Whelen Engineering Company 400 Series User manual

Page 1
©2002 Whelen Engineering Company Inc.
Form No.13642D (120210)
®
ENGINEERING COMPANY INC.
Automotive: Lightheads
For warranty information regarding this product, visit www.whelen.com/warranty
Installation Guide:
400 Series Lighthead
Halogen Warning,
Halogen Brake / Tail / Turn,
Halogen-LED Warning
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]
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!

Page 2
PILOT HOLE
FOR#6SMS
(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"
CUT-OUT AND REMOVE THIS AREA
CUT-OUT AND REMOVE THIS AREA
CUT-OUT AND REMOVE THIS AREA
2" Minimum
mounting depth
3.01"
1.86"
4=2 POS DEUTSCH
without CABLE
CABLE:
0AMP=
1=
2=
3=
AMP
DEUTSCH
DEUTSCH
without CABLE
with CABLE
without CABLE2=
without CABLE
without CABLE
with CABLE
with CABLE
COLOR:
RRED=
B=
G=
A=
C=
=
5=
2=
4=
1=
BLUE
GREEN
AMBER
CLEAR
SPLIT
RED-CLEAR
BLUE-CLEAR
GREEN-CLEAR
AMBER-CLEAR
C
HALOGEN ONLY
STYLE
WARNING LIGHT=
1=
2=
BRAKE/TAIL/TURN
HALOGEN /
-
LED WARNING
01-0663477___
PART
NUMBER
KEY:
CABLE
COLOR
STYLE
4
23
6
5
2
3
ITEM PART NUMBER DESCRIPTION
QTY QTY QTY
4
5
6
11
12
13
14
15
16
21
17
22
18
23
19
24
26
20
25
8
9
10
1
MODEL 400 SERIES HALOGEN
SCREW, #6 x 1 1/2" PPHSMS
MODEL 400 SERIES HALOGEN-LED
MODEL 400 SERIES BRAKE/TAIL/TURN
LENS, AMBER
LENS, BLUE
LENS, CLEAR
LENS, GREEN
LENS, RED
ASS'Y., REFLECTOR, HALOGEN-WARNING, AMP
CABLE ASS'Y., KITwith
SPLIT LENS, HALOGEN ONLY, SPECIFY COLORS
ASS'Y., REFLECTOR, HALOGEN WARNING, DEUTSCH
ASS'Y., REFLECTOR, DEUTSCHBRAKE/TAIL/TURN,
CABLE ASS'Y., with KIT, WATERPROOF
ASS'Y, REFLECTOR HALOGEN-LED, AMBER
ASS'Y, REFLECTOR HALOGEN-LED, BLUE
ASS'Y, REFLECTOR HALOGEN-LED, WHITE
ASS'Y, REFLECTOR HALOGEN-LED, GREEN
ASS'Y, REFLECTOR HALOGEN-LED, RED
ASS'Y, REFLECTOR HALOGEN-LED, RED, DEUTSCH
ASS'Y, REFLECTOR HALOGEN-LED, GREEN, DEUTSCH
ASS'Y, REFLECTOR HALOGEN-LED, BLUE, DEUTSCH
ASS'Y, REFLECTOR HALOGEN-LED, AMBER, DEUTSCH
ASS'Y, REFLECTOR HALOGEN-LED, WHITE, DEUTSCH
01-0663477-__
15-061416-240
68-1183726-1S
68-1183726-2S
68-1183726-3S
68-1183726-4S
68-1183726-5S
02-0363189-00
01-0440624-15
02-0363189-01
01-06634771___
02-0363483__S
02-0363189-02
02-0363189-03
01-0442199-15
01-06634772___
02-0363318-H1
02-0363318-H2
02-0363318-H3
02-0363318-H4
02-0363318-H5
02-03633181H5
02-03633181H4
02-03633181H3
02-03633181H2
02-03633181H1
A/R
1
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/RA/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/RA/R
A/R
A/R
11
A/R A/R
A/R
A/R
A/R
A/R
A/R
A/RA/RA/R
444
ASS'Y., REFLECTOR (BRAKE/TAIL/TURN) AMP
GASKET, SURFACE MOUNT
38-0463924-00
ASS'Y., REFLECTOR (HALOGEN WARNING) 2P DEUTSCH
A/R 02-0363189-07
10
8
1
11
15
20
17 191816
25
22 24
23
21
12
13
9
14
26
HALOGEN: WARNING
HALOGEN: B-T-T
LED: STEADY
LED: BRAKE-TAIL-TURN
+12 VDC
GROUND
TAILLIGHT / +12VDC
BRAKE LIGHT / +12VDC
GROUND
+12 VDC
GROUND
BRAKE LIGHT / +12VDC
TAILLIGHT / +12VDC
GROUND
HALOGEN: WARNING
HALOGEN: BRAKE/TAIL/TURN
LED: STEADY
LED: BRAKE/TAIL/TURN
RED
WHITE
RED
BLACK
WHITE
This wire will be the
BLACK-WHITE (24V)
YELLOW
BROWN
WHITE
GREEN or WHITE
or BLACK (12V)
WIRING:
color of the LED
Installation:
Caution: Permanent mounting of this
product will require drilling. It is
absolutely necessary to make sure that
no other vehicle components could be
damaged by this process. Check both
sides of the mounting surface before
starting. If damage is likely, select a
different mounting location.
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!
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.
2. Remove the lighthead. Measure and
mark off onto the mounting surface,
the mounting holes and cut-out shown
in the mounting diagram.
3. Use a #30 drill bit to drill 4 pilot holes.
4. Using a cutting tool, cut an opening in
the mounting surface as indicated.
5. Extend the wires (or route the cable
assembly if included) to the power
source (see wiring). Test operation of
lighthead before securing to vehicle.
6. Secure the assembly onto the
mounting surface with the supplied
sheet metal screws.
IMPORTANT! Before returning the
vehicle to active service, visually
confirm the proper operation of this
product, as well as all vehicle
components/equipment.
CAUTION! DO NOT LOOK DIRECTLY
AT THESE LED’S WHILE THEY ARE
ON. MOMENTARY BLINDNESS AND/
OR EYE DAMAGE COULD RESULT!
IMPORTANT WARNING!