Whelen Engineering Company 4500 Series Installation guide

Brand: Whelen Engineering Company

Model: 4500 Series

Type: Installation guide

Page 1

Installation Guide:

4500 Series Lightbar

Form No.13738F (111110)

ENGINEERING COMPANY INC.

51 Winthrop Road

Chester, Connecticut 06412-0684

Phone: (860) 526-9504

Fax: (860) 526-4078

Internet: www.whelen.com

Sales e-mail: autosale@whelen.com

Canadian Sales e-mail: canadiansales@whelen.com

Customer Service e-mail: custserv@whelen.com

Automotive: Lightbars

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!

For warranty information regarding this product, visit www.whelen.com/warranty

Page 2

Lighthead mounting holes, fit onto raised bosses on mounting bracket.

LED LIGHTHEAD

STROBE

LIGHTHEAD

Clips on bracket snap

over edge of lighthead.

Fig. 4

Rotator base

sits on tape

Rotator base

sits

on tape

Rotator Removal and Installation

Rotator base

sits on tape

Tape

Fastex

Grommet

Side View

TAPE

Fig. 3

Screws thread into fastex grommet

that is inserted into base.

Removal and

Installation of Lens

and Lenscap

Fig. 2

Fastex grommet

snaps into bracket.

(

Do not remove

)

Remove screws

from end of lenscap

Remove screws and lens

retainer, then remove

lens or lenscap

IMPORTANT! The lightbar should be located a minimum of 16" from any radio

antennas!

Installation:

Note: When routing wires, it is important to choose a path that will keep them away from

excessive heat or any vehicle equipment that could compromise the wires integrity.

1. This lightbar attaches to the vehicle by 1-1/4” bolts extending from the rear of the housing. Position the unit in its

proposed mounting location to ensure that it fits properly. With the lightbar in place, use an awl or other suitable

tool and scribe the areas to be drilled (Fig. 1).

2. Remove the lightbar and, using an appropriately sized drill bit, drill a hole in each of the areas scribed in step 1,

than return the lightbar to its mounting location and using the supplied hardware, secure it to the vehicle.

Wiring:

Extend the control wires to your switch panel and make the appropriate connections using the

wiring information provided in this manual. Read all warnings before installing this lightbar.

IMPORTANT! All Positive (+) input wires must be individually fused. Due to the large number of

possible configurations, each with their own fusing requirements, it is the installation

technician's responsibility to determine the maximum current draw for each input wire and to

fuse that wire at 125% of that value.

Servicing your lightbar:

NOTE: Before opening your lightbar for service or repair always be sure to Disconnect the

lightbar from it’s power source. (See strobe light warning below.)

Lens or Lenscap: Removal or Installation

To remove a lenscap, remove the 2 screws from the end of the lenscap, and the 2 screws from the opposite side that

thread through the lens retainer into the lighthead mounting bracket. Pull the lenscap off (Fig. 2).

To remove a lens, remove the 4 phillips head screws that thread

through the lens retainer into the lighthead mounting bracket and

then pull the lens off.

Removing an Existing Rotator:

1. Disconnect the lightbar from power. For lightbars with strobe lights, wait a minimum of 10 minutes before proceeding.

2. Remove the lens or lenscap in front of the rotator you wish to replace.

3. Disconnect the rotator from the lightbar’s harness by unplugging the Amp 2 position pin connector. NOTE: It is easier

to remove the existing rotator from the extrusion if the reflector is facing the front of the lightbar (Fig. 3).

4. Using a phillips head screwdriver, loosen the two screws that secure the rotator base to the extrusion (2 or 3 turns).

5. Lift the rear of the rotator base then remove the rotator from the extrusion.

Installation of a New Rotator:

1. Remove any adhesive tape on the lightbar base left from the old rotator.

2. Remove the backing from the piece of 2-sided tape and apply it to the lightbar base in the same location as the

previous tape (Fig. 3).

3. Plug the new rotator into the old rotator’s harness plug.

4. Place the new rotator inside the extrusion in the same area the old rotator was removed from but don’t tighten the

screws yet.

5. Remove the backing from the tape and press the rotator base down onto the lightbar base firmly, being careful not

pinch any wires between the base and extrusion, then tighten the mounting screws.

