Whelen Engineering Company 400 Series User manual

Page 1
Installation Manual:
400 Series Strobe Lighthead
©2002 Whelen Engineering Company Inc.
Form No.13659A (071107)
®
ENGINEERING COMPANY INC.
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Canadian Sales e-mail: [e-mail]
Customer Service e-mail: [e-mail]
Automotive: Lightheads
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.
• 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.
• 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!
For warranty information regarding this product, visit www.whelen.com/warranty

Page 2
TIE RING TERMINALS TO
CHASSIS GROUND
(STROBE LIGHT UNITS ONLY)
Pilot Hole
for #6 SMS
(Qty 4)
1.187"
2.375"
1.375"
2.75"
1.58"
.790"
4.200"
2.100"
4.60"
2.300"
1.685"
3.37"
1.75" MINIMUM
MOUNTING
DEPTH
1.46"
2.61"
400-SERIES LINEAR STROBE LIGHTHEAD
A/R
10
1
9
1
8
7
A/R 6
A/R 5
A/R 4
A/R 3
A/R 2
41
A/R
DESCRIPTION
PART NUMBER
ITEM
QTY
CABLE ASSEMBLY with KIT
GASKET
REFLECTOR LINEARASSEMBLY /
LENS RED/
LENS GREEN/
LENS CLEAR/
LENS BLUE/
LENS AMBER/
#6 x 1 1/2" PHILLIPS PAN HEAD SMS
LENS KKKE-SPEC RED/
MODEL 400 SERIES LINEAR STROBEASSEMBLY /
ASSEMBLY / SPLIT LENS
01-0440624-15
38-0262867-00
02-0362824-00
68-3183725-5S
68-3183725-4S
68-3183725-3S
68-3183725-2S
68-3183725-1S
01-0663478-( )
68-3183725E5S
02-0363484**S
A/R
11
10
11
9
1
2 3 4 5
6 7 8
SPECIFICATIONS
VOLTAGE ANODE = 225 VDC (MIN.)
VOLTAGE TRIGGER = 150 VDC (MIN.)
CABLE:
0=without CABLE
1=with CABLE
COLOR:
R=
B=
G=
A=
RED
BLUE
GREEN
AMBER
01-0663478- _ _
CABLE REQ.
COLORBASIC P/N
CLEAR
SPLIT
"E" SPEC
RED
C=
=
5=
C
5=
REMOVE THIS AREA
REMOVE THIS AREA
MOUNTING DIMENSIONS
REMOVE THIS AREA
1. Position the lighthead in its approximate mounting location.
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.
2. Remove the lighthead. Measure and mark off onto the
mounting surface, the mounting holes and cut-out as shown.
3. Using an appropriately sized drill bit, drill the pilot holes.
4. Cut out and remove the area indicated in the mounting
diagram.
5. Route the cable assembly towards the strobe power supply.
Be sure that both ring terminals are grounded to the vehicle
chassis ground.
6. Plug the lighthead into the cable and plug
the cable into the strobe power supply.
Test operation of the lighthead before
securing it to the vehicle.
7. Secure the assembly onto the mounting
surface with the supplied sheet metal
screws.
Installation:
WARNING! The strobe light power supply is a high
voltage device. Do not touch or remove the strobe tube
assembly while in operation. Wait 10 minutes after
disconnecting the power source before starting any
work on the power supply or system.
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!