Whelen LT2AAAAP User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684

Installation Guide:

LFL Liberty Mini Edge

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

©2003 Whelen Engineering Company Inc.
Form No.13764J (091510)

Page 1

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

Permanent Mounting:

1. Locate the mounting foot and plate included with your lightbar. If not already
present, install the mounting plate onto the 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 the closest point. With the mounting feet in their proper position,
lightly tighten the 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.

Standard
Mounting

BoltBolt

Mounting
Plate

Foot

Mounting
Plate

Nut

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.

Washer

Mounting

Pad

Mounting

Pad

Washer

Nut

Adjustable
Mounting
Foot

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. With the mounting feet in their proper position, lightly
tighten the foots 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

Insert foot into extrusion with locking plate
attached.

Twist mounting foot into
position

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. Remove
enough so that the area where the mounting strap will be 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. 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.

Loosely secure foot and locking plate.

ANCHOR
PLATE

Page 2

Standard Mounting Foot / Model MKEZ

Adjustable Mounting Foot / Model MKAJ

Tension

Bolt

Mounting
Screw

Mounting

Pad

Mounting

5" Mounting Foot

METAL SCREW

SHEET
METAL
SCREWS

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

vehicles. The strap

NOTE:

for your vehicle

NOTE:

Foot

BOLT

STRAP

Mounting
Strap

Tinnerman

Plate

Mounting

Plate

shown here is for example only. The strap

may look different.

Tighten screws

with torque

set at 35 to 40 in/lbs

MOUNTING FOOT

EXTENSION

NUT

SPLIT LOCK
WASHER

wrench

TINNERMAN

NUT

FOOT

ANCHOR

PLATE

VEHICLE ROOF

Mounting

Screw

Adjustment

Plate slides into
lightbar extrusion

SET
SCREW

Tension

screws

Bolt

Lock

Washer

Mounting

Strap

Locking
Plate

Tinnerman
Plate

Nut

Mounting
Foot

Mounting
Pad

CAUTION: Permanent mounting will require drilling. The installer must be sure that no
vehicle components or other vital parts will be damaged. Be aware of the location of
any front, side or upper air bags.

CAUTION: 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 of
the cable access hole until the hole can be drilled without contacting this support
member.

with

DRILLING THE CABLE ACCESS HOLE

FRONT OF LIGHTBAR

For

lightbars

cables exiting

the Driver-side

of the extrusion

For

lightbars

cables exiting

with

the Passenger-side

of the extrusion

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!

Drill cable access hole in appropriate area

for your lightbar (see note)

CAUTION: Using a magnetic mounted light on the outside of a vehicle, while in motion,
is not recommended and is at the sole risk of the user.

Installation:

1. To protect the headliner from damage caused by

1/2" Minimum Clearance at Closest Point

NOTE: Unless otherwise specified, the lightbar mounting feet must be sitting as close to the

edge of the roof as possible. Mounting feet must also be in full contact with the roof and not
be hanging off the edge.

the vehicle. Use RTV silicone to weatherproof the access hole after the cable(s) are pulled into the vehicle.

4. When routing the cable(s), be sure to use a path that avoids any vehicle components or other vital parts that may be damaged. Also be careful not to interfere with any
vehicle air bags (front, side, etc.). Route the cable(s) towards your switch panel and refer to the instructions included with the switch panel for wiring information.

Page 3

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. Use a
round file to smooth and de-burr the edges and insert
a 1” grommet (user supplied).

3. Insert the cable(s) through the cable access hole into

Replace

fuse

here

Wiring:

The cigarette plug model plugs it into your cigarette lighter and requires no further
wiring.

If you have a lightbar that has an 11-conductor cable, refer to the chart below for
important wiring information.

NOTE: For internal fuse replacement see information on next page.

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
BREAKERS WITH THIS PRODUCT!

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

WIRE COLOR (VOLTAGE) FUNCTION FUSE @

RED (+12VDC) . . . . . . . . . . .LED Flasher (+) Positive . . 5 Amps

BLK / YEL (+12VDC) . . . . . .Scan-Lock™. . . . . . . . . . . . . 1 Amp

GRY (+12VDC) . . . . . . . . . . .Front Corner LEDs . . . . . . . . 1 Amp

WHT (+12VDC) . . . . . . . . . . .Halogen 1 . . . . . . . . . . . . . . 5 Amps

WHT/BLK (+12VDC) . . . . . .Inboard LEDs . . . . . . . . . . . 5 Amps

YEL (+12VDC) . . . . . . . . . . .Halogen 2 . . . . . . . . . . . . . . 5 Amps

WHT / BLU (+12VDC) . . . . .Rear Corner LEDs . . . . . . . . 1 Amp

BLK / WHT (-) . . . . . . . . . . . .Halogen 1 & 2 Ground . . . . . . . N/A

WHT / VIO (+12VDC) . . . . . .Endcap LEDs . . . . . . . . . . . . 1 Amp

VIO (+12VDC). . . . . . . . . . . .Low Power . . . . . . . . . . . . . . 1 Amp

BLK (-) . . . . . . . . . . . . . . . . .LED Flasher (-) Negative . . . . . N/A

Hi/Low Control:

Option 1: Latching Mode: By applying +voltage to the VIOLET wire for less than 1
sec., the power supply is “latched” into Low power operation. The unit must be turned
off and then back on to restore normal, Hi power operation. A momentary switch is
best for this method.