6. Reconnect lightbar to power and test for proper operation then return any lenscaps or lenses you had to remove.

Servicing Lightheads: Strobe, Halogen or LED WARNING: The strobe light power supply is a high voltage device. Do

not touch or remove the strobe tube assembly while in operation.

Wait 10 minutes after disconnecting the unit from its power source

before starting any work or trouble shooting.

Removal and Installation

1. Disconnect the lightbar from it’s power source.

2. To remove the lighthead, first remove the lens or lenscap necessary to access

the lighthead you wish to service or replace.

3. Now pull the clips back on the mounting bracket that secure the lighthead as

you lift the lighthead off of the raised bosses on the bracket (Fig. 4).

4. Being careful not to pull out any wires, lift the lighthead out of the lightbar base,

disconnect its connector from the lightbar wiring harness, then lift the lighthead

out of the lightbar.

5. To reinstall the lighthead, plug the lightheads connector into the lightbar, snap it

back into the brackets and replace any lenses or lenscaps you had to remove.

WARNING: 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!

STEP BOLT

Fig. 1

Mounting the Lightbar

to the vehicle

3/8" X 16 HEX NUT

3/8" LOCKWASHER

3/8" FLATWASHER

Page 3

MODEL: 45CL*

ITEM PART NUMBER DESCRIPTION

QTY QTY QTY QTY

1111

2222

1111

EXTRUSION is shown for reference only.

Options:

The following pages show the options

available for the 4500 Series Lightbar,

their assembly and parts listings.

Fig. 7

Load

Light

Mounting

Bracket

Slide

grommets

into base

Fig. 8

A Single light MR11

bracket (each side) is

mounted in the single

and the center hole of

the bottom 3 holes.

A Double light MR11

bracket (center mount)

is mounted in the single

and center hole of

the top 3 holes.

SIDE VIEW

OF BRACKET

Front

Single hole

Side view / Base extrusion

Housing

snaps

into base

extrusion

Housing

is then

secured

to base

using

supplied

screws

Halogen,

(

New style housing

)

Strobe or LED

Lighthead

400 Linear Split LED with MR11 Load Light / TA only

A/RA/RA/R A/R

SUB ASS'Y CORNER LINEAR LED 12V / WHITE

SUB ASS'Y CORNER LINEAR LED 12V / BLUE

SUB ASS'Y CORNER LINEAR LED 12V / AMBER

SCREW/6X3/8PPHSMS/ 410 SS TYPE A

ASS'Y CORNER LED RED AMP/

ASS'Y CORNER LED WHITE AMP/

ASS'Y CORNER LED BLUE AMP/

SUB ASS'Y / BRACKET & BASE

ASS'Y CORNER LED AMBER AMP/

SCREW GROMET / #6/#8 FASTEX

BRACKET / CORNER STROBE

02-0484303-22

02-0484303-20

02-0484303-19

02-0484303-21

02-0342934-00

01-02 -306B807

01-026B807-10

01-02 -206B807

13-062C40-16J

15-061416-060

07-26C091-000

SUB ASS'Y CORNER LINEAR LED 12V / RED

HARNESS ASS'Y / CORNER LINEAR LED

46-0743113-00

01-02 -506B807

CORNER

STROBE

SUPPORT

BRACKET

SCREW, #6

X 3/8" PPHSMS

LIGHTHEAD

TAB

#6 FASTEX SCREW GROMMETS

(Install into lightbar base)

END OF LIGHTBAR

Bracket slides

into lightbar

LIGHTBAR BASE

Fastex

grommet

Clips snap over

edge of lighthead.

CORNER STROBE

Snap Lighthead mtg. holes

onto bosses on bracket.

Snap Lighthead mtg. holes

onto

bosses on bracket.

Fig. 5

Snap Lighthead mtg. holes

onto bosses on bracket.

Fig. 6

Corner Strobe: Removal & Installation:

Removal:

1. Disconnect the lightbar from it’s power source and remove the endcap in front of the

lighthead you wish to replace or service and wait 10 minutes before proceeding.

2. Spread the ends of the corner strobe support bracket (A) apart to disengage it from the

tab on the lighthead, and lift this end of the lighthead out (Fig. 5).

