Whelen 4ILKT1 User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]

400 Series Lighthead Housing

Installation Guide:

2001 Navistar

Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Canadian Sales e-mail: [e-mail]
Customer Service e-mail: [e-mail]

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

©2001 Whelen Engineering Company Inc.
Form No.13639A (071307)

Page 1

End of body panel

G

R

F

R

O

N

T

W

H

E

E

L

W

E

L

L

First find the center point
using these dimensions.

I

L

L

14"

FIG. 1

Drill mounting
hole here.

FRONT TIRE

5.188"

Drill mounting

hole here.

4.5"

Bottom of
wheel well

HEADLIGHT

This line must be level with
the road. Vehicle must

NOTE:

be parked on a level surface.

Outside view of right (passengers)
side of vehicle shown.

2.75"2.75"

4.6"4.6"

HEADLIGHT

FRONT FENDER

HEADLIGHT

Using your center line, mark off and drill two
mounting holes using a #5 or 7/32" drill.

FIG. 2

Installation:

You will need to park the vehicle on a level surface for the
installation. As the diagram shows, the horizontal mounting hole line

must be level with the road. Draw this line using a level.

1. Find the center line of your lighthead using the dimensions in
Figure 1. Measure from the end of the body panel and draw the
verticle line. Measure from the bottom of the wheel well and,
using a level, draw the horizontal line.

2. Measure and drill the 2 mounting holes (Fig. 2).

3. If you are installing a strobe or halogen lighthead measure out
from the center line and cut-out and remove the area shown in
Figure 3 . If you have an LED lighthead you will just need to drill
a 1” wire hole as shown in Figure 4.

4. Attach the lighthead to the vehicle (Fig. 5). Be sure to locate the
wire exit hole (in the rear casting) on the bottom and run the
wires through before tightening the mounting bolts.

5. Extend the lighthead wires to your power source.

Draw these dimensions from your center line
and remove the shaded area.

FIG. 3

STROBE OR HALOGEN LIGHTHEAD

7/8"

1" diameter

wire access hole

FIG. 4

LED LIGHTHEAD

HEADLIGHT

Page 2