Whelen Engineering Company Worklight Series User manual

Page 1
Installation Guide:
Worklight Series LED Floodlight (12V)
Horizontal Mount
©2011 Whelen Engineering Company Inc.
Form No.14461A (051711)
®
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
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

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PART NUMBER DESCRIPTION
Worklight Series LED Floodlight (Single)
Worklight Series LED Floodlight (Dual)
01-0686898-00
01-0686897-00
67
67
2
2
1
1
1
-
-
-
3
3
-
-
-
1
1
1
ITEM DESCRIPTION
QTYQTY
44
2
3
4
5
6
7
8
9
10
11
12
13
1
Light Bracket (Single)
Light Bracket (Dual)
Flat Washer
Horizontal Mounting Bracket (Single)
Horizontal Mounting Bracket (Dual)
Seal (Single)
Seal (Dual)
Washer, Split-Lok
Bolt, 3/8-16 x 3/4 Hex Head
Bolt, 5/16-18 x 1 1/4 Hex Head
Rivnut
Washer, #10 Internal Tooth Lock
Screw, 10-24 x 3/8 PPHM
3
3
4
4
Horizontal Mounting Kit (Single)
Horizontal Mounting Kit (Dual)
*All switches and fuses
customer supplied
1
2
87
3
10 11
12
13
Dual Worklight Shown
For Reference Only
Mounting Surface
Material Thickness:
Min. - 0.027
Max. - 0.150
Hole Size (Dia.):
Min. - 0.531
Max. - 0.537
Mounting Hole Specifications
5 6
4
2
3
9
Worklight Dimensions & Wiring
4.25"
14.05"
Worklight (Dual)
RED - LED #1 To +12VDC
To +12VDC
To Chassis
Ground
SP/ST
Switch*
SP/ST
Switch*
5A
Fuse*
5A
Fuse*
RED - LED #2
Alternate Wiring Style
2.80"
4.25"
8.18"
Worklight (Single)
To +12VDC
To Chassis
Ground
RED
SP/ST
Switch* 5A Fuse*
BLK
BLK - Ground #1
BLK - Ground #2
RED - LED #1 To +12VDC
To Chassis
Ground
SP/ST
Switch* 10A Fuse*
RED - LED #2
BLK - Ground #1
BLK - Ground #2
Mounting...
1. Position the appropriate mounting bracket (Item #5 or #6) 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
Mounting Hole Specifications shown below).
IMPORTANT NOTE! This installation uses Rivnuts to secure the brackets to the
vehicle. This type of hardware requires the use of a specialized installation
tool. Refer to the owners manual included with this tool for proper installation
techniques. Be sure to follow the mounting hole specifications precisely!
3. With the Rivnuts properly installed, position the appropriate seal (#7 or #8) over
the mounting holes and position the mounting bracket onto the seal. The bracket
can now be mounted onto the vehicle using the appropriate hardware (Items #4,
#2 & #3). Apply a drop of LocTite 242 to each of the mounting bolts and insert
them into their Rivnut. Tighten each bolt to 50 in/lbs.
4. Secure the appropriate worklight mounting bracket (Item #10 or #11) to the
worklight assembly using Items #12 & #13 (apply a drop of LocTite® 242 to the
threads).
5. Using the appropriate hardware (Items #1, #2 & #3), install the floodlight assembly
onto the mounting bracket.
6. Adjust the floodlight to the desired angle and tighten the hardware firmly to
maintain that angle.
Wiring...
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!
Worklight Single...
1. Extend the RED wire to the customer supplied SP/ST switch. From the switch,
extend an appropriately sized wire to the POS battery terminal. Fuse this wire @ 5
Amps (customer supplied fuse).
2. Extend the BLACK wire to chassis ground
Worklight Dual...
1. Extend one of the RED wires to the customer supplied SP/ST switch designated
to control LED Board #1. From this switch, extend an appropriately sized wire to
the POS battery terminal. Fuse this wire @ 5 Amps (customer supplied).
2. Extend the other RED wire to the customer supplied SP/ST switch designated to
control LED Board #2. From this switch, extend an appropriately sized wire to the
POS battery terminal. Fuse this wire @ 5 Amps (customer supplied).
3. Extend and connect the BLK wires to chassis ground.
Alternate Wiring Style - If the user chooses, a single switch of sufficient capacity
may be used to activate both LED boards simultaneously (see below). From this
switch, extend an appropriately sized wire to the POS battery terminal. Fuse this wire
@ 10 Amps (customer supplied).
IMPORTANT! Before returning the vehicle to active service, visually confirm
the proper operation of this product, as well as all vehicle components/
equipment.