3. Pull the clips back on the mounting bracket (B) as you lift the lighthead off of the two

raised bosses on the bracket, then carefully lift the lighthead out of the lightbar base and

disconnect the power cord (C), and remove the lighthead from the lightbar.

Installation:

1. Plug the lighthead into the wiring harness (C).

2. Insert the end of the bracket into the 2 bosses, and snap the side of the lighthead into

the clips in the bracket (B), then snap the lighthead tab into the corner strobe support

bracket (A) and replace the endcap. Reconnect to power.

Halogen Lighthead:

Load Light / Rear Facing

Removal:

1. Disconnect the lightbar from it’s power source and remove the

lens and/or endcap in front of the lighthead you wish to service.

2. Unscrew the 4 lens screws which hold the lighthead to its 2

brackets (Fig 6).

3. Disconnect the lighthead from power, then remove the lighthead from the lightbar.

Installation:

1. Plug the lightheads connector into the lightbar harness.

2. Attach the lighthead (and lens) to its mounting brackets using the lens screws you removed.

3. Replace the lightbar lenses or endcaps and the installation is complete.

Page 4

MODEL 45ADDAST

01-0440624-25

13-062C40-16J

07-26C091-000

46-0941245-00

02-0363171-00

15-061416-060

26-0215001-03

02-0484303-16

02-0342933-00

07-263103-000

CABLE ASSEMBLY - 25'

ASS'Y. / CORNER LINEAR STROBE

BRACKET / CORNER STROBE

HARNESS ASS'Y. / STROBE

SUB ASS'Y. / MOUNTING BRACKET

ASS'Y. / CORNER LINEAR STROBE

BRACKET / LIGHTHEAD MOUNTING

SCREW / #6 x 3/8" PPHSMS

SCREW GROMMET

TY WRAP - 3"

ITEM PART NUMBER DESCRIPTION

QTY

MODEL 45ADDHAL

ITEM PART NUMBER DESCRIPTION

QTY

700 REFL CT 2 WIRE 2 POS AMPE OR. -

12V 60W SNAP-IN-LAMP-

SCREW / #6 x 1-1/4" PPHSMS

LENS CLEAR OPTIC/

BRACKET MOUNTING/

SCREW #8 x 1/2" PPHSMS/

ASS'Y 700 SERIES HALOGEN/

15-081416-080

07-284353-000

02-0484303-02

15-061416-200

34-0041987-07

02-0383709-02

68-1183582-3S

EXTRUSION is shown for reference only.

NOTE: When two model 45ADROTA are

placed adjacent to one another, the left

and right mirrors are replaced with the

V mirror (ITEM #5) as shown.

Rotator

shown for

reference

Rotator

shown for

reference

Left mirror

shown for

reference

MODEL 45ADROTA

ITEM PART NUMBER DESCRIPTION

QTY

68-5463532-00

"V" MIRROR BRACKET

HALF MIRROR LEFT

TAPE / METALIZED

HALF MIRROR RIGHT

ROTATING REFLECTOR

ROTATOR

02-0342949-00

02-0484303-01

02-0342945-00

02-0342949-01

68-5943171-01

A/R

MODEL 792H & MODEL 45000PTI

ITEM PART NUMBER DESCRIPTION

QTY QTY

07-263401-000

01-5015970-29

01-0417074-00

13-104111-063

46-0968085-25

16-100220-500

14-104066-100

15-061416-060

01-5015970-29

13-062C40-16J

BOLT 10-24 X 5/8" CARRIAGE S//S

ASS'Y / 3M LC EMIT CABLE / 25' CONXALL

BRACKET MOUNTING 792/4500/

MODEL 792H OPTICOM EMITER

OPTION PREWIRE PLUS FOR OPTICOM/

NUT 10-24 CAD PLATED WHIZ/

WASHER #10 FLAT .631 x .060 / THK SS//

SCREW #6 x 3/8" PPHSMS/

SCREW GROMET #6/#8 FASTEX/

MODEL 792H OPTICOM EMITER

EXTRUSION is shown for reference only.

