Whelen DI2S800 User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road, Chester, Connecticut 06412 Phone: (860) 526-9504

Delta™ Independence™ Lightbar

Installation Guide:

(10/14 Function)

Fax: (860) 526-4078 Internet: www.whelen.com Sales e-mail: autosale@whelen.com Canadian Sales e-mail: autocan@whelen.com Customer Service e-mail: custserv@whelen.com

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

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

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

Routing the Cables:

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.

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).

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.

For lightbars with cables exiting the

Passenger side of

the extrusion

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

Control Cable

Color Fuse @

GREEN

GRN/WHT

WHITE/BLK

WHITE

YELLOW

BLUE

RED/WHITE

RED

RED/BLACK

WHT/VIO

To Chassis Ground

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

Function

Oscillators

Front Flashers

Take-Down

Drivers Alley

Passenger Alley

Rear Flashers

Outer

Inner

Center

Scan-Lock™

15 Amps

7.5 Amps

15 Amps

3Amps

Lower Level

Upper Level

Misc.

Route cable to customer supplied switch box.

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.

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

IMPORTANT WARNING!

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.

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

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

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 take-

downs, use a 3 amp fuse.

Page 4

Available Configurations:

UPPER LEVEL

CORNER

UPPER LEVEL

UPPER LEVEL DUAL CENTER

LOWER LEVEL

CORNER

LOWER LEVEL

CORNER

OSC OSC

DUAL / CENTER

ROTATOR

ASSEMBLY

Options:

FOR

REFERENCE

MIRROR:

DIAMOND

UPPER LEVEL

CONFIGURATION

CORNER

CONFIGURATION

400 SERIES

LIGHTHEAD

MIRROR:

FLAT

OSC OSC

500 SERIES LIGHTHEAD

CORNER CONFIGURATION

LIGHTHEAD

TIR3

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

2 1

6

4

3

6

51637

849

2

OSCILLATOR ASSEMBLIES

LOWER LEVEL: 500 SERIES HALOGEN FLASHER

QTY QTY

ITEM

34

111

1

A/R

LOWER LEVEL CONFIGURATIONS

SINGLE CENTER

PART NUMBER

02-0484131-__

01-0269831-01

111

02-0364086-00

2

09-1363542-00

3

46-0784112-02

4

5

01-06835772A3

01-06835772B3

6

7

01-06835772C3

8

01-06835772G3

01-06835772R3

9

DUAL

CENTER

CORNER CONFIGURATION

PART DESCRIPTION

DELTA ADD 1 500 HALOGEN FLASHER

DELTA ADD 2 500 HALOGEN FLASHERS

ELEC 2 CH FLASHER DELTA

RETAINER LIGHTHEAD MTG / DELTA

FILLER PANEL 500 SERIES/

HARNESS FLASHER / DELTA SERIES

500 HALOGEN/2 WIRE /2 POS AMP/AMB

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/

SINGLE / CENTER

QTYQTYQTYQTY

2 121

4

2

4

2

8

4

2

QTY QTY QTY QTY

2

1

4

2

4

2

8

4

2

5

ITEM PART NUMBER DESCRIPTION

12

4

2

4

2

UPPER LEVEL: ROTATOR OPTIONS

02-0484131-02

02-0484131-00

02-0484131-04

02-0484131-35

02-0484131-03

02-0484131-01

02-0484131-05

02-0484131102

1

02-0363716-00

2

02-0363716-02

3

13-062C40-16J

4

15-081416-060

5

17-0510040-30

6

68-5443033-00

DELTA ADD 400 SERIES LED FLASHER

QTY

ITEM

10

A/R

PART NUMBER

02-0484131-__

01-0269831-01

1

2

1

2

8

2

1

2

A/R

2

1

3

1

4

5

4

6

1

7

1

8

1

9

10

11

12

13

14

02-0364086-00

09-1363542-00

07-263737-000

013-062C40-16J

15-061416-240

15-081416-080

46-0784112-02

46-0784112-04

01-0286361211

01-0286361222

01-0286361233

01-0286361244

01-0286361255

DESCRIPTION

1 - 400 LINEAR FLASHER

2 400 LINEAR FLASHER-S

ELEC 2 CH FLASHER DELTA

RETAINER LIGHTHEAD MTG

FILLER PANEL 500 SERIES/

MTG. KT. /BR 400 SERIES

SCREW GRMT #6 #8 FASTX./

SCREW 6 x 1-1/2" PPHSMS/

8 x 1/2" PPHSMS / 410 SS

HARNESS FLASHER / DELTA

HARNESS UPPER LED ADAPT.

