Whelen S341 User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684

Liberty™ WeCan® Tri-Color Lightbar

Installation Guide:

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

©2011 Whelen Engineering Company Inc.
Form No.14463 (022211)

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 allen screws. MKAJ: On the adjustable mounting foot, you must first
drill the hole in the foot, that is mentioned here in step 6. Use the hole in the mounting pad as a guide.

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° counter-clockwise. Make sure that the edges of
the foot slide under the extrusion mounting lip (See illustrations A & B).

Locking
Plate

Mounting
Foot

Metal
Screw

Allen
Screws

Mounting
Pad

screws

Lock Washer

Hex Nut

ent

Fig.1

Adjustm

Model
MKAJ

NOTE: Unless otherwise specified, the lightbar mounting

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

Strap Mounting:

1. Locate the mounting foot, anchor plate and locking plate included with your lightbar. If not
already present, install the locking plate onto the mounting foot using the supplied allen set
screws.

2. Flip the lightbar upside-down to expose the bottom of the extrusion and place the mounting
foot onto the extrusion (See illustrations A & B above).

3. Rotate the foot 90° counter-clockwise. Make sure that the edges of the foot slide under the
extrusion mounting lip. Install an anchor plate onto the extrusion in the same manner.

4. Repeat this procedure for the remaining mounting foot and anchor 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 roof and lightbar (See above). When the mounting feet are in
position, carefully tighten the locking plate allen set screws.

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 feet and anchor plates
in position, firmly tighten all of the allen set screws (2 or 4 per side). Flip the lightbar over and
return it to its mounting position.

8. Open both drivers side doors. In the area directly below the mounting foot, pull the weather­strip away from the vehicle so the area where the mounting strap will be secured is exposed.
Repeat for the other 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 anchor plate, into the tinnerman nut. Tighten slightly with a long-shafted,
Phillips screwdriver. Repeat procedure for passenger side.

10. If your mounting strap has mounting holes on the end of the strap, use these holes as a
template to drill appropriately sized pilot holes through the strap and into the vehicle. Secure
the strap to the vehicle with the supplied mounting screws. Repeat steps 8 - 10 for the
passenger side of the vehicle.

11. Firmly tighten the tension bolts to secure lightbar to vehicle.

Repeat this procedure for the remaining mounting foot and return the lightbar
to its right side-up position.

4. Position the lightbar onto the vehicle roof in the desired mounting location.
One often selected location is directly above the Bpillars. 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.

5. Adjust the two feet outwards so that they are as close to the edge of the roof
as possible (See below). Make sure that both mounting feet are in full contact
with the roof and that there is no less than 1/2” clearance between roof and
lightbar. When the mounting feet are in position, carefully tighten the locking
plate allen head set screws.

6. With the lightbar in its exact mounting position, use the hole in the mounting
foot as a guide and mark the mounting hole location off onto the mounting
surface.

7. Remove the lightbar and drill the mounting holes you marked off in step 6.

8. Place the lightbar back onto the vehicle lined up with the mounting holes and
secure it to the vehicle using the supplied hardware.

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, use a torque wrench set at 35 to
40 in./lbs.

1/2" Minimum Clearance at Closest Point

Vehicle Roof

Standard Foot Model MKEZ

Tension Bolt

Mounting Screw

Adjustable Foot Model MKAJ

Mounting Strap

Tension

Bolt

Mounting

Screw

Washer

Adjustment

screws

A.

Twist mounting foot into

A.

position, under lip

B.

Loosely secure

with the l

B.

foot ocking

he anchor plate is

p.T

B.

late

used for strap mounting

B.

For strap mounted lightbars, be sure you have the right
sized bar for your vehicle. The bar should be about the
same width as the vehicle roof. If the bar is too large or
small it will not mount properly to the vehicle and may
shift or come loose during driving.

Locking

Plate

Mounting Strap

Lock

.

Anchor Plate

Locking Plate

Anchor Plate

Nut

Mounting Foot

Mounting Pad

ANCHOR PLATE
(strap mounting only)

Tinnerman
Nut

Tinnerman Nut

Base

Mounting
Foot

Allen
screws

Page 2

5" Mounting Foot

METAL SCREW

BOLT

SHEET
METAL
SCREWS

STRAP

NOTE: Mounting straps are made to fit the contours of individual

vehicles. The strap shown is for example only. The strap for your
vehicle may look different. 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 this illustrations for assembly. Mounting to the lightbar
is the same.

Routing the Lightbar Cable(s):

MOUNTING FOOT

EXTENSION

NUT

SPLIT LOCK
WASHER

TINNERMAN

NUT

ANCHOR

PLATE

VEHICLE ROOF

SET

SCREW

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
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
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.

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

Connecting the Communication Cable:

DRILLING THE CABLE ACCESS HOLE

FRONT OF LIGHTBAR

For

lightbars

cables exiting

with

the Driver-side

of the extrusion

Drill cable access hole in appropriate area

for your lightbar (see note)

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 then use a round file to smooth
and de-burr the edges of the hole. Install a 1” grommet (user supplied).

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. 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.

4. Route the cable(s) one at a time to their respective destinations (power cable to
vehicle battery; control cable to switch panel). 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.

