Fax: (860) 526-4078
Internet: www.whelen.com
Sales e-mail: autosale@whelen.com
Canadian Sales e-mail: canadiansales@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.
•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 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
IMPORTANT! The lightbar should be a minimum of 16" from any
Insert foot into extrusion with locking plate
attached.
Twist mounting foot into
position
ANCHOR
PLATE
Loosely secure foot and locking plate.
radio antennas!
Permanent Mounting:
1.Locate the mounting foot and mounting 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-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 sure 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
mounting foot 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, 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 using the supplied
hardware as shown.
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-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. 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.
8.Open both drivers side doors. In the area directly below the mounting
foot, carefully pull the drivers side weatherstrip away from the vehicle.
Page 2
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
may look different.
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
Remove enough so that the area where the mounting strap will be
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.
IMPORTANT: For strap mounted bars, be sure you have the right sized
lightbar for your vehicle. The lightbar should be approximately the same
width as the vehicle roof. If too large or small it will not mount properly
to the vehicle and may come loose during driving.
secured to the vehicle is exposed. Repeat procedure for passenger 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.
Insert the tension bolt through the mounting strap and into the tinnerman
nut on the tinnerman plate. 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 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 in./lbs.
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
IMPORTANT! It is the responsibility of the installation technician
DRILLING THE CABLE ACCESS HOLE
Drill cable access hole in appropriate area
for your lightbar (see note)
FRONT OF LIGHTBAR
For
cables exiting
the Driver-side
of the extrusion
lightbars
with
For
cables exiting
the Passenger-side
of the extrusion
lightbars
with
POWER CABLE
2.
BLACK Wire
CHASSIS GROUND
2.
COMMUNICATIONS CABLE
2. GREY / CAN L
1. GREEN / CAN H
1. +12VDC / RED Wire / Requires a fuse, customer supplied.
30 AMP Fuse: Freedom & Liberty
to make sure that the installation and operation of this product will
not interfere with or compromise the operation or efficiency of any
vehicle equipment!
Routing your 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.
NOTE: There may be 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.
3.Use a round file to smooth and de-burr the edges of the hole.
4.Install 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.
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
installation technician'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.
IMPORTANT AIR BAG WARNING!Do not install this product or route any wires in the air bag deployment zone of your vehicle. Equipment
mounted or located in air bag deployment zones 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 owners manual to learn the air bag deployment zones for the vehicle. The User/Installer
assumes full responsibility to determine proper mounting location, based on providing ultimate safety to all passengers inside the vehicle.
Connecting the Power Cable:
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!
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 cable. NOTE: Remove the fuse from the fuse block before connecting any wires to the battery.
3.Connect the BLACK wire to Chassis Ground.
Connecting the Communication Cable:
Splice the GREEN and GREY wires from the lightbar to the GREEN
and GREY wires from the Whelen WC Controller.
Troubleshooting:
Your lightbar should now be fully operational. If it is not functioning
properly, check your connections for 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 is installed in the
fuse block (See illustration above, for the specific fuse rating
for your lightbar).
•The ground wire (BLACK) is properly connected to the factory ground. Be sure that the wire is fully grounded to this location.
•The two communication wires (GREEN and GREY) are properly connected to their communication designations.
If these connections are good, contact your Whelen® representative for further assistance.
Page 4
Lighthead mounting holes
snap into the raised bosses
on the lighthead bracket.
Ears on lighthead bracket
slide inton channels in
extrusion (base).
Snap lighthead
into bracket.
Mounting Lightheads to Extrusion
BASE
EXTRUSION
LR-11 Take-down and Alley Light
LR-11 Alley Light
BASE EXTRUSION SIDE VIEW
LIGHTHEAD
Endcap, Gasket , Lenses & Spacers Installation
Gasket & Halogen Alley Light
BARB
BOSS
Halogen Lighthead
snaps into extrusion
Align lighthead
reflector up with 4
bosses in endcap.
Press reflector into
place.
Servicing: Liberty Lightbar
Servicing: Freedom™ Lightbar
Remove the screws (A) that hold the endcapon and pull the endcap and gasket (C) off.4(B)Slide lenses
(D) out of the lightbar, to gain access to the extrusion. When reinstalling the lenses and spacers, install the
cord seal (NFPA / See below). 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.
D
D
C
Insert cord seal into track in lens
A
B
Seal Cord Installation / NFPA Only:
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.
1 2 3 -
4 -
3 3 -
4 4 -
. Lefree.
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.
6 -
7 -
6 -
7 -
From the opposite end of the
lightbar, pull the seal
cord tight and install
the remaining lenses
and divider.
5 -
5 5 5 5 -
NOTE: Lens dividers must
be installed as each lens is
put into position
Installing Corner Linear-LED®
Insert the tabs on the lighthead housing, into the channels in the extrusion.