Page 2
Installation
IMPORTANT! The lightbar should be located a minimum of
15” from any radio antennas!
Note: When routing the wires, it is very important that you
choose a path that will keep the wires away from excessive
heat or any vehicle equipment that could compromise the
integrity of the wires (ex. trunk lids, door jams, etc.).
The following instructions use a 39” lightbar as an example.
1. Place the lightbar onto its proposed mounting location. Draw
a pencil line the exact length of the extrusion onto the
mounting surface along the top and bottom of the extrusion.
Do not include the end light assemblies on this length.
Remove the lightbar and draw a line positioned halfway
between the upper and lower line. This is the centerline of
your lightbar.
2. For every 10” of extrusion length, a mounting hole is required.
Using a 39” bar for example, measure and mark a location on
the centerline 6" inward from both ends of the centerline. Now
measure and mark a location on the centerline approximately
18" inward from both ends of the centerline. You should now
have 4 equally spaced marks.
3. Using an appropriately sized bit, drill four, 1/4" mounting
holes at the locations marked in the previous step.
4. Measure and mark the wire passage hole. Be sure to confirm
that the area marked will be aligned with the cable when the
lightbar is mounted.
5. Drill a 3/4” wire passage hole at the location marked in the
previous step. De-burr all holes before proceeding.
6. Locate the carriage bolts, flat washers and elastic stop nuts
included with your lightbar. Using the side opposite of the
cable exit, insert the bolts into the opening at the end of the
extrusion. Slide these bolts along the extrusion until they are
aligned with the mounting holes. Be sure to place a disc
gasket onto each of the mounting bolts.
7. Feed the lightbar cable through the wire passage hole before
positioning it against the mounting surface. Apply a generous
amount of RTV silicone around the wire passage hole.
8. With the mounting bolts aligned with their respective
mounting holes, place the lightbar against the mounting
surface. Install a flat washer and elastic stop nut onto each of
the 4 mounting bolts and tighten the hardware to secure the
lightbar firmly against the mounting surface.
Wiring
Refer to the appropriate wiring diagram on the following page for
information on wire functions. Note that all switches and fuses are
customer supplied.
Important! Whelen Engineering requires the use of
waterproof butt splices and/or connectors if that connection
could be exposed to moisture.
Mounting
Surface
Disc Gasket
Flat Washer
#10-24 Carriage Bolt
Elastic Stop Nut
