13856 - Whelen Engineering

®
ENGINEERING COMPANY INC.
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: (860) 526-9504
Fax: (860) 526-4078
Internet: www.whelen.com
Sales e-mail: autosale@whelen.com
Canadian Sales e-mail: autocan@whelen.com
Customer Service e-mail: custserv@whelen.com
Installation Guide:
Freedom Mini Edge®
4 Corner LED Lightbar
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.
Automotive: D.O.T.
• 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.
• If this product contains strobe light(s), halogen light(s) or high-intensity LEDs, do not stare directly into these
lights at a close distance. 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. Lens 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
©2003 Whelen Engineering Company Inc.
Form No.13856C (030110)
Page 1

Mounting:
Permanent Style mounting is not covered here. Refer to the Lightbar
mounting guide included with your lightbar.
Magnetic Style mounting allows you to simply Place the lightbar onto the
vehicle and wire it to power (Fig. 1).
WARNING! The use of any magnetically mounted warning light on the
outside of a vehicle, while in motion, is not recommended and is at the
sole discretion and risk of the user.
Models featuring a cigar plug adaptor plug into your vehicles cigar lighter for
a power connection. For models with a 5 conductor cable, the wiring diagram
below provides the necessary wiring information.
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!
Fig. 1
For lightbars
with cables exiting
the Driver-side
of the extrusion
DRILLING THE CABLE ACCESS HOLE
FRONT OF LIGHTBAR
For lightbars
with cables exiting
the Passenger-side
of the extrusion
Drill cable access hole in appropriate area
for your lightbar (see note)
IMPORTANT! Before returning the vehicle to active service, visually confirm the proper operation of this product, as well as all
vehicle components/equipment.
Freedom LED Mini Edge®
DOT Lightbar
Wiring Diagram
WHITE Low Power Connect to switch
(See "Low Power")
Low Power
GREEN
SYNC
SYNC
RED (+)Positive (See note) (+)Positive (See note)
BLACK (-) Ground (-) Ground
WHITE
GREEN
RED
BLACK
NOTE: All fuses, fuse holders and
switches are customer supplied.
10 AMP FUSE between power source
and each RED power wire.
NOTE: Positive voltage for your lightbar will depend upon whether you have a 12 or 24 volt Mini-Edge.
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 positive voltage to the WHITE wire
for less than 1 sec., 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 preferred)
Green / SYNC:
When you connect the GREEN wires together from both lightbars,
the lightbars will flash simultaneously with each other.
Level Mode: Applying positive voltage to the WHITE wire for
more than 1 sec. holds the power supply in low power mode until
voltage is removed. (A toggle switch is preferred)
Page 2

