Whelen Engineering Company T-103 User manual

Page 1
©1997 Whelen Engineering Company Inc.
Form No.13256A (092199)
Automotive: Lightbars
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!
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.
Installation Guide:
Towman’s Model T-103
2 Light Strobe System
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
WIRING DIAGRAM TOWMAN’S “SYSTEM T-103”
CONNECTING THE UPS-64LX POWER SUPPLY TO THE POWER SOURCE
WITH 2 THREE POSITION SWITCHES MOUNTED INTO A BRACKET ASSEMBLY.
For connection to strobe light head cable assemblies see page 2.
™
WARNING...
WAIT 10 MINUTES AFTER TURNING OFF POWER BEFORE
STARTING WORK OR ANY TROUBLE SHOOTING.
The Whelen Strobe Light Power Supply is a high
voltage device. Do not remove strobe tubes or touch strobe
light head assemblies while system is in operation.
MICRO EDGE 360 DEGREES
REMOTE STROBE LIGHT HEAD
ASSEMBLIES MOUNTED ON
EACH SIDE OF CAB.
UPS 64LX STROBE
POWER SUPPLY.
FOR MOUNTING
INSTRUCTIONS
SEE PAGE 3.
CAUTION: Reverse polarity
(reversing positive (+) and
negative (-) input wires) during
installation of the strobe power
supply will blow the 15 amp fuse
incorporated into the unit, or the
switch assembly fuse, or both.
The fuse clip securing the fuse
protecting the strobe power supply
is located beside the 3 position
socket power input connector,
making the fuse easy to replace.
BLACK, NEGATIVE (-) GROUND
BACK VIEW OF SWITCH ASSEMBLY
SWITCH
MICRO EDGE
REAR
™
5 CONDUCTOR CABLE,
8 FEET (244cm) LONG
FUSED LEAD, COLOR YELLOW, POSITIVE (+) TO BATTERY
ORANGE
BLACK, NEG. (-) GROUND
RED
GREEN
BLACK
WHITE
WHITE
ORANGE
GREEN
BLACK
RED
AMP 3 PIN CONNECTORS
SWITCH
MICRO EDGE
FRONT
™
POWER SUPPLY OUTLETS
CONTROL POWER
POWER SUPPLY
ASSEMBLY
™
UPS 64LX
1234
IN LINE 15 AMP FUSE
FACTORY INSTALLED
NOTE: The outer surfaces of this product
may be cleaned with mild soap and water.
Use of any other chemicals may void the
product warranty. Do not use a pressure
washer.
CONTROL
N/C

Page 3
WIRING DIAGRAM TOWMAN’S “SYSTEM T-103”
CONNECTING THE UPS-64LX POWER SUPPLY TO THE™™ TWO MICRO EDGE STROBE LIGHT ASSEMBLIES.
For Connection to Power Source See Page 1. For Parts See Page 5.
REAR FACING
COMBO REFLECTOR
NOTE: CONNECTORS CONNECTING
CONTROL CABLES AND LIGHT HEAD
ASSEMBLIES ARE LOCATED INSIDE
THE MODEL MICRO EDGE LIGHT
HEAD ASSEMBLY.
FRONT FACING
COMBO REFLECTOR
POWER SUPPLY ASSEMBLY
(FOR DESCRIPTION SEE PAGE 3)
™
UPS 64LX
2
3
1
3
1
22
1
3
1
3
2
1
2
3
3
2
1
1
2
3
3
2
1
FRONT OF VEHICLE
6
CONDUCTOR
CABLE
6 CONDUCTOR CABLE
20 FEET LONG,
PN / 46-0741502-20
WHITE
BLACK
RED
ORANGE
BROWN
GREEN
WHITE
BLACK
RED
ORANGE
BROWN
GREEN
RED
BLACK
WHITE
WHITE
BLACK
RED
RED
BLACK
WHITE
WHITE
BLACK
RED
WHITE
ORANGE
BROWN
GREEN
BLACK
RED
ORANGE
WHITE
BLACK
RED
BROWN
GREEN
321 12 3 12 3 12 3
AMP 3 PIN
CONNECTORS
AMP 3 SOCKET
CONNECTORS
AMP 3 PIN
CONNECTORS
AMP 3 SOCKET
CONNECTORS
AMP 3 PIN
CONNECTORS
REAR FACING
COMBO REFLECTOR
FRONT FACING
COMBO REFLECTOR
FRONT FACING
STROBE LIGHT
REAR FACING
STROBE LIGHT
FRONT FACING
STROBE LIGHT
REAR FACING
STROBE LIGHT
TOP VIEW
MICRO EDGE
PASSENGER SIDE
™
TOP VIEW
MICRO EDGE
DRIVER SIDE
™
POWER SUPPLY OUTLETS
CONTROL POWER
1234
CONTROL
N/C

