Whelen M6HDLMTK User Manual

®

ENGINEERING COMPANY INC.

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

Fire Truck Headlight Bucket Adapter

Installation Guide:

(M6 Lighthead)

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.

• 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

©2008 Whelen Engineering Company Inc.
Form No.14248 (120408)

Page 1

Fig. 4

Unhook spring

Fig. 3

Fig. 5

Fig. 1

Fig. 2

Installation:

1. Remove the 6 screws that hold the headlight bezel on and remove
the bezel (Fig. 1).

Fig. 1

Fig. 1

2. Remove the 4 screws holding the headlight trim ring on and remove
the trim ring (Fig. 2).

Fig. 2

Fig. 2

BEZEL

TRIM RING

5. Mount the headlight insert (supplied) onto the headlight insert
adapter (supplied). Apply a drop of LocTite® 242® to these 4 screws
before installing them (Fig. 6). NOTE: You will not use the rubber

mounting gasket that comes with the lighthead in this
application.

Fig. 5

Fig. 5

HEADLIGHT
INSERT
ADAPTER

6. Wire the lighthead than mount it to the headlight insert adapter. Refer
to the lighthead manual for wiring information.

7. Replace the headlight bezel and installation is complete.

NOTE: The M6 lighthead and its mounting screws are not included
with this kit.

3. Unplug and remove the headlight. Remove the 2 screws holding the
headlight bucket on, unhook the adjustment spring and remove the
headlight bucket (Fig. 3). Save the headlight bucket in case you want
to reinstall the headlight later.

Fig. 3

Fig. 3

Unhook spring

Unhook spring

HEADLIGHT
BUCKET

4. Install the headlight insert adapter (supplied) onto the vehicle
headlight mounting bracket replacing the 2 existing screws with the
supplied 10-24X 5/8” PPHMS (Figs. 4 & 5).

Fig. 4

Fig. 4

Replace with the
supplied screws

HEADLIGHT
MOUNTING
BRACKET

Fig. 6

HEADLIGHT

INSERT

FASTEX

GROMMET

#8 X 1"
PPHSMS

HEADLIGHT

INSERT

ADAPTER

8 - 32 X 1/2"
PPHMS

10-24 X 5/8"

MOUNT TO VEHICLE

PPHMS

10-24 X 5/8"

PPHMS

Apply LocTite® 242®
(4 places)

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

IMPORTANT WARNING!

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

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