Mounting

bracket

shown for

reference

Mounting

bracket

shown for

reference

Mounting

bracket

shown for

reference

6543

MODELS: 45ADL8R / 45ADL8C / 45ADL8B / 45ADL8A

SUB ASS'Y. / 700 LINEAR LED / RED

SUB ASS'Y. / 700 LINEAR LED / WHITE

SUB ASS'Y. / 700 LINEAR LED / BLUE

700 SERIES LINEAR LED / RED

700 SERIES LINEAR LED / WHITE

700 SERIES LINEAR LED / BLUE

700 SERIES LINEAR LED / AMBER

SUB ASS'Y. / 700 LINEAR LED / AMBER

SCREW / #8 x 1/2" PPHSMS

BRACKET / MOUNTING

02-0484303-06

02-0484303-05

02-0484303-04

02-0484303-03

02-03 45286419

02-03 43286419

02-03 42286419

15-081416-080

02-0386419412

07-284353-000

LENS / CLEAR OPTIC

SCREW / #6 x 1-1/4" PPHSMS

68-1183582-3S

15-061416-200

ITEM PART NUMBER DESCRIPTION

QTY QTY QTY QTY

4444

1111

4444

1111

Page 5

EXTRUSION is shown

for reference only.

3-6

6-10

3-6

2-6

6-10

11 12

3-6

NOTE: Lightheads shown in standard positions.

LOAD LIGHTS: position adjacent to CENTER LEDs.

NOTE: Extrusion shown for reference only

MODEL: 45KRL

68-3983799-10

68-3983799-50

02-0342934-00

07-26C091-000

13-062C40-16J

15-061416-060

07-284354-00

46-0784112-04

01-026B807-50

15-061416-160

02-0386361255

02-0386361211

02-0484303-18

-1

SCREW GROMET #6 #8 FASTEX/-

SCREW 6 X 3/8 PPHSMS / 410 SS TYPE A/

BRACKET MTG 400 SERIES LIGHTHEAD/

SCREW 6X1 PPHSMS TYPE A/

SUB ASS'Y 400 LINEAR LED SPLIT / RED RED/-

SUB ASS'Y 400 LINEAR LED SPLIT / AMB AMB/-

OPTION KKK LED PACKAGE/ REAR

UPPER LED ADAPTER

LENS AMBER NON OPTIC 16.57" 4500 SERIES//

LENS RED NON OPTIC 16.57"/4500 SERIES/

SUB ASS'Y BRACKET & BASE/

BRACKET CORNER STROBE/

ASS'Y CORNER LED RED AMP 4500 SERIES/

02-483910-00

SUB ASS'Y / LOAD LIGHTS /4500 SERIES

ITEM

PART NUMBER

DESCRIPTION

QTY

MODEL 45KRS

ITEM PART NUMBER DESCRIPTION

QTY

BRACKET MOUNTING/

SCREW / #8 x 1/2" PPHSMS

SCREW / #6 x 1" PPHSMS

OPTION / KKK REAR STROBE PKG. 4500 SERIES

LENS / CLEAR NON OPTIC 16.57 / 4500 SERIES

LENS / RED NON OPTIC 16.57 / 4500 SERIES

LENS AMBER NON OPTIC 16.57 / 4500 SERIES/

-2

07-284353-000

02-0484303-15

68-3983799-30

68-3983799-50

15-081416-080

15-061416-160

68-3983799-10

ASS'Y 700 LINEAR REFLECTOR/

02-0362641-00

46-0941245-00

HARNESS ASS'Y. / STROBE

01-0440624-25

CABLE ASSEMBLY - 25'

46-0941248-00

HARNESS ASS'Y / STROBE CENTER

02-0483910-00

SUB ASS'Y / LOAD LIGHT 4500 SERIES

NOTE: Extrusion shown

for reference only

NOTE: Extrusion shown

for reference only

MODEL: 45FLASH

ITEM

PART NUMBER

DESCRIPTION

QTY

4500 OPTION / ADD INTERNAL FLASHER

ASSY / FLASHER INPUT HARNESS

ASSY / HARNESS / 400 LED with FLASHER

ASS'Y / 2 CHANNEL FLASHER / 4500 SERIES LED

46-0764668-00

02-0343046-00

02-0484303-32

46-0743203-00

MODEL 45ADDSTR

ITEM PART NUMBER DESCRIPTION

QTY

700 LINEAR REFLECTOR

SCREW, #6 x 1" PPHSMS

BRACKET, MOUNTING

SCREW, #8 x 1/2" PPHSMS

07-284353-000

15-061416-160

02-0362641-00

15-081416-080

46-0941245-00

HARNESS ASS'Y., STROBE

01-0440624-25

CABLE ASSEMBLY - 25'

A/R

46-0941248-00

HARNESS ASS'Y STROBE CTR

700 SERIES LINEAR STROBE

A/R

02-0484303-07

POWER TO PASSENGER

SIDE LOAD LIGHT.

