Installation, Important warning, Page 2 – Whelen 400 Series Lighthead User Manual

Page 2: Wiring

Page 2

PILOT HOLE

FOR #6 SMS

(QTY 4)

1.187"

2.375"

1.375"

2.75"

1.58"

.790"

4.200"

2.100"

4.60"

2.300"

1.685"

3.37"

CUT-OUT AND REMOVE THIS AREA

2" Minimum

mounting depth

3.01"

1.86"

4 = 2 POS DEUTSCH

without CABLE

CABLE:
0 AMP

1 =

2 =

3 =

AMP

DEUTSCH

without CABLE

with CABLE

without CABLE

2 =

without CABLE

with CABLE

COLOR:
R RED

B =
G =
A =
C =

5 =
2 =
4 =
1 =

BLUE

GREEN

AMBER

CLEAR
SPLIT

RED-CLEAR
BLUE-CLEAR
GREEN-CLEAR

AMBER-CLEAR

HALOGEN

ONL

STYLE

WARNING LIGHT

1 =
2 =

BRAKE/TAIL/TURN
HALOGEN /

LED WARNING

0 1 - 0 6 6 3 4 7 7 _ _ _

PART

NUMBER

KEY:

CABLE
COLOR
STYLE

3
6

2
3

ITEM

PART NUMBER

DESCRIPTION

QTY QTY QTY

4
5
6

11
12
13
14
15
16

8
9

MODEL 400 SERIES HALOGEN

SCREW, #6 x 1 1/2" PPHSMS

MODEL 400 SERIES HALOGEN-LED

MODEL 400 SERIES BRAKE/TAIL/TURN

LENS, AMBER
LENS, BLUE
LENS, CLEAR
LENS, GREEN
LENS, RED

ASS'Y., REFLECTOR, HALOGEN-WARNING, AMP

CABLE ASS'Y.,

KIT

with

SPLIT LENS, HALOGEN ONLY, SPECIFY COLORS

ASS'Y., REFLECTOR, HALOGEN WARNING, DEUTSCH
ASS'Y., REFLECTOR,

DEUTSCH

BRAKE/TAIL/TURN,

CABLE ASS'Y., with KIT, WATERPROOF
ASS'Y, REFLECTOR HALOGEN-LED, AMBER
ASS'Y, REFLECTOR HALOGEN-LED, BLUE
ASS'Y, REFLECTOR HALOGEN-LED, WHITE
ASS'Y, REFLECTOR HALOGEN-LED, GREEN
ASS'Y, REFLECTOR HALOGEN-LED, RED

ASS'Y, REFLECTOR HALOGEN-LED, RED, DEUTSCH

ASS'Y, REFLECTOR HALOGEN-LED, GREEN, DEUTSCH

ASS'Y, REFLECTOR HALOGEN-LED, BLUE, DEUTSCH

ASS'Y, REFLECTOR HALOGEN-LED, AMBER, DEUTSCH

ASS'Y, REFLECTOR HALOGEN-LED, WHITE, DEUTSCH

0 1 - 0 6 6 3 4 7 7 - _ _

1 5 - 0 6 1 4 1 6 - 2 4 0
6 8 - 11 8 3 7 2 6 - 1 S
6 8 - 11 8 3 7 2 6 - 2 S
6 8 - 11 8 3 7 2 6 - 3 S
6 8 - 11 8 3 7 2 6 - 4 S
6 8 - 11 8 3 7 2 6 - 5 S

0 2 - 0 3 6 3 1 8 9 - 0 0

0 1 - 0 4 4 0 6 2 4 - 1 5
0 2 - 0 3 6 3 1 8 9 - 0 1

0 1 - 0 6 6 3 4 7 7 1 _ _ _

0 2 - 0 3 6 3 4 8 3 _ _ S

0 2 - 0 3 6 3 1 8 9 - 0 2
0 2 - 0 3 6 3 1 8 9 - 0 3
0 1 - 0 4 4 2 1 9 9 - 1 5

0 1 - 0 6 6 3 4 7 7 2 _ _ _

0 2 - 0 3 6 3 3 1 8 - H 1
0 2 - 0 3 6 3 3 1 8 - H 2
0 2 - 0 3 6 3 3 1 8 - H 3
0 2 - 0 3 6 3 3 1 8 - H 4
0 2 - 0 3 6 3 3 1 8 - H 5

0 2 - 0 3 6 3 3 1 8 1 H 5

0 2 - 0 3 6 3 3 1 8 1 H 4

0 2 - 0 3 6 3 3 1 8 1 H 3

0 2 - 0 3 6 3 3 1 8 1 H 2

0 2 - 0 3 6 3 3 1 8 1 H 1

A/R

A/R
A/R

A/R

A/R
A/R

A/R

A/R
A/R

A/R A/R

A/R

ASS'Y., REFLECTOR (BRAKE/TAIL/TURN) AMP

GASKET, SURFACE MOUNT

3 8 - 0 4 6 3 9 2 4 - 0 0

ASS'Y., REFLECTOR (HALOGEN WARNING) 2P DEUTSCH

A/R

0 2 - 0 3 6 3 1 8 9 - 0 7

HALOGEN: WARNING

HALOGEN: B-T-T

LED: STEADY

LED: BRAKE-TAIL-TURN

+12 VDC

GROUND

TAILLIGHT / +12VDC

BRAKE LIGHT / +12VDC

GROUND

+12 VDC

GROUND

BRAKE LIGHT / +12VDC

TAILLIGHT / +12VDC

GROUND

HALOGEN: WARNING

HALOGEN: BRAKE/TAIL/TURN

LED: STEADY

LED: BRAKE/TAIL/TURN

RED

WHITE

RED

BLACK

WHITE

This wire will be the

BLACK-WHITE (24V)

YELLOW

BROWN

WHITE

GREEN or WHITE

or BLACK (12V)

WIRING:

color of the LED

Installation:

Caution:

Permanent mounting of this

product will require drilling. It is
absolutely necessary to make sure that
no other vehicle components could be
damaged by this process. Check both
sides of the mounting surface before
starting. If damage is likely, select a
different mounting location.
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
approximate mounting location to
make sure that the lighthead will not
interfere with any existing equipment.
Also be aware of any and all items on
the opposite side of the mounting
surface to prevent any possible
damage to existing components.

Remove the lighthead. Measure and
mark off onto the mounting surface,
the mounting holes and cut-out shown
in the mounting diagram.

Use a #30 drill bit to drill 4 pilot holes.

Using a cutting tool, cut an opening in
the mounting surface as indicated.

Extend the wires (or route the cable
assembly if included) to the power
source (see wiring). Test operation of
lighthead before securing to vehicle.

Secure the assembly onto the
mounting surface with the supplied
sheet metal screws.

IMPORTANT! Before returning the
vehicle to active service, visually
confirm the proper operation of this
product, as well as all vehicle
components/equipment.

CAUTION! DO NOT LOOK DIRECTLY

AT THESE LED’S WHILE THEY ARE

ON. MOMENTARY BLINDNESS AND/

OR EYE DAMAGE COULD RESULT!

IMPORTANT WARNING!