Whelen Engineering Company 835 Series User manual

Page 1
®
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
Installation Guide:
835 Series Brake-Tail-Turn Lighthead
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
©2001 Whelen Engineering Company.
Form No.13594 (053101)

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Installation:
NOTE:There are two ways to mount the 835 lighthead, each
offering it’s own benefits:
• Secured to the vehicle using the supplied sheet metal screws.
• Secured to the vehicle using an industry-strength, double-
sided adhesive tape, like Scotch™ brand VHB™ model 4956
foam tape.
This manual will outline the first procedure:
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.
1. Remove the lenses and position the reflector assembly on it’s
mounting location. Make sure the lighthead will not interfere
with any existing equipment.
2. With the reflector assembly positioned on the mounting location,
temporarily secure it to the surface with masking tape. Be sure the
reflector assembly is FLAT against the surface.
3. Mark the 4 mounting holes and the 1 wire access holes using the
reflector as a template.
4. Remove the reflector and drill the mounting holes with a #16 drill bit.
5. It is a good idea to deburr the wire holes and install a rubber grommet
(customer supplied) to protect the wires.
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!
6. Wire the light using the wiring diagram shown.
7. Mount lenses onto reflector and secure with supplied lens screws.
NOTE: When mounting the lenses make sure the drain hole is on
the bottom.
IMPORTANT! It is the responsibility of the installation technician to
make sure that the installation and operation of this product will not
interfere with or compromise the operation or efficiency of any
vehicle equipment! Before returning the vehicle to active service,
visually confirm the proper operation of this product, as well as all
vehicle components/equipment.
9
8
7
6 16
5 15
4
12
2 3
1
2.875"
4"
2"
8"
.375" DIA.
1.784"
3.568"
5.750"
CENTER
Mounting
Dimensions
(This is Not a Template)
WIRE HOLE
MT. HOLE
#10 SMS
MT. HOLE
#10 SMS
INPUT CURRENT: @12.8VDC - 3.9 AMPS
INPUT VOLTAGE: 13.5VDC +/- 20%
SPECIFICATIONS
MODEL 830 SERIES FLUSH MOUNT LIGHTHEAD / DUAL FILAMENT
LAMP: - = SNAP-IN
1 = BAYONETLAMP:
COLOR: A = AMBER
R = REDCOLOR:
FLANGE: 0 = without CHROME COVER
1 = with CHROME COVER
AU AMBER LENS
OU NO COVER
SNAP-IN
FLANGE:
:=
=SNAP-IN:
PART NUMBER KEY:
LAMP
01-0662393___
COLORBASIC P/N FLANGE
RED
BLACK
WHITE
Tail Lamp
Brake Lamp
Ground
835 SERIES
LIGHTHEAD
10
11
MODEL 830 SERIES ASS'Y
GASKET, REFLECTOR
REFLECTOR, DIRECTIONAL MET/W/SEAL
#10 x 1" PPHSMS
LAMP ASSY 12.8V-14V, 27/12 WATT
LAMPHOLDER ASSY DUAL FILAMENT
#6x7/16" PPH PLASTI-LOK
LENS, RED
LENS, AMBER
8-32 X 1/2 PPHMS SS
LABEL, MADE IN THE U.S.A. FLAG
LABEL, MODEL
1
A/R
A/R
A/R
A/R
2
1
2
1
1
1
68-1182469-50
68-1182469-10
14-082216-080
01-0662393___
38-0262283-00
68-5982541-02
15-101416-160
34-0062389-00
33-0042149-00
15-065419-070
10-0320776-00
10-0522103-02
COVER, FLANGE
TAPE, VHB 3"
TAPE, VHB 4"
LAMP, STOP/TAIL/TURN #1157
LAMPHOLDER ASSY, BAYONET DUAL FILAMENT
A/R
A/R
A/R
A/R
A/R
11-783522-002
66-0422788-03
66-0422788-04
34-0021562-00
33-0042822-00
2
3
ITEM PART NUMBER DESCRIPTION
QTY
11
12
13
14
15
16
4
5
6
7
8
9
10
1
FLANGE COVER
TAPE DETAIL
13
12