audible warning devices should be installed and operated in accordance with the standards established by the National Fire Protection Association.

Safety First

This document provides all the necessary information to allow your Whelen product to be properly and safely installed. 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.

WARNING: This product can expose you to chemicals including Methylene Chloride which is known to the State of California to cause cancer, and Bisphenol A, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

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

• Whelen Engineering requires the use of waterproof butt splices and/or connectors if that connector could be exposed to moisture.

• Any holes, either created or utilized by this product, should be made both air- and watertight using a sealant recommended by your vehicle manufacturer.

• Failure to use specified installation parts and/or hardware will void the product warranty.

• 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 sides of the mounting surface before drilling begins. Also de-burr the 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 alcohol and water 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 determine proper mounting location, based on providing ultimate safety to all passengers inside the vehicle.

• For this product to operate at optimum efficiency, a good electrical connection to chassis ground must be made. The recommended procedure requires the product ground wire to be connected directly to the NEGATIVE (-) battery post (this does not include products that use cigar power cords).

• If this product uses a remote device for activation or control, make sure that this device is located in an area that allows both the vehicle and the device to be operated safely in any driving condition.

• Do not attempt to activate or control this device in a hazardous driving situation.

• This product contains either strobe light(s), halogen light(s), high-intensity LEDs or a combination 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 condition have significantly reduced effectiveness and should be replaced immediately. Inspect and operate this product regularly to confirm its proper operation and mounting condition. Do not use a pressure washer to clean this product.

• It is recommended that these instructions be stored in a safe place and referred to when performing maintenance and/or reinstallation of this product.

• FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTRUCTIONS COULD RESULT IN DAMAGE TO THE PRODUCT OR VEHICLE

Automotive: Lightbars

AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!

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

Page 1

Page 2

Mounting

Pad

Adjustable Mounting Foot

Washer

Nut

Mounting Plate

Standard Mounting Foot

Mounting

Pad

Washer

Nut

Mounting Plate

BoltBolt

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

NOTE: Unless otherwise specified, the lightbar mounting feet must be sitting as close to the edge of the roof as possible. They must also be in full contact with the roof and not be hanging off the edge.

IMPORTANT: For strap mounting, be sure you have the right sized lightbar for your vehicle. The bar should be approximately the same width as the vehicle roof. If too large or small it will not mount properly and may come loose during driving.

1/2" MIN. CLEARANCE

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 using the supplied set screws. This plate should be centered from side to side on the mounting foot.

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

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

4. Repeat procedure for remaining foot and return 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 your lightbars cable exit location, to be sure that the lightbar is facing the proper direction.

6. Adjust the two mounting feet outwards as close to the edge of the roof as possible. Make sure that both mounting feet are in full contact with the roof (See below). There should be no less than 1/2” clearance between the roof and the lightbar at their closest point. When the mounting feet are in the proper position, lightly tighten the 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. Note that 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.

9. Place the lightbar in its final mounting position on the vehicle and mark the mounting hole locations off onto the mounting surface. Remove 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 using the supplied hardware.

Slide Bolt Mounting (Permanent):

1. Position the slide bolt mounting plates onto the bottom of the lightbar extrusion. These plates rotate into position the same way as the mounting foot. Position the plates as far outward as possible (if a 3rd mounting plate is used, it should be positioned under the center of the lightbar).

2. Secure the plates to the extrusion using the set screws provided.

3. Position the lightbar onto the vehicle and mark the mounting bolt locations. Drill the necessary mounting holes using an appropriately sized drill bit sized for a 1/2” bolt.

Strap Mounting:

1. Locate the mounting foot, mounting plate and tinnerman plate included with your lightbar. If not already present, install the mounting plate onto the mounting foot. When properly positioned, this plate is centered from side-toside 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. Install a tinnerman plate onto the extrusion in the same manner.

4. Repeat this procedure for the remaining mounting foot and tinnerman plate 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. Both mounting feet must be 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 mounting foot allen head set screws.

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

Page 2

Page 3

MOUNTING FOOT

TINNERMAN

NUT

FOOT

ANCHOR

PLATE

SET SCREW

Plate slides into lightbar extrusion

5" Mounting Foot

NUT

BOLT

SPLIT LOCK WASHER

METAL SCREW

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

vehicles. The strap

maylookdifferent.

shown here is for example only. The strap

for your vehicle

NOTE: NOTE:

STRAP

SHEET METAL SCREWS

EXTENSION

VEHICLE ROOF

Tinnerman

Plate

Locking Plate

Mounting

Plate

Mounting Foot

Nut

Mounting Pad

Adjustment

screws

Lock

Washer

Mounting

Foot

Mounting

Pad

Tinnerman Plate

Mounting

Strap

Mounting

Screw

Tension

Bolt

Adjustable Mounting Foot / Model MKAJ

Standard Mounting Foot / Model MKEZ

Tighten screws

with torque wrench

set at 35 to 40 in/lbs

Mounting Strap

Mounting Screw

Tension

Bolt

8. When both mounting feet are in their proper position, lightly tighten the allen head set screws.

9. 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 foot and anchor plate in their proper positions firmly tighten all of the set screws (2 or 4 per side). Flip the lightbar right sideup and return it to its mounting position.

