Whelen Engineering Company Outer Edge Pillar Mount LC Lightbar Operating and maintenance instructions

Page 1
Installation Guide:
Outer Edge® Pillar Mount LC Lightbar
2011-2016 Ford Interceptor Utility
©2016 Whelen Engineering Company Inc.
Form No.14A31 (102516)
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [email protected]
Canadian Sales e-mail: [email protected]
Customer Service e-mail: [email protected]
Automotive: Lightbars
®
ENGINEERING COMPANY INC.
For warranty information regarding this product, visit www.whelen.com/warranty
Warnings to Installers
Whelen’s emergency vehicle warning devices must be properly mounted and wired in order to be effective and safe. Read and follow all of Whelen’s
written instructions when installing or using this device. Emergency vehicles are often operated under high speed stressful conditions which must be
accounted for when installing all emergency warning devices. Controls should be placed within convenient reach of the operator so that they can operate
the system without taking their eyes off the roadway. Emergency warning devices can require high electrical voltages and/or currents. Properly protect
and use caution around live electrical connections.Grounding or shorting of electrical connections can cause high current arcing, which can cause
personal injury and/or vehicle damage, including fire. Many electronic devices used in emergency vehicles can create or be affected by electromagnetic
interference. Therefore, after installation of any electronic device it is necessary to test all electronic equipment simultaneously to insure that they operate
free of interference from other components within the vehicle. Never power emergency warning equipment from the same circuit or share the same
grounding circuit with radio communication equipment. All devices should be mounted in accordance with the manufacturer’s instructions and securely
fastened to vehicle elements of sufficient strength to withstand the forces applied to the device. Driver and/or passenger air bags (SRS) will affect the way
equipment should be mounted. This device should be mounted by permanent installation and within the zones specified by the vehicle manufacturer, if
any. Any device mounted in the deployment area of an air bag will damage or reduce the effectiveness of the air bag and may damage or dislodge the
device. Installer must be sure that this device, its mounting hardware and electrical supply wiring does not interfere with the air bag or the SRS wiring or
sensors. Mounting the unit inside the vehicle by a method other than permanent installation is not recommended as unit may become dislodged during
swerving; sudden braking or collision. Failure to follow instructions can result in personal injury. Whelen assumes no liability for any loss resulting from the
use of this warning device. PROPER INSTALLATION COMBINED WITH OPERATOR TRAINING IN THE PROPER USE OF EMERGENCY WARNING
DEVICES IS ESSENTIAL TO INSURE THE SAFETY OF EMERGENCY PERSONNEL AND THE PUBLIC.
Warnings to Users
Whelen’s emergency vehicle warning devices are intended to alert other operators and pedestrians to the presence and operation of emergency vehicles
and personnel. However, the use of this or any other Whelen emergency warning device does not guarantee that you will have the right-of-way or that
other drivers and pedestrians will properly heed an emergency warning signal. Never assume you have the right-of-way. It is your responsibility to proceed
safely before entering an intersection, driving against traffic, responding at a high rate of speed, or walking on or around traffic lanes. Emergency vehicle
warning devices should be tested on a daily basis to ensure that they operate properly. When in actual use, the operator must ensure that both visual and
audible warnings are not blocked by vehicle components (i.e.: open trunks or compartment doors), people, vehicles, or other obstructions. It is the user’s
responsibility to understand and obey all laws regarding emergency warning devices. The user should be familiar with all applicable laws and regulations
prior to the use of any emergency vehicle warning device. Whelen’s audible warning devices are designed to project sound in a forward direction away
from the vehicle occupants. However, because sustained periodic exposure to loud sounds can cause hearing loss, all audible warning devices should be
installed and operated in accordance with the standards established by the National Fire Protection Association.
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.
• Whelen Engineering requires the use of waterproof butt splices and/or connectors if that connector could be exposed to moisture.
• Any holes, either created or utilized by this product, should be made both air- and watertight using a sealant recommended by your vehicle
manufacturer.
• Failure to use specified installation parts and/or hardware will void the product warranty.
• 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 the 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 (this does not include products that use
cigar power cords).
• If this product uses a remote device for activation or control, make sure that this device is located in an area that allows both the vehicle and
the device 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!

Page 2
Apply tape
3 places
Drilling a Pilot Hole:
Bottom view of mounting bracket
MOUNTING
BRACKET
Fig. 3
Inner width of screw.
Pilot hole should not
exceed this width.
Mounting Hole
Mounting Hole
Mounting Hole
IMPORTANT! The lightbar should be a minimum of 16" from radio
antennas!
Installation:
1. Place the lightbar housing onto the D-pillar. The trimmed edge of the
housing should be flush with the bottom and outer edges of the D-pillar
(Fig. 1).
