Whelen 70F000AR User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684

700 Series Halogen Lighthead

Installation Guide:

Phone: [phone]
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.

• Failure to use specified installation parts and/or hardware will void the product warranty!

• 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.13626H (120811)

Page 1

Available Mounting Options

Housing (w/studs):
Housing:
Mounting Hardware & Gasket:

11-483530-011

11-483530-111

01-0483596-00

Housing:
Housing w/Studs:
Mounting Hardware & Gasket:

11-463255-011

11-463255-111

01-0463331-00

Surface Mount Housing:
Black:
Chrome:

01-0464758-00

01-0464758-01

Lighthead Housing:
Drivers Side:
Passengers Side:

01-0462735-01

01-0462736-01

KIT / 700 Flange Halogen / Strobe 15° Surface Mount
WHITE / / CHROME / BLACK01-0484709-02 / 01-0484709-01 01-0484709-00

BLACK +12VDC / BRAKE

(-) GROUND

RED +12VDC / TAIL

WHITE

BRAKE/
TAIL/TURN
or ARROW

WHITE

RED +12VDC

(-) GROUND

BACK-UP or

SCENELIGHT

Installation:

3.438"

6.876"

.454"

.909"

1.380"

2.760"

1.188"

2.375"

3.281"

6.562"

3.050"

6.100"

1/4” Mounting

Hole (Qty. 4)

CUT-OUT and REMOVE THIS AREACUT-OUT and REMOVE THIS AREACUT-OUT and REMOVE THIS AREA

MOUNTING DIAGRAM / 700 SERIES HALOGEN LIGHTHEADMOUNTING DIAGRAM / 700 SERIES HALOGEN LIGHTHEAD

NOT TO SCALE / For reference only.NOT TO SCALE / For reference only.NOT TO SCALE / For reference only.

1. Using the measurements in the mounting diagram, mark off the 4 mounting holes and center cut-out.

2. Drill the 4 mounting holes and cut-out center area using the measurements shown here.

3. Attach the lighthead securely to the vehicle using the 4 Phillips head sheet metal screws and flange grommet supplied.

4. Extend the wires to their connections.

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!

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

WARNING: Do not replace Halogen
Bulbs with ones of higher wattage
than (see Parts List).recommended

WARNING: Do not replace Halogen Bulbs with ones of higher wattage

than ( ee Parts List)recommended s .WARNING:

WATTAGE:

12V - 35W
12V - 50W
12V - 60W
12V - 27W
12V - 20W

12.8V - 14V, 27/12W
28V - 35W

0 =
1 =
2 =
3 =
4 =
5 =
6 =

CONNECTOR / CABLE

3 POS. 2 WIRE AMP CONN without CABLE
3 POS. 2 WIRE AMP CONN with CABLE
2 WIRE DEUTSCH CONN without CABLE
2 WIRE DEUTSCH CONN with CABLE
2 POS. AMP CONN without CABLE
3 POS. 3 WIRE AMP CONN without CABLE
3 POS. 3 WIRE AMP CONN with CABLE
3 WIRE DEUTSCH CONN without CABLE
3 WIRE DEUTSCH CONN with CABLE

0 =
1 =
2 =
3 =
4 =
5 =
6 =
7 =
8 =

WATTAGE

BASIC P/N

COLOR CONNECTOR & CABLE REQ.

01-0683709_ _ _

PART NUMBER KEY:

NOTE: If you have a

scene light lens, the
date stamp on the
lens must be located
on the top when
mounted.

9
8

8

7

6

5

4

2

3

2

1

1

1
1

1

0

9

700 SERIES HALOGEN LIGHTHEAD

, l , , Brake/ /Snap-In Style: Warning Scene ight Back-Up Tail Turn

LENS TYPE & COLOR
A=
R =
Q =
T =

AMBER OPTIC
RED OPTIC

RED ARROW

AMBER ARROW

CABLE & CONNECTOR

Without Cable / AMP CONNECTOR
With Cable & AMP CONNECTOR
Without Cable / DEUTSCH CONNECTOR
With Cable & DEUTSCH CONNECTOR

0 =
1 =
2 =
3 =

PART NO. KEY:

CABLE & CONNECTOR

BASIC P/N

LENS TYPE & COLOR

01-0683742-_ _

700 SERIES HALOGEN LIGHTHEAD

/Bayonet Style: Brake/Tail Turn

NOTE: Cables shown are
for reference only and are
not included.

NOTE: Cables shown are
for reference only and are
not included.