400 LED SPLIT / AMB AMBLIN -

400 LIN LED SPLIT / BLU BLU-

400 LIN LED SPLIT / CLR CLR-

400 LIN LED SPLIT / GRN GRN-

400 LIN LED SPLIT / RED-RED

DELTA STD. ROT CTR/ATOR/.

DELTA 2 STD INBD/ ROTATOR .

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

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

DELTA HI C R/ ROTATOR / T

DELTA 2 HI INBOARD/ ROTATOR

DELTA HI with MIRRORS DUAL C RROT. T

DELTA 2 HI with MIRRORS DUAL C RROT. T

ROTATING REFLECTOR 150-12-H1

ROTATING REFLECTOR 175-12-H1

SCREW GROMMET #6 #8 FASTEX/

SCREW 8 x 3/8 PPHSMS / 410 SS/

RIVET POP AVEX 1691-0512/

MIRROR / CTR. MNT. ROT. / DELTA

5

101311

12

14

6

7

3

2

Page 5

8

6

2

4

5

9

4

9

8

1

3

1

UPPER LEVEL: HALOGEN FLASHER

ITEM PART NUMBER DESCRIPTION

QTY QTY

11

2

1

10

8

121

1

2

1

5

4

1

10

A/RA/R

12

13

A/RA/R

14

02-0484131-__

01-0269831-01

1

02-0363189-00

2

02-0364086-00

3

07-263737-000

4

5

09-1363542-00

6

13-062C40-16J

15-061416-240

7

15-081416-080

8

46-0784112-02

9

68-1183726-1S

11

68-1183726-2S

68-1183726-3S

68-1183726-4S

68-1183726-5S

1 - 400 HALOGEN FLASHER

2 - 400 HALOGEN FLASHERS

ELEC 2 CH FLASHER DELTA

REFLECT. 400 SERIES HALO.

RETAINER LIGHTHEAD MTG

MTG. BRCKT 400 SERIES

FILLER PANEL 500 SERIES/

GROMMET #6 #8 FASTEX

SCREW 6x11/2"PPHSMS/

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

HARNESS FLASHER / DELTA

LENS AMB 400 OPTIC / SEAL/

LENS BLU 400 OPTIC / SEAL/

LENS CLR 400 OPTIC / SEAL/

LENS GRN 400 OPTIC / SEAL/

LENS / RED 400 OPTIC / SEAL

10 11 12

13 14

7

21

4

3

DELTA™ LIGHTBAR / Available Options

5

LOWER LEVEL: OSCILLATORS

QTY

ITEM

1

2

1

3

4

5

1

PART NUMBER

02-0484131-09

02-0384055-00

02-0384055-01

13-062C40-16J

15-081416-060

46-0784112-00

5 6 7 8

DELTA ADD 2 OSCILLATORS/

ASS'Y OSCILLATOR DRIVER/

ASS'Y OSCILLATOR PASSENGER/

SCREW GROMMET #6 #8 FASTEX/

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

ASS'Y / HARNESS TAKEDOWN LIGHT / DELTA

2

DESCRIPTION

1 3

4

LOWER LEVEL: 500 SERIES 5MM FLASHERS

QTY QTY

ITEM

A/R

PART NUMBER

02-0484131-__

01-0269831-01

1

4

1

A/R

2

3

4

1

5

6

7

8

02-0364086-00

09-1363542-00

46-0784112-02

02-0383558A12

02-0383558A22

02-0383558A52

02-0383558AC2

OPT DELTA ADD 1 500 5MM LED FLASHER

OPT DELTA ADD 2 500 5MM LED FLASHERS

ASS'Y ELEC 2 CH FLASHER DELTA/

ASS'Y RETAINER LIGHTHEAD MTG / DELTA/

FILLER PANEL 500 SERIES/

ASS'Y HARNESS FLASHER / DELTA SERIES/

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

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//

DESCRIPTION

(

continued

3

)

