®
ENGINEERING COMPANY INC.
51 Winthrop Road
Chester, Connecticut 06412-0684
400 Series LED Lighthead
Installation Guide:
Phone: (860) 526-9504
Fax: (860) 526-4078
Internet: www.whelen.com
Sales e-mail: autosale@whelen.com
Canadian Sales e-mail: canadiansales@whelen.com
Customer Service e-mail: custserv@whelen.com
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.
• Proper installation of this product requires the installer to have a good understanding of automotive electronics,
systems and procedures.
• 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 any 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.
• If this product uses a remote device to activate or control this product, make sure that this control is located in
an area that allows both the vehicle and the control 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
For warranty information regarding this product, visit www.whelen.com/warranty
©2002 Whelen Engineering Company Inc.
Form No.13660J (030813)
Page 1
1" Dia. Hole
Mounting hole
for #6 sheet metal
screws (4 places)
2.100"
4.200"
1.187"
2.375"
1.070"
2.140"
1.735"
3.470"
.312"
DIA HOLE.
(2) PLACES
1" DIA.
WIRE
HOLE
Caution: This product is designed for improved visibility. Prior to
installing this product on any vehicle, check your state
motor vehicle codes to confirm that this product
complies with any and all state statutes.
Mounting:
1. Using the dimensions below, mark off and drill the two 5/16”
diameter vent tube holes and the 1” center wire hole into the
mounting surface. Check measurements before drilling.
Note: Make sure lighthead will not interfere with existing
equipment and be aware of any items on the opposite side
of the mounting surface.
2. Insert the 2 vent tubes extending from the rear of the lighthead
into their holes. With a scribe or similar tool, mark off the 4
mounting holes.
3. Using a drill bit sized for a #6 sheet metal screw (and the
thickness of the mounting surface), drill the four mounting holes.
Install a grommet (customer supplied) into the 1” wire hole.
4. Using appropriately sized wires (minimum 18 AWG wire size),
run the lighthead wires to their connections (see wire
designations on pg. 3). Fuse the +VBAT connections at 3 Amps
and test operation of lighthead before securing it to vehicle.
5. Position the lighthead onto the mounting surface and secure to
the vehicle using four #6 x 1-1/4” sheet metal screws.
Caution: 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. DO NOT
USE CIRCUIT BREAKERS WITH THIS PRODUCT!
Caution: This product draws significantly less current than a
standard incandescent automotive bulb. If your flasher
does not operate properly, it may be necessary to
replace your existing flasher module with a Whelen
3TERM flasher module. Contact your sales
representative for specific vehicle application.
Scan-Lock™ (White/Violet)
WARNING: Pattern selection requires the LED to be turned on.
Do not look directly at LEDs while the unit is in operation.
IMPORTANT: If you have a 24 volt lighthead, you will apply 24
volts to the Scan-Lock wire for flash pattern selection.
TO CHANGE PATTERNS: Apply +12 volts to the WHITE/VIOLET
wire for less than 1 second and release to cycle forward to the next
available pattern. Apply +12 volts to the WHITE/VIOLET wire for more
than 1 second and release to cycle back to the previous pattern.
TO CHANGE THE DEFAULT PATTERN: When the desired pattern is
displayed, allow it to run for more than 5 seconds. The lighthead will
now display this pattern when initially activated.
TO RESTORE THE FACTORY DEFAULT PATTERN: With the power
to the lighthead off, apply +12 volts to the WHITE/VIOLET wire. Now
turn power to the lighthead on. The factory default pattern should now
be displayed.
NOTE: A Normally Open momentary switch can be used to
control Scan-Lock™ operation.
Flash Patterns: SignalAlert™ 75 > SignalAlert™ 150 > SingleFlash
375 > SingleFlash 150 > SingleFlash 75 > SingleFlash 150 >
DoubleFlash 150 > DoubleFlash 75 > CometFlash® 75 >
ActionFlash™ > ModuFlash™ > ComAlert™ > ActionScan™ >
SignalAlert™ Steady > Steady (Brake) Available Brake Patterns:
SignalAlert™ Steady > Steady Brake
IMPORTANT! Before returning this vehicle to active service,
visually confirm the proper operation of this product, as well as
all vehicle components/equipment.
Page 2
21
14 15
16
23
29
18 1910
22
234
1
131211
67895
27 28262524
17
01-0683759 _ _ _
TERMINATION
LED / LENS COLOR
STYLE
ORDERING INFORMATION
STYLE
L.E.D. / LENS COLOR
TERMINATION
B T T (MIN)
WIDE-ANGLE
FLOOD
BACK-UP
TURN-CLEARANCE
B T T (MAX)
BACK-UP (24V)
E = B T T (MAX - 24V)
NONE
DEUTSCH
2 = / /
5 =
6 =
7 =
9 =
B = / /
G =
//
0 =
1 =
A=
B =
C =
G =
R =
1 =
2 =
4 =
5 =
AMBER / AMBER
BLUE / BLUE
WHITE / CLEAR
GREEN / GREEN
RED / RED
AMBER / CLEAR
BLUE / CLEAR
GREEN / CLEAR
RED / CLEAR
WIRE COLOR
FUNCTION
WIDE ANGLE / FLOOD
Colored Wire
Wire color is whatever the color its
LED is, when the light is switched on.
