Whelen Engineering Company Micro Edge Freedom User manual

Page 1
Installation Guide:
Micro Edge Freedom® Lightbar
©2003 Whelen Engineering Company Inc.
Form No.13789F (030110)
®
ENGINEERING COMPANY INC.
51 Winthrop Road
Chester, Connecticut 06412-0684
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]
Automotive: Lightbars
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!
For warranty information regarding this product, visit www.whelen.com/warranty

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Micro Edge®
Mounting
Bracket
Extension
Flange
Mirror
Bracket
U-Bolt
Fig. 1
Fig. 5
Wiring the Micro Edge:
The Micro Edge harness cable(s) must now be routed to the battery. The path the cables
follow will vary, depending upon where the power supply has been mounted. If the power
supply has been mounted against the rear cab wall, the path would be:
1. Secure harness cable to Micro Edge mounting bracket with ties (Fig. 4).
2. Now have the harness cable follow the factory mirror bracket to the point where the
bracket meets the vehicle door. Secure the cable with heavy-duty wire ties.
3. Remove the interior door panel. When you are sure that no door components will be
damaged, drill a hole in the door just below the point where the factory mirror
bracket connects to the door. Insert a rubber grommet to prevent water leakage.
4. Insert the harness cable through the hole and route it towards the door’s hinge
panel. Drill a hole in the hinge panel and insert the harness cable. Be sure the cable
does not interfere with the movement of any door or window components (Fig. 5).
5. Route the cable into the cab through the kick panel and then under the rocker panel
molding. Make sure that the harness cable does not bind up when the door is
opened and closed.
6. Extend the wires to their destinations as shown in the wiring diagram. Be sure to
use the proper size wires (see wire size warning).
IMPORTANT! The lightbar should be located a
minimum of 16" from any radio antennas!
Mounting the Micro Edge®:
The West Coast mirror mount brackets shown are
purchased separately. Begin the mounting procedure
by loosely assembling the mounting bracket (Fig.1).
Position this partial assembly on the mirror bracket
(Fig. 2). Mount the assembly to the mirror bracket
using the U-Bolt hardware supplied with the brackets
(Fig. 3). Insert the mounting bolt on the Micro Edge
through the hole provided in the extension flange.
Secure as shown in Fig. 3. Adjust the bracket
assembly until the Micro Edge is properly aligned and
tighten the bracket bolts firmly. Repeat procedure for
remaining door. NOTE: There is also a mirror mount
bracket available for the 2002 International 7400
Series Navistar® truck not shown here (sSee parts
list).
Fig. 3
Wire
Tie Fig. 4
Fig. 2

Page 3
WHITE Low Power Low Power
SYNC SYNC
RED (+) Flasher (+) Flasher
BLACK (-) Flasher (-) Flasher
WHITE
GREEN GREEN
RED
BLACK
Connect to switch. See "Low Power".
Micro Edge Freedom® LED Lightbar / Wiring Diagram
Connect to switch. See "Low Power".
10 AMP FUSE
(EACH)
SP/ST SWITCH
(EACH)
(+)
Battery
(-)
White (Low Power):
The type of switch used depends on how the operator wishes the Hi/Low
feature to function:
Latching Mode: By applying +12VDC to the WHITE wire for less than 1
second, the power supply is “latched” into low power. The unit must be
turned off and then back on to restore normal Hi power operation. A
momentary switch is typically used here.
Level Mode: Applying +12VDC to the WHITE wire for more than 1 second
holds the power supply in low power mode until voltage is removed. A
toggle switch is typically used here.
Green (SYNC):
When you connect the GREEN wires together from both lightheads, the
lightheads will flash simultaneously with each other.
NOTE: All fuses, fuse holders and switches are
customer supplied.
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!

Page 4
15
P/N 01-0362332-00 West Coast Mirror Mt. Bracket Mirror Bracket for 2002 International
7400 Series Truck P/N 02-0383831-00
ITEM PART NUMBER DESCRIPTION
12V DOT LED FLASHER SCREW, 6-32 x ½” PPHMS HOUSING, BALLAST 6-32 x 3/8”SEMS MOUNTING BRACKET ASS’Y
#6-32 WHIZ NUT CABLE, 4/C TPR 20’ EXTRUDED BASE 4.00” LENS, AMBER 4.00”
LENS, BLUE 4.00”
LENS, CLEAR 4.00” LENS, GREEN 4.00”
LENS, RED 4.00”
GROMMET, 1” RING TERMINAL SEAL, INTERFACE 4 POS MINI HARNESS, OUTPUT 1 HARNESS, OUTPUT 2
01-0269857-1S 11-483978-000 02-038132309S 46-0743146-00 11-342978-000 68-1183491A16 68-1183491B16 68-1183491C16 68-1183491G16 68-1183491R16 21-11263204-0 25-0145521-05 39-2H17429-04 46-0769852-01 46-0769853-01
QTY
21 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
1 1 1 5 1 1 1 1 2
A/R A/R A/R A/R
1 4 1 1 1
SCREW, #6 x ½” PLASTI-LOK 8”TY WRAP ½” GROMMET LABEL
15-065419-080
4
1 1 2
2
3
ITEM PART NUMBER DESCRIPTION
10-24 x 1-1/4”TH w/SHOULDER ENDCAP, AMBER ENDCAP, BLUE ENDCAP, CLEAR ENDCAP, GREEN ENDCAP, RED GASKET, ENDCAP CORNER LED (AMBER) CORNER LED (BLUE) CORNER LED (WHITE) CORNER LED (RED) HOUSING, PLUG 2x2 POS SEAL, GANG 4 POS #6 FASTEX®SCREW GROMMET BRACKET, CORNER
14-104286-16J 68-1183707-10 68-1183707-20 68-1183707-30 68-1183707-40 68-1183707-50 38-0261131-00
01-026B807-1D
01-02 -2D6B807
01-02 -3D6B807
01-02 -5D6B807 39-0917425-04 39-2H17430-04 13-062C40-16J 07-26C112-000
QTY
11
12
13
14
15 16 17 18 19
1
1
4 2
4
5
6
7
8
9
10
A/R A/R A/R A/R
2 2
A/R
A/R A/R
2
18
27
25
33 13
12
20
22
23
35
36
26
24
19
18
28 29 30 31 32
14
17
23
16
34
21
37
28 31
29 32
30
12
2
1
3
3
8
4
4
9
5
5
10
14
16
6
6
11
7
7