Whelen Engineering Company Delta Independence User manual

Page 1
Installation Guide:
Delta™ Independence™ Lightbar
Quebec Provincial Police
©2008 Whelen Engineering Company Inc.
Form No. 14219A (052010)
®
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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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.
IMPORTANT! The lightbar should be a minimum of 16"
from any 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.
Mounting
Pad
Adjustable
Mounting
Foot
Washer
Nut
Mounting
Plate
Standard
Mounting
Foot
Mounting
Pad
Washer
Nut
Mounting
Plate
BoltBolt
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.

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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
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.
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. 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 ft. lbs.
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
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.
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.

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Route to customer supplied switch box.
Take Downs
Front LED's
Rear LED's
Center Take-Downs
GREEN
RED/WHITE
GRN/WHT
RED
RED/BLACK
WHT/VIO
WHITE/BLK
WHITE
YELLOW
BLUE
Inner Rotators
Outer Rotators
N/C
Low Power
Left Side Alley
Right Side Alley
10 Amps
15 Amps
7.5 Amps
15 Amps
N/C
1 Amp
5 Amps
5 Amps
5 Amps
10 Amps
Color Fuse @
To Chassis Ground
Function
REAR
FLASHER
FRONT
FLASHER
CENTER TAKEDOWN
BLUE RED
CENTER TAKEDOWN
LINEAR LED / BLUE
ALLEY LIGHT
LINEAR LED / BLUE
LINEAR LED / BLUE LINEAR LED / BLUE
LINEARLED/R
ED
LINEAR LED / RED
ALLEY LIGHT
OUTBOARD
TAKE DOWN
LINEAR LED / BLUE LINEAR LED / RED
OUTBOARD
TAKE DOWN
UPPER
LEVEL
UPPER
LEVEL
UPPER
LEVEL UPPER
LEVEL
UPPER
LEVEL
UPPER
LEVEL
TIR LED / BLUE
TIR LED / BLUE
UPPER
LEVEL
UPPER
LEVEL
UPPER
LEVEL
TIR LED / RED
??
TIR LED / RED
UPPER
LEVEL
UPPER
LEVEL
UPPER
LEVEL
Operation:
With the Lightbar's ground wire secured to a
chassis ground:
To activate light o
Options:
ptions:
Applying + 12 volts DC to a control wire activates
that control wire's function.
When you activate "ALL FRONT LED's" or "ALL
REAR ", all the LED lightheads in either the
front or rear will be activated
and flashing.
LED's
(except take-downs)
Pattern: SignalAlert™ Simultaneous.
Low Power Operation:
Applying +12VDC to the ORANGE wire will cause
the lightbar to step down to low power mode. The
unit will continue to operate in low power mode
until this voltage is removed.
Warning: It is the responsibility of
the installation technician to make
sure the installation and operation
of this product will not interfere
with or compromise the operation
or efficiency of any vehicle
equipment!
Warning: Before returning the
vehicle to active service, visually
confirm the proper operation of
this product, as well as all vehicle
components/ equipment.
Control Cable
OUTER ROTATORSINNER ROTATORS
INNER ROTATORS
OUTER ROTATORS
CAUTION! DO NOT LOOK DIRECTLY AT
THESE LED’S WHILE THEY ARE ON.
MOMENTARY BLINDNESS AND/OR EYE
DAMAGE COULD RESULT!
IMPORTANT WARNING!
FRONT
For lightbars with
cables exiting the
Driver side of the
extrusion
Drill cable access hole in an area
appropriate for your lightbar
(see Warning).
For lightbars with
cables exiting the
Passenger side of
the extrusion
Routing the Cables:
1. To protect the headliner from damage caused by drilling the cable
access hole through the vehicle roof, lower the headliner before
drilling to allow a 5” to 7” distance between roof and headliner.
WARNING! There is 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. Refer to “Safety First” on Page 1 for important
precautionary information.
2. Using a 1” hole saw, drill the cable access hole.
3. Use a round file to de-burr the edges of the cable access hole and
insert a 1” grommet (customer supplied) into the hole.
4. Insert the cables through the cable access hole into the vehicle. Use
RTV silicone to weatherproof the access hole after the cables are
pulled completely into the vehicle.
5. Route the cables one at a time to your power source. It is left to the
installation technician’s discretion where to run the cables, as
vehicles will vary.
Control Cable:
Route the cable towards a high-current switch panel such as the Whelen
model PCC10. Note: The use of switches with an insufficient current
rating will cause switch failure! Switches with a current rating of less
than 20 amps should not be used. For proper operation The ground
cable (BLACK) must be connected to the vehicle’s chassis ground.
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!