MODEL: 45LRLOAD

ITEM

PART NUMBER

DESCRIPTION

QTY

14-062216-061

07-286741-000

02-0484303-48

14-062216-160

68-7744081-00

02-016B644-30

68-5944082-31

07-26C834-000

56-043625-000

46-0941243-00

46-0744083-00

39-0402313-04

15-061416-060

13-062C40-16J

SCREW, 6-32 X 3/8 PPHMS SMS IT LCK WSHR SS

6-32 X 1" PPHMS SS SCREW

PCB 3 LED LR11 WHT ALLY/TD XP-E

BRCKT, MTG LR11 LD LT SINGLE 4500

DIFFUSR, LR11 LD LT 4500 SERIES

REFLECTOR, TIR LR11 LD LT 4500

THERMAL PAD, CO-THERM LR11

BRCKT, MTG LR11 LD LT DUAL 4500

LR11 LOAD LIGHT OPTION

SCENE LIGHT HARNESS

HARNESS LR11 LOAD LIGHT 4500

HSNG, 2 POS PIN COMM MATE-N-LOK

SCREW,6X3/8PPHSMS 410 SS TYPE A

SCREW GROMMET, #6/#8 FASTEX

Page 6

6-10

2-6

3-6

6-10

2-6

3-6

3-8

3-83-8

3-8

NOTE:Lightheads shown in standard

positions. EXTRUSION is shown

for reference only.

DEL 45KFH

ASS'Y. 12V 60W SNAP-IN-LAMP/-

ASS'Y. 700 REFLECTOR 2 WIRE/2 POS AMP/

KKK FRONT HALOGEN PKG. 4500 SERIES

LENS RED NON OPTIC 16.57 / 4500 SERIES/

LENS CLEAR NON OPTIC 16.57 / 4500 SERIES/

68-3983799-30

02-0484303-120

68-3983799-50

SCREW #6 x 1-1/4" PPHSMS/

LENS CLEAR OPTIC/

SCREW #8 x 1/2" PPHSMS/

BRACKET MOUNTING/

34-0041987-07

68-1183582-3S

15-061416-200

02-0383709-02

15-081416-080

07-284353-000

ITEM PART NUMBER DESCRIPTION

QTY

-1

NOTE: Lightheads are shown in standard

positions. EXTRUSION is shown for

reference only.

Position Load Lights

adjacent to center

halogen.

MODEL 45KRH

LENS / AMB NON OPTIC 16.57 / 4500 SERIES

BRACKET MOUNTING/

LENS CLEAR OPTIC/

SCREW #8 x 1/2" PPHSMS/

ASS'Y. 700 REFLECTOR 2 WIRE 2 POS AMP//

ASS'Y. 12V/60W SNAP-IN-LAMP/

SCREW #6 x 1-1/4" PPHSMS/

KKK REAR HALOGEN PKG. 4500 SERIES

LENS CLEAR NON OPTIC 16.57 / 4500 SER/.