LOWER LEVEL: 500 SERIES TAKE DOWN

QTY QTY

ITEM

PART NUMBER

1

12

2

12

3

11

02-0484131-06

02-0484131-07

02-0364086-00

02-0383577-23

46-0784112-00

2

1

LOWER LEVEL TAKE DOWN: MR11 ALLEY LIGHTS or

QTY QTY

ITEM

112

12

2

3

11

PART NUMBER

02-0484131-82

02-0484131-80

02-0484131-81

02-0364086-00

02-0363847-00

46-0784112-00

DELTA ADD 2 MR11 ALLEY LIGHTS

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

DESCRIPTION

LOWER LEVEL: 500 SERIES ALLEY LIGHTS

QTY

ITEM

12

2

3

1

PART NUMBER

02-0484131-08

02-0364086-00

01-06835772C3

46-0784112-01

5

DESCRIPTION

DELTA ADD 2 HALOGEN ALLEY LT.'S

RETAINER LT. HEAD MTG / DELTA

500 HALO./2WIRE/2POSAMPCLR

HARNESS ALLEY LIGHT / DELTA

4

3

DESCRIPTION

3

2

1

2

1

DELTA ADD 1 HALOGEN TAKE DOWN LIGHT

DELTA ADD 2 HALOGEN TAKE DOWN LIGHTS

ASSY / RETAINER LIGHTHEAD MTG / DELTA

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

ASSY / HARNESS TAKEDOWN LIGHT / DELTA

1 3

8

4

7

LOWER LEVEL (

For use with Delta Oscillators only

QTY

ITEM

PART NUMBER

02-0484131-__

01-0269831-01

1

02-0364086-00

2

07-243041-000

3

2

07-243110-000

2

4

09-1363542-00

5

1

11-763742-001

6

2

13-062C40-16J

7

4

15-061416-120

8

4

15-081416-060

9

-4 15-081416-080

10

4

46-0784112-02

1

11

02-0363752212

A/R

12

02-0363752222

13

A/R

02-0363752232

A/R

14

02-0363752242

15

A/R

02-0363752252

16

A/R

3

14

13

15 16

: 2 TIR 3 LEDS

DELTA: 2 TIR3 LED LOWER LEVEL

ELEC 2 CH FLASHER / FILLER PANEL

RETAINER LT. HEAD MOUNTING DELTA

BRACKET MOUNTING TIR3 / DELTA/

BRACKET MOUNTING PDM/

FILLER PANEL 500 SERIES/

FLANGE SURFACE MT TIR3 LTHD/./.

SCREW GROMET #6 #8 FASTEX/

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

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

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

HARNESS FLASHER / DELTA SERIES

TIR3 LED LTHD STEADY AMB AMP//

TIR3 LED LTHD STEADY BLU AMP//

TIR3 LED LTHD STEADY CLR AMP//

TIR3 LED LTHD STEADY GRN AMP//

TIR3 LED LTHD STEADY RED AMP//

DESCRIPTION

R

11

1 5

6

91210

2

678

910

2

LOWER LEVEL: MR11 ALLEY & TIR3 LED

QTY

ITEM

1

4

1

A/R

PART NUMBER

02-0484131-__

01-0269831-01

1

02-0364086-00

2

09-1363542-00

3

46-0784112-02

4

5

46-0784112-01

02-0363859-10

6

02-0363859-20

7

02-0363859-30

8

02-0363859-40

9

02-0363859-50

10

DESCRIPTION

DELTA: ADD 1 500 HALOGEN FLASHER

ELEC 2 CH FLASHER DELTA

RETAINER LIGHTHEAD MTG / DELTA

FILLER PANEL 500 SERIES/

HARNESS FLASHER / DELTA SERIES

HARNESS ALLEY LIGHT / DELTA SERIES

SUB ASY MR11/AMB TIR3 LED / DELTA/

SUB ASY MR11/BLU TIR3 LED / DELTA/

SUB ASY MR11/CLR TIR3 LED / DELTA/

SUB ASY MR11/GRN TIR3 LED / DELTA/

SUB ASY / MR11 RED TIR3 LED / DELTA/

)