For

lightbars

cables exiting

with

the Passenger-side

of the extrusion

POWER CABLE

1. +12VDC RED/ Wire /

2.

CHASSIS GROUND
BLACK Wire

2.

Requires fuse / customer supplied.

30 amp

COMMUNICATIONS CABLE

1. GREEN / CAN H

2. GREY / CAN L

Splice the GREEN and GREY wires from the lightbar to the GREEN and GREY wires
from the 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 30 amp fuse is installed in the fuse block.

• 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.

Refer to your controller instructions for connections and operation.

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!

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

IMPORTANT WARNING!

Page 3

OPTIONAL ALLEY LIGHT SHOWN (REF)

PASSENGER SIDE

39
38
37
36

PS4

PP4

PT4

35

13

PTD

PS3

PT3

PP3

12

PS2

PT2

PP2

7.5

AMP

14

PS1

PT1

PP1

DS1

DT1

FRONT OF LIGHTBAR

DP1

20 AMP

6

QTY QTY QTY

3
2
1

PA

PS5

PP5

PT5

11

PS6

10

PT6

9

PP6

8
7

18

4

PS7

PT7

PP7

20 AMP

PS8

PT8

PP8

DS8

DP8 DT8

33

25
26

30

1

1

2

1

1

1

1

1

10

1

A/R

2

A/R

1

1

4

A/R

4

2

4

8

2

8

1

1

1

1

1

1

1

1

111

111

1

1

1

1

12

12

111

121012

A/R

A/R

2

A/R

A/R

1

4

4

A/R

A/R

44

4

6

2

88

1

1

1

1

1

1

1

ITEM

1

1

2

3

4

5

212

6

7

8

1

9

1

10

1

11

12

13

14

15

16

2

17

18

11

19

1

20

21

4

22

23

24

25

26

27

28

4

29

30

6

31

2

32

33

1

34

1

35

1

36

1

37

1

38

1

39

1

PART NUMBER

01-0686912- 00

01-0686912- 01

01-0686912- 02

11-363312-044

11-363312-049

11-363312-038

21-11245004-1

21-7263998-00

01-026D153-00

46-0743196-17

46-0743903-17

14-0023347-00

26-0115663-10

13-104111-063

11-483564-000

46-0786890-00

09-1363542-00

01-026D045___

02-036B855-00

01-026B855-30

38-0142783-00

11-26B607-044

11-26B607-049

11-26B607-038

14-104216-06J

07-243170-000

01-026D046___

68-1983567-30

68-1963333C03

68-1983818-30

68-1983819-30

68-1963333C08

02-0342791-30

02-036A035-30

14-104286-16JB

10-0322935-00

10-0522960-00

46-0786873-00

46-0786873-02

46-0786873-01

46-0786873-03

46-0786890-01

DESCRIPTION

LIBERTY 48.50" TRI COLOR

LIBERTY 54.00" TRI COLOR

LIBERTY 43.13" TRI COLOR

BASE, EXTRUDED (44.00")

BASE, EXTRUDED (49.39")

BASE, EXTRUDED (38.61")

GROMMET, 1.562"

PLUG, VENT (3/4")

ELECT WC DUO LIBERTY I/O

INPUT CABLE ASS'Y., (2C-10GA.) 17'

CABLE, 17/C 22GA (17')

SCREW, 10-24 x 1.25" TX PHD

CABLE CLAMP, 5/8"

#10-24 WIZ NUT

HOUSING, LIGHTHEAD (SNAP-IN)

HARNESS TRICOLOR LIBERTY

PANEL, FILLER

SUB ASSY, 500 TRI-COLOR

END SUPPORT BRACKET

LR11 ALLEY LIGHT (WHITE)

INSULATOR, FOAM PAD

TOP, EXTRUDED (44.00")

TOP, EXTRUDED (49.39")

TOP, EXTRUDED (38.61")

#10-24 X 3/8 PPH SCREW

SPACER, CORNER

EXT CORNER TRI-COLOR LIBERTY

LENS, 15.800" LG. (CLEAR)

LENS, 10.500" LG. (CLEAR)

LENS, 5.062" LG. (CLEAR)

LENS, 5.687" LG. (CLEAR)

LENS, 8.375" LG. (CLEAR)

LENS DIVIDER (CLEAR)

SUB ASSY, ENDCAP CLEAR

#10-24 X 1-1/4" TX. PHD. W/SHOULDER

LABEL, "FRONT" LIGHTBAR ASS'Y.

LABEL, MODEL & SERIAL # not shown

HARNESS PRIMARY DRIVER DUO LIBERTY

HARNESS PRIMARY PASS DUO LIBERTY

HARNESS SECONDARY DRIVER DUO LIBERTY

HARNESS SECONDARY PASS DUO LIBERTY

HARNESS TRICOLOR LIBERTY

DTD

24

DS2

DT2

DP2

5

DS7

DP7 DT7

28
29

19

23

20

DS6

21

DT6

DP6

31

32

15

27

DS3

DT3

DP3

DT4

DS4

DP4

DA

DT5

DS5

DP5

DRIVERS SIDE

22

16

17

Page 4