Whelen 7GCV6LRC User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road,
Chester, Connecticut 06412
Phone: [phone]
Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]

Vehicle Specific Lighthead Housings

for M4, M7, LINZ6, TIR3,

400, 500 & 700-series Lightheads

Installation Guide:

2005 - present

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

©2005 Whelen Engineering Company Inc.
Form No.13996J (050609)

Page 1

Installation:

WARNING: Lights on the front of the vehicle must be mounted a minimum of 18” apart,
measured from the center of the lighthead. They must also be a minimum of 30” from the road
and be mounted below the windshield.

1. Before mounting, be sure the vehicle is parked on a level surface. First install the supplied rubber
gasket onto the housing. Start the gasket at the bottom of the housing. The gasket is made longer
than needed and you will have to cut off the excess so it will fit. Pinching the back of the gasket
together as you install it, will make the job easier (see illustration). No gasket is needed for most
grille mount flanges.

2. Find the mounting location photo of the vehicle and lighthead you are doing the installation on.
The photo will show the mounting location for your vehicle. Some photos may have specific
mounting instructions for that particular vehicle.

3. Position the housing onto the mounting surface in the area indicated in the photo for your vehicle.
The housing is contoured to the body of each model vehicle and will fit perfectly when in the exact
mounting position it is designed for. In the part number of the housing there will be an “L” or an “R”
to indicate whether it goes onto the left or right of the vehicle.

Front fender of vehicle: Mount housing as far forward as possible for maximum effectiveness.

Front of vehicle: The housing mounts to the front of the hood. No less than 18” apart.

Vehicle grille: The housing will mount approximately to the upper corner of the grille. Each housing is

contoured to fit around the grille of the vehicle it is designed for (see photo for mounting location). No
gasket is used for most. The supplied clamp hooks into the grillee as shown below and on page 4.

4. When the housing is positioned in its exact location (fitting perfectly to the vehicle with no space at
all between vehicle and housing) check it with a level. When you have it level mark the mounting
holes off onto the mounting surface.

CAUTION: When mounting onto fiberglass, after you drill the mounting holes,
chamfer the top of the hole to prevent the fiberglass from cracking with use.

5. Drill the mounting holes with an appropriately sized drill bit. You will also need to
drill a wire hole. Refer to the lighthead manual for size and location.

6. Secure housing (with lighthead) to vehicle using supplied mounting hardware.

IMPORTANT: Certain housings may have up to four different sized mounting screws to match the
vehicle contour. To be sure you use the correct screws, insert them into the housing before
mounting. All four screws should extend out of the housing the same amount.

Chamfered

drill hole

"L" or "R" in part number
indicates left or right side
of vehicle

Start gasket on
bottom of housing

Gasket

Installation

Tip:

When installing the gasket,
pinch the top together to
open the gasket, which will

HOUSING

make installation easier.

Make sure the housing is
level with the road.

Also be sure that the
lighthead projects
straight forward
and not up or
down.

HOUSING

These drawings indicate

Grille clip mounting hardware

the order of mounting
hardware, lenses and
gaskets. Most grille light
housings do not use
gaskets. Certain models
use clamps which hook

Grille
mount
only

Use the lower, inner mounting hole for the grille
mount clip as shown above.

into the grille.

Mounting Gasket

500 Series

400/500 Series 18-1/2"
P/N 38-0542989-04

Grille
mount
only

400 Series

700 Series

IMPORTANT NOTE: This manual covers vehicle specific custom lighthead housings. If you
have a standard flat housing the mounting location will not be as critical as described here.
Housings mounted to the front of the vehicle must still be at least 18” apart.

Clamp will hook
around grille here

Grille
mount
only

Mounting Gasket

700 Series / 23"

P/N 38-0542989-05

Page 2