576

4

8

1 3

10

9

2

Page 6

LOWER LEVEL: 500 SERIES TIR6 LED FLASHER

QTY QTY

ITEM

PART NUMBER

02-0484131-__

01-0269831-01

11

1

02-0364086-00

34

2

09-1363542-00

3

A/R

111

A/R

1

24

46-0784112-02

4

5

01-026B670212

01-026B670222

6

01-026B670232

7

01-026B670252

8

68-1963583-30

9

15-065419-080

10

1

2

DESCRIPTION

ADD 1 500 TIR6 LED FLASHER

ADD 2 500 TIR6 LED FLASHERS

ELEC 2 CH FLASHER DELTA

RETAINER LT. HEAD MTG / DELTA

FILLER PANEL 500 SERIES/

HARNESS FLASHER / DELTA SERIES

S ASY 500 TIR LTBR MT / STDY AMB./

S. ASY / 500 TIR LTBR MT / STDY BLU

S. ASY / 500 TIR LTBR MT / STDY CLR

S. ASY / 500 TIR LTBR MT / STDY RED

LENS CLR OPTIC LED 20° 500 SERIES/

SCREW /6x1/2PPHPLASTI / SS

(

6

DELTA™ LIGHTBAR / Available Options

continued

)

7

5

QTY QTY QTY QTY

1

4

2

A/R

LOWER LEVEL: TRAFFIC ADVISORTIR6 LED

ITEM PART NUMBER DESCRIPTION

02-0484131-22

02-0484131-23

02-0484131-24

02-0484131-25

01-0682340-00

1

2222

01-0663530-AA

2

2222

02-0364086-00

3

212

39-0402023-04

4

11221

5

39-0416313-04

A/R

A/R A/R

A/R

A/RA/R

46-0743070-00

6

46-0763757-01

7

DELTA OPT 5 LIGHT TIR6 LED TRAFFIC ADVISOR/

DELTA OPT 6 LIGHT TIR6 LED TRAFFIC ADVISOR/

DELTA OPT 7 LIGHT TIR6 LED TRAFFIC ADVISOR/

DELTA OPT 8 LIGHT TIR6 LED TRAFFIC ADVISOR/

ASSY ACTRL1A CONTROL HEAD/T

ASSY 500 SERIES TIR LED AMBER / AMBER/

ASSY RETAINER LIGHTHEAD MTG / DELTA/

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

3

6

4

7

5

1

QTY QTY QTY QTY

2

6

LOWER LEVEL: 5MM LED TRAFFIC ADVISOR

ITEM PART NUMBER DESCRIPTION

02-0484131-18

02-0484131-19

02-0484131-20

02-0484131-21

01-0683850-00

11111

02-0383558AA2

5678

2

5

02-0364086-00

3

678

5

4

5

1111

6

1111

7

1111

39-0402023-04

39-0416313-04

46-0743070-00

46-0763757-01

678

DELTA OPT 5 LIGHT 5MM LED TRAFFIC ADVISOR/

DELTA OPT 6 LIGHT 5MM LED TRAFFIC ADVISOR/

DELTA OPT 7 LIGHT 5MM LED TRAFFIC ADVISOR/

DELTA OPT 8 LIGHT 5MM LED TRAFFIC ADVISOR/

ASSY TRAFFIC ADV C L HEAD LED TACTLD1/TR/

SUB ASSY 500 LED STEADY MAX AMB/AMB//

ASSY RETAINER LIGHTHEAD MTG / DELTA/

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

3

7

8

10

11

9

5

12

2

3

1

DELTA / LR11 SINGLE OR DUAL

QTYQTY

ITEM

PART NUMBER

222

A/R

A/R A/R

4

1

A/R

1

2

3

4

5

6

7

8

4

9

10

1

11

12

02-0484131___

07-243718-000

02-0364086-00

13-062C40-16J

01-026B085-__

46-0743226-00

14-062216-041

15-065419-080

14-082216-120

46-0784112-00

46-0784112-01

07-243733-000

DELTA ADD 2 LR11 TAKE DOWN LIGHTS

DELTA ADD 2 LR11 ALLEY LIGHTS

BRACKET MTG LR11 ALLEY DELTA/

ASS'Y RETAINER LIGHTHEAD MTG / DELTA/

SCREW GROMMET #6 #8 FASTEX/

SUB ASY DUAL LR11 DELTA LOWER LEVEL/

SUB ASY SINGLE LR11 DELTA LOWER LEVEL/

"Y" HARNESS INTERIOR BAR

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

SCREW 6 x 1/2 PPH PLASTI / SS/

SCREW 8-32 X 3/4 PPHMS SS/

HARNESS TAKEDOWN LIGHT / DELTA

HARNESS ALLEY LIGHT / DELTA

MTG BRACKET PDM with LR11

10 11

78

DESCRIPTION

LOWER LEVEL: TRAFFIC ADVISOR: ADD HALOGEN

ITEM PART NUMBER DESCRIPTION

QTY QTY

Page 7

QTY QTY

8

1

02-0484131-14