2. Tuck any loose lighthead wires into the housing so they do not interfere
with contact of the D-pillar to the housing. Be sure the lightheads have a
sufficient service loop for lighthead maintenance.
Mounting the housing:
1. Mount the 2-sided tape to the bottom of the mounting bracket (Fig. 3).
2. Using isopropyl alcohol wipes (included), clean the vehicle where it will
come in contact with the mounting tape then prime those areas with the
supplied 3M Keel Primer.
3. There is a driver and passenger side housing. Be sure to mount
them on the
correct sides.
Remove the
backing from the
tape you
mounted in step
1 and line the
rear and bottom
edges of the
housing up with
the “D” Pillar.
While keeping
the edges lined
up, bring the
opposite side of
the housing
down onto the “D” Pillar and press the housing firmly against the
mounting surface to secure it.
WARNING! The adhesive used in this procedure is fully bonded
after 72 hours @ 70°F (21°C). During this period, do not expose
housings to unnecessary force, such as a high-pressure car wash.
4. Remove the three 6-32 X 3/8 Phillips Pan Head Machine Screws that
hold the Outer Edge housing to the mounting bracket (Fig. 1). Carefully
remove the housing only. The mounting bracket remains on the vehicle.
5. With the housing removed, press down firmly on the mounting bracket
where the tape is, to assure a good bond. Drill three pilot holes (Figs 2
& 3) into the “D” Pillar and secure the mounting bracket with the
supplied 8 X 1/2 Phillips Pan Head Sheet Metal Screws.
6. Drill a 3/8” wire passage hole in the approximate location shown in
figure 3. It is recommended you install a rubber grommet (customer
supplied) in the wire passage hole to protect the wires.Feed the wire
harness into the wire hole and apply RTV sealer around the hole when
the harness is in position.
7. With the bracket mounted and all wires in place, remount the housing to
the bracket and extend the wires to your power source.
Mounting the Flasher:
The location the flasher is mounted is left to the installers discretion. Using
the double sided adhesive tape provided, mount the flasher to the vehicle.
Extend the wires to power and make all electrical connections using the
information in the Wiring section. It is suggested that you follow the
vehicles factory wiring harness whenever possible.
WARNING! 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! Before returning the vehicle to active service,
visually confirm the proper operation of this product, as well as all
vehicle components/equipment.

Page 3
Activate
BLUE
& GREY
Wires
Split
33
22
11
Activate
GREY
Wire
gRi ht
16
25
34
Activate
BLUE
Wire
Left
61
52
43
1 - RED
2-BLK
1 - ORG
2-BLU
1 - WHT
2-GRN
1 - WHT
2-GRN
1 - ORG
2-BLU
1 - RED
2-BLK
Driver & Passngr
8 POS MINI UMNL
position & wire color
ORG
BLU
RED
BLK
WHT
GRN
5
6
7
8
1
2
3
4
FLASHER
PASS
(PFL)
DRIVER
(DFL)
Momentary
SP/ST
SP/ST
Power or
Flashers
Ground
Scan-Lock™
NOTE: All fuses and switches
are customer supplied.NOTE:
Right Sequence
RED
BLK
BLK
BLU
GRY
WHT
1 AMP
1 AMP
1 AMP
1 AMP
SP/ST
Low Power
(+)
Battery
(-)
33
22
11
Fuses Switches
Left Sequence
SP/ST
10 AMP
Wiring and Operation:
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
Power Cable:
(BLACK) - Ground - Extend the GROUND wire to Chassis Ground.
(RED) - Positive (+) - Extend the Positive wire to +VBAT via an SP/ST
switch. Fuse @ 10 AMPS.
Function Cable:
(WHITE) - Scan-Lock™ To change flash patterns, the light must be on.
The lightheads come programmed with the default flash pattern
(SignalAlert™75).
To advance to the next flash pattern apply +VBAT to the WHITE wire for
less than 1 second and release.
To cycle back to the previous pattern apply +VBAT to the WHITE wire
for more than 1 second and release.
Allow the selected pattern to run for more than 5 seconds to set it as the
default pattern.
To restore the factory default pattern, with the light turned off, apply
power to the WHITE wire. With power applied to the WHITE wire, turn light
on. Allow the unit to run for 3 seconds before removing power from the
WHITE wire.
(BLACK) - Low Power Activating the BLACK wire will switch the lightbar
to low power until voltage is removed.
(BLUE) - Left Sequence Activate the BLUE wire and lights will start on
the bottom right and travel to the bottom left and then repeat.
(GREY) - Right Sequence Activate the GREY wire and lights will start on
the bottom left and travel to the bottom right and then repeat.
