Whelen 45B52 - Manual (Page 2)

Page 2
Lighthead mounting holes, fit onto raised bosses on mounting bracket.
LED LIGHTHEAD
S T R O B E
LIGHTHEAD
Clips on bracket snap
over edge of lighthead.
Fig. 4
Rotator base
sits on tape Rotator base
sits on tape
Rotator Removal and Installation
Rotator base
sits on tape
Tape
Fastex
Grommet
Side View
TAPE
Fig. 3
Screws thread into fastex grommet
that is inserted into base.
IMPORTANT! The lightbar should be located a minimum of 16" from any radio antennas!
Installation:
Note: When routing wires, it is important to choose a path that will keep them away from
excessive heat or any vehicle equipment that could compromise the wires integrity.
1. This lightbar mounts with 1-1/4” bolts extending from the rear of the housing. Position the unit in its exact
mounting location and use an awl or other suitable tool to scribe the areas to be drilled (Fig. 1).
2. Remove the lightbar. Using a drill bit sized for a 3/8” step bolt, drill a hole in each of the areas scribed in
step 1. Return the lightbar to its mounting location and secure it to the vehicle with supplied hardware.
Wiring:
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!
IMPORTANT! All Positive input wires must be individually fused. Due to the large number of possible configurations, each with their own
fusing requirements, it is the installation technician's responsibility to determine the maximum current draw for each input wire and fuse that
wire at 125% of that value.
Servicing your lightbar:
NOTE: Before opening your lightbar for service or repair always be sure to
Disconnect the lightbar from it’s power source. (See strobe light warning below.)
Lens or Lenscap: Removal or Installation
1.To remove a lenscap, remove the 2 screws from the end of the lenscap, and the 2
screws from the opposite side that thread through the lens retainer into the lighthead
mounting bracket. Pull the lenscap off (Fig. 2).
2.To remove a lens, remove the 4 phillips head screws that thread through the lens
retainer into the lighthead mounting bracket and then pull the lens off.
Removing an Existing Rotator:
1. Disconnect the lightbar from power.
WARNING: For lightbars with
strobe lights, wait a minimum of 10
minutes before proceeding.
2. Remove the lens or lenscap in front of
the rotator you wish to replace.
3. Disconnect the rotator from the
lightbar’s harness by unplugging the Amp 2 position pin connector. NOTE: It is easier to remove the
existing rotator from the extrusion if the reflector is facing the front of the lightbar (Fig. 3).
4. Loosen the two screws that secure the rotator base to the extrusion (2 or 3 turns) and lift the rear of the
rotator base then remove the rotator from the extrusion.
Installation of a New Rotator:
1. Remove any adhesive tape on the lightbar base left from the old rotator.
2. Remove the backing from the piece of 2-sided tape and apply it to the lightbar base in the same location
as the previous tape (Fig. 3).
3. Plug the new rotator into the old rotator’s harness plug.
4. Place the new rotator inside the extrusion in the same area the old rotator was removed from but don’t
tighten the screws yet.
5. Remove the backing from the tape and press the rotator base down onto the lightbar base firmly, being careful not pinch any wires between the base
and extrusion, then tighten the mounting screws.
6. Reconnect lightbar to power and test for proper operation then return any lenscaps or lenses you had to remove.
Removal and
Installation of Lens
and Lenscap
Fig. 2
Remove screws
from end of lenscap
Remove screws and lens
retainer, then remove
lens or lenscap
LENS RETAINER
MOUNTING
BRACKET
Fig. 1
Mounting the Lightbar
to the vehicle
3/8" X 16 HEX NUT
3/8" LOCKWASHER
3/8" FLATWASHER
3/8 -16 X 1-1/4 STEP BOLT
Servicing Lightheads: Strobe, Halogen or LED
WARNING: The strobe light power supply is a high voltage device. Do
not touch or remove the strobe tube assembly while in operation. Wait 10
minutes after disconnecting the unit from its power source before
starting any work or trouble shooting.
Removal and Installation
1. Disconnect the lightbar from it’s power source.
2. To remove the lighthead, first remove the lens or lenscap necessary to
access the lighthead you wish to service or replace.