920-0002-00 Rev. B
Page 2 of 8
DETERMINED BY USER
SHOULD BE SYMMETRICAL
.5 MIN.
Notes:
1. Larger wires and tight connections will provide longer service life for components. For high current wires it is highly recommended that
terminal blocks or soldered connections be used with shrink tubing to protect the connections. Do not use insulation displacement
connectors (e.g., 3M Scotchlock type connectors).
2. Route wiring using grommets and sealant when passing through compartment walls. Minimize the number of splices to reduce volt
age drop. High ambient temperatures (e.g., under-hood) will significantly reduce the current carrying capacity of wires, fuses, and
circuit breakers. All wiring should conform to the minimum wire size and other recommendations of the manufacturer and be protected
from moving parts and hot surfaces. Looms, grommets, cable ties, and similar installation hardware should be used to anchor and
protect all wiring.
3. Fuses or circuit breakers should be located as close to the power takeoff points as possible and properly sized to protect the wiring and
devices.
4. Particular attention should be paid to the location and method of making electrical connections and splices to protect these points from
corrosion and loss of conductivity.
5. Ground termination should only be made to substantial chassis components, preferably directly to the vehicle battery.
6. Circuit breakers are very sensitive to high temperatures and will “false trip” when mounted in hot environments or operated close to
their capacity.
Wiring Instructions:
Figure 1
L I G H T B A R
M O U N T I N G B O L T S
M O U N T I N G F O O T
R O O F ( C U T O U T )
F E N D E R W A S H E R S
N Y L O C N U T S
Figure 2
2. Position the light bar on the mounting feet. Be sure that the light
bar is facing the proper direction. The cable from the light bar
exits via a hole drilled in the drivers side of the light bar.
3. With the location determined, adjust the two mounting feet to
a desired symmetrical location on the bar. Make sure that both
mounting feet are in full contact with the roof and not hanging off
the edge. Also, be sure that there is no less than ½” clearance
between the roof and the light bar at their closest point (Fig. 1).
When the feet have been placed in their desired location, mark
the drilling hole locations. The center distance between the
holes on each foot is 3.937 inches [100 mm].
4. Determine the routing plan for the cable. If it is to go through the
roof of the vehicle, determine the location to be drilled.
5. Drill holes for mounting feet and cable. The mounting bolts are
5/16” diameter. Typical hole sizes for 5/16” bolt is a “P” (.3230”)
for a close fit or a “Q” (.3320”) for a free fit. The cable is a .34”
nominal diameter. The cable should be protected with a user-
supplied grommet. The hole size drilled for the cable is depen
dent on the grommet selected. Silicone RTV can be used to
seal the holes.
6. Insert the heads of the mounting bolts into the opening at the
end of slots on the base of the light bar and place the rubber feet
onto the bolts. These feet mount between the bottom of the light
bar and the mounting surface.
7. Mount the light bar with the bolts through the holes drilled in
step 5 above, and secure with the Fender washer and Nyloc nut
as shown in Figure 2.
8. Wire the light bar (see the section on wiring).
