Whelen Engineering Company 400 Series User manual

Page 1
Installation Guide:
400-series Strobe-Halogen
or Strobe-LED Lighthead
©2002 Whelen Engineering Company Inc.
Form No.13655E (071107) For warranty information regarding this product, visit www.whelen.com/warranty
• Proper installation of this product requires the installer to have a good understanding of automotive electronics, systems and procedures.
• Whelen Engineering requires the use of waterproof butt splices and/or connectors if that connector could be exposed to moisture.
• Any holes, either created or utilized by this product, should be made both air- and watertight using a sealant recommended by your vehicle
manufacturer.
• 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 the 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 (this does not include products that use
cigar power cords).
• If this product uses a remote device for activation or control, make sure that this device is located in an area that allows both the vehicle and
the device 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!
Automotive: Lightheads
Warnings to Installers
Whelen’s emergency vehicle warning devices must be properly mounted and wired in order to be effective and safe. Read and follow all of Whelen’s written
instructions when installing or using this device. Emergency vehicles are often operated under high speed stressful conditions which must be accounted for
when installing all emergency warning devices. Controls should be placed within convenient reach of the operator so that they can operate the system without
taking their eyes off the roadway. Emergency warning devices can require high electrical voltages and/or currents. Properly protect and use caution around
live electrical connections.Grounding or shorting of electrical connections can cause high current arcing, which can cause personal injury and/or vehicle
damage, including fire. Many electronic devices used in emergency vehicles can create or be affected by electromagnetic interference. Therefore, after
installation of any electronic device it is necessary to test all electronic equipment simultaneously to insure that they operate free of interference from other
components within the vehicle. Never power emergency warning equipment from the same circuit or share the same grounding circuit with radio
communication equipment. All devices should be mounted in accordance with the manufacturer’s instructions and securely fastened to vehicle elements of
sufficient strength to withstand the forces applied to the device. Driver and/or passenger air bags (SRS) will affect the way equipment should be mounted. This
device should be mounted by permanent installation and within the zones specified by the vehicle manufacturer, if any. Any device mounted in the deployment
area of an air bag will damage or reduce the effectiveness of the air bag and may damage or dislodge the device. Installer must be sure that this device, its
mounting hardware and electrical supply wiring does not interfere with the air bag or the SRS wiring or sensors. Mounting the unit inside the vehicle by a
method other than permanent installation is not recommended as unit may become dislodged during swerving; sudden braking or collision. Failure to follow
instructions can result in personal injury. Whelen assumes no liability for any loss resulting from the use of this warning device. PROPER INSTALLATION
COMBINED WITH OPERATOR TRAINING IN THE PROPER USE OF EMERGENCY WARNING DEVICES IS ESSENTIAL TO INSURE THE SAFETY OF
EMERGENCY PERSONNEL AND THE PUBLIC.
Warnings to Users
Whelen’s emergency vehicle warning devices are intended to alert other operators and pedestrians to the presence and operation of emergency vehicles and
personnel. However, the use of this or any other Whelen emergency warning device does not guarantee that you will have the right-of-way or that other
drivers and pedestrians will properly heed an emergency warning signal. Never assume you have the right-of-way. It is your responsibility to proceed safely
before entering an intersection, driving against traffic, responding at a high rate of speed, or walking on or around traffic lanes. Emergency vehicle warning
devices should be tested on a daily basis to ensure that they operate properly. When in actual use, the operator must ensure that both visual and audible
warnings are not blocked by vehicle components (i.e.: open trunks or compartment doors), people, vehicles, or other obstructions. It is the user’s responsibility
to understand and obey all laws regarding emergency warning devices. The user should be familiar with all applicable laws and regulations prior to the use of
any emergency vehicle warning device. Whelen’s audible warning devices are designed to project sound in a forward direction away from the vehicle
occupants. However, because sustained periodic exposure to loud sounds can cause hearing loss, all audible warning devices should be installed and
operated in accordance with the standards established by the National Fire Protection Association.
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.
WARNING: This product can expose you to chemicals including Methylene Chloride which is known to the State of California to cause cancer, and
Bisphenol A, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to
www.P65Warnings.ca.gov.
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Customer Service e-mail: [email protected]
®
ENGINEERING COMPANY INC.

Page 2
IMPORTANT NOTE:
2 Inch Minimum
Required Mounting Depth
1.86
STYLEBASIC P/N COLOR CABLE
REQ.
