Whelen 508 User Manual

®

ENGINEERING COMPANY INC.

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

Installation Guide:

508 Series Lighthead

(Linear Strobe)

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

©2004 Whelen Engineering Company.
Form No.13886A (091406)

Page 1

Installation:

There are two ways to mount the 508 lighthead, each offering
its own benefits:

• Secured to vehicle using supplied #8 x 1½” sheet
metal screws.

• Secured to vehicle using an industry-strength, double­sided adhesive tape, like Scotch® brand VHB™ model
4956 foam tape.

This manual will outline the first procedure.

1. Position the 508 lighthead in its mounting location. Make
sure that the 508 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.

2. Position the supplied mounting template on the mounting
location and temporarily secure it to the surface. Be sure
the template is FLAT against the surface.

NOTE: Before proceeding, place the reflector against the
template and confirm that the mounting holes on the
template line up with the actual mounting holes on the
reflector.

NOTE: Be sure the drainage provisions for both the
reflector and gasket are on the bottom. Each gasket is
labeled.

3. Using a .250” drill bit, drill the mounting holes as shown
on the template.

4. Using a .375” drill bit, drill a wire passage hole where
indicated on the template.

5. Route the cable assembly through the wiring hole
towards the strobe power supply. Be sure that both ring
terminals are grounded to the vehicle chassis ground.

6. Plug the 508 into the cable and plug the cable into the
strobe power supply. Test operation of the 508 before
securing it to the vehicle.

7. Install the round hole grommets into the mounting holes.
Position the lens onto the reflector. Place this assembly
onto the mounting surface and secure using the supplied
mounting screws.

WARNING! To insure proper mounting of this product,
special round hole screw grommets have been included
with your mounting hardware. Do not install this product
without these grommets! Over-tightening the mounting
screws may cause permanent damage to the reflector
and/or lens!

Ring Terminals

(to chassis ground)

Mounting Screw

(#8 x 1.5“ PPHSMS)

Reflector
AMP
Deutsch

02-0362189-00
02-0362189-01

(Deutsch)
A Anode (Red)
B Cathode (Black)
C Trigger (White)

Lens, Amber

Blue

Clear

Green

Red

E-spec Red

Split

Cable (Deutsch - 15’)

P/N 01-0442199-15

(AMP)
1 Anode (Red)
2 Cathode (Black)
3 Trigger (White)

68-3183365-10
68-3183365-20
68-3183365-30
68-3183365-40
68-3183365-50
68-3183365E50
02-0383470-**

Cable (AMP - 15’)

P/N 01-0440624-15

Round Hole

Screw Grommets

P/N 21-1708080603

Mounting Gasket

P/N 38-0462719-00

(not used with

adhesive-type mounting)

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