LENS / RED NON OPTIC 16.57 / 4500 SERIES

07-284353-000

68-1183582-3S

02-0484303-14

68-3983799-30

68-3983799-50

68-3983799-10

15-081416-080

02-0383709-02

15-061416-200

34-0041987-07

ITEM PART NUMBER DESCRIPTION

QTY

-2

SUB ASS'Y / LOAD LIGHTS / 4500 SERIES

02-0483910-00

3-8

MODEL: 45KFL

NOTE: Lightheads are shown in standard positions. EXTRUSION

is shown for reference onl

SCREW 6X1 PPHSMS TYPE A/

UPPER LED ADAPTER

OPTION KKK FRONT LED PACKAGE/

SUB ASS'Y 400 LINEAR LED SPLIT / WHT-WHT/

SUB ASS'Y 400 LINEAR LED SPLIT / RED RED/-

ASS'Y CORNER LED RED AMP 4500 SERIES/

SCREW 6X3/8 PPHSMS 410 SS TYPE A//

SCREW GROMET #6 #8 FASTEX/-

15-061416-060

15-061416-160

01-026B807-50

02-0484303-17

02-0386361233

02-0386361255

46-0784112-04

13-062C40-16

07-284354-00

BRACKET MTG 400 SERIES LIGHTHEAD/

68-3983799-30

68-3983799-50

02-0342934-00

07-26C091-000

-1

LENS / CLEAR NON OPTIC 16.57" 4500 SERIES/

LENS RED NON OPTIC 16.57" 4500 SERIES//

SUB ASS'Y BRACKET & BASE/

BRACKET CORNER STROBE/

ITEM

PART NUMBER

DESCRIPTION

QTY

MODEL: 45FL*

DESCRIPTION

1111

4444

QTY

22222

11111

PART NUMBER

QTY QTY QTY QTY

567

EXTRUSION is shown for reference only.

02-0484303-30

02-0484303-29

02-0484303-27

02-0484303-28

02-0484303-31

15-081416-080

07-284354-000

15-061416-160

01-0386361222

01-0386361211

46-0784112-04

01-0386361244

01-0386361255

01-0386361233

8 X 1/2 PPHSMS

6 X 1 PPHSMS TYPE "A"

400 LINEAR LED AMB AMP

400 LINEAR LED BLU AMP

400 LINEAR LED WHT AMP

400 LINEAR LED GRN AMP

400 LINEAR LED RED AMP

S. ASY / 400 LED SPLIT RED-RED

S ASY 400 LED SPLIT GRN GRN./ -

S ASY 400 LED SPLIT WH WH./ T-T

S ASY 400 LED SPLIT BLU BLU./ -

BRACKET MTG 400 LTHD/

S ASY 400 LED SPLIT AMB AMB./ -

HARNESS UPPER LED ADAPT/.

Page 7

3-6

LOAD

LIGHT

Wire Harness / MR11 Load Lights

Extrusion

To Control Head

(not shown)

For Reference

Grommet shown for reference

FLASHER

NOTE: Model 45TA8

shown. For Model 45TA6

drop out the center two

lightheads.

EXTRUSION,

CORNER LEDs and

CENTER LENS are shown

for reference only.

WHT/RED

RED

WHT/ORG

YELLOW

WHT/YEL

ORANGE

CABLE ASSY

BLUE

WHT/GRN

WHT/BLU

GREEN

LOAD

LIGHT

VIOLET

WHT/VIO

VIOLET

1212 12 12

123

321

123

321

123

321

BLACK

BLUE

21 21 21 21 21 21

RED

TA1

TA2

AMB

TA3

AMB

TA4

AMB

TA5

AMB

TA6

GRN

BLK

RED

TRAFFIC ADVISOR OPTION W/MR-11 LOAD LIGHTS

4 4 4 4 4 4 4

07-284353-000

15-061416-160

02-0362641-00

15-081416-080

46-0941245-00

01-0440624-25

68-3983799-30

68-3983799-50

02-0484303-13

ASS'Y 700 LINEAR REFLECTOR/

SCREW #6 x 1" PPHSMS/

SCREW #8 x 1/2" PPHSMS/

HARNESS ASS'Y STROBE/

CABLE ASSEMBLY - 25'

LENS CLEAR NON OPTIC 16.57 / 4500 SERIES/

LENS RED NON OPTIC 16.57 / 4500 SERIES/

BRACKET MOUNTING/

46-0941248-00

HARNESS ASS'Y / STROBE CENTER

MODEL 45KFS

ITEM PART NUMBER DESCRIPTION

QTY

-1

KKK FRONT STROBE PKG. 4500 SERIES

EXTRUSION is shown for reference only.

NOTE: Lightheads shown in standard

positions.