10.Open both drivers side doors. In the area directly below the mounting foot, carefully pull the drivers side weather-strip away from the vehicle. Remove enough so that the area where the mounting strap will be secured to the vehicle is exposed. Repeat for passenger side.

11.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. Insert the tension bolt through the mounting strap and into the anchor

plate and secure it with the tinnerman nut. Tighten slightly with a long shafted, Phillips screwdriver. Repeat procedure for passenger side.

12. If your mounting strap has mounting holes in the end, use these holes as a template to drill holes through the strap and into the vehicle and secure it with sheet metal screws. Repeat passenger side.

13.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 foot 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 40 ft. lbs.

Installation: If your lightbar has a 5” 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.

Page 3

Page 4

FRONT

For lightbars with cables exiting the Driver side of the extrusion

Drill cable access hole in an area

appropriate for your lightbar

(see Warning).

For lightbars with cables exiting the

Passenger side of

the extrusion

Routing the Cables:

Route cable to customer supplied switch box.

Oscillators

Front Flashers

Rear Flashers

Take-Down

GREEN

RED/WHITE

GRN/WHT

RED

RED/BLACK

WHT/VIO

WHITE/BLK

WHITE

YELLOW

BLUE

Inner

Outer

Center

Scan-Lock™

Drivers Alley

Passenger Alley

15 Amps

7.5 Amps

15 Amps

3 Amps

7.5 Amps

Color Fuse @

Lower Level

Upper Level

Misc.

NOTE: If dual, lower level MR-11 lightheads are used, their control lines must be fused at 15 Amps.

To Chassis Ground

Function

Control Cable

CAUTION! DO NOT LOOK DIRECTLY AT THESE LED’S WHILE THEY ARE ON. MOMENTARY BLINDNESS AND/OR EYE DAMAGE COULD RESULT!

IMPORTANT WARNING!

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

WARNING! There is a roof support member that spans the distance between the driver’s and passenger’s side. DO NOT DRILL THROUGH THIS MEMBER! Adjust the location until the hole can be drilled without contacting this support member. Refer to “Safety First” on Page 1 for important precautionary information.

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

3. Use a round file to de-burr the edges of the cable access hole and insert a 1” grommet (customer supplied) into the hole.

4. Insert the cables through the cable access hole into the vehicle. Use RTV silicone to weatherproof the access hole after the cables are pulled completely into the vehicle.

5. Route the cables one at a time to your power source. It is left to the installation technician’s discretion where to run the cables, as vehicles will vary.

Control Cable:

Route the cable towards a high-current switch panel such as the Whelen model PCC10. Note: The use of switches with an insufficient current

rating will cause switch failure! Switches with a current rating of less than 20 amps should not be used. For proper operation The ground

cable (BLACK) must be connected to the vehicle’s chassis ground.

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

Scan-Lock™ (white-violet)

With the desired lighthead activated:

TO CHANGE PATTERNS: To cycle forward to the next available pattern

apply +12 volts to the WHITE-VIOLET wire for less than 1 second and release. To cycle back to the previous pattern apply +12 volts to the WHITE-VIOLET wire for more than 1 second and release.

TO CHANGE THE DEFAULT PATTERN: When the desired pattern is displayed, allow it to run for more than 5 seconds. The lighthead will now display this pattern when initially activated.

Flash Patterns:

1. SignalAlert™ 1 Alternates with 2

2. SignalAlert™ 1 & 2 Simultaneous

3. SignalAlert™ 3 Cycles of 1A & 3

Cycles of 1B

4. CometFlash® 1 Alternates with 2

5. CometFlash® 1 & 2 Simultaneous

6. CometFlash® 3 Cycles of 2A & 3

Cycles of 2B

7. DoubleFlash 1 Alternates with 2

8. DoubleFlash 1 & 2 Simultaneous

9. DoubleFlash 3 Cycles of 3A and 3

Cycles of 3B

10. SingleFlash 1 Alternates with 2

11. SingleFlash 1 & 2 Simultaneous

12. SingleFlash 3 Cycles of 4A and 4

Cycles of 4B

13. SteadyFlash 1 & 2 Steady / 3 & 4

Single Flash

14. Steady 1, 2, 3 & 4 Steady

TO RESTORE THE FACTORY DEFAULT PATTERN: Turn power to the

lighthead off. While applying +12 volts to the WHITE-VIOLET wire, turn power to the lighthead on. The factory default pattern is now displayed.

Use a Normally Open Momentary Switch for Scan-Lock™ operation.

IMPORTANT! Before returning this vehicle to active service, visually confirm the proper operation of this product, as well as all vehicle components/equipment.

CONTROL CABLE: A control cable with all available options for the DELTA™ is shown for reference. Not all options are available in all lightbars. For the wire I.D. of your lightbar, refer to the list included with the lightbar. You will have either a 10 or 17 conductor cable.

