Whelen Engineering Company 400 Series User manual

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Installation Guide:
400 Series Linear-LED® Lighthead
©2003 Whelen Engineering Company Inc.
Form No.13829H (030110) For warranty information regarding this product, visit www.whelen.com/warranty
• 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!
Automotive: Lightheads
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.
WARNING: This product can expose you to chemicals including Methylene Chloride which is known to the State of California to cause cancer, and
Bisphenol A, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to
www.P65Warnings.ca.gov.
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Customer Service e-mail: [email protected]
®
ENGINEERING COMPANY INC.

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8
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5
11
6
12
13
7
19
14
20
15
21
16
22
17
23
18
2.375"
2.75"
Pilot Hole for #6
(Qty. 4)
Sheet Metal Screw
CUT-OUT
AND REMOVE
THIS AREA
CUT-OUT
AND REMOVE
THIS AREA
CUT-OUT
AND REMOVE
THIS AREA
4.60”
4.20”
.79"
1.58"
1.685"
3.37"
2.30”
1.375"
2.10”
1.187"
Model 400 Lighthead
Mounting Dimensions
BLACK
(Lower LED)
(-) Ground
LED COLOR
(Upper LED)
+12 Volts
Lighthead / Rear View
LED COLOR
(Lower LED)
+12 Volts
BLACK
( LED)Upper
(-) Ground
BLACKNEGATIVE / Ground:
POSITIVE / +12 VDC: Wire color is whatever the color
of the LED is when the lighthead is switched on.
(AMBER, BLUE, WHITE, GREEN or RED)
WIRING:
CONNECTORBASIC P/N LED COLOR 1 LED COLOR 2
01-0663783___
CONNECTOR:
2=
=
2 POS AMP
4 2 POS DEUTSCH
LEDCOLOR1or2:
1 = AMBER
2=BLUE
3 = WHITE
4 = GREEN
5=RED
PART NUMBER KEY:
IMPORTANT:
1¼”Minimum Required Mounting Depth
ITEM PART NUMBER DESCRIPTION
QTY QTY
2
3
11
12
13
14
15
16
17
18
19
20
21
22
23
4
5
6
7
8
9
10
1
SUB ASSY 400 LED SPLIT GRN/GRN/AMP/
SUB ASSY 400 LED SPLIT WHT/RED/AMP/
SUB ASSY 400 LED SPLIT BLU/RED/AMP/
SUB ASSY 400 LED SPLIT BLU/WHT/AMP/
SUB ASSY 400 LED SPLIT AMB/RED/AMP/
SUB ASSY 400 LED SPLIT AMB/WHT/AMP/
SUB ASSY 400 LED SPLIT AMB/BLU/AMP/
SUB ASSY 400 LED SPLIT WHT/WHT/AMP/
SUB ASSY 400 LED SPLIT RED/RED/AMP/
SUB ASSY 400 LED SPLIT BLU/BLU/AMP/
SUB ASSY 400 LED SPLIT AMB/AMB/AMP/
LENS CLEAR NON OPTIC W/ SEAL/
SCREW #6 X 1-1/2" PPHSMS/
SUB ASSY 400 LED SPLIT AMB-AMB DEUTSCH//
SUB ASSY 400 LED SPLIT BLU-BLU DEUTSCH//
LIGHTHEAD 400 Linear-LED® / AMP
LIGHTHEAD 400 DEUTSCH Linear-LED®
4
1
4
1
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
01-0286361255
01-0286361233
01-0286361222
01-0286361211
68-3183725-3S
15-061416-240
01-0286361244
01-0286361422
01-0286361235
01-0286361225
01-0286361223
01-0286361215
01-0286361213
01-0286361212
01-0286361411
GASKET SURFACE MOUNTING/
SUB ASSY / 400 LED SPLIT WHT-RED / DEUTSH
SUB ASSY 400 LED SPLIT BLU-RED DEUTSCH//
SUB ASSY 400 LED SPLIT BLU-WHT DEUTSCH//
SUB ASSY 400 LED SPLIT AMB-WHT DEUTSCH//
SUB ASSY 400 LED SPLIT AMB-BLU DEUTSCH//
SUB ASSY 400 LED SPLIT RED-RED DEUTSCH//
SUB ASSY 400 LED SPLIT WHT-WHT DEUTSCH//
SUB ASSY 400 LED SPLIT AMB-RED DEUTSCH//
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
11
01-0286361425
01-0286361435
01-0286361423
01-0286361415
01-0286361413
01-0286361412
01-0286361433
01-0286361455
38-0463924-00
01-06637832__
01-06637834__
24
1.98"
.83"
IMPORTANT NOTICE! This product has been
designed for improved visibility. Prior to installing
this product on any vehicle, check your state
motor vehicle codes to confirm that this product
complies with all state statutes.
WARNING! The LED must be connected to an
electronic flasher. Allowing the LED to steady
burn will damage the lighthead and void the
warranty.
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!
Installation:
1. Position the lighthead in its approximate mounting
location to make sure that the lighthead will not interfere
with any existing equipment. Also be aware of any and
all items on the opposite side of the mounting surface to
prevent any possible damage to existing components. A
1¼” minimum mounting depth is required.
2. Remove the lighthead. Measure and mark the mounting
holes off onto the mounting surface and cut-out as
shown.
3. Using an appropriately sized drill bit for a #6 sheet metal
screw, drill the 4 pilot holes.
4. Cut out and remove the area indicated in the mounting
dimensions.
5. Route the wires to power (cables are customer
supplied).
6. Plug the lighthead in and test the operation before
securing it to the vehicle.
7. Secure the assembly onto the mounting surface with
the supplied sheet metal screws.