Whelen PBA106 User Manual

ENGINEERING COMPANY INC.

51 Winthrop Road Chester, Connecticut 06412-0684 Phone: (860) 526-9504 Fax: (860) 526-4078

Pioneer™ Series LED Floodlight

Installation Guide:

Horizontal Mount

Vertical Mount

Internet: www.whelen.com Sales e-mail: autosale@whelen.com Canadian Sales e-mail: autocan@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.

• 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

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Pioneer Dual Shown For Reference Only

Mounting Surface Material Thickness: Min. - 0.027 Max. - 0.150

Hole Size (Dia.): Min. - 0.531 Max. - 0.537

Mounting Hole Specifications

7 8

111210

13 14

07-243735-000

16-1503220-60

16-1402420-05

07-26B090-001

07-286084-001

07-286082-001

38-0243736-00

38-0243669-00

16-1532220-10

16-1431920-08

14-148B26-180

14-130536-04M

13-148F18-000

444

---

111

ITEM PART NUMBER DESCRIPTION

01-0486084-00

01-0486082-00

01-046B090-00

14-156B36-120

QTYQTYQTY

444

Light Bracket , Floodlight

3/8 Flat Washer, S.S.

5/16 S.S.Flat Washer,

Horizontal Mounting Bracket (Single)

Horizontal Mounting Bracket (Dual)

Vertical (Dual)Mounting Bracket

Seal (Single)

Seal (Dual)

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

5/16 S.S.Washer, Split-Lok

Soc. Button Head Screw, 3/8-16 X 3/4 S.S.

Soc. 5/16-18 X 1 1/8 S.S.Button Head Screw,

Screw, 1/4-20 X 1/4 Socket set S.S. w/Cup Point

Rivnut 5/16-18

Pioneer™ (Single) Mounting Kit - Horizontal Mount

Pioneer™ (Dual) Mounting Kit - Horizontal Mount

Pioneer™ (Dual) Mounting Kit - Vertical Mount

Pioneer Mounting Bracket, Single

Pioneer Mounting Bracket, Dual

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

07-243901-001

07-26B854-001

14-104116-060

344

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)

01-0686136_ _ _

-00 = 12V / White

-01 = 12V / White (15' (Dual Only))

-02 = 12V / Black (15' )

-07 = 12V / Black

-24 = 24V / White

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

(Dual Only)

(Pioneer Plus-only)

Sample Part Number Key

2.80"

CAUTION-Hot Surface!

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

Mounting...

1. Position the appropriate mounting bracket (Item #7 or #8) onto the proposed mounting surface. Mark the areas where the mounting holes are to be drilled.

2. Drill the mounting holes required using an appropriately sized drill bit (refer to the Mounting Hole Specifications shown below).

IMPORTANT NOTE! This installation uses Rivnuts to secure the brackets to the vehicle. This type of hardware requires the use of a specialized installation tool. Refer to the owners manual included with this tool for proper installation techniques. Be sure to follow the mounting hole specifications precisely!

3. With the Rivnuts properly installed, position the appropriate seal (#9 or #10) over the mounting holes and position the mounting bracket onto the seal. The floodlight can now be mounted onto the vehicle using the appropriate hardware (Items #4, #5 & #6). Insert the bolts into their holes with the hardware shown.

4. Apply a drop of LocTite 242 to each of the four mounting bolts and insert them into their Rivnut. Tighten each bolt to 50 in/lbs.

5. Secure the appropriate Pioneer mounting bracket (Item #12 or #13) to the Pioneer assembly using Item #14 (apply a drop of LocTite®

242 to the threads). Insert the floodlight brackets (Item #16) into the mounting bracket as shown. Secure these brackets using the hardware provided (#15).

6. Using the appropriate hardware (Items #1, #2 & #3), install the floodlight assembly onto the mounting bracket.

7. Adjust the floodlight to the desired angle and tighten the hardware firmly to maintain that angle.

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!

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.

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