Positive(+
)
Black(12V
)
White/Violet
Ground
Scan-Lock™
Yellow
Brown
White(12V
)
White/Violet
White/Black(24V
)
Black/
White(24V
)
Black/
White(24V
)
Ground
Ground
Ground
White
Black
Stop, Turn
Positive(+
)
/ Positive(+
)
Taillight /
Ground
Scan-Lock™
Positive(+
)
Ground
BRAKE / TAIL / TURN
BACK-UP / TURN
GASKET
38-0262867-00
LABEL
10-0522905***
SUB ASSY, B/T/T
01-026E462-50
SUB ASSY TURN CLEARANCE AMBER,/ ,
01-0283458-19
SUB ASSY BACK-UP WHITE,,
01-0283458-37
SUB ASSY LED FLOOD WHITE,,
01-0283458-36
SUB ASSY LED WIDE ANGLE RED,-,
01-0283458-55
SUB ASSY LED WIDE ANGLE GREEN,-,
01-0283458-45
SUB ASSY LED WIDE ANGLE WHITE,-,
01-0283458-35
SUB ASSY LED WIDE ANGLE BLUE,-,
01-0283458-25
SUB ASSY LED WIDE ANGLE AMBER,-,
01-0283458-15
SUB ASSY LED MIN, B/T/T,
01-0283458-52
LENS, OPTIC, withRED SEAL
68-1183726-5S
LENS, OPTIC, withGREEN SEAL
68-1183726-4S
1
LENS, OPTIC, withCLEAR SEAL
68-1183726-3S
LENS, OPTIC, withBLUE SEAL
68-1183726-2S
LENS OPTIC AMBER SEAL, , with
68-1183726-1S
LENS, NON OPTIC, withRED SEAL
68-3183725-5S
LENS, NON OPTIC, withCLEAR SEAL
68-3183725-3S
LENS NON OPTIC AMBER SEAL, , with
68-3183725-1S
15-061416-200
SCREW #6 X 1 1/4" PPHSMS,
LIGHTHEAD 400 LED WIDE ANGLE GREEN-,
LIGHTHEAD 400 LED WIDE ANGLE WHITE-,
LIGHTHEAD 400 LED WIDE ANGLE BLUE-,
LIGHTHEAD 400 LED WIDE ANGLE AMBER-,
LIGHTHEAD 400 LED BACK-UP WHITE,
LIGHTHEAD 400 LED FLOOD WHITE,
LIGHTHEAD 400 LED WIDE ANGLE RED-,
LIGHTHEAD 400 LED TURN/CLEARANCE AMBER,
LIGHTHEAD 400 LED B/T/T, RED LENS
LIGHTHEAD 400 LED B/T/T, RED LENS (DEUTSCH®)
01-06837599A0
01-06837597C*
01-06837596C0
01-06837595R0
01-06837595G0
01-06837595C0
01-06837595B0
01-06837595A0
01-06837596C1
01-066E462-R1
01-066E462-R0
LIGHTHEAD 400 LED FLOOD, WHITE (DEUTSCH)
01-026E462-51
1
SUB ASSY DEUTSCH, B/T/T ( )
SUB ASSY LED FLOOD WHITE DEUTSCH,,()
02-0383458136
1
01-06837595*1
LIGHTHEAD 400 LED WIDE-ANGLE (DEUTSCH)
02-0383458115
A/R SUB ASSY LED WIDE ANGLE AMBER DEUT, - , ( SCH)
02-0383458125
A/R
SUB ASSY LED WIDE ANGLE BLUE DEUT, - , , ( SCH)
02-0383458155
SUB ASSY LED WIDE ANGLE RED DEUT, - , ( SCH)
01-0683759GC1
LIGHTHEAD 400 LED BACK-UP 24V WHITE DEUTSCH,, ( )
02-0383458137
A/R SUB ASSY BACK-UP WHITE DEUTSCH,,( )
02-038345813G
1
SUB ASSY BACK-UP 24V WHITE DEUTSCH,,,( )
LIGHTHEAD 400 LED B T T MAX 24V RED DEUT/ / , , , ( SCH)
01-0683759ER1
02-038345815E
1
SUB ASSY, B/T/T, MAX, 24V (DEUTSCH)
QTY
ITEM
PART NUMBER
DESCRIPTION
QTYQTYQTYQTYQTY
QTYQTYQTY QTYQTYQTYQTYQTY
26
21
20
1
2
3
4
5
6
7
8
9
14
13
12
11
10
15
16
17
18
19
23
22
24
25
27
28
29
A/R
4 44
1
4
1
1
4
44
1
1
1
1
1
1
1
1
1
1
1
44441444
A/R
1
111
A/R
A/R
11111111111111
11111111111111
CAUTION! DO NOT LOOK DIRECTLY AT
THESE LEDS WHILE THEY ARE ON.
MOMENTAR Y BLINDNESS AND/OR EYE
DAMAGE COULD RESULT!
IMPORTANT WARNING!
Page 3
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