Whelen DI2S800 User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road,
Chester, Connecticut 06412
Phone: [phone]

Delta™ Independence™ Lightbar

Installation Guide:

(10/14 Function)

Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Canadian Sales e-mail: [e-mail]
Customer Service e-mail: [e-mail]

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.

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

• 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 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 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.

• If this product uses a remote device to activate or control this product, make sure that this control is located in
an area that allows both the vehicle and the control 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 AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!

Automotive: Lightbars

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

©2004 Whelen Engineering Company Inc.
Form No.13913J (060810)

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 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).

Note that on the adjustable foot, use the hole in the pad as a guide to drill the two holes into

8.

Standard
Mounting
Foot

Mounting
Plate

Nut

Washer

Mounting

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.

BoltBolt

Pad

Mounting

Pad

Washer

Nut

Adjustable
Mounting
Foot

Mounting
Plate

IMPORTANT: For strap mounting, be sure you have the right sized
lightbar for your vehicle. The bar should be approximately the same

1/2" MIN. CLEARANCE

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.

width as the vehicle roof. If too large or small it will not mount properly
and may come loose during driving.

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

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.

Standard Mounting Foot / Model MKEZ

Mounting

Foot

Mounting
Strap

Tinnerman

Mounting

Plate

Plate

Tension

Bolt

Mounting

Mounting
Screw

Pad

5" Mounting Foot

METAL SCREW

BOLT

SHEET
METAL
SCREWS

STRAP

Tighten

with

set at 35

torque

MOUNTING FOOT

EXTENSION

NUT

SPLIT LOCK
WASHER

screws

wrench

to

40

in/lbs

TINNERMAN

NUT

FOOT

ANCHOR

PLATE

VEHICLE ROOF

Mounting

Screw

Adjustment

screws

Plate slides into
lightbar extrusion

SET
SCREW

Adjustable Mounting Foot / Model MKAJ

Mounting

Strap

Tension

Bolt

Lock

Washer

Locking
Plate

Tinnerman
Plate

Nut

Mounting
Foot

Mounting
Pad

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

vehicles. The strap

NOTE:

for your vehicle

NOTE:

shown here is for example only. The strap

may look different.

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