Option 2: Level Mode: Applying +voltage to the VIOLET wire for more than 1 sec.
holds the power supply in Low power mode until that voltage is removed. A toggle
switch is best for this method.

Scan-Lock™:

To cycle forward through all patterns: Apply power to the control wire of the
function you want to change, then apply power to the BLK/YEL (Scan-Lock™) wire
for less than 1 second and release. This will change the pattern. Repeat for next
pattern.

To choose a pattern: While cycling through the patterns, when you find the pattern
you want let it run for more than 5 seconds and it will lock in and become the default
pattern.

To reset to the factory default pattern: Turn off power. While applying power to the
Scan-Lock™ wire, turn power on to the light(s) you want to reset.

Scan-Lock can be connected to a customer supplied SPST switch.

Corners / Cross Corners / Alternating

NOTE: The available flash patterns are

shown here. This will show how FRONT
LEDs (optional) and CORNER LEDs
react to Alternating and Cross flash patterns.

Available Flash Patterns:

1A

SignalAlert™

B

1

SignalAlert™

C

1

SignalAlert™

2A

CometFlash

B

2

CometFlash

C

2

CometFlash

3A

DoubleFlash

B

3

DoubleFlash

C

3

DoubleFlash

4A

SingleFlash

B

4

SingleFlash

C

4

SingleFlash

6

SteadyFlash

7

Steady

3 cycles of 1A & 3 cycles of 1B
®
®
®

3 cycles of 1A & 3 cycles of 1B

3 cycles of 1A & 3 cycles of 1B

3 cycles of 1A & 3 cycles of 1B

Alternating

Cross

Alternating

Cross

Alternating

Cross

Alternating

Cross

1 & 2 Steady 3 & 4

SingleFlash (SIM.)

1, 2, 3 & 4 Steady

Wiring Diagram

CORNER LED #3

GREEN

WHT/ORG

500 LED #1

BLUE

WHT/BRN

WHITE

BLACK

500 HALO. #1

BLUE

WHT/BRN

CORNER LED #1

AB

500 HALOGEN #2

Replace

Replace

fuse here

fuse here

YELLOW

BLACK

Front of Lightbar (4 Light Shown)

500 HALO. #1

WHITE

BLACK

10

FUSE

10AMP

Installing Lens and Lighthead
Housing into extrusion

500 LED #3

GREEN

WHT/ORG

444645

GREEN

WHT/RED

500 LED #2

Lens

fits

here

47

CORNER LED #2

GREEN

WHT/RED

BLUE

WHT/YLW

CORNER LED #4

48

500 LED #4

BLUE

WHT/YEL

YELLOW

BLACK

500 HALOGEN #2

Top and bottom of extrusion
secure to Support Bracket.

SUPPORT
BRACKET

Servicin our Li htbargy g

Use the illustrations shown if you
need to gain access to the lightbar
to service or replace parts.

With
Alley
Light

#6x5/8"PPH
PLAST-LOC

Without
Alley
Light

#6-32 x 5/8"

PPHMS

Installing Corner Linear-LED®

Lighthead into extrusion

#6-32 ELASTIC

STOP NUT

Installing a lighthead

into its housing

Insert the tabs on the lighthead housing,
into the channels in the extrusion.

Page 4

Insert the tabs on the lighthead housing,

into the channels in the extrusion.

QTY QTYQTY QTY

11

141

4

4

4

4

A/R

A/R

A/R

A/R

A/R

A/R

A/R A/R A/R A/R

4

A/R

11

1

1

1

1

1

1

1

1

1

1

2

2

111

2211

2

2

2

A/R

A/R2A/R

A/R

A/R A/R

A/R

A/R

A/R

A/R

A/R

A/R

1

121

4

4

212

22

4

4

4

4

4

4

2

2

242

A/R

A/R

A/R

ITEM

PART NUMBER

01-0684207-( )

01-0684207-( )

01-0684207-( )

01-0684207-( )