VIOLET . . . . . . . . . . . . Optional Flashers . . . . . . . . . . . Fuse @ 7.5 amps

WHITE/YELLOW. . . . . Optional Flashers . . . . . . . . . . .Fuse @ 7.5 amps

BLACK/WHITE . . . . . . Optional Flashers . . . . . . . . . . .Fuse @ 7.5 amps

BLUE/ORANGE . . . . . Optional Flashers . . . . . . . . . . .Fuse @ 7.5 amps

BLUE/BLACK . . . . . . . Optional Flashers . . . . . . . . . . .Fuse @ 7.5 amps

BLUE/WHITE . . . . . . . Optional Flashers . . . . . . . . . . . Fuse @ 7.5 amps

GREEN/BLACK . . . . . Optional Flashers . . . . . . . . . . . Fuse @ 7.5 amps

WHITE/VIOLET . . . . . . Scan-Lock™ . . . . . . . . . . . . . . . . . Fuse @ 1 amp

WHITE/BLACK . . . . . . Take-Downs . . . . . . . . . . . . . . .Fuse @ 7.5 amps

GREEN/WHITE . . . . . . Optional Flashers . . . . . . . . . . .Fuse @ 7.5 amps

WHITE . . . . . . . . . . . . . Drivers Side Alley . . . . . . . . . . .Fuse @ 7.5 amps

YELLOW . . . . . . . . . . . Passengers Side Alley. . . . . . . . Fuse @ 7.5 amps

BLUE. . . . . . . . . . . . . . Optional Flashers . . . . . . . . . . .Fuse @ 7.5 amps

RED . . . . . . . . . . . . . . . Inner Rotators . . . . . . . . . . . . . . Fuse @ 15 amps

RED/WHITE . . . . . . . . Outer Rotators . . . . . . . . . . . . . . Fuse @ 15 amps

RED/BLACK . . . . . . . . Center Rotators . . . . . . . . . . . . . Fuse @ 15 amps

GREEN . . . . . . . . . . . . Oscillating Rotators . . . . . . . . . . Fuse @ 15 amps

NOTE: For 400 Series LED flashers, LR11 Alley lights or LR11 takedowns, use a 3 amp fuse.

Page 4

Page 5

02-0363716-00

ROTATING REFLECTOR 150-12-H1

DELTA STD. ROT CTR/ATOR/.

DELTA 2 STD INBD/ ROTATOR .

02-0484131-02

02-0484131-00

SCREW GROMMET #6 #8 FASTEX/

SCREW 8 x 3/8 PPHSMS / 410 SS/

RIVET POP AVEX 1691-0512/

13-062C40-16J

02-0363716-02

17-0510040-30

15-081416-060

2 121

02-0484131-04

02-0484131-35

DELTA STD C R MIRROR/ ROT. / T / with

02-0484131-05

02-0484131102

DELTA HI with MIRRORS DUAL C RROT. T

02-0484131-01

02-0484131-03

DELTA HI C R/ ROTATOR / T

DELTA 2 HI INBOARD/ ROTATOR

ROTATING REFLECTOR 175-12-H1

68-5443033-00

MIRROR / CTR. MNT. ROT. / DELTA

DELTA 2 STD MIRROR DUAL C R/ ROT. / / T

DELTA 2 HI with MIRRORS DUAL C RROT. T

ITEM PART NUMBER DESCRIPTION

QTY QTY QTY QTY

QTYQTYQTYQTY

UPPER LEVEL: ROTATOR OPTIONS

Options:

options shown are available for the Delta™ lightbar, assembly and parts.

2 1

FOR

REFERENCE

01-06835772G3

01-0269831-01

02-0484131-__

01-06835772C3

01-06835772B3

01-06835772A3

02-0364086-00

09-1363542-00

46-0784112-02

DELTA ADD 1 500 HALOGEN FLASHER

DELTA ADD 2 500 HALOGEN FLASHERS

500 HALOGEN/2 WIRE /2 POS AMP/AMB

RETAINER LIGHTHEAD MTG / DELTA

HARNESS FLASHER / DELTA SERIES

ELEC 2 CH FLASHER DELTA

FILLER PANEL 500 SERIES/

01-06835772R3

500 HALOGEN WIRE /2 POS AMP/BLU/

500 HALOGEN 2 WIRE /2 POS AMP/CLR/

500 HALOGEN 2 WIRE /2 POS AMP/GRN/

500 HALOGEN 2 WIRE/ 2 POS AMP/RED/

111

ITEM

PART NUMBER

PART DESCRIPTION

QTY QTY

A/R

111

LOWER LEVEL: 500 SERIES HALOGEN FLASHER

51637

849

ROTATOR

ASSEMBLY

UPPER LEVEL

MIRROR:

DIAMOND

UPPER LEVEL

CORNER

400 SERIES

LIGHTHEAD

UPPER LEVEL

MIRROR:

FLAT

UPPER LEVEL

DUAL CENTER

500 SERIES LIGHTHEAD

LOWER LEVEL

OSCILLATOR ASSEMBLIES

TIR3

LIGHTHEAD

LOWER LEVEL

CORNER

CORNER CONFIGURATION

OSC OSC

CORNER CONFIGURATION

OSC OSC

LOWER LEVEL

CORNER

LOWER LEVEL CONFIGURATIONS

DUAL

CENTER

SINGLE CENTER

SINGLE / CENTER

DUAL / CENTER

Available Configurations:

