Whelen T0A00MAR User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684

2” Round LED Lighthead

Installation Guide:

Phone: [phone]
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

©2002 Whelen Engineering Company Inc.
Form No.13678C (061207)

Page 1

For flange mounting you may choose from 3 types of flange. A 2.9” or

3.5” flat flange (in kit# TADAPTB) or a raised flush mount flange (kit#
TFLANGEC or TFLANGEB). For grommet mounting you may choose
from 2 styles. A 2” grommet that the lighthead fits directly into
(TGROM2) or use the plastic adapter included in kit# TADAPTB to
adapt the lighthead to fit a customer supplied 2.5” grommet.

Note: This product draws significantly less current than a

standard incandescent automotive bulb. If your flasher
does not operate properly, it may be necessary to replace
your existing flasher module with a Whelen 3TERM flasher.
All customer supplied wires must be sized to supply at
least 125% of the maximum operating current and be sized
at the battery to carry the load.

Flange Mount:

1. Depending on which flange you choose, position the flange (or the
mounting gasket if mounting the flush flange) against the
proposed mounting surface at the desired location. Make sure the
assembly will not interfere with existing equipment and be aware
of any items on the opposite side of the mounting surface.

2. Using a scribe or similar tool, mark off the mounting holes and the
1” wire access hole onto the mounting surface.

3. Using a drill bit sized for the mounting screw and the thickness of
the mounting surface, drill 3 mounting holes (2 for flush flange).

4. Drill the 1” diameter wire access hole in the area marked. Be sure
to install a grommet (customer supplied) into this hole.

5. Extend the lighthead wires (Minimum wire size / 18 AWG) through
the wire passage hole and to their designations (see wiring
diagram). Fuse the +12VDC connections at 3 Amps and test
lighthead before securing to vehicle.

6. For the 2 flat flange mounts, first mount the flange onto the LED
assembly using the lens screws from the lighthead as shown and
then mount the entire unit to the vehicle using the supplied
mounting hardware. For the flush flange mount, mount as shown
in the diagram (the mounting screws secure the unit).

2.9" SMALL FLAT FLANGE MOUNT

Adapter In Kit:TADAPTB

Mount to adapter with lighthead lens screws

TOP

#8 X 1/2"
PPHSMS

3.5" LARGE FLAT FLANGE MOUNT

Adapter In Kit:TADAPTB

Mount to adapter with lighthead lens screws

TOP

#8 X 1/2"
PPHSMS

FLUSH / FLANGE MOUNT Kit: TFLANGEC

TFLANGEB

Mounting
Gasket

42871

(Chrome) and
(Black)Kit:

Grommet Mount:

Make sure the assembly will not interfere with existing equipment and
be aware of any items on the opposite side of the mounting surface.

1. Using a scribe or similar tool, mark off the hole size of the
grommet onto the desired mounting location. This will be either a
2-5/16” hole for the Whelen 2” grommet or the size indicated in the
instructions included with the customer supplied 2.5” grommet.

2. Now cut the mounting hole out and deburr it.

3. Insert the lighthead into the grommet (if using the large grommet,
first attach the lighthead to the adapter with the lighthead lens
screws as shown) then snap the grommet into the mounting hole.

4. Extend the lighthead wires (minimum wire size / 18 AWG), through
the wire passage hole and to their designations (see wiring
diagram). Fuse the +12VDC connections at 3 Amps and test the
lighthead before securing it to the vehicle.

WIRING

+12VDC

LIGHT

HEAD

*This wire will be the same color
as the LED in the lighthead.

*

BLACK

GROUND

#8 X 3/4"
PPHSMS

2" GROMMET
Kit: TGROM2

5

16

2 " mtg. hole

Page 2

Adapter for 2.5" GROMMET

is Included In Kit: TADPTB

Mount to adapter with lighthead lens screws.

Grommet is customer supplied.