QTY QTY ITEM PART NUMBER DESCRIPTION
01-0684068-10 FREEDOM MINI / 4 CORNER LED LIGHTBAR ( 24V)
01-0684068-A0 FREEDOM MINI / 4 CORNER LED LIGHTBAR ( 12V)
1 1 1 11-363732-001 BASE / EXTRUSION / 13.50" with STANDOFFS
1
1
1
1
1
1
1
1
2
3
4
5
21-11245004-1
14-104216-160
13-104111-063
26-0115037-04
GROMMET / 1.562"
#10-24 x 1 PPHM SCREW
NUT / #10-24 WHIZ
1/4" CABLE CLAMP
1 6 01-0269857-1S DOT / LED FLASHER
2 2 7 14-062216-080 SCREW / 6-32 X 1/2 PPHMS
4 4 8 25-0145521-05 RING TERMINAL
4 4 9 20-0042765-00 SPACER / CORNER
8 8
4
A/R
A/R
A/R
10
11
12
13
14
14-104286-16JB#10-24 x 1-1/4" TX. PHD. SCREW w/SHOULDER
01-026B80721D LED / AMBER CORNER
01-026B80722D LED / BLUE CORNER
01-026B80723D LED / WHITE CORNER
01-026B80725D LED / RED CORNER
2
2
2
2
A/R
2
2
2
2
A/R
15
16
17
18
19
02-0341448-00
07-263103-000
38-0283381-00
68-1183369-10
68-1183369-20
LENS DIVIDER
MOUNTING BRACKET
GASKET / ENDCAP
ENDCAP / AMBER
ENDCAP / BLUE
A/R A/R 20 68-1183369-30 ENDCAP / CLEAR
A/R A/R 21 68-1183369-40 ENDCAP / GREEN
A/R A/R 22 68-1183369-50 ENDCAP / RED
1 1 23 39-2H17430-04 SEAL / GANG 4 POS MINI UMNL
1 1 24 39-0917425-04 HOUSING / PLUG 2 X 2 POS MINI UMNL
4 4 25 68-1983817-10 LENS SECTION / AMBER / 6.562"
A/R
A/R
A/R
A/R
26
27
68-1983817-20
68-1983817-30
LENS SECTION / BLUE / 6.562"
LENS SECTION / CLEAR / 6.562"
A/R A/R 28 68-1983817-40 LENS SECTION / GREEN / 6.562"
A/R A/R 29 68-1983817-50 LENS SECTION / RED / 6.562"
2 2 30 02-038132309S MOUNTING STUD ASSEMBLY
1 1 31 46-0742938-00 INPUT CABLE ASS'Y / 5C TPR / 20' LG
1 1 32 21-11263204-0 GROMMET / 1.00"
1 1 33 10-0523082-*0 LABEL
1 1 34 46-0769730-01 HARNESS EXTENSION
4
A/R
A/R
35
36
37
01-026B807-1D
01-026B807-2D
01-026B807-3D
LED / AMBER CORNER
LED / BLUE CORNER
LED / WHITE CORNER
A/R
1 1
38
39
01-026B807-5D
46-0769852-02
LED / RED CORNER
HARNESS ASSEMBLY / OUTPUT 1
1 1 40 46-0769853-02 HARNESS ASSEMBLY / OUTPUT 2
1 1 41 39-2H17429-04 SEAL / INTERFACE 4 POS MINI UMNL
20
19
22
18 21
39
38
37
36
FRONT OF LIGHTBAR / TOP / TRANSPARENT VIEW
14
13
12
11
41
29
28
27
26
25
9
17
ORANGE-WHT/ORG
WIRED CONNECTION
ORANGE-WHT/ORG
WIRED CONNECTION
7
6
32
5
4
2
10
BROWN-WHT/BRN
WIRED CONNECTION
5
BROWN-WHT/BRN
WIRED CONNECTION
1
31
16
15
IMPORTANT WARNING!
CAUTION! DO NOT LOOK DIRECTLY AT THESE LED’S
WHILE THEY ARE ON. MOMENTARY BLINDNESS AND/OR
EYE DAMAGE COULD RESULT!
PART NUMBER KEY:
01-0684068-_0
LENS COLOR
COLOR & VOLTAGE & VOLTAGE
1=AMBER / 24V
2= BLUE / 24V
3= WHITE / 24V
4= GREEN / 24V
5= RED / 24V
A= AMBER / 12V
B= BLUE / 12V
C= WHITE / 12V
G= GREEN / 12V
R= RED / 12V
8
CONTROL CABLE
RED
BLACK
GREEN
WHITE
+12VDC or +24VDC
(-) GROUND
SYNC
LOW POWER
Servicing your Lightbar:
BARB
BOSS
This section covers the installation and removal of the components of your lightbar for service or troubleshooting.
Endcap, Lenses and Gasket
Remove the four screws (A) that hold the endcap on (B)
and pull the endcap and gasket (C) off. Slide
D
the lenses (D) out of the lightbar to gain
access to the inside of the extrusion.
When you reinstall the end cap,
first place the gasket into
position on the endcap.
Line up the tabs and
holes on the
Alley light Installation
Align the lighthead reflector up with the 4 bosses in the end cap and press the
reflector into place. The 4 barbs in the end cap should engage around the lighthead
as it snaps into place.
Installing a Corner LED
Snap lighthead
into bracket here
TOP VIEW
CORNER LED
CENTER OF EXTRUSION
Front
Passenger
Spacer
Extrusion
END VIEW
Slide Spacer in here
Lighthead Tabs
slide into extrusion
Front
Passenger
Page 3
GASKET
C
Installing the Endcap Gasket
Place endcap gasket into position on the
endcap locating all tabs and holes.
B
gasket with
the ones on
the endcap
A