UPPER LEVEL

CONFIGURATION

CORNER

CONFIGURATION

UPPER LEVEL: HALOGEN FLASHER

121

ELEC 2 CH FLASHER DELTA

2 - 400 HALOGEN FLASHERS

1 - 400 HALOGEN FLASHER

02-0484131-__

FILLER PANEL 500 SERIES/

SCREW 8 x 1/2" PPHSMS / 410 SS/

MTG. BRCKT 400 SERIES

LENS AMB 400 OPTIC / SEAL/

HARNESS FLASHER / DELTA

SCREW 6 x 1 1/2" PPHSMS/

RETAINER LIGHTHEAD MTG

REFLECT. 400 SERIES HALO.

02-0363189-00

02-0364086-00

09-1363542-00

07-263737-000

01-0269831-01

15-061416-240

68-1183726-1S

15-081416-080

46-0784112-02

13-062C40-16J

GROMMET #6 #8 FASTEX

68-1183726-2S

LENS BLU 400 OPTIC / SEAL/

68-1183726-3S

LENS CLR 400 OPTIC / SEAL/

68-1183726-5S

68-1183726-4S

LENS GRN 400 OPTIC / SEAL/

LENS / RED 400 OPTIC / SEAL

ITEM PART NUMBER DESCRIPTION

QTY QTY

A/RA/R

10 11 12

13 14

101311

DELTA ADD 400 SERIES LED FLASHER

ITEM

PART NUMBER

DESCRIPTION

02-0484131-__

02-0364086-00

09-1363542-00

07-263737-000

01-0269831-01

013-062C40-16J

ELEC 2 CH FLASHER DELTA

2 400 LINEAR FLASHER-S

1 - 400 LINEAR FLASHER

FILLER PANEL 500 SERIES/

MTG. KT. /BR 400 SERIES

RETAINER LIGHTHEAD MTG

SCREW GRMT #6 #8 FASTX./

46-0784112-02

15-061416-240

01-0286361233

01-0286361255

01-0286361244

01-0286361211

15-081416-080

46-0784112-04

01-0286361222

A/R

QTY

A/R

400 LIN LED SPLIT / RED-RED

400 LIN LED SPLIT / GRN GRN-

400 LIN LED SPLIT / CLR CLR-

400 LIN LED SPLIT / BLU BLU-

HARNESS FLASHER / DELTA

SCREW 6 x 1-1/2" PPHSMS/

8 x 1/2" PPHSMS / 410 SS

400 LED SPLIT / AMB AMBLIN -

HARNESS UPPER LED ADAPT.

QTY

Page 5

Page 6

LOWER LEVEL: OSCILLATORS

ASS'Y OSCILLATOR DRIVER/

SCREW 8 x 3/8" PPHSMS / 410 SS/

SCREW GROMMET #6 #8 FASTEX/

DELTA ADD 2 OSCILLATORS/

13-062C40-16J

15-081416-060

02-0384055-00

02-0484131-09

ASS'Y / HARNESS TAKEDOWN LIGHT / DELTA

46-0784112-00

02-0384055-01

ASS'Y OSCILLATOR PASSENGER/

ITEM

PART NUMBER

DESCRIPTION

QTY

5 6 7 8

1 3

LOWER LEVEL: 500 SERIES 5MM FLASHERS

01-0269831-01

46-0784112-02

02-0484131-__

09-1363542-00

02-0364086-00

ASS'Y ELEC 2 CH FLASHER DELTA/

ASS'Y HARNESS FLASHER / DELTA SERIES/

ASS'Y RETAINER LIGHTHEAD MTG / DELTA/

FILLER PANEL 500 SERIES/

02-0383558A12

SUB ASSY 500 LED STEADY AMB 2 POS. AMP//

02-0484131-__

OPT DELTA ADD 2 500 5MM LED FLASHERS

02-0383558A22

02-0383558AC2

02-0383558A52

OPT DELTA ADD 1 500 5MM LED FLASHER

SUB ASSY 500 LED STEADY BLU 2 POS. AMP//

SUB ASSY 500 LED STEADY RED 2 POS. AMP//

SUB ASSY 500 LED STEADY CLR 2 POS. AMP//

ITEM

PART NUMBER

DESCRIPTION

QTY QTY

A/R

1 3

576

1 5

91210

15 16

DELTA ADD 1 MR11 TAKE DOWN LIGHT

DELTA ADD 2 MR11 TAKE DOWN LIGHTS

ASSY RETAINER LIGHTHEAD MTG / DELTA/

SUB ASSY SINGLE MR11 / DELTA SERIES/

ASSY / HARNESS TAKE DOWN LIGHT / DELTA

02-0484131-80

02-0363847-00

46-0784112-00

02-0484131-81

02-0364086-00

ITEM

PART NUMBER

DESCRIPTION

QTY QTY

112

LOWER LEVEL TAKE DOWN: MR11 ALLEY LIGHTS or

DELTA ADD 2 MR11 ALLEY LIGHTS

02-0484131-82

DELTA™ LIGHTBAR / Available Options

(

continued

)