02-0484131-15

02-0484131-16

02-0484131-17

01-0682340-00

11

7

1

111

5

2

5

3

5

4

5

1

6

1

7

1

01-06835772A4

02-0364086-00

39-0402023-04

39-0416313-04

46-0743070-00

46-0763757-01

6

678

1

DELTA OPT 5 LIGHT HALOGEN TRAFFIC ADVISOR/

DELTA OPT 6 LIGHT HALOGEN TRAFFIC ADVISOR/

DELTA OPT 7 LIGHT HALOGEN TRAFFIC ADVISOR/

DELTA OPT 8 LIGHT HALOGEN TRAFFIC ADVISOR/

ASSY TACTRL1A CONTROL HEAD/

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

ASSY RETAINER LIGHTHEAD MTG / DELTA/

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

4

6

5

NOTE: 5 LIGHT TA SHOWN

2

7

1

9

4

12

2

3

1

3

500

Series

Lighthead

400

Series

Lighthead

Hook bracket over

extrusion.

Secure bracket to fastex grommets installed into base.

Insert retainers tabs into

slots in the base

Oscillator

(

Top

View

)

1.

Servicing your Lightbar:

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 identification.

Dome:

Rotator:

Install the 2 grommets into the lightbar inside

1.

Install the 2 grommets into the lightbar inside

cover to which the rotator will mount.

1.

cover to which the rotator will mount.

Secure the front of the rotator by slipping its base

2.

Secure the front of the rotator by slipping its base

over the 2 bosses protruding from the inside

2.

over the 2 bosses protruding from the inside

ecure the rear to the grommets you

cover. S

2.

cover. Secure the rear to the grommets you

installed

2.

installed using the 2 supplied sheet metal screws.

The rotator plugs into the distribution board

3.

on the lower level.

3.

using the 2 supplied sheet metal screws.

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

Removal: Installation:

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

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

Place dome on lightbar base making sure it sits properly.

INSIDE COVER

Upper

Lower

Dome

500 Series

Lighthead

Lighthead slides into slots in retainer

BASE

EXTRUSION

Insert retainers tabs

into slots in the base

500 Series:

Slide lighthead into retainer and remove backing from double sided tape on bottom.

1.

Insert tabs on back of retainer into slots in lightbar base ress down

2.

Reinstall upper cover. The 3 tabs on top of the lighthead will fit into 3 slots in the cover.

3. NOTE: A is MR11,

.

P so tape will stick.

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

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

Oscillator:

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

Oscillator

(

Top View

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

Secure bracket to extrusion using supplied sheet metal screws

)

6 X 3/4" PPHSMS 410 / SS

REAR BRACKET

The oscillator does not use a mounting bracket.

FRONT BRACKET

INSIDE COVER

Remove protective backing from tape before mounting

.

8 X 3/8" PPHSMS 410 SS

Connect to other MR11

RUBBER BUMPER

Mounting bracket

Connector plugs into distribution module on lower level.

To power distribution board

R

RUBBER BUMPER

Secure bracket to

fastex grommets

fastex grommet

installed into

base.

