Whelen 90F000AR User Manual

ENGINEERING COMPANY INC.

51 Winthrop Road Chester, Connecticut 06412-0684 Phone: (860) 526-9504

Installation Guide:

900 Series Lighthead

Halogen & Strobe

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.

• 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

Page 1

STYLE 1 - WARNING 2 3 4 5 6

- SCENE

- B /T/T

- STROBE

- BACK-UP

- SCENE / 24V

COLOR / LENS TYPE R - RED B G A C

- BLUE

- GREEN

- AMBER

- CLEAR

CABLE: 01- AMP no CABLE

- AMP with CABLE 2- DEUTSCH no CABLE 3- DEUTSCH with CABLE

PART NUMBER KEY:

STYLEBASIC P/N CABLECOLOR

01-0683694_ _ _

8 9

11 12

IMPORTANT NOTE: Only use replacement

bulbs of the same specifications.

- AMBER ARROW

- GRADIENT SCENE

T Z

NOTE: Halogen cable shown for reference only and is not included.

C D

This list includes 900 Series Replacement Parts Exclusive to Lightheads using the Any lenses, gaskets, wire harneses or mounting hardware for this reflector are listed below.

Max Beam Reflector.

DIRECTIONAL MAX BEAM REFLECTOR W/ SEAL

BRAKE/TAIL/TURN LAMP #1157

34-0021562-00

33-0042829-00

LAMPHOLDER ASSY BAYONET WARNING- AMP / TWIST-IN

01-0683692-( )

900 SERIES FINAL ASSY. / AMP

68-5981389-08

LAMPHOLDER ASSY BAYONET WARNING- DEUTSCH / TWIST-IN

33-0042829-01

900 SERIES FINAL ASSY. / DEUTSCH

01-0683692-( )

PART NUMBER

DISCRIPTION

QTY

ITEM

QTY

MAX-BEAM REFLECTOR

5 * Y X Q

- KKKE RED

- SPLIT

- 13 SCENE

- 26 SCENE

- RED ARROW

º º

CABLE 0 1

- AMP without CABLE

- AMP with CABLE

- DEUTSCH without CABLE

- DEUTSCH with CABLE

2 3

COLOR

PART NUMBER

CABLE REQ.

01-0683692-_ _

COLOR RA- RED

- AMBER

- RED ARROW

- AMBER ARROW

Q T

900 Series Lighthead / Replacement Parts

30 32

NOTE: Tie the ring terminals to the chassis ground. (STROBE ONLY)

900 SERIES BACK-UP/

QTY QTY

900 SERIES STROBE/

PART NUMBERITEMQTY

DESCRIPTION

900 SERIES WARNING LIGHT/

QTYQTY

900 SERIES SCENE 12V//

900 SERIES / BRAKE/TAIL/TURN

QTY

900 SERIES SCENE 24V//

QTY

900 SERIES GRADIENT SCENE 12-24V//

01-06836945C_ _

01-06836944_ _

01-06836943_ _

01-06836942_ _

01-06836941 _ _

01-06836946_ _

01-0683694 _Z _

34-0041987-03

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

A/R

REFLECTOR, 900 STROBE ASSY (WATERPROOF)

A/R A/R

HARNESS, 2 WIRE 3 POS DEUTSCH

46-0722159-02

A/R

HARNESS, 3 WIRE 3 POS DEUTSCH

46-0722159-01

0 2 - 0 3 8 3 6 7 8 - 0 1

A/R

02-0383678-00

A/R

38-0481690-00

68-5983540-02

01-0440624-15

A/R

15-081416-240

A/R

68-1183542-10

A/R

34-0041987-00

34-0041987-07

46-0722879-00

HARNESS, 2 WIRE 3 POS PIN HSG

HARNESS, 3 WIRE 3 POS PIN HSG

46-0722879-01

68-1183542-20

68-1183542-30

68-1183542-40

68-1183542-50

68-1183542E50

02-0361457-26

02-0361457-13

68-1181745L1P

68-1181745L5P

34-0062389-00

02-0363407-**

A/R

111

A/RA/R

A/R

A/R A/R A/R A/R

01-0442199-15

CABLE ASSY. (DEUTSCH)

11-786976-000

11111

FLANGE GROMMET, 900 SERIES

A/R

34-0041987-02

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

A/R

ASSY, SNAP-IN LAMP (12V-50H)

34-0041987-01

A/R

68-1983892-30

A/R

46-0723682-00

HARNESS, 2 WIRE 2 POS DEUTSCH

REFLECTOR 900 STROBE METAL with SEAL

///

#8 X 1 1/2" PHILLIPS PAN HEAD SMS

GASKET

CABLE ASSEMBLY

LENS RED/

LENS GREEN/

LENS CLEAR/

LENS BLUE/

LENS AMBER/

SNAP-IN LAMP 12V-35H

SNAP-IN LAMP 12V-60W

LENS KKKE-SPEC RED//

REFLECTOR / 900 HALOGEN / /

METAL with SEAL

LENS ASSEMBLY SCENELIGHT 26

LENS ASSEMBLY SCENELIGHT 13

ARROW LENS AMBER with PAINT LEFT HAND

ARROW LENS RED with PAINT LEFT HAND

DUAL FILAMENT LAMP 27W-12W

LENS ASSY 900 SERIES HALOGEN SPLIT

LENS GRADIENT SCENE CLEAR

Mounting:

1. Using the mounting diagram on the next page, mark off the mounting holes and the “cut-out” area.

2. Using a 1/4ʺ drill bit, drill the mounting holes then carefully cut and remove the area of the mounting surface as shown. Do not remove the mounting surface where the mounting holes are drilled.

3. Insert the supplied flange grommet into the mounting holes.

4. Route the cable through the wiring hole to the power supply. (For strobe, be sure that both ring terminals are grounded to the vehicle chassis.) Plug the cable into the power supply and test the operation of the lighthead, then position the Lighthead components onto the mounting surface and secure them to the vehicle using the four #8 x 1½” sheet metal screws.

NOTE: When mounting a “gradient” scenelight lens, the word “TOP” imprinted on the lens must be located on top of the lens when mounted.

WARNING! The strobe light power supply is a high voltage device. Do not remove strobe tubes or dismantle strobe lightheads in system while in

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operation. Wait 10 minutes after turning off power before working or troubleshooting.

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 that load. DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT!

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