Whelen Engineering Company Pioneer Series User manual

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©2010 Whelen Engineering Company Inc.
Form No.14413A (012216)
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [email protected]
Canadian Sales e-mail: [email protected]
Customer Service e-mail: [email protected]
Automotive: Lightheads
Installation Guide:
Pioneer™ Series LED Floodlight
115 Volts AC
Pedestal Mount
®
ENGINEERING COMPANY INC.
For warranty information regarding this product, visit www.whelen.com/warranty
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.
• 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.
• 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!

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Mounting...
1. Position the Flange Base (#12) onto the proposed mounting surface. Mark the
areas where the mounting holes are to be drilled.
2. Drill the mounting holes required using an appropriately sized drill bit (refer to the
Flange Base Mounting Information shown below).
3. Slide an O-Ring (#17) onto the Pivot Pin (#13) until it reaches the base. Insert the
Pivot Pin up through the bottom of the Flange Base and position the Flange Base/
Pivot Pin assembly onto the mounting surface. Secure the Flange Base to the
mounting surface using the hardware provided (#11, #14, #15 & #16).
4. Slide the remaining O-Ring (#17) onto the Pivot Pin. Thread the Clamp Nut Collar
(#18) into the Pivot Pin. Do not tighten this collar yet. Place the Pivot Arm (#19)
onto the Pivot Pin so that the tapped holes are aligned with the dimples on the
Pivot Pin.
5. Insert a Socket Set Screw (#10) into each of the two tapped holes in the Pivot
Arm. Tighten to secure to the Pivot Pin.
6. Attach the appropriate pole mount bracket (#3 or #4) onto the Pioneer using the
hardware provided (#2). Apply a drop of LocTite®242 or equivalent to the threads.
7. Secure the Handle (#1) onto the Pole Mount Bracket using the hardare provided
(#5).
8. Install the Pivot Bracket (#22) onto the pole mount bracket studs and firmly secure
using the hardware provided (#6, #7 & #8).
9. Insert the Pioneer/Pivot Bracket assembly into the receiving cup of the Pivot Arm.
Insert the Hex Bolt (#9) through the Pivot Bracket and Pivot arm. Install the
internal tooth lockwasher (#21) and the Knob (#20) onto this hex bolt.
10.When the Pioneer has been adjusted to the desired angle and rotation, tighten the
Knob and Collar firmly to maintain that angle.
Wiring...
All components, equipment and installation procedures shall conform to NFPA
1901, Standard For Automotive Fire Apparatus and NFPA National Electical
Code.
• Make sure that power is OFF before connecting any wires to the power
source!
• Make sure that the power source used features an appropriately sized
circuit protection device!
• If necessary, extend lighthead wires using minimum 16 AWG wire.
Refer to the wiring guide included with your Pioneer for wire functions, fuse
values and optional switch connections.
Product Specifications...
Operating Voltage . . . . . . . . . . . . . . . . . . 115VAC / 60Hz
Watts / Amps (Pioneer Single). . . . . . . . . 75W / 0.625A
Watts / Amps (Pioneer Dual) . . . . . . . . . . . 150W / 1.25A
IMPORTANT! Before returning the vehicle to active service, visually confirm
the proper operation of this product, as well as all vehicle components/
equipment.
5/16 Washer, Split Loc
Nut, Elastic Stop 5/16 - 18
Washer, Internal Tooth 7/16
3/8 Washer, Flat
Bracket, Pivot
Nut, Collar/Clamp
O-Ring, .987" ID X .103" Cross Section
Base, Flange
Knob
Pin, Pivot
3/8 Washer, Split Lok
Nut, 3/16 Hex
Arm, Pivot
Bolt, Hex HD 7/16 - 14 X 2 1/2
Screw, #10-24 X 3/8 PFHMS SS
Bracket (Single), Pole Mount
Bracket (Dual), Pole Mount
Screw, 1/4-20 X 3/4 Socket Head Cap, SS
Handle, Floodlight
Screw, Soc Button HD 5/16 - 18 X 1 1/8
Screw 1/4 - 20 x 1/2", Socket Set, SS
5/16 Washer, Flat
16-1431920-08
13-148120-082
16-1622520-12
16-1503220-60
16-1532220-10
13-156120-090
07-26B108-002
11-76B111-007
38-0417941-00
11-36B112-001
08-016B110-01
22-066B113-00
14-164436-400
14-130526-080
14-104116-060
07-26C071-001
07-26C070-001
14-130A26-120
08-0486106-00
14-148B26-180
16-1402420-05
44
44
11
11
11
11
44
44
34
1
1
-
11
11
11
22
22
2
-
2
22
2
2
2
2
11
ITEM PART NUMBER DESCRIPTION
Pioneer™ (Single) Pedestal Mounting Kit
Pioneer™ (Dual) Pedestal Mounting Kit
01-0486251-00
01-0486251-02
08-146B109-01
QTYQTY
11
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1
Drill
.342" dia.
Mounting
Hole
(4 Places)
4" dia.
Bolt Circle
Flange Base
Mounting Information
Attach the pole mount bracket (#3 or #4) onto
the Pioneer using the provided hardware
(#2). Mount the Pioneer/bracket onto the
handle (#1) as shown using the hardware
provided (#5).
1
11
12
13
14
15
16
10
Note:
Apply LocTite® 242
or equivalent
to Item #2
Note: Apply RTV to cable
hole to keep water out!
22
18
17
Mounting
Surface
34
2
9
5
20
19
8
7
6
21
Pioneer Dimensions
Pioneer™ Floodlight
GRN - Chassis Ground
WHT - Neutral
BLK - Power
Wiring: Pioneer Single & Pioneer Dual
PART NUMBER DESCRIPTION
Pioneer LED Floodlight (Single )PLUS - 115VAC / White
Pioneer LED Floodlight ( )PLUS - 115VAC Dual / White
Pioneer LED Floodlight ( )PLUS - 115VAC SIngle / Black
Pioneer LED Floodlight ( )PLUS - 115VAC Dual / Black
01-0686566-01
01-0686567-01
01-0686566-00
01-0686567-00
8.18"
4.25"
Pioneer (Single)
4.25"
14.05"
Pioneer (Dual)
2.80"
Proper Handle
Orientation