Whelen Engineering Company 13310 User manual

Page 1
©1998 Whelen Engineering Company Inc.
Form No.13310C (061614)
51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Customer Service e-mail: [email protected]
Installation Guide:
Harley-Davidson® Pole Light Assembly
®
ENGINEERING COMPANY INC.
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 Lead which is known to the State of California to cause cancer and birth defects or
other reproductive harm. For more information go to www.P65Warnings.ca.gov.

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This unit is designed to operate from a 12 VDC
24 VDC power source (nominal).or
When inserting the flash
tube assembly into the
strobe power supply
assembly, align the 3
prongs on the flash tube
assembly with the slots
on the strobe power
supply assembly.
The pole strobe light assembly is assembled
and shipped without a connector attached to
the wires. A connector kit (shown on page 2)
is supplied with the pole strobe assembly.
It contains all parts needed to match the
connector hardware used on the motorcycle
wiring harness.
22.00 CLOSED / 42.00 OPEN
36" FROM MAST
TO CONNECTOR
END OF CABLE
BLACK (GROUND)
RED (+12VDC)
6
21
10
7
11
8
16
21
12
14
9
IMPORTANT NOTE:
See page 3 for instructions
about proper installation of
Spring-Transistor-Retainer
IMPORTANT NOTE:
Hand tighten the mounting nuts
securely using channel lock
pliers or similar tool, tighten the top
mounting nut an additional 1/8 of
a turn. Use Loctite #262 (Red) or
equivalent thread-locking compound
to ensure these nuts do not loosen.
then,
21 15-041416-080
# 4 x 1/2 PHILLIPS PAN HD SMS SS
PARTS LIST
DESCRIPTIONITEM PART NUMBER
25 25-0116521-05
RING LUG 1/4" INSUL #31904
24 39-0401313-04
1 POS AMP PIN HOUSING
28 39-1H02014-35
2 POS DEUTSCH HSG (DTO4-2-FOOY)
29 39-1H00316-35
PIN TERMINAL DEUTSCH
30 39-0015982-00
SECONDARY LOCK DEUTSCH
31 03-0610017-00
PLASTIC BAG 2 1/2 x 5
22 01-0415983-00
KIT, INSTALLATION
16 39-0402023-04
AMP 2 SOCKET CONNECTOR
17 39-0501326-04
AMP SOCKET
18 02-0262362-02
MAST & CABLE ASS'Y W/ PINS - 36" CABLE
14 06-180842-003
BASE-STROBE
615-065410-100
6 X 5/8 PPH PLASTI SS
836-0341567-00
FLASH TUBE ASSY. (FT-20A)
921-17020602-3
GROMMET, #4 FASTEX
12 23-0320760-00
SPRING-TRANSISTOR RETAINING
*01-0680866-00
LIGHT ASSEMBLY (12V OR 24V)
268-2180452-50
OPTIC DOME (RED) LEXAN
168-2180452-20
OPTIC DOME (BLUE) LEXAN
10 02-0167204-01
STROBE POWER SUPPLY ASSY.
11 56-000000-100
CHO-THERM INSULATOR
715-066939-056
6-32 x 5/16" HEX WASH HD THD FORM SCREW
526-0215001-06TY WRAP 6"
27 39-0501316-04
AMP PIN
WARNING:
Wait 10 Minutes
The Strobe Power Supply is a High Voltage
Device. Do Not Remove Tubes or Dismantle the Strobe
Light Head Assembly While in Operation.
After Turning Off Power Before Starting
Work or Any Trouble Shooting.
17
5
BLACK
RED
29
25
27
28
1
2
30
24
RED
BLACK
18
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.

