Whelen Engineering Company 45KRH Installation guide

45KRH
Brand
Whelen Engineering Company
Model
45KRH
Type
Installation guide
Page 1
Installation Guide:
4500 Series Lightbar
©2002 Whelen Engineering Company Inc.
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
1
1
1
1
MODEL: 45CL*
2
3
ITEM PART NUMBER DESCRIPTION
QTY QTY QTY QTY
4
5
6
7
8
1
1111
2222
9
2222
1111
1
EXTRUSION is shown for reference only.
1
9
4
3
2
78
56
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.
B
C
Fig. 5
A
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
2
3
4
5
6
7
8
9
1
2
1
1
1
1
1
1
1
2
MODEL 45ADDHAL
ITEM PART NUMBER DESCRIPTION
QTY
2
3
4
5
6
1
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
1
1
1
4
4
1
EXTRUSION is shown for reference only.
8
9
1
5
6
2
4
3
7
6
5
4
3
2
1
8
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
3
2
1
MODEL 45ADROTA
ITEM PART NUMBER DESCRIPTION
QTY
2
3
4
1
68-5463532-00
"V" MIRROR BRACKET
5
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
1
1
1
1
A/R
5
MODEL 792H & MODEL 45000PTI
2
3
ITEM PART NUMBER DESCRIPTION
QTY QTY
4
5
6
7
8
1
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
1
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
4
4
2
2
2
1
1
4
2
7
6
5
1
4
3
EXTRUSION is shown for reference only.
EXTRUSION is shown for reference only.
Mounting
bracket
shown for
reference
Mounting
bracket
shown for
reference
Mounting
bracket
shown for
reference
2
1
8
7
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
2
3
ITEM PART NUMBER DESCRIPTION
QTY QTY QTY QTY
4
5
6
7
8
1
4444
1111
4444
1111
1
1
1
1
Page 5
4
7
3
1
5
2
EXTRUSION is shown
for reference only.
1
3-6
3-6
2
8
9
15
3-6
7
7
11
6-10
3-6
2-6
1
1
2-6
6-10
11 12
3-6
13
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
4
2
2
4
16
12
4
1
2
2
-1
2
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
2
3
ITEM
PART NUMBER
DESCRIPTION
QTY
4
5
6
7
8
1
9
10
11
12
13
MODEL 45KRS
ITEM PART NUMBER DESCRIPTION
QTY
1
2
3
4
5
6
7
8
9
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
10
11
1
3
1
12
12
3
3
2
1
1
NOTE: Extrusion shown
for reference only
NOTE: Extrusion shown
for reference only
6
10
MODEL: 45FLASH
2
3
ITEM
PART NUMBER
DESCRIPTION
QTY
1
4500 OPTION / ADD INTERNAL FLASHER
ASSY / FLASHER INPUT HARNESS
ASSY / HARNESS / 400 LED with FLASHER
ASS'Y / 2 CHANNEL FLASHER / 4500 SERIES LED
1
1
1
1
3
2
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
4
4
07-284353-000
15-061416-160
02-0362641-00
15-081416-080
46-0941245-00
HARNESS ASS'Y., STROBE
1
01-0440624-25
CABLE ASSEMBLY - 25'
A/R
46-0941248-00
HARNESS ASS'Y STROBE CTR
2
3
4
5
6
7
1
700 SERIES LINEAR STROBE
A/R
1
02-0484303-07
1
POWER TO PASSENGER
SIDE LOAD LIGHT.
13
MODEL: 45LRLOAD
2
3
ITEM
PART NUMBER
DESCRIPTION
QTY
4
5
6
7
8
1
9
10
11
14-062216-061
4
07-286741-000
2
02-0484303-48
14-062216-160
68-7744081-00
02-016B644-30
68-5944082-31
07-26C834-000
56-043625-000
6
2
6
6
6
18
46-0941243-00
46-0744083-00
39-0402313-04
15-061416-060
13-062C40-16J
8
6
8
1
2
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
12
13
9
10
2
8
5
3
7
4
6
11
12
1
Page 6
6-10
2-6
3-6
6-10
2-6
3-6
11
12
1
15
1
3-8
3-83-8
3-8
2
9
10
NOTE:Lightheads shown in standard
positions. EXTRUSION is shown
for reference only.
M
O
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
2
3
4
5
6
1
3
3
12
12
1
-1
7
8
3
3
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
3
4
5
6
1
7
8
9
3
3
3
12
1
-2
12
3
1
SUB ASS'Y / LOAD LIGHTS / 4500 SERIES
02-0483910-00
10
1
1
3-8
3-8
2
MODEL: 45KFL
NOTE: Lightheads are shown in standard positions. EXTRUSION
is shown for reference onl
y
.
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/-
12
2
2
2
16
4
4
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
4
07-284354-00
BRACKET MTG 400 SERIES LIGHTHEAD/
68-3983799-30
68-3983799-50
02-0342934-00
07-26C091-000
1
2
-1
2
LENS / CLEAR NON OPTIC 16.57" 4500 SERIES/
LENS RED NON OPTIC 16.57" 4500 SERIES//
SUB ASS'Y BRACKET & BASE/
BRACKET CORNER STROBE/
2
3
ITEM
PART NUMBER
DESCRIPTION
QTY
4
5
6
7
8
1
9
10
11
12
1
1
1
1
1
MODEL: 45FL*
2
3
DESCRIPTION
4
5
6
7
8
1
1111
4444
9
QTY
1
4
22222
11111
1
PART NUMBER
QTY QTY QTY QTY
8
2
9
3
1
567
4
EXTRUSION is shown for reference only.
6
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/.
1
Page 7
2
1
3-6
3-6
7
8
9
3-6
7
1
7
LOAD
LIGHT
Wire Harness / MR11 Load Lights
Extrusion
To Control Head
(not shown)
For Reference
For Reference
Grommet shown for reference
FLASHER
TA
NOTE: Model 45TA8
shown. For Model 45TA6
drop out the center two
lightheads.
EXTRUSION,
CORNER LEDs and
CENTER LENS are shown
for reference only.
21
12
WHT/RED
WHT/RED
RED
RED
WHT/ORG
YELLOW
WHT/YEL
ORANGE
CABLE ASSY
BLUE
WHT/GRN
WHT/BLU
GREEN
LOAD
LIGHT
VIOLET
WHT/VIO
WHT/VIO
VIOLET
21
12
21
21
12
21
12
21
12
21
12
21
12
21
12
21
12
21
12
21
12
21
12
21
12
21
12
21
12
21
12
21
12
21
12
1212 12 12
123
321
123
321
123
321
BLACK
BLUE
21 21 21 21 21 21
RED
RED
RED
RED
TA1
TA1
TA2
AMB
TA3
AMB
TA4
AMB
TA5
AMB
TA6
TA6
GRN
BLK
8
9
RED
RED
RED
RED
TRAFFIC ADVISOR OPTION W/MR-11 LOAD LIGHTS
4
5
1
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
2
3
4
5
6
7
8
1
9
1
-1
3
3
12
12
2
3
1
KKK FRONT STROBE PKG. 4500 SERIES
EXTRUSION is shown for reference only.
NOTE: Lightheads shown in standard
positions.
