Whelen HA239CD User Manual

®

ENGINEERING COMPANY INC.

Route 145, Winthrop Road,
Chester, Connecticut 06412
Phone: [phone]
Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Canadian Sales e-mai l: auto [e-mail]
Customer Service e-mail: [e-mail]

Important!!!

The Deutsch water-proof connector will not function properly
unless it is connected exactly as the manufacturer intended. A
Deutsch crimpi ng to o l (Wh elen p/n 66T05 164 35 119C) is requir ed f or
proper termina l crimp ing an d sh ould be us ed when ever poss ible. If
a non-Deutsch crimp tool is used, the cable wires must first be
pushed through the rubber connector grommet BEFORE the pin
terminal is crimped. This will reduce the possibility of damaging the
water-tight seal around the wires. Whelen Engineering does not
recognize the use of a non-Deutsch crimping tool, therefore any
resulting damage would void the warranty.

Wires coming from the lamp MUST
housing; NOT
overview of all related components.

If your current lighting system utilizes an AMP water-proof
connector, it will be necessary to remove th e AMP assembly from
the supply cable . The wire e nds must then be stripped so that the
correct “barrel”-style pins can be attatched using the Deutsch
crimping tool. T he Deuts ch rece ptacle c an then be atta tched t o the
cable as outlined in the following “Assembly” section. Be sure to
insert the wires into the receptacle so that they will connect with the
correct plug wire. Exa mple: The wir e in receptacle section A is the
wire that is designated to be connected to the wire in plu g section
A.

the receptacl e housing. Refer to Diagram 1 for an

be connected to the plug

Assembly...

1. Locate the cable that will be used be tween the power supply and

the receptacle section of the water-proof connector.

Assembly/Disassembly

Deutsch Water-Proof Connectors

W441D (Receptacle)

W442D (Plug)

2. Locate the leads that h ave the “barr el”-style pi ns crimped onto the
wires.

3. Grasp the wire approximately 1 inch behind the contact barrel.

4. Hold the receptacle so that the rear grommet is facing you.

5. Push the pin straight into the grommet until a “click” is felt. A gentle
tug will confirm that it is properly locked into place.

6. Once all the pins are installed, insert the wedge into the receptacle.
Be sure that the arrow on the wedge is pointing towards the
exterior locking housing. If the wedge being used is rectangular, the
arrow alignment does not apply.

NOTE: Although the above text outlines the procedure for assembling
the receptacle, the same procedure is used for the Plug section. The plug
section utilizes a faceplate instead of a wedge. It can be removed with a
small screwdriver.

Contact Removal...

1. Remove the wedge with either a pair of needle nose pliers (if
removing contacts from the receptacle section) o r a small, reg ular
screwdriver (for the faceplate of the plug section).

2. To remove the contacts, gent ly pull the desired wire back away
from the grommet. At the sam e time, release the l ocking finger by
moving it away from the contact with a screwdriver.

3. Be sure to hold the rear seal in place, a s removing the contact will
disrupt its position.

Diagram 1

Receptacle

(W441D)

Plug

(W442D)

Automotive: Other

©1996 Whelen Engineering Company Inc.
Form No.13137H (030702)

A three-position Deutsch water-proof
connector is shown here for dem onstra tion
purposes only! The above procedure is not
limited to the three position connector and
applies to both larger and smaller
connectors.

Receptacle

Pin Terminal

(with barb)

Connector

Grommet

Pin Terminal

(with barrel)

To

Power

Supply

Connector:
1 = RED (OR GREEN)
2 = BLACK
3 = WHITE

Page 1

Hasp

Release

Hasp

Faceplate

B

Plug

B

Receptacle:
A = RED (OR GREEN)
B = BLACK
C = WHITE

Water Block

NOTE:In the event of a situation where the
number of wires to be inserted into either
the receptacle or the plug is fewer than the
number of available openings, insert the
water block into the unused opening.