5-9

3 3

1011

5-9

MODEL: 45TA with MR11 Load Lights

DESCRIPTION

02-0484303-35

PART NUMBER

QTY

01-0269809-06

01-0669813-00

02-0342933-00

02-0386361211

02-0463931-00

46-0743112-00

46-0769810-05

46-0743119-00

4500 T/A FLASHER 6 LAMP

SUB ASS'Y 400 LINEAR LED SPLIT AMB AMB/-

TADCTL1 CONTROL HEAD DOMINATOR TA/

SUB ASS'Y MOUNTING BRACKET/

SUB ASS'Y MR11 LOAD LIGHTS / 4500 SERIES/

HARNESS MR11 LOAD LIGHTS

CABLE T/A OPTION

HARNESS 4500 TA6 DBL RED-ORG-YEL//

SUB ASS'Y MODEL 45TA MR11 LOAD LTS//

46-0769810-06

HARNESS 4500 TA6 DBL VIO BLU GRN//--

EXTRUSION

(REF

MODELS: 45TA6 / 45TA8

MOUNTING BRKT. 400 . LTHD

SUB AS'Y / 400 LED SPLIT AMB-AMB

SCREW / #6 X 1" PPHSMS

4500 INTERNAL HARNESS / TA

8 LAMP TA / 4500 SERIES

HOUSING / AMP 12 POS. PIN

6 LAMP TA / 4500 SERIES

TA CONTROL HEAD 12V LED

CABLE ASS'Y / 9-C 35' 4" STRIP

39-0412014-14

07-284354-000

15-061416-160

01-0386361211

01-0683850-00

46-0784545-00

46-0741346-35

Y HARNESS 6" ASSEMBLY

SCREW / #8 X 1/2" PPHSMS

WASHER 1/2" I.D.

16-1766430-08

46-0784112-04

15-081416-080

26-0121053-00

CLAMP 3/8"