1 3

678

910

LOWER LEVEL: 500 SERIES TAKE DOWN

DELTA ADD 1 HALOGEN TAKE DOWN LIGHT

DELTA ADD 2 HALOGEN TAKE DOWN LIGHTS

SUB ASSY 500 HALO REFL / LAMP 2 POS AMP//

ASSY / RETAINER LIGHTHEAD MTG / DELTA

02-0484131-07

02-0383577-23

46-0784112-00

02-0484131-06

02-0364086-00

ASSY / HARNESS TAKEDOWN LIGHT / DELTA

ITEM

PART NUMBER

DESCRIPTION

QTY QTY

LOWER LEVEL: 500 SERIES TIR6 LED FLASHER

68-1963583-30

01-026B670252

01-026B670232

01-026B670222

01-026B670212

02-0364086-00

02-0484131-__

01-0269831-01

46-0784112-02

09-1363542-00

RETAINER LT. HEAD MTG / DELTA

ADD 2 500 TIR6 LED FLASHERS

ADD 1 500 TIR6 LED FLASHER

ELEC 2 CH FLASHER DELTA

LENS CLR OPTIC LED 20° 500 SERIES/

S ASY 500 TIR LTBR MT / STDY AMB./

HARNESS FLASHER / DELTA SERIES

FILLER PANEL 500 SERIES/

15-065419-080

SCREW/6x1/2PPHPLASTI / SS

S. ASY / 500 TIR LTBR MT / STDY BLU

S. ASY / 500 TIR LTBR MT / STDY CLR

S. ASY / 500 TIR LTBR MT / STDY RED

ITEM

PART NUMBER

DESCRIPTION

QTY QTY

111

A/R

LOWER LEVEL: 500 SERIES ALLEY LIGHTS

DELTA ADD 2 HALOGEN ALLEY LT.'S

500 HALO. / 2 WIRE / 2 POS AMP CLR

HARNESS ALLEY LIGHT / DELTA

02-0484131-08

01-06835772C3

46-0784112-01

02-0364086-00

RETAINER LT. HEAD MTG / DELTA

ITEM

PART NUMBER

DESCRIPTION

QTY

LOWER LEVEL (

For use with Delta Oscillators only

)

: 2 TIR 3 LEDS

02-0364086-00

11-763742-001

02-0484131-__

01-0269831-01

09-1363542-00

07-243041-000

RETAINER LT. HEAD MOUNTING DELTA

FLANGE SURFACE MT TIR3 LTHD/./.

