Whelen Engineering Company 700 Series User manual

Page 1
Installation Guide:
700 Series Linear Strobe Lighthead
©2001 Whelen Engineering Company Inc.
Form No.13625A (030702)
©2006 Whelen Engineering Company Inc.
Form No.13625D (121511)
®
ENGINEERING COMPANY INC.
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.
• 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 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
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [email protected]
Canadian Sales e-mail: canad[email protected]
Customer Service e-mail: cust[email protected]

Page 2
Installation:
WARNING: The strobe light power supply is a high voltage device.
Do not remove strobe tubes or dismantle strobe lightheads in
system while in operation. Wait 10 minutes after turning off power
before working or trouble shooting
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. DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT!
1. Using the mounting diagram, mark off the mounting holes and “cut-
out” area onto the mounting surface.
2. Using a 1/4” drill bit, drill the mounting holes then carefully cut and
remove the area of the mounting surface as shown. Do not remove
the mounting surface where the mounting holes are drilled.
3. Insert the supplied flange grommet into the mounting holes.
4. Route the cable through the wiring hole to the power supply. (Be sure
that both ring terminals are grounded to the vehicle.)
5. Position the lighthead components onto the mounting surface and
secure them to the vehicle using the four #6 x 1½” phillips pan head
screws.
6. Plug the cable into your power supply and test the operation of the
lighthead.
IMPORTANT! Before returning this vehicle to active service, visually
confirm the proper operation of this product, as well as all vehicle
components/equipment.
68-3183573E5S
02-0362641-01
02-0363418__S
68-3183573-5S
68-3183573-4S
68-3183573-3S
68-3183573-2S
01-0683710-__
15-061416-240
68-3183573-1S
02-0362641-00
10-0320776-00
10-0522891-02
38-0463342-00
LENS KKKE-SPEC RED SEAL/ with
700 LIN REFLECTOR WATERPROOF/
LENS SPLIT SEAL/ with
LENS RED SEAL/ with
LENS GREEN with SEAL/
LENS CLEAR SEAL/ with
LENS BLUE SEAL/ with
MODEL 700 LINEAR STROBE
#6 X 1 1/2" PHIL PAN HD SMS
LENS AMBER SEAL/ with
700 LINEAR REFLECTOR ASSY
MADE IN THE USA FLAG LABEL
LABEL 700 LINEAR FINAL ASSY/
GASKET 700 SERIES/
13
12
11
10
9
8
7
6
5
4
3
2
1
ITEM DESCRIPTION
PART NUMBER
A/R
A/R
1
A/R
1
A/R
A/R
A/R
A/R
A/R
A/R
4
QTY
1
01-0442199-15
KIT / CABLE ASSY WATERPROOF/
01-0440624-15
CABLE ASSY with KIT
14
A/R
15
A/R
16
1
WIRINGMOUNTING
DIAGRAM
3.438"
6.876"
.454"
.909"
1.380"
2.760"
1.188"
2.375"
3.281"
6.562"
3.050"
6.1"
L
C
L
C
1/4" DIA.
MOUNTING HOLE
(4) PLACES
CUT-OUT
COLOR:
R
B
G
= RED
= BLUE
= GREEN
= AMBER
= CLEAR
= SPLIT
= KKK E-SPEC
RED
A
C
*
5
5=
CONNECTOR-CABLE REQUIRED:
0.
1.
= AMP CONN without CABLE
= AMP CONN with CABLE
BASIC P/N
COLOR CONNECTO R
& CABLE REQ.
01-0683710-__
= DEUTSCH CONN without CABLE
= DEUTSCH CONN with CABLE
2.
3.
9 10
15
14
16
1
Tie ring
terminals
to chassis
ground.
5678
234
Mini-Grill-Master Housing:
Black:
Chrome:
01-0483777-01
01-0483777-02
Swivel Mount Kit:
Black:
Chrome:
11-481138-00
01-0441293-00
For use with: STROBE
or LED lightheads
Swivel
Mount
Kit
Lighthead Housing:
Drivers Side:
Passengers Side:
01-0462735-01
01-0462736-01
For use with:
HALOGEN, STROBE
or LED lightheads
3-SOCKET
DEUTSCH
CONNECTOR
WH / TRIGGER /T SOCKET C
BLK / CATHODE / SOCKET B
RED / ANODE / SOCKET A
3-PIN AMP
CONNECTOR
BLK / CATHODE / PIN 2
WHT / TRIGGER / PIN 3
RED / ANODE / PIN 1
123
HALOGEN, STROBE
or LED lightheads
Available Housings for
the 700 Series Strobe
CUT-OUT
Housing:
Housing w/Studs:
Mounting Hardware & Gasket:
11-463255-011
11-463255-111
01-0463331-00
For use with:
HALOGEN, STROBE
or LED lightheads
KIT / 700 Flange Halogen / Strobe
15 Degree Surface mount
WH T :
C
BL K
I E 01-0484709-02
HROME: 01-0484709-01
AC : 01-0484709-00
Housing (w/studs):
Housing:
Mounting Hardware & Gasket:
11-483530-011
11-483530-111
01-0483596-00
11-76D257-000
FLANGE GROMMET, 700 SERIES
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