ITEM

PART NUMBER DESCRIPTION

QTY QTY

02-0484303-34

02-0484303-33

Page 8

32 33

26 27

16 15

10 11

444

44 444

111

686

13.61

2222

666

11.28 9.28 7.94

9.46

22222

5.616.61

8.13 7.13

2.88

4.44

222

14.27

15.79 15.46

13.94

15.13

14.80

13.28

14.47

12.95

13.47

11.95

12.80 10.80

A/R A/R

444444444444

8866

555

222

666

333

16 16

12 12 12 12

10 6 66

A/R

A/R A/R

A/R A/R A/R

A/R A/RA/R A/R A/R A/RA/R A/R A/R A/R

A/R

A/R A/R

01-0684303122

01-0684303138

01-0684303144

01-0684303 76_

01-0684303 82_

01-0684303 72_

01-0684303 60_

01-0684303 84_

01-0684303 86_

01-0684303 90_

01-0684303 88_

11-463582-100

01-0684303 52_

11-463582-106

11-463582-109

11-463582-001

11-463582-027

11-463582-016

11-463582-002

11-463582-023

02-0342932-00

11-463582-003

11-463582-005

11-463582-026

11-463582-028

14-104286-16J

01-0441771-00

10-0522977-01

21-11263204-0

02-0320397-00

02-0342933-00

38-0316275-00

38-0522954-00

68-3983813-**

68-3963615-**

15-06121B-082

69-3983799-**

02-0342941-00

02-0483903-A0

15-08121B-082

02-0483903-R0

02-0483903CA0

02-0483903CR0

46-0764014-00

01-0684303_94

11-463582-030

21-3117552-00

46-0941569-00

46-0941244-00

EXTRUSION 17.31" ICC M H/ without tg oles

4500 SERIES LIGHTBAR-22" without ICC LT.

4500 SERIES LIGHTBAR-38" ICC LTwithout .

4500 SERIES LIGHTBAR-44" ICC LTwithout .

4500 SERIES LIGHTBAR-52" / See P/N Key

4500 SERIES LIGHTBAR-60" / See P/N Key

4500 SERIES LIGHTBAR-72" / See P/N Key

4500 SERIES LIGHTBAR-76" / See P/N Key

4500 SERIES LIGHTBAR-82" / See P/N Key

4500 SERIES LIGHTBAR-84" / See P/N Key

4500 SERIES LIGHTBAR-86" / See P/N Key

4500 SERIES LIGHTBAR-88" / See P/N Key

4500 SERIES LIGHTBAR-90" / See P/N Key

EXTRUSION 33.67"/ without ICC Mtg Holes

EXTRUSION 39.67"/ without ICC Mtg Holes

EXTRUSION 47.67"/ with ICC Mtg Holes

EXTRUSION 55.67"/ with ICC Mtg Holes

EXTRUSION 67.67"/ with ICC Mtg Holes

EXTRUSION 71.67"/ with ICC Mtg Holes

MOUNTING BASE ASSEMBLY

EXTRUSION 77.67"/ with ICC Mtg Holes

EXTRUSION 79.67"/ with ICC Mtg Holes

EXTRUSION 81.67"/ with ICC Mtg Holes

EXTRUSION 83.67"/ with ICC Mtg Holes

EXTRUSION 85.67"/ with ICC Mtg Holes

#10-24 x 1.25" SHLDR PHTX TRI PT.

KIT EXTRUSION STEP BOLT MTG. 1-1/4"/

LABEL P/N M/N S/N / not shown

GROMMET 1" SLIM LINE/

LOUVER 1" FILTER/ with

MOUNTING BRACKET ASSEMBLY

GASKET REAR EXTRUSION/

SEAL CORD 3/16"/

LENSCAP

LENSCAP SPLIT/

SCREW #6 x 1/2" PPHSMS BLACK//

LENS

ASS'Y LENS GASKET/RETAINER/

ASS'Y LED ICC LIGHTS - AMBER/

SCREW #8 x 1/2" PPHSMS BLACK//

ASS'Y LED ICC BRAKE LIGHTS - RED//

ASS'Y C R LED ICC LIGHTS - AMBER/T

ASS'Y C R LED ICC BRAKE LTS - RED/T /

ASS'Y / HARNESS

4500 SERIES LIGHTBAR-94" / See P/N Key

EXTRUSION 89.67"/ with ICC Mtg Holes

PLUG 9.65MM GROOVE DIA. R R BLK//B.

ASS'Y CENTER ROTATORS HARNESS//

ASS'Y ROTATORS HARNESS/

A/R

16.46

14.94

ITEM

PART NUMBER DESCRIPTION

QTYQTY QTYQTY QTY QTY QTY

QTYQTY QTY QTY QTY QTY

111

1111

111

22222222

A/RA/RA/RA/RA/RA/RA/R

4444444

11111

A/RA/RA/RA/RA/RA/RA/R

CAUTION! DO NOT LOOK DIRECTLY AT

THESE LED’S WHILE THEY ARE ON.

MOMENTARY BLINDNESS AND/OR EYE

DAMAGE COULD RESULT!

IMPORTANT WARNING!

YEL +12VDC/

VIO +12VDC/

BLK/WHT GND/

BLK GND/

BRN +12VDC/

RED +12VDC/

GRN / +12VDC

BLK/WHT GND/

BLU +12VDC/

BLK GND/

ORG +12VDC/

BLK G D/N

BLK GROUND/

BLK GND/

GRY +12VDC/

ROTATOR

LED or

HALOGEN

(

OUTBOARD

)

ROTATOR

LED or

HALOGEN

INBOARD

()

ROTATOR

LED or

HALOGEN

CENTER

()

ROTATOR

LED or

HALOGEN

(INBOARD)

GREEN

BLK/WHT

RED

VIOLET

BLACK

ORANGE

GREY

BLACK

ROTATOR

LED or

HALOGEN

ROTATOR

LED or

HALOGEN

ROTATOR

LED or

HALOGEN

ROTATOR

LED or

HALOGEN

ROTATOR

LED or

HALOGEN

ROTATOR

LED or

HALOGEN

ROTATOR

LED or

HALOGEN

121212 12 12 12

BLK/WHT

BLACK

BROWN

YELLOW

BLK/WHT

BLACK

ROTATOR

LED or

HALOGEN

BLUE

4500 SERIES WIRING

12121212121212

12 12

Length of Lightbar

ICC Light Requirements

01-0684303___

PART NUMBER KEY:

ICC LIGHT REQUIREMENTS

1= A=

Without ICC Lights With AMBER ICC Lights

With RED ICC Lights

NOTE: 52", 60", 72" & 76" Lightbars available

without ICC Lights or with Center ICC Lights

only (RED or AMBER)

121212

Whelen Engineering Company 4500 Series Installation guide

Whelen Engineering Company 4500 Series Installation guide

Whelen Engineering Company 4500 Series Installation guide

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