DELTA: 2 TIR3 LED LOWER LEVEL

BRACKET MOUNTING TIR3 / DELTA/

FILLER PANEL 500 SERIES/

ELEC 2 CH FLASHER / FILLER PANEL

13-062C40-16J

15-061416-120

SCREW GROMET #6 #8 FASTEX/

SCREW 6 x 3/4" PPHSMS / 410 SS/

07-243110-000

BRACKET MOUNTING PDM/

SCREW 8 x 1/2" PPHSMS / 410 SS/

A/R

HARNESS FLASHER / DELTA SERIES

15-081416-080

46-0784112-02

02-0363752212

TIR3 LED LTHD STEADY AMB AMP//

SCREW 8 x 3/8" PPHSMS / 410 SS/

15-081416-060

-4

02-0363752222

02-0363752232

02-0363752242

02-0363752252

TIR3 LED LTHD STEADY BLU AMP//

TIR3 LED LTHD STEADY CLR AMP//

TIR3 LED LTHD STEADY GRN AMP//

TIR3 LED LTHD STEADY RED AMP//

ITEM

PART NUMBER

DESCRIPTION

QTY

A/R

LOWER LEVEL: MR11 ALLEY & TIR3 LED

RETAINER LIGHTHEAD MTG / DELTA

02-0364086-00

ELEC 2 CH FLASHER DELTA

DELTA: ADD 1 500 HALOGEN FLASHER

02-0484131-__

01-0269831-01

SUB ASY MR11/AMB TIR3 LED / DELTA/

HARNESS FLASHER / DELTA SERIES

HARNESS ALLEY LIGHT / DELTA SERIES

FILLER PANEL 500 SERIES/

46-0784112-02

09-1363542-00

46-0784112-01

02-0363859-10

02-0363859-20

SUB ASY MR11/BLU TIR3 LED / DELTA/

02-0363859-30

SUB ASY MR11/CLR TIR3 LED / DELTA/

02-0363859-40

SUB ASY MR11/GRN TIR3 LED / DELTA/

02-0363859-50

SUB ASY / MR11 RED TIR3 LED / DELTA/

ITEM

PART NUMBER

DESCRIPTION

QTY

A/R

Page 6

Page 7

NOTE: 5 LIGHT TA SHOWN

LOWER LEVEL: 5MM LED TRAFFIC ADVISOR

LOWER LEVEL: TRAFFIC ADVISORTIR6 LED

46-0743070-00

39-0416313-04

02-0364086-00

01-0663530-AA

01-0682340-00

39-0402023-04

02-0484131-25

02-0484131-24

02-0484131-22

02-0484131-23

46-0763757-01

DELTA OPT 5 LIGHT TIR6 LED TRAFFIC ADVISOR/

DELTA OPT 8 LIGHT TIR6 LED TRAFFIC ADVISOR/

DELTA OPT 7 LIGHT TIR6 LED TRAFFIC ADVISOR/

DELTA OPT 6 LIGHT TIR6 LED TRAFFIC ADVISOR/

ASSY CABLE 16/C 20 GA. 20' / DELTA SERIES/

HOUSING 2 POS SOCKET / COMM MATE N LOK/

ASSY RETAINER LIGHTHEAD MTG / DELTA/

ASSY 500 SERIES TIR LED AMBER / AMBER/

HOUSING 16 POS PIN MOTOT MT/

ASSY ACTRL1A CONTROL HEAD/T

ASSY / CABLE ADAPTER CNTRL HD / SWITCH GND

ITEM PART NUMBER DESCRIPTION

QTY QTY QTY QTY

2121122

A/R

A/RA/R

A/R

A/R A/R

A/R

2222

02-0484131-21

02-0484131-20

02-0484131-19

02-0484131-18

46-0763757-01

46-0743070-00

39-0416313-04

39-0402023-04

02-0364086-00

02-0383558AA2

01-0683850-00

DELTA OPT 8 LIGHT 5MM LED TRAFFIC ADVISOR/

DELTA OPT 7 LIGHT 5MM LED TRAFFIC ADVISOR/

DELTA OPT 6 LIGHT 5MM LED TRAFFIC ADVISOR/

DELTA OPT 5 LIGHT 5MM LED TRAFFIC ADVISOR/

ASSY / CABLE ADAPTER CNTRL HD / SWITCH GND

ASSY CABLE 16/C 20 GA. 20' / DELTA SERIES/

HOUSING 16 POS PIN MOTOT MT/

HOUSING 2 POS SOCKET / COMM MATE N LOK/

ASSY RETAINER LIGHTHEAD MTG / DELTA/

SUB ASSY 500 LED STEADY MAX AMB/AMB//

ASSY TRAFFIC ADV C L HEAD LED TACTLD1/TR/

ITEM PART NUMBER DESCRIPTION

QTY QTY QTY QTY

5678

11111

678

1111

LOWER LEVEL: TRAFFIC ADVISOR: ADD HALOGEN

HOUSING 2 POS SOCKET / COMM MATE N LOK/

HOUSING 16 POS PIN MOTOT MT/

ASSY CABLE 16/C 20 GA. 20' / DELTA SERIES/

ASSY / CABLE ADAPTER CNTRL HD / SWITCH GND

DELTA OPT 5 LIGHT HALOGEN TRAFFIC ADVISOR/

ASSY 500 HALOGEN 2 WIRE 2 POS AMP/AMBER///

ASSY RETAINER LIGHTHEAD MTG / DELTA/

ASSY TACTRL1A CONTROL HEAD/

39-0402023-04

39-0416313-04

46-0743070-00

46-0763757-01

02-0484131-14

01-0682340-00

01-06835772A4

02-0364086-00

02-0484131-15

02-0484131-16

02-0484131-17

DELTA OPT 6 LIGHT HALOGEN TRAFFIC ADVISOR/

DELTA OPT 7 LIGHT HALOGEN TRAFFIC ADVISOR/

DELTA OPT 8 LIGHT HALOGEN TRAFFIC ADVISOR/

ITEM PART NUMBER DESCRIPTION

QTY QTY

111

QTY QTY

678

DELTA™ LIGHTBAR / Available Options

(

continued

)

MTG BRACKET PDM with LR11

SCREW 6 x 1/2 PPH PLASTI / SS/

SCREW 6-32 X 1/4 PPHMS SEMS IT LOCK/ with

"Y" HARNESS INTERIOR BAR

SUB ASY SINGLE LR11 DELTA LOWER LEVEL/

SUB ASY DUAL LR11 DELTA LOWER LEVEL/

HARNESS TAKEDOWN LIGHT / DELTA

HARNESS ALLEY LIGHT / DELTA

ASS'Y RETAINER LIGHTHEAD MTG / DELTA/

SCREW 8-32 X 3/4 PPHMS SS/

DELTA ADD 2 LR11 TAKE DOWN LIGHTS

DELTA ADD 2 LR11 ALLEY LIGHTS

BRACKET MTG LR11 ALLEY DELTA/

SCREW GROMMET #6 #8 FASTEX/

02-0484131___

07-243733-000

15-065419-080

14-062216-041

46-0743226-00

01-026B085-__

46-0784112-00

46-0784112-01

02-0364086-00

14-082216-120

13-062C40-16J

07-243718-000

A/R A/R

A/R

222

A/R

DELTA / LR11 SINGLE OR DUAL

ITEM

PART NUMBER

DESCRIPTION

QTYQTY

10 11

Page 7

Page 8

BASE

EXTRUSION

BASE

EXTRUSION

Upper

Lower

8 X 3/8" PPHSMS 410 SS

Servicing your Lightbar:

To power distribution board

Connect to other MR11

Remove protective backing from tape before mounting

Secure bracket to extrusion using supplied sheet metal screws

Insert grommets into extrusion

500 Series Lighthead

Dome

400 Series Lighthead

MR11 TIR3

Flasher

Dome

6 X 3/4" PPHSMS 410 / SS

8-32 X 3/4 PPHMS

BASE EXTRUSION

FRONT BRACKET

REAR BRACKET

INSIDE COVER

NOTE: If you need to remove the oscillator from the lightbar you must re-mount it in the exact same position.

