Whelen Engineering Company 64 Series User manual

Page 1
®
ENGINEERING COMPANY INC.
Route 145, Winthrop Road,
Chester, Connecticut 06412
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
Installation Guide
64-series Brushless Rotator
Flange Mount
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 product is mounted with 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 owners
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!
©1997 Whelen Engineering Company Inc.
Form No.13198A (092199)

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MODEL 64 SERIES
PAT.P
END.
PAT. PE ND .
WHELEN ENG. CO.
#10 X 3/4"
PPH S.M.S.
FASTEX
SCREW
GROMMET
#6-32 X 1/2" PHMS
SELF TAPPING (TYPE "F")
OPTIONAL
CORNER
RADII .25
C
L
L
CAREA
TO BE
CUTOUT
#10
MOUNTING
HOLE
TYP (4)
PLACES
4.050
2.025
6.625 3.312
3.250
1.625
7.250 3.625
MOUNTING HOLE CONFIGURATION
Installation...
1. Using the dimensions shown in the grey area of Fig. 1,
create a template out of cardboard or other similar
material.
2. Place this template onto the desired mounting surface.
When the template is in a satisfactory mounting location,
trace the outline of the template onto the mounting
surface with a pencil, awl or other similar tool.
Note: As the following step involves removing
surface material from the vehicle, it is
necessary to confirm the following:
• That the area outlined in step 2 conforms to the
dimensions indicated in Fig. 1.
• That there are no vehicle components behind the
mounting surface (wires, etc.) that could be
damaged by cutting and removing the outlined area.
• That the proposed mounting area can accomodate
the depth of the casting as shown in Fig. 2.
Fig. 2
Fig. 3Fig. 1
2.656"
3. Remove the mounting surface area outlined in step 2.
4. Position the 64 casting onto its mounting surface. While
holding the 64 in its mounting area, locate the 4
mounting holes in the flange section of the housing.
Using the 64 housing as a template, drill four, 1/8”
mounting screw holes as shown in Fig. 3.
5. Remove the 64 housing from the vehicle and install the
mounting gasket into the housing as shown in Fig.3.
6. With the gasket mounted, locate the two wires from the
housing. Connect the RED wire to switched 12VDC and
fused at 10 Amps. Connect the BLACK wire to chassis
ground.
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 the load!
7. Reposition the 64 housing onto its mounting surface and
secure it to the vehicle using the supplied sheet metal
screws. Be sure that the mounting gasket does not
distort or “pucker” during mounting.
8. With the housing mounted, confirm proper lamp
operation.
The outer surfaces of this product may be cleaned with
mild soap and water. Use of any other chemicals may
void product warranty. Do not use a pressure washer.