01-0663479_ _ _
LENS & LED COLOR:
R=
B=
G=
A=
C=
RED-RED
BLUE-BLUE
GREEN-GREEN
AMBER-AMBER
CLEAR-WHITE
CABLE:
0=
1=
without CABLE
with CABLE
STYLE:
1=
2=
3=
4=
OPEN-HALOGEN
STROBE-HALOGEN
STROBE-LED
STROBE-LED
(B/T/T)
CLEAR-RED
CLEAR-BLUE
CLEAR-GREEN
CLEAR-AMBER
5=
2=
4=
1=
2.375"
2.75"
Pilot Hole for #6
(Qty. 4)
Sheet Metal Screw
CUT-OUT
AND REMOVE
THIS AREA
CUT-OUT
AND REMOVE
THIS AREA
CUT-OUT
AND REMOVE
THIS AREA
4.6"
4.2"
.79"
1.58"
1.685"
3.37"
2.3"
1.375"
2.1"
1.187"
Model 400 Lighthead
Mounting Dimensions
11
Snap-In Lamp
Assembly
34-0041987-04
15 16 17
12 13 14
8 9
2 3 4
5 6 7
1
10
Tie Ring Terminals
to Chassis Ground
(Strobe Lights Only)
To strobe
power supply
ASS'Y. REFLECTOR STROBE-LED B-T-T// /
1
ASS'Y. REFLECTOR STROBE-LED RED// /
A/R
ASS'Y. REFLECTOR STROBE-LED AMBER// /
A/R
A/RA/R
11
A/R
A/RA/R
A/R
A/R
MODEL 400 SERIES ASS'Y STROBE-LED/
MODEL 400 SERIES ASS'Y STROBE-LED B-T-T//
1ASS'Y. REFLECTOR OPEN-HALOGEN//
MODEL 400 SERIES ASS'Y. OPEN-HALOGEN/
MODEL 400 SERIES ASS'Y. STROBE-HALOGEN/
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
CABLE ASS'Y. with KIT
A/R
GASKET
ASS'Y. REFLECTOR STROBE-HALOGEN//
LENS RED/
LENS GREEN/
LENS CLEAR/
LENS BLUE/
LENS AMBER/
A/R
#6 x 1 1/2" PPHSMS
A/R ASS'Y. REFLECTOR STROBE-LED BLUE// /
A/R ASS'Y. REFLECTOR STROBE-LED WHITE// /
ASS'Y. REFLECTOR / STROBE-LED / GREEN/
LENS SPLIT HORIZONTAL/
02-0363172-B0
02-0363172-50
02-0363172-10
01-06634794R( )
01-06634793( )
02-0363172-01
01-06634791( )
01-0440624-15
38-0262867-00
02-0363172-00
68-3183725-5S
68-3183725-4S
68-3183725-3S
68-3183725-2S
68-3183725-1S
01-06634792( )
02-0363172-20
02-0363172-30
02-0363172-40
02-0363485**S
2
3
ITEM PART NUMBER DESCRIPTION
QTY QTY QTY QTY
11
12
13
14
15
16
17
4
5
6
7
8
9
10
1
A/R
1
11
A/R
A/R A/R
A/R
A/R
A/R
A/R
4444
IMPORTANT NOTICE! This product has been
designed for improved visibility. Prior to
installing this product on any vehicle, check
your state motor vehicle codes to confirm that
this product complies with all state statutes.
Installation:
WARNING! DO NOT CONNECT the LED or
HALOGEN connector to a strobe power supply!
WARNING! The LED must be connected to
an electronic flasher. Allowing the LED to
steady burn will damage the lighthead and void
the warranty.
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!
1. Position the lighthead in its mounting location.
Make sure the lighthead doesn’t interfere with
any existing equipment. Be aware of any items
on the opposite side of the mounting surface
and possible damage to existing components.
Allow a 2 inch mounting depth (see above).
2. Remove the lighthead. Measure and mark off
onto the mounting surface, the mounting holes
and cut-out.
3. Drill 4 pilot holes for a #6 sheet metal screw,
than cut out and remove the area indicated in
the mounting diagram.
4. Extend the wires to your power source (LEDs
must first be connected to a flasher). Follow the
wiring below.
5. Secure the assembly onto the mounting
surface with the supplied sheet metal screws.
WIRING:
LED / Steady
LED / B-T-T
STROBE
HALOGEN
This wire will be the
BLACK-WHITE
YELLOW
BROWN
WHITE
BLACK
RED
WHITE
RED
WHITE
color of the LED
color of the LED
LED / Steady
color of the LED
+12 VDC
Ground
Brake light / +12VDC
Tail Light / +12VDC
Ground
Cathode
Anode
Trigger
+12 VDC
Ground