Hook bracket over extrusion.

Secure bracket to fastex grommets installed into base.

Secure bracket to fastex grommet installed into base.

This section covers the removal and installation of the components of your lightbar for repair or replacement purposes. All options plug into the distribution module which is mounted on the base extrusion on the lower level. The sockets on the distribution module are labeled for easy

Fastex grommet

Mounting bracket

Connector plugs into distribution module on lower level.

Dome:

Removal: Installation:

The domes are held on by 8-32x1/2" phillips pan head metal screws

Remove the dome mounting screws and Pull dome(s) off.

Place dome on lightbar base making sure it sits properly.

Secure dome(s) with supplied 8-32 X 1/2 Inch metal screws.

RUBBER BUMPER

Hook bracket over extrusion here.

500 Series:

3. NOTE: A is MR11,

Slide lighthead into retainer and remove backing from double sided tape on bottom. Insert tabs on back of retainer into slots in lightbar base ress down Reinstall upper cover. The 3 tabs on top of the lighthead will fit into 3 slots in the cover.

500 Series LED shown. 500 Series 5MM, 500 Series HALOGEN

500 SERIES TIR, LR11's and Flashers mount the same.

P so tape will stick.

The oscillator mounts directly to two fastex grommets inserted into the extrusion.

The oscillator does not use a mounting bracket.

Oscillator:

500 Series:

Lighthead slides into slots in retainer

Insert retainers tabs into slots in the base

400 Series:

Install 4 grommets into the mounting bracket & 1 into the cover

the lightbar. Secure lighthead to mounting bracket using

Secure bracket (with lighthead) to base cover using supplied sheet metal screws

inside

lighthead lens screws.

and plug

Install 4 grommets into the mounting bracket & 1 into the cover

the lightbar.

inside of Secure lighthead to mounting bracket using lighthead lens screws. Secure bracket (with lighthead) to base cover using supplied sheet metal screws. .

400 Series:

Same as 500 Series

Flasher:

INSIDE COVER

BOSSES

GROMMET

Oscillator

(

Top View

)

Oscillator

(

Top View

)

Flasher

Install the 2 grommets into the lightbar inside cover to which the rotator will mount. Secure the front of the rotator by slipping its base over the 2 bosses protruding from the inside

ecure the rear to the grommets you

using the 2 supplied sheet metal screws. The rotator plugs into the distribution board on the lower level.

cover. S installed

Rotator:

Install the 2 grommets into the lightbar inside cover to which the rotator will mount. Secure the front of the rotator by slipping its base over the 2 bosses protruding from the inside cover. Secure the rear to the grommets you installed using the 2 supplied sheet metal screws. The rotator plugs into the distribution board on the lower level.

Dome:

identification.

RUBBER BUMPER

BASE

EXTRUSION

LR11

Slide bracket into extrusion. 2 screws to secure.

LR11 Alley:

TIR3:

Secure lighthead to front bracket

lighthead lens screws. Insert 2 fastex grommets into extrusion. Place lighthead/bracket onto extrusion. Slip rear bracket over extrusion and

with 2 sheet metal screws.

