Whelen PBA0127 User Manual

®

ENGINEERING COMPANY INC.

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

Pioneer™ Series LED Floodlight

Brow Mount (2.75” Radius)

Mounting Guide:

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.14205F (062812)

Page 1

1 2 3 4

5

8

9

10

11 12

13

17

6

7

Cordgrip Installation

5

6

.343" Dia.

7

8

.670" dia.
Clearance
Hole

Pioneer Cable

Sealing

Nut

Cordgrip
Pigtail

Collet

Seal

Locking

Nut

MOUNTING

SURFACE

Make sure the mounting hardware
is positioned as shown.

Mounting Specifications

01-0686136_ _ _

-00 = 12V / White

-01 = 12V / White (15')*

-02 = 12V / Black (15')*

-07 = 12V / Black

-24 = 24V / White

-27 = 24V / Black
D27= 24V / Desert Sand**

*Pioneer Dual-only

**Pioneer Plus-only

Sample Part Number Key

ITEM PART NUMBER DESCRIPTION

Pioneer Mounting Kit - Brow Mount (2.75" RAD.)

Light Bracket, Floodlight

Adjustable Mounting Bracket, Driver Side

3/8 Flat Washer, S.S.

3/8 Washer, S.S.Split-Lok

Soc. Button Head Screw, 3/8-16 X 1 1/2 S.S.

Screw, 1/4-20 X 1/4 Socket Set, S.S.

Adjustable Mounting Bracket, Pass.Side

Cordgrip Pigtail

Pioneer Mounting Bracket, Single

Pioneer Mounting Bracket, Dual

Seal

Nut, Locking

Screw, 5/16-18 X 1 1/2 Soc. HD Cap Scr., S.S.

Screw, #10- 24 X 3/8 PFHMS, S.S.

5/16 Elastic Stop Nut

5/16 Flat Washer

Washer, Rubber

01-0486048-00

07-243735-000

07-286048-001

16-1503220-60

16-1532220-10

14-156B36-240

14-130536-04M

07-243901-001

07-26B854-001

14-104116-060

07-286049-001

21-4016659-01

16-0017992-00

13-15S140-176

14-148826-240

13-148120-082

16-1402420-05

16-0017882-00

QTY

4

4

4

4

4

A/R

A/R

1

1

1

1

2

1

4

4

4

4

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

1

PART NUMBER DESCRIPTION

Pioneer™ Series LED Floodlight (Single)

Pioneer Series LED Floodlight (Single)PLUS

Pioneer eries LED Floodlight (Dual)S

Pioneer eries LED Floodlight (Dual)S PLUS

01-0686489_ _ _

01-0686449_ _ _

01-0686487_ _ _

01-0686448_ _ _

Pioneer Dimensions

8.18"

4.25"

Pioneer (Single)

4.25"

14.05"

Pioneer (Dual)

2.80"

14

15

16

Pioneer Dual Shown
For Reference Only

CAUTION-Hot Surface!

Make sure to route all wires
away from the heat sink fins.

Mounting...

1. Secure the appropriate Pioneer™ mounting bracket (Item #11 or #12)
to the Pioneer assembly using Item #13 (apply a drop of LocTite® 242
to the threads). Insert floodlight brackets (Item #9) into the mounting
bracket as shown. Secure these brackets using the hardware provided
(#10).

2. Using the appropriate hardware (Items #1, #2 & #3), install the
Adjustable mounting brackets (Items #4 & #17) onto the floodlight
brackets.

3. Position the floodlight/mounting bracket assembly onto its proposed
mounting location. Make sure that the mounting brackets fit properly
onto the mounting surface.

4. When the best location has been determined, carefully mark the areas
where the mounting holes are to be drilled. Remove the assembly from
the mounting area.

5. Using an 11/32” drill bit, drill 4 mounting holes through the brow. The
floodlight can now be mounted onto the vehicle using the appropriate
hardware (Items #5, #6, #7 & #8). Insert the bolts into their holes in the
mounting bracket and install a rubber washer (Item #6) onto each bolt.

6. Install a 5/16 flat washer (#7) and a elastic stop nut (#8) onto each bolt.
Using a torque wrench, tighten each nut until a value of between 10-12
ft./lbs. has been achieved.

Wiring...
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!

Drill and de-burr a 0.670” dia. wire passage hole through the mounting
surface. Route the Pioneer cable through the cordgrip pigtail components
and the mounting surface as shown. Be sure all unions are joined
securely. Do not overtighten.

Refer to the Wiring Guide included with your Pioneer for wire
functions, fuse values and optional switch connections.

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