CAUTION! DO NOT LOOK DIRECTLY AT THESE LED’S WHILE THEY ARE ON.
MOMENTARY BLINDNESS AND/OR EYE DAMAGE COULD RESULT!
IMPORTANT WARNING!
Sequence Patterns:
1. SEQ. ON SOLID
2. SEQ. ON - SEQ. OFF
3. 1 LAMP TRIPLE FLASH
4. 2 LAMP TRIPLE FLASH
Flash Patterns:
1. SignalAlert™ 75
2. CometFlash® 75
3. SingleFlash 300
4. SingleFlash 120
5. SingleFlash 75
6. ActionFlash™
7. ActionScan™

Page 4
PFL
DFL
1
2
1
2
1
2
1
2
POSITION 1 - WHT
POSITION 2 - GRN
1
2
POSITION 1 - ORG
POSITION 2 - BLU
1
2
POSITION 1 - RED
POSITION 2 - BLK
POSITION 1 - RED
POSITION 2 - BLK
POSITION 1 - ORG
POSITION 2 - BLU
POSITION 1 - WHT
POSITION 2 - GRN
PASSENGER SIDE
2
DRIVER SIDE
23 131
48
15
WIRE SIDE VIEW
48
15
WIRE SIDE VIEW
2
6
8
7
BLU
ORG
4
5
3 WHT
GRN
BLK
DFL
8 POS MINI UMNL
COLORPOS.
1 RED
PLUG
PLUG
14
2
6
8
7
4
5
3
PFL
8 POS MINI UMNL
POS.
1
BLU
ORG
WHT
GRN
BLK
COLOR
RED
PLUG
PLUG
1
2
POSITION 1
POSITION 2
CONNECTOR REAR VIEW
POS. 1
INDICATOR
TRIM SNAP TABS (2 PLACES) TYP.
ON ALL ASSEMBLIES
18
15 16 17
11
14
13
12
10
7
6
5
3
21
3
2
1
9
4
8
RED = +12V
BLK = GRD
BLK - LOW PWR
WHT - S/L
GRY - RIGHT
BLU - LEFT
19
20
01-0688242L00
ION PILLAR EDGE, LC, EXPLORER
111-488197-L00
HOUSING, DRVR REAR PILLAR ION 2016 EXPLORER TRIMMED
111-488197-R00
HOUSING, PASS REAR PILLAR ION 2016 EXPLORER TRIMMED
614-06221C-060
SCREW, 6-32 X 3/8 PPHMS SS BLACK OXIDE
6
07-288211-023
BRACKET, MTG DRVR ION BLK PILLAR EDGE 2016 EXPLORER
1
07-288211-123
BRACKET, MTG PASS ION BLK PILLAR EDGE 2016 EXPLORER
1
66-0416678-00
TAPE, VHB DOUBLE STICK BLACK .062 X 3/4" X 108' 3M4979F
6
15-018680-056 SCREW, 6 X 5/16 PHIL HWH TFS PLASTITE 48-2 302 SS
12
601-026D816-__
SUB ASSY, ION LT 2-WIRE
146-0788212-01
ASSY, CABLE HARNESS 6/C 5' OUTER EDGE
146-0788212-00
ASSY, CABLE HARNESS 6/C 3' OUTER EDGE
639-2H17430-02
SEAL, GANG 2 POS MINI UMNL
639-0917426-02
HOUSING, CAP, 2 X 1 POS MINI UMNL, SEALED
239-2H17430-00
SEAL, CAVITY PLUG 1 POS MINI UMNL
239-2H17430-08
SEAL, GANG 8 POS MINI UMNL
239-0917425-08
HOUSING, PLUG, 2 X 4 POS MINI UMNL, SEALED
239-2H17429-08
SEAL, INTERFACE 8 POS MINI UMNL
101-026H084-00
ASSY, ELECT FLASHER OUTER EDGE
146-0747747-01
ASSY, CABLE POWER ION OUTER EDGE
146-0747747-00
ASSY, CABLE INPUT ION OUTER EDGE
15-081416-080 SCREW, 8 X 1/2 PPHSMS 410 SS
1
4
66-0117352-00
66-0418909-00
ALCOHOL, PREP 70 ISOPROPYL
TAPE SILICONE FOAM 1/2 W X .062 CUT TO 1-5/8
1
1
66-0110008-01
10-0323905-01
ALCOHOL, ISOPROPYL 55 GAL DRUM C.E.#127-568
LABEL PRE PRODUCTION
2
3
ITEM PART NUMBER DESCRIPTION
QTY
11
12
13
14
15
16
17
18
19
20
4
5
6
7
8
9
10
1
21
23
22
24