Whelen JV8AAAA User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684

Installation Guide:

Justice® WC Lightbar

Phone: [phone]
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

©2007 Whelen Engineering Company Inc.
Form No.14115C (060810)

Page 1

IMPORTANT! The lightbar should be 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. Center this plate from side­to-side on the mounting foot.

2. Flip lightbar upside-down to expose bottom of extrusion. 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 the mounting foot at

8.

Standard
Mounting
Foot

Mounting
Plate

Nut

Washer

Mounting

Pad

BoltBolt

Mounting

Pad

Washer

Mounting
Plate

Nut

Adjustable
Mounting
Foot

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.

Cable Access Hole

Driver-side

cable exit

FRONT

Passngr.-side

cable exit

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.

Drill the cable
access hole in
the appropriate
area for your
lightbar.

Strap Mounting:

1. Locate the mounting foot, locking plate, anchor plate and tinnerman nut

supplied with the lightbar. If not already present, install the locking plate
onto the mounting foot. Center this plate from side-to-side on the foot.

2. Flip the lightbar upside-down to expose the bottom of the extrusion.

First slide the anchor plate into the extrusion, then place the mounting
foot onto the extrusion.

3. Rotate the mounting foot counter-clockwise 90°. The edges of the

mounting foot must swing into position under the extrusion mounting
lip.

Insert mounting foot into extrusion
with locking plate attached.

ANCHOR
PLATE

Twist foot into position

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.

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. Both mounting feet must be in full contact

with the roof. Be sure that there is no
less than 1/2” clearance between the

loosely secure foot and locking plate.

roof and the lightbar at their closest
point.
When both mounting feet are in their
proper position, lightly tighten the allen
head set screws.

Page 2

7. Return the lightbar to an upside-down position. Slide each anchor plate
outwards until it is fully engaged with its corresponding mounting foot.
With the mounting 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.

8. 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.

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

10. If your mounting strap has mounting holes in the end, 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.

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.

Adjustable Mounting Foot / Model MKAJ

Mounting

Strap

Mounting

Screw

Adjustment

screws

Tension

Bolt

Lock

Washer

Locking
Plate

Mounting
Foot

Nut

Mounting
Pad

5" Mounting Foot

METAL SCREW

BOLT

SHEET
METAL
SCREWS

STRAP

Tinnerman
Nut

Anchor
Plate

MOUNTING FOOT

EXTENSION

NUT

SPLIT LOCK
WASHER

Model
MKAJ

Tighten

with

set at 35

torque

to

Mounting

Screw

TINNERMAN

NUT

FOOT

ANCHOR

PLATE

VEHICLE ROOF

screw

s

wrench

40

in/lbs

Mounting

Tension

Bolt

Plate slides into
lightbar extrusion

SET
SCREW

Strap

Standard Mounting Foot / Model MKEZ

Anchor

Mounting
Foot

Locking
Plate

Plate

Tinnerman
Nut

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

IMPORTANT! It is the responsibility of the installation technician 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. 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.

2. Use a round file to smooth and de-burr the edges of the hole. Install a 1” grommet (user supplied) into the cable access hole.

3. 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
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 30 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 of the Whelen® WC
Controller.

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

Justice® WC Lightbar

COMMUNICATIONS CABLE

GREEN / Communications wire "A"
SHIELD WIRE
GREY / Communications wire "B"

POWER CABLE

RED (+)12VDC
BLACK (+)12VChassis Ground

Fuse @ 30 Amps

Troubleshooting:

Your lightbar is now fully operational. If it does not function properly, check these connections:

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

IMPORTANT WARNING!

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

• A working fuse of the correct amperage is installed in the fuse block (See illustration above, for the specific fuse rating).

• 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.

LR11 / Removal & Installation / Alley Light

LR-11 LED / Angle Adjustment

The LR11 mounting brackets angle
is adjustable in whichever position it
is installed in. An alley light is shown here.

3

Remove screws
and pull housing
part way out.

4-40
X3/8
Tor x
Head

Remove

1

dome
screws
(QTY 6)

Remove dome

2

LR11's can be adjusted up

to 7.5 to either side.°

Page 4