Page 4
The UPS64LX Strobe Power Supply, like all Whelen com-
ponents, can be installed in many different types of vehicles.
The guidelines for the installation of this product are written
so that no matter what vehicle is being used, the installation
and operation of the UPS64LX will be simple and straight
forward.
Selecting a Mounting Location...
The most common choice for a mounting area would be a
trunk or similar compartment. However, due to the wide
variety of vehicles onto which the UPS64LX could be
installed, this is not always possible. The following
guidelines will help the installer select an acceptable
alternative:
A) The UPS64LX™ should be mounted on a metal surface
to aid heat dissipation. Be sure that this surface is not
one that either generates or is exposed to excessive
heat during normal operation of the vehicle.
B) Do not select a location where the UPS64LX™ will be
exposed to potential damage from any unsecured or
loose equipment in the vehicle.
C) Be sure the area selected will not allow the UPS64LX™
to be exposed to water!
D) When routing the UPS64LX’s wires, it is important to
choose a path that will keep these wires away from
excessive heat and from any vehicle equipment that
could compromise the integrity of the wires (ex. trunk
lids, door jams, etc.).
E) When the best mounting location has been determined,
securely fasten the UPS64LX™ to it’s mounting surface
using the supplied hardware.
WARNING: The Strobe Light Power Supply is a high voltage
device. Do not touch or remove tube assembly in strobe light
head assemblies while in operation. Wait 10 minutes after dis-
connecting the unit from its power source before starting work or
troubleshooting on power supply or system.
CAUTION: As it will be necessary to drill holes into the mounting
surface, 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!
Installation...
1. Position the UPS64LX in its proposed mounting location to
ensure that it fits properly. With the UPS64LX™ in place,
insert an awl or other suitable tool into the mounting screw
area of the power supply and scribe the areas to be drilled.
2. Remove the UPS64LX™ from its mounting area and, using
a drill bit sized for a #10 sheet metal screw, drill a hole in
each of the areas scribed in the previous step.
3. Return the UPS64LX™ to its mounting location and using
the supplied #10 sheet metal screws, mount the
UPS64LX™ onto its mounting surface.
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!
Wiring...
2. Connect the RED wire to a fuse block (customer supplied)
and then to the POSITIVE terminal on the battery.
NOTE! Although a 15 amp fuse (customer supplied) is required
to be used in the fuse block, do not install the fuse until all of the
wire connections are completed.
3. Connect the BLACK wire to the factory chassis ground
adjacent to the battery.
CAUTION: Reversing polarity (Reversing Positive and Ground-
wires) during the installation of a strobe light power supply, will
blow either the 15 amp fuse incorporated into the unit, or the
inline 15 amp fuse located on the positive (+) wire connected to
the power source.
3POSITION
STROBE LIGHT
CONNECTORS
3POSITION
CONTROLCONNECTOR
3POSITION
PATTERN SELECTION
CONNECTOR
3POSITIONSOCKET
POWERINPUT CONNECTOR.
15 AMPFUSE FOR STROBE
POWERSUPPLY PROTECTION
UPS-64LX
POWER SUPPLY
™
The Micro-Edge™
is a dual Xenon tube, 270º remote strobe light head assem-
bly. Each unit is either designed for left or right side mounting
on vehicle. The cable assembly used to connect the Micro-
Edge™ light head assemblies to the Model UPS-64LX™
Strobe Light Power Supply, is a 6 conductor cable 20 feet
long. One end of the cable is connected on the inside of the
Micro-Edge™, and on the other end to factory installed 3 pin
connectors. Each one of the Micro-Edge™ light head assem-
blies is labeled underneath to indicate on which side of the
vehicle they should be mounted. When connecting the con-
nectors to the strobe light power supply, observe the color
coding and proper positioning of these connectors.
(See Wiring Diagram, Page 2.)
NOTE: During installation, when passing the cable through metal
surfaces, remove the burrs from the edges of the holes and if
possible use rubber grommets to protect the cable. It is also
advisable to support the cable with ty-wraps, cable clamps, or
any other means to prevent the cable from shifting around or
putting tension on the connectors.
The wiring assembly which connects the UPS-64LX™ strobe
power supply to the switch control assembly is a 5 conductor
cable assembly, 8 feet long.