12

30

20

36

23

24

19

18

13

22

21

25 26 27

28 29 35

1

234

56

7

89

10

11

13

1

8

14

17

15

6

7

16

9210311 12

COLOR:
A=
B =
C =
G =
R =

=
5 =
Q =
T =
S =

AMBER
BLUE
CLEAR

GREEN
RED
SPLIT

KKKE-SPEC RED

RED ARROW

AMBER ARROW

SCENELIGHT

R

1

LABEL, 700 SERIES SCENELIGHT

10-0522890-04

1

MODEL 700 SCENELIGHT

01-06837090S_

MODEL 700 STOP/TAIL/TURN

01-06837095__

A/R

A/R

46-0742624-03

46-0742651-03

SNAP-IN CLIP (3 WIRE) WATERPROOF

SNAP-IN CLIP (3 WIRE)

A/R

A/R

A/R

A/R

4

1

1

1

A/R

A/R

1

1

1

A/R

A/R

A/R

4

A/R

A/R

1

1

1

A/R

1

1

A/R

A/R

1

1

10-0522890-03

LABEL, 700 SERIES STOP/TAIL/TURN

ASSY, LAMP, 12.8V-14V, 27/12W

34-0062389-00

LENS, RED ARROW W/ SEAL

68-1183529-5S

LENS, AMBER ARROW W/ SEAL

68-1183529-1S

LENS, SCENELIGHT W/ SEAL

68-1183464-3S

TAPE, STRAIN RELIEF

1

66-0422787-00

A/R

68-1183582E5S

LENS, KKKE-SPEC RED W/ SEAL

SNAP-IN CLIP (2 WIRE) 2 POS. AMP

46-0742684-01

A/R

A/R

A/R

34-0041987-04

34-0041987-03

ASSEMBLY, SNAP-IN LAMP (12V-27H)

ASSEMBLY, SNAP-IN LAMP (12V-20W)

10-0522890-02

1

22-0463039-00

HOUSING, RIGHT ANGLE CLIP DETAIL

02-0363417__S

A/R

LENS, SPLIT W/ SEAL

A/R

46-0742624-02

SNAP-IN CLIP (2 WIRE)

34-0041987-00

ASSEMBLY, SNAP-IN LAMP (12V-35W)

68-1183582-5S

LENS, RED W/ SEAL

68-1183582-4S

LENS, GREEN W/ SEAL

68-1183582-3S

LENS, CLEAR W/ SEAL

68-1183582-2S

LENS, BLUE W/ SEAL

A/R

1

1

1

1

A/R

A/R

A/R

A/R

A/R

4

01-0683709___

MODEL 700 HALOGEN

15-061416-240

#6 X 1 1/2" PHIL PAN HD SMS

68-1183582-1S

LENS, AMBER W/ SEAL

68-5983140-01

38-0463342-00

10-0320776-00

01-0440624-15

700 HALOGEN REFLECTOR

GASKET

MADE IN THE USA FLAG LABEL

LABEL, 700 SERIES HALOGEN

KIT, CABLEASSEMBLY

A/R

01-0442199-15

KIT, CABLEASSEMBLY (WATERPROOF)

A/R

46-0742651-02

SNAP-IN CLIP (2 WIRE) WATERPROOF

34-0041987-01

ASSEMBLY, SNAP-IN LAMP (12V-50W)

A/R

A/R

A/R

66-0716286-00

ADHESIVE GEL

A/R

66-0716886-00

PRIMER

ASSEMBLY, SNAP-IN LAMP (12V-60W)

34-0041987-07

A/R

34-0041987-02

A/R

ASSEMBLY, SNAP-IN LAMP (28V-35W)

4

1

1

1

1

1

1

A/R

A/R

1

1

1

01-06837093S0

MODEL 700 BACK-UP

11-76D257-000

1111

FLANGE GROMMET, 700 SERIES

2

3

11

26

12

27

13

28

14

29

15

30

16

31

17

32

18

33

19

34

20

35

4

5

6

21

7

22

8

23

9

24

10

25

1

ITEM PART NUMBER DESCRIPTION

QTY QTY QTYQTY

36

5

EPOXY

66-0716003-1C

11-76D257-000

FLANGE GROMMET, 700 SERIES

1

2

3

ITEM

PART NUMBER

DESCRIPTION

QTY

11

12

13

14

15

16

17

4

5

6

7

8

9

10

1

A/R

A/R

A/R

4

1

A/R

A/R

1

A/R

A/R

A/R

A/R

A/R

A/R

1

A/R

SOCKET ASS'Y AMP,

REFLECTOR TAIL TURN 700 SERIES, STOP/ / ,

MODEL 700 SERIES TAIL TURN, STOP/ /

SCREW #6 X 1-1/2" PPHSMS,

LENS MODEL 700 SERIES ARROW RED,,

LENS MODEL 700 SERIES RED,,

SOCKET ASS'Y DEUTSCH,

DEUTSCH 3 POS SOCKET WEDGE

DEUTSCH 3 POS SOCKET CONNECTOR

LENS MODEL 700 SERIES AMBER,,

LAMP TAIL TURN #1157, STOP/ /

3 POS PIN HOUSING

LENS MODEL 700 SERIES ARROW AMBER,,

KIT CABLE ASS Y WATERPROOF,',

KIT CABLE ASS Y AMP,',

GASKET MOLDED MODEL 700,,

38-0463342-00

01-0442199-15

01-0440624-15

33-0517116-02

68-5983700-01

39-1H16424-3S

39-1H03024-35

68-1183582-1S

68-1183582-5S

34-0021562-00

33-0517116-01

39-0403013-04

15-061416-240

01-0683742-__

68-1183529-1S

68-1183529-5S

Page 3