1

11-363336-017

2

08-0640834-01

3

65-0010192-00

4

14-130216-100

5

66-0715403-00

6

46-0742901-00

7

21-11245004-1

1

8

14-104216-080

1

9

13-104111-063

1

10

26-0115037-07

12

11-443158-000

13

02-0169672-00 FLASHER, LIGHTBAR LED

14

11-483564-000

15

02-0383577-03

16

01-026B625210

17

01-026B625220

18

01-026B625230

19

01-026B625240

20

01-026B625250

11-26B607-017

21

15-065419-080

2

22

23

68-1983818-30

24

02-0342791-30

25

4

68-1983819-30

26

38-0283572-00

PERM MT (Liberty™) 4 LED LIGHTHEADS

MAG MT ( ) 4 LED LIGHTHEADSLiberty™

PERM MT ( ) 8 LED LIGHTHEADSLiberty™

MAG MT ( ) 8 LED LIGHTHEADSLiberty™

BASE EXTRUSION
MOUNTING PAD

MAGNET X-80

1/4-20 x 5/8" PPHMS

THREADLOCKER, LOCTITE 242

INPUT CABLE ASS'Y. (11C COMPOSITE)

GROMMET, 1.562"

SCREW, 10-24 x 1/2" PPHMS

#10-24 WHIZ NUT

CABLE CLAMP, 7/16"

HOUSING, LED FLASHER

HOUSING, LIGHTHEAD (SNAP-IN)

SUB-ASS'Y., 500 HALOGEN W/3 POS.

ASS'Y-CORNER LINEAR (12) LED -AMBER

ASS'Y-CORNER LINEAR (12) -BLUELED

ASS'Y-CORNER LINEAR (12) -WHITELED

ASS'Y-CORNER LINEAR (12) -GREENLED

ASS'Y-CORNER LINEAR (12) -REDLED

TOP EXTRUSION

SCREW, 6 X 1/2 PPH PLASTI-

LENS, 5-1/16" (CLEAR)

ASS'Y., LENS DIVIDER

LENS, 5-11/16" (CLEAR)

GASKET, ENDCAP

DESCRIPTION

QTY QTYQTY QTY

2

2

2

A/R

A/R

A/R2A/R

A/R

A/R

A/R A/R

4

4

212

1

11

1

1

8

8

8

1

1

1

4

4

4

1

1

1

1

44

44

2

2

2

1

2

1

1

1

2

2

1

A/R1A/R

A/R

A/R

A/R

A/R

A/RA/R

A/R

A/R

A/R

A/R

A/R

A/R

A/R

A/R

A/R

A/R

A/R

A/R

A/R

A/R

A/R

A/R

2

2

2

4

4

4

ITEM

28

29

30

31

32

33

34

35

8

36

1

37

4

38

1

39

1

40

22

41

2

42

2

43

1

44

1

45

46

47

48

49

50

51

52

53
54

55

2

56

4

PART NUMBER

68-1963237-30

15-065410-100

14-062216-100

13-062120-052

26-0115037-04

02-0240837-01

10-0220700-02

14-104286-16J

39-0416323-04

20-0042765-00

10-0522960-00

01-0483969007

13-062111-053

14-062116-120

09-1363542-00

20-0608089304

46-0784200-02

46-0784200-03

46-0784200-00

46-0784200-01

46-0763985-01

01-026B827650

01-026B827640

01-026B827630

01-026A068220

01-026B827610
10-0323206-00

02-036B855-00

14-104216-06J

LENS, 500 SERIES OPTIC (CLEAR)

DESCRIPTION

#6 x 5/8" PPH PLAST-LOC

#6-32 x 5/8" PPHMS

#6-32 ELASTIC STOP NUT

CABLE CLAMP, 1/4"

INPUT CABLE ASS'Y. CIGAR PLUGwith

LABEL, CAUTION-MAGNET MTG.

#10-24 x 1-1/4" TX. PHD. SHOULDERwith

16 POS SOCKET

SPACER, CORNER RETENTION

LABEL, MODEL & SERIAL NO.

MOUNTING KIT 7S

NUT / 6-32 X 5/16 WHIZ LOCK

SCREW / 6-32 X 3/4 PFMS

FILLER PANEL / 500 SERIES

SPACER / 3/16 LG X 1/4 OD X .166 ID

HARNESS / 4 LED POWER/CONTROL / 11C

HARNESS / 4 LED POWER/CONTROL / CIG

HARNESS / 8 LED POWER/CONTROL / 11C

HARNESS / 8 LED POWER/CONTROL / CIG

HARNESS / 4 LED / 30"

LINEAR 500 LED RED

LINEAR 500 LED GREEN

LINEAR 500 LED WHITE

LINEAR 500 LED BLUE

LINEAR 500 LED AMBER

LABEL, NASCAR BAR LOGO CLEAR

SUB ASSY, END SUPPORT BRACKET

SCREW, 10-24 X 3/8 PPH TRILOBULAR

12

35 26 25

43

31

13

40

41

12

10

21

16

18

17

19

24

REAR OF LIGHTBAR

23

14

20

8-LT
VERSION
ONLY

37

12

36

1

15

49 50 51

2

52 53

3

36

4

22

POS. 16-BLK

Smooth

POS. 1-BLK

6

Grooved

55

56

33

Page 5