Whelen G1MM90 User Manual

®

ENGINEERING COMPANY INC.

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

for the Guardian™ Lightbar

Kit# G1MM90 & G7MM90

Installation Guide:

Cigar Cord Conversion

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: Lightbars

For warranty information regarding this product, visit www.whelen.com/warranty

© 2003 Whelen Engineering Company Inc.
Form No.13801F (031009)

Page 1

GUARDIAN
STROBE
POWER
SUPPLY

IMPORTANT! The lightbar should be located a minimum of 16" from any radio

Secure
strain

relief

here.

antennas!

Magnet Installation:

WARNING: The use of any magnetic or suction cup mounted warning light on the
outside of a vehicle, while in motion, is not recommended and is at the sole discretion
and risk of the user.

WARNING: The strobe light power supply is a high voltage device. Do not remove strobe
tubes or dismantle strobe lightheads in the system while it is in operation. Wait 10
minutes after turning off power before starting work or any trouble shooting.

Enlarge 4 mounting
holes with 7/32 drill.

Fig 2 G1 / G2 / G3 & G4 Series

REAR OF LIGHTBAR

)

POS(+

RIBBED

W

IRE

SMOOTH

WIRE

NEG (-)

90 LB MAGNET

1/4" INTERNAL TOOTH

IMPORTANT WARNING!

CAUTION! DO NOT LOOK DIRECTLY AT
THESE LEDS WHILE THEY ARE ON.
MOMENTARY BLINDNESS AND/OR EYE
DAMAGE COULD RESULT!

LOCKWASHER1/4"

#14 X 3/4 HEX HEAD
"A" POINT SMS

To install magnets as shown, you will first need to enlarge the mounting screw holes in
the base using a 7/32 drill bit.

Cigar plug conversion:

1. Remove the dome to access the inside of the
lightbar (see lightbar manual.)

2. Remove the strain relief and only
wiring you are replacing. You will replace only the
wiring exiting the lightbar, with the cigar plug and
wire that comes with the kit.

3. Run the new wire up through the wire exit hole in
the lightbar base and plug it into the terminals as
shown.

4. The G1, G2, G3, G4, & G5 series will have faston
connectors that you will plug into the lightbar’s
center terminal (Figs. 2 & 3).

5. In the G7 series, you will use the 4-position
connector that comes with the kit and wire as
shown (Fig. 4). In the G8 series you will connect
the wires to the internal wiring harness with
supplied butt splices (Fig. 5).

6. All models require you to replace the strain relief to protect the wiring (Fig. 1).

the existing

Fig 1

Secure

Secure
strain relief

strain relief

here.

here.

Fig 3 G5 Series

REAR OF LIGHTBAR

RIBBED

WIRE

GUARDIAN

BLACK-WHITE

ORANGE

BLACK

STROBE
POWER
SUPPLY

)

POS(+

SMOOTH

W

IRE

NEG (-)

Fig 4 G7 Series

4 POSITION CONN.

POS. 1
POS. 2
POS. 3
POS. 4

REAR OF LIGHTBAR

/ SMOOTH
/ RIBBED

N/C

/

N/C

/

WIRE

WIRE

BLACK-WHITE

ORANGE

BLACK

IMPORTANT ELECTRICAL WARNINGS!

Guardian models equipped with cigar cords are intended for short duration, intermittent
operation only! Prolonged operation requires the Guardian to be wired to the vehicle.

DO NOT use a cigar lighter socket as a power source for this or any electrical
accessory! Use a 12-volt accessory power port or auxiliary power outlet of sufficient
capability. Do not exceed the manufacturers power rating for the selected port/outlet.

DO NOT pull on the power plug wires when removing the plug from the outlet! To
remove, firmly grasp the power plug housing and pull.

ANY DEVIATIONS FROM THE ABOVE ELECTRICAL GUIDLINES WILL VOID THE
PRODUCT WARRANTY.

IMPORTANT! It is the responsibility of the installation technician to make sure that the
installation and operation of this product will not interfere with or compromise the
operation or efficiency of any vehicle equipment!

IMPORTANT! Before returning the vehicle to active service, visually confirm the proper
operation of this product, as well as all vehicle components/equipment.

Page 2

Fig 5 G8 Series

BUTT

BUTT

SMOOTH

WHT/VIO

BLACK

BUTT

GROOVED

RED

FROM

WIRING

HARNESS