using

secure

MR11 /

Page 8

Page 9

273028

30 31

3333

2929

FRONT OF LIGHTBAR

123

6059

Page 9

Page 10

NS = Not shown or hidden in parts drawing

ITEM

PART NUMBER DESCRIPTION

QTY QTY QTY QTYQTYQTYQTYQTYQTYQTY

NUT 10-24 CAD PLATED WHIZ//NS

2 STD ROT 72 11/16 DELTA IND. LIGHTBAR

2 STD ROT 61 13/16 DELTA IND. LIGHTBAR

2 STD ROT 56 5/16 DELTA IND. LIGHTBAR

2 STD ROT 49 3/4 DELTA IND. LIGHTBAR

2 STD ROT 44 5/16 DELTA IND. LIGHTBAR

HOUSING 1 POS 75A BLACK / POWERPOLE 75///

BRACKET MOUNTING PDM ASSYS / DELTA SERIES/

2 HI ROT 72 11/16 DELTA IND. LIGHTBAR

2 HI ROT 61 13/16 DELTA IND. LIGHTBAR

2 HI ROT 56 5/16 DELTA IND. LIGHTBAR

2 HI ROT 44 5/16 DELTA IND. LIGHTBAR

GROMET SPECIAL / 1.562 THERMOPLASTIC RUBBER/

GASKET EXTRUSION DELTA SERIES / 100' ROLL/

BOLT 10-24 X 1/2" CARRIAGE / STAINLESS STEEL/

LENS BASE CLEAR CORNER MODULE-DELTA

LENS BASE CLEAR DUAL-CENTER DELTA

CABLE CLAMP 5/8"D 1/2" W/.203 MTG HOLE BLK / NS

LENS BASE CLEAR SINGLE-CENTER DELTA

PLUG VENT .750 HOLE DIA BLACK/HEYCO/

BASE EXTRUSION MACHINED-DELTA42.00"/

BASE EXTRUSION MACHINED/DELTA36.531"/

2 HI ROT 49 3/4 DELTA IND. LIGHTBAR

BASE EXTRUSION MACHINED DELTA 48.612"/-

BASE EXTRUSION MACHINED DELTA 64.937"/-

BASE EXTRUSION MACHINED DELTA 54.062"/-

ELEC. HC PDM DELTA

WIRE 8 GA 20' BLACK / CONTACT/

SCREW 10-24 X 1" PPHMS//NS

ASS'Y CABLE 10/C COMPOSITE 20'/

DIVIDER with GASKET JOB 9077 DELTA

39-0001007-00

07-243110-000

01-0269815-00

11-363721-054

11-363721-048

01-0684131-09

01-0684131-08

01-0684131-07

01-0684131-06

01-0684131-02

01-0684131-04

01-0684131-03

01-0684131-05

11-363721-048

11-363721-054

11-363721-064

21-11245004-1B

21-7263998-00

38-0143029-00

02-0363798-00

14-104066-080

02-0384054-30

67-1N00800M00

02-0363812-30

02-0363813-30

14-104216-160

46-0743114-20

26-0115663-10

01-0684131-00

01-0684131-01

13-104120-062

16-1001220-06

01-5015970-29

01-0463929-01

01-0463929-00

46-0743399-00

10-0523072-02

68-4983959-10

68-4983959-20

68-4983959-30

68-4983959-90

68-4983960-10

68-4983960-20

68-4983960-30

68-4983960-90

68-4983958-10

68-4983958-20

68-4983958-30

68-4983958-40

08-0617449-00

02-0363716-00

11-283961-000

11-283979-000

11-283970-000

13-062C40-16J

68-5963707-D10

02-0363716-02

15-081416-060

68-5963707-P10

68-4983960-50

68-4983958-50

68-4983960-40

68-4983959-40

68-4983959-50

14-082216-080

13-104111-063

39-1V04017-00

46-0984112-00

09-1343082-00

A/R

DOME BLUE CTR MODULE DUAL / DELTA SERIES/

DOME CLEAR CTR MODULE DUAL / DELTA SERIES/

DOME BLACK CTR MODULE DUAL / DELTA SERIES/

DOME AMBER CTR MODULE SINGLE / DELTA SERIES/

DOME BLUE CTR MODULE SINGLE / DELTASERIES/

DOME CLEAR CTR MODULE SINGLE / DELTASERIES/

DOME BLACK CTR MODULE SINGLE / DELTASERIES/

ASS'Y ROTATING REFL 175-12-H1 DELTA SERIES/

COVER INSIDE CENTER DUAL / DELTA SERIES/

COVER INSIDE CORNER BLACK / DELTASERIES/

COVER INSIDE CENTER SINGLE / DELTASERIES/

ASS'Y ROTATING REFL 150-12-H1 DELTA SERIES/

ASS'Y MIRROR PASSENGER SIDE / DELTA SERIES/

DOME RED CTR MODULE SINGLE / DELTASERIES/

DOME GREEN CTR MODULE SINGLE / DELTASERIES/

DOME GREEN CTR MODULE DUAL / DELTA SERIES/

DOME RED CTR MODULE DUAL / DELTA SERIES/

ASS'Y HARNESS I O C ROT LED / DELTA SERIES/---

PANEL WIRE MANAGEMENT / DELTA LIGHTBAR/

HOUSING 4 POS PLUG / UNIVERSAL MATE N LOK//NS

DOME RED CORNER MODULE/

BUMPER, GROMMET STYLE RUBBER / BLACK

SCREW GROMMET #6/#8 FASTEX

SCREW 8 X 3/8 PPHSMS / 410 SS/

ASS'Y MIRROR DRIVER SIDE / DELTA SERIES/

DOME AMBER CORNER MODULE/

DOME BLUE CORNER MODULE/

DOME CLEAR CORNER MODULE/

DOME GREEN CORNER MODULE/

KIT 3M 792 OPTICOM MOUNTING CABLE DELTA/ / with /

DOME AMBER CTR MODULE DUAL / DELTA SERIES/

WASHER #10 FLAT 18-8 STAINLESS//

NUT / 10-24 ELASTIC STOP STAINLESS/

MODEL 792H OPTICOM EMITTER / NS

KIT 3M 792 OPTICOM MOUNTING DELTA///NS

HARNESS EXTENSION DELTAROT/LED/

LABEL M N S N DELTA SERIES "HC" MODEL/--- /NS

SCREW 8-32 X 1/2 PPHMS SS//NS

Page 10