Page 3
FIGURE 2. Route cable to left side cover. Crimp ring
terminal and AMP pin terminal on Black and Red
wires. Insert pin in 1 position AMP connector. Connect
Red wire with pin connector to main harness, and
ground Black wire with ring terminal.
Models FLHTP and FXRP 1988-1992
CONNECTOR KIT P/N 01-0415983-00 CONTAINS:
DESCRIPTIONQTY. PART NUMBER
239-1H00316-35
Deutsch Pin Terminals
139-0501316-04
Amp Pin Terminal
139-0015982-00
Deutsch Orange Pin Wedge
125-0116521-05
1/4 inch Insulated Ring Lug
139-0401313-04
1 Position Amp Pin Connector
139-1H02014-35
Deutsch 2 Position Pin Housing
Once the two pin terminals are in place
inside the connector housing, use a needle nose
pliers to insert the orange pin wedge inside the
connector housing from the other end. The pin
wedge will have to be fitted inside the cavity
below the two pins. Connect the pin connector
to main harness at the back of the radio carrier.
FIGURE 6.
Push pin terminal all the way inside the
rear seal of the connector until a click is felt. A slight
tug on the wire will confirm that the pin terminal is
properly locked in place.
FIGURE 5.
To insert pin inside rear seal of connector,
hold wire approximately one inch behind pin terminal.
FIGURE 4.
Crimp DEUTSCH pin terminals to Red
and Black wires using DEUTSCH crimping tool
DTT1600. Cut White wire flush with cable jacket.
FIGURE 3.
FIGURES 3 TO 6. Cut cable to 10 inches long.
Pins
End View of Connector
Orange Pin Wedge
Red Wire
Black Wire
Amp 1 Position Pin Housing
1/4 Inch Insulated Ring Lug To Be Crimped on Black Wire FIGURE 2
IMPORTANT NOTE: WIRES MUST BE INSERTED
INTO THE PROPER POSITIONS AS SHOWN IN
FIGURES ON THIS PAGE, SINCE POLARITY
IS IMPORTANT.
In supplied connector kit, choose connector
hardware to match motorcycle Model number, and
install onto wires of the pole strobe light assembly.
2.
1. Determine the Model number of motorcycle the
pole strobe light assembly is to be mounted on.
FIGURE 1
Crimp Tall Cradle
Over Wire Insulation.
Crimp Short Cradle
Over Bare Wire.
Strip Wire to
Approx. 1/8 Inch.
Model FLHTP 1994
Strip Wire to Approx.
3/8 Inch and Slip
Bare Wire Inside
Pin Barrel
Crimp Large Cradle
over Bare Wire
Crimp Small Cradle
over Wire Insulation
Pin BarrelDeutsch Pin
Terminal
FIGURE 3
Red Wire Position 1
FIGURE 6
Black Wire Position 2
Rear
Seal
FIGURE 5
Pin Position Numbers are on Side of Connector Housing
Rear Seal
Pin Barrel
FIGURE 4
Deutsch 2 Position Pin Housing

Page 4
POWER SUPPLY ASSEMBLY
MOUNTING HOLES TRANSISTOR
MOUNTING
STUDS
TRANSISTOR
MOUNTING BOSS
TRANSISTOR
SPRING CLIP
CHO-THERM
INSULATOR
ASSEMBLY INSTRUCTIONS OF STROBE LIGHT
POWER SUPPLY ASSEMBLY TO CAST ALUMINUM
BASE, TO PREVENT ELECTRICAL SHORT CIRCUIT
BETWEEN THESE TWO PARTS
WARNING:
FIGURE 1.
FIGURE 2.
FIGURE 3.
The strobe light power supply is a high voltage device.
Do not touch or remove strobe tube assembly while unit is in operation.
Wait at least 10 minutes after turning off power before starting work or
any trouble shooting on the unit. On this page is described the assembly
procedure of the strobe light power supply to the cast aluminum base.
It is extremely important that the assembly steps, as described below,
be followed exactly, to insure the proper insulation of the strobe light
power supply from the cast aluminum base.
Lower the power supply assembly onto the cast aluminum
base, with the three mounting holes lined up with the holes located on
the three mounting studs of the cast aluminum base. During this ass-
embly operation, the transistor on the power supply assembly has to be
positioned on the outside of the transistor mounting boss. Secure the
strobe light power supply assembly to the mounting studs with enclosed
self tapping screws.
Slightly bend the transistor on the power supply away from
the transistor mounting boss. Slip the Cho-Therm insulator behind the
transistor with the hole directed towards the top (see figure 4 “A”).
Position the top of the Cho-Therm insulator against the circuit board
of the power supply assembly, making sure that some of it shows below
the transistor (See figure 4 “B”). It is important that the transistor on the
power supply assembly does not contact the transistor mounting boss at
any place, as to prevent a damaging electrical short circuit between the
strobe light power supply and the cast aluminum base.
Use the transistor spring clip to secure firmly the Cho-Therm
insulator and the power supply transistor to the mounting boss of the
cast aluminum base. Wrap one end of the clip around one side of the
mounting boss, then press the other end in position using needle nose
pliers. (See figure 5 and note in figure 4 “B”).
TOP VIEW OF TRANSISTOR
MOUNTING BOSS
SPRING CLIP AROUND ONE END OF
TRANSISTOR MOUNTING BOSS
PUSH OTHER END OF TRANSISTOR SPRING CLIP
AROUND OTHER END OF TRANSISTOR
MOUNTING BOSS
CHO-THERM INSULATOR AND TRANSISTOR TO BE SECURED
BETWEEN TRANSISTOR SPRING CLIP AND TRANSISTOR
MOUNTING BOSS (SEE NOTE IN FIGURE 4 “B”)
FIGURE 5.
FIGURE 1.
FIGURE 2.
FIGURE 3.
TRANSISTOR
SPRING CLIP
MUST PRESS
AGAINST THIS
PART OF THE
TRANSISTOR
“B” “A”
FIGURE 4.