Page 5
STEP 1
CONNECT LIGHT
HEADASSEMBLY
TOCONTROL
CABLE ANDSLIDE
UNIT INSIDE
HOUSING.
STEP 2
SECURE HEX
STANDOFFS
TOLIGHT HEAD
ASSEMBLY.
HOUSING
CENTER
PARTITION
CENTERING
BRACKET
NOTE:
TOCENTERLIGHT
HEADASSEMBLY
INSIDEHOUSING,
POSITIONTABS
OFCENTERING
BRACKET ONEACH
SIDEOFHOUSING
CENTERPARTITION.
Control Switch Assembly
The switch control assembly is factory assembled to the 5
conductor cable. and consists of two DPDT (Double Pole,
Double Throw) switches.
The DPDT switches are 3-position “ON-OFF-ON” switches,
which control both the front and rear strobe modules of the
remote strobe lighthead assemblies.
The DPDT switches when pushed downward, puts the strobe
lights into low power, or 30% of their high power intensity.
This feature is most useful when full light intensity at high
power may not be needed, such as for night use. To set the
strobe lights into the high power mode, position the switches
into the up-ward position. (Switch positions are indicated on
the face of the switch assembly.)
When installing, secure cable properly to prevent it from shift-
ing. Place switch assembly in a convenient and accessable
location.
When connecting the cable to the power source, be sure that
the control switches on the control switch assembly are in the
“OFF” (horizontal) position. Connect the BLACK WIRE, Negative
(-) to the battery negative, and connect the YELLOW WIRE with
the factory installed 15 amp fuse to 13 volts DC battery positive
(+).
FRONT STROBE
MODULES
HI-OFF-LOW
CONTROL
SWITCH
CONTROLSWITCH
REAR STROBE
MODULES
HI-OFF-LOW
CONTROL
SWITCH

Page 6
12
14
27
13
10
7
6
4
3
1
5
22
23
8
29
30
28 36 37 38
39 40
231 32 33 34 35
TOWMAN “SYSTEMT-103” REPLACEMENTPARTS LIST
ITEMDESCRIPTIONPART NUMBERQTY.
39-0403023-04
10 AMP 3 SOCKET CONNECTOR
2
54-140890-003
12 EXTRUSION
1
26-0215001-08
13 8" TY WRAP
2
21-11121602-0
14 1/2" GROMMET
1
10-0320809-01
16 IDENT. LABEL (PASSENGER)
A/R
10-0320809-00
15 IDENT. LABEL (DRIVERS)
A/R
14-104286-16J
110-24 X 1.25 TORX HEAD
8
68-1181528-10
2ENDCAP (AMBER)
A/R
38-0261131-00
3ENDCAP GASKET
2
15-041816-160
4#4 X 1 PPHSMS (WASHER HEAD)
2
07-241473-000
5CENTERING BRACKET
1
02-0361417-00
6EDGE COMBO
2
38-0315811-01
7FOAM STRIP, PSA ONE SIDE-2.5"
2
20-0021911-00
8#6-32 X 5-5/8 LG HEX STANDOFF
2
01-0280971-()
*
MICRO-EDGE STROBE LIGHT ASSY
*
ITEMDESCRIPTIONPART NUMBERQTY.
36-0141409-00
23 FLASH TUBE, LINEAR2
14-062216-100
22 #6-32 X 5/8 LG PPHMS4
10-0520810-02
26 MODEL NO. LABEL
1
39-0403013-04
27 AMP 3 PIN CONNECTOR
2
68-1141474-10
28 LENS (AMBER)A/R
46-0741710-20
29 WIRING HARNESS 20'1
02-038132309SC
30 MTG. BKT. ASS'Y.1
68-1181528-20
31 ENDCAP, BLUEA/R
68-1181528-30
32 ENDCAP, CLEARA/R
68-1181528-40
33 ENDCAP, GREENA/R
68-1181528-50
34 ENDCAP, REDA/R
68-1181528-V0
35 ENDCAP, VIOLETA/R
68-1141474-20
36 LENS, BLUE 3.750"A/R
68-1141474-30
37 LENS, CLEAR 3.750"A/R
68-1141474-40
38 LENS, GREEN 3.750"A/R
68-1141474-50
39 LENS, RED 3.750"A/R
40 68-1141474-V0 LENS, VIOLET 3.750"A/R
MICRO-EDGE™ STROBE LIGHT
4.67