Whelen 7GCV6LRC - Manual (Page 2)

Page 2
Clamp will hook
around grille here
Use the lower, inner mounting hole for the grille
mount clip as shown above.
Grille clip mounting hardware
500
Series
Grille
mount
o n l y
400
Series
Grille
mount
o n l y
700
Series
Mounting Gasket
400/500 Series 18-1/2"
P/N 38-0542989-04
Grille
mount
o n l y
These drawings indicate
the order of mounting
hardware, lenses and
gaskets. Most grille light
housings do not use
gaskets. Certain models
use clamps which hook
into the grille.
Mounting Gasket
700 Series / 23"
P/N 38-0542989-05
IMPORTANT NOTE: This manual covers vehicle specific custom lighthead housings. If you
have a standard flat housing the mounting location will not be as critical as described here.
Housings mounted to the front of the vehicle must still be at least 18” apart.
Installation:
WARNING: Lights on the front of the vehicle must be mounted a minimum of 18” apart,
measured from the center of the lighthead. They must also be a minimum of 30” from the road
and be mounted below the windshield.
1. Before mounting, be sure the vehicle is parked on a level surface. First install the supplied rubber
gasket onto the housing. Start the gasket at the bottom of the housing. The gasket is made longer
than needed and you will have to cut off the excess so it will fit. Pinching the back of the gasket
together as you install it, will make the job easier (see illustration). No gasket is needed for most
grille mount flanges.
2. Find the mounting location photo of the vehicle and lighthead you are doing the installation on.
The photo will show the mounting location for your vehicle. Some photos may have specific
mounting instructions for that particular vehicle.
3. Position the housing onto the mounting surface in the area indicated in the photo for your vehicle.
The housing is contoured to the body of each model vehicle and will fit perfectly when in the exact
mounting position it is designed for. In the part number of the housing there will be an “L” or an “R”
to indicate whether it goes onto the left or right of the vehicle.
Front fender of vehicle: Mount housing as far forward as possible for maximum effectiveness.
Front of vehicle: The housing mounts to the front of the hood. No less than 18” apart.
Vehicle grille: The housing will mount approximately to the upper corner of the grille. Each housing is
contoured to fit around the grille of the vehicle it is designed for (see photo for mounting location). No
gasket is used for most. The supplied clamp hooks into the grillee as shown below and on page 4.
4. When the housing is positioned in its exact location (fitting perfectly to the vehicle with no space at
all between vehicle and housing) check it with a level. When you have it level mark the mounting
holes off onto the mounting surface.
CAUTION: When mounting onto fiberglass, after you drill the mounting holes,
chamfer the top of the hole to prevent the fiberglass from cracking with use.
5. Drill the mounting holes with an appropriately sized drill bit. You will also need to
drill a wire hole. Refer to the lighthead manual for size and location.
6. Secure housing (with lighthead) to vehicle using supplied mounting hardware.
IMPORTANT: Certain housings may have up to four different sized mounting screws to match the
vehicle contour. To be sure you use the correct screws, insert them into the housing before
mounting. All four screws should extend out of the housing the same amount.
Chamfered
drill hole
Also be sure that the
lighthead projects
straight forward
and not up or
down.
Make sure the housing is
level with the road.
Start gasket on
bottom of housing
"L" or "R" in part number
indicates left or right side
of vehicle
When installing the gasket,
pinch the top together to
open the gasket, which will
make installation easier.
Gasket
Installation
Tip:
HOUSING HOUSING