8 X 3/8" PPHSMS 410 SS

GROMMET

400 Series:

1.

Install 4 grommets into

1.

the mounting bracket &

1.

1 into the cover

of

1.

the lightbar.

of

2.

Secure lighthead to

2.

mounting bracket using

lighthead lens screws.

2.

lighthead lens screws. Secure bracket (with

3.

Secure bracket (with

lighthead) to base cover

3.

lighthead) to base cover

using supplied sheet

3.

using supplied sheet

metal screws. .

3.

metal screws

Fastex grommet

Flasher

GROMMET

BOSSES

inside

and plug

400 Series

Lighthead

Flasher:

Same as 500 Series

8-32 X 3/4 PPHMS

Hook bracket

over extrusion.

over extrusion here.

BASE EXTRUSION

Insert grommets into extrusion

BASE

EXTRUSION

MR11 TIR3

MR11 /

1.

2.

3.

4.

TIR3:

Secure lighthead to front bracket using

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.

secure

Page 8

BASE

EXTRUSION

LR11

LR11 Alley:

Slide bracket into extrusion. 2 screws to secure.

17

49

50

48

51

38

47

39

52

37

40

36

38

39

37

53

36

40

30 31

26

3333

33

32

2929

34

273028

15

24

10

12

35

12

32

33

35

14

31

26

11

6059

123

45

25

18

16

7

6

19

14

FRONT OF LIGHTBAR

Page 9

10

24

16

A/R

24

A/R

24

QTY QTY QTY QTYQTYQTYQTYQTYQTYQTY

1

2

9

24

4

1

2

1

2

3

1

2

1

4

1

2

-

2

3

1

16

-

2

4

16

2

A/R

24

1

2

A/R

24

1

2

7

8

6

10

16

4

1

2

1

2

3

1

4

1

2

3

-

2

4

2

A/R

1

2

A/R

24

2

1

2

1

2

1

4

1

2

-

1

-

1

16

-

2

4

16

2

A/R

24

1

A/R

16

24

16

24

1

2

9

8

24

4

1

2

1

2

3

1

3

2

1

4

1

2

-

3

2

-

3

1

16

2

-

4

16

2

A/R

24

1

2

A/R

24

ITEM PART NUMBER DESCRIPTION

A/R

01-0684131-01

01-0684131-00

01-0684131-02

01-0684131-03

01-0684131-04

01-0684131-05

01-0684131-06

01-0684131-07

01-0684131-08

01-0684131-09

1

11-363721-048

1

2

11-363721-054

3

11-363721-048

4

11-363721-054

5

A/R

1

6

2

7

6

8

16

9

2

10

1

11

2

12

1

13

2

14

15

1

16

1

18

1

19

1

20

1

21

1

22

1

23

4

24

1

25

2

26

1

27

-

28

16

29

2

30

-

31

4

32

16

33

2

34

2

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

16

53

1

54

55

56

57

58

16

59

16

60

11-363721-064

21-11245004-1B

21-7263998-00

38-0143029-00

14-104066-080

02-0363798-00

01-0269815-00

07-243110-000

39-0001007-00

02-0384054-30

02-0363813-30

02-0363812-30

67-1N00800M00

46-0743114-20

14-104216-160

26-0115663-10

13-104111-063

39-1V04017-00

09-1343082-00

46-0984112-00

11-283961-000

11-283970-000

11-283979-000

13-062C40-16J

02-0363716-00

02-0363716-02

08-0617449-00

15-081416-060

68-5963707-P10

68-5963707-D10

68-4983958-50

68-4983958-40

68-4983958-30

68-4983958-20

68-4983958-10

68-4983960-90

68-4983960-50

68-4983960-40

68-4983960-30

68-4983960-20

68-4983960-10

68-4983959-90

68-4983959-50

68-4983959-40

68-4983959-30

68-4983959-20

68-4983959-10

14-082216-080

10-0523072-02

46-0743399-00

01-0463929-00

01-0463929-01

01-5015970-29

16-1001220-06

13-104120-062

1

2

7

16

2

1

2

1

2

1

4

1

2

-

1

16

2

-

4

16

2

16

1

16

2 STD ROT 44 5/16 DELTA IND. LIGHTBAR

2 STD ROT 49 3/4 DELTA IND. LIGHTBAR

2 STD ROT 56 5/16 DELTA IND. LIGHTBAR

2 STD ROT 61 13/16 DELTA IND. LIGHTBAR

2 STD ROT 72 11/16 DELTA IND. LIGHTBAR

2 HI ROT 44 5/16 DELTA IND. LIGHTBAR

2 HI ROT 49 3/4 DELTA IND. LIGHTBAR

2 HI ROT 56 5/16 DELTA IND. LIGHTBAR

2 HI ROT 61 13/16 DELTA IND. LIGHTBAR

2 HI ROT 72 11/16 DELTA IND. LIGHTBAR BASE EXTRUSION MACHINED/DELTA 36.531"/

BASE EXTRUSION MACHINED-DELTA 42.00"/

BASE EXTRUSION MACHINED DELTA 48.612"/-

BASE EXTRUSION MACHINED DELTA 54.062"/-

BASE EXTRUSION MACHINED DELTA 64.937"/-

GROMET SPECIAL / 1.562 THERMOPLASTIC RUBBER/

PLUG VENT .750 HOLE DIA BLACK/HEYCO/

GASKET EXTRUSION DELTA SERIES / 100' ROLL/

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

DIVIDER with GASKET JOB 9077 DELTA

ELEC. HC PDM DELTA

BRACKET MOUNTING PDM ASSYS / DELTA SERIES/

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

LENS BASE CLEAR CORNER MODULE-DELTA

LENS BASE CLEAR DUAL-CENTER DELTA

LENS BASE CLEAR SINGLE-CENTER DELTA

WIRE 8 GA 20' BLACK / CONTACT/

ASS'Y CABLE 10/C COMPOSITE 20'/

SCREW 10-24 X 1" PPHMS//NS

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

NUT 10-24 CAD PLATED WHIZ//NS

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

PANEL WIRE MANAGEMENT / DELTA LIGHTBAR/

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

COVER INSIDE CORNER BLACK / DELTA SERIES/

COVER INSIDE CENTER SINGLE / DELTA SERIES/

COVER INSIDE CENTER DUAL / DELTA SERIES/

SCREW GROMMET #6/#8 FASTEX

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

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

BUMPER, GROMMET STYLE RUBBER / BLACK

SCREW 8 X 3/8 PPHSMS / 410 SS/

ASS'Y MIRROR PASSENGER SIDE / DELTA SERIES/

ASS'Y MIRROR DRIVER SIDE / DELTA SERIES/

DOME RED CORNER MODULE/

DOME GREEN CORNER MODULE/

DOME CLEAR CORNER MODULE/

DOME BLUE CORNER MODULE/

DOME AMBER CORNER MODULE/

DOME BLACK CTR MODULE SINGLE / DELTA SERIES/

DOME RED CTR MODULE SINGLE / DELTA SERIES/

DOME GREEN CTR MODULE SINGLE / DELTA SERIES/

DOME CLEAR CTR MODULE SINGLE / DELTA SERIES/

DOME BLUE CTR MODULE SINGLE / DELTA SERIES/

DOME AMBER CTR MODULE SINGLE / DELTA SERIES/

DOME BLACK CTR MODULE DUAL / DELTA SERIES/

DOME RED CTR MODULE DUAL / DELTA SERIES/

DOME GREEN CTR MODULE DUAL / DELTA SERIES/

DOME CLEAR CTR MODULE DUAL / DELTA SERIES/

DOME BLUE CTR MODULE DUAL / DELTA SERIES/

DOME AMBER CTR MODULE DUAL / DELTA SERIES/

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

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

HARNESS EXTENSION DELTA ROT/LED/

KIT 3M 792 OPTICOM MOUNTING DELTA///NS

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

MODEL 792H OPTICOM EMITTER / NS

WASHER #10 FLAT 18-8 STAINLESS//

NUT / 10-24 ELASTIC STOP STAINLESS/

NS = Not shown or hidden in parts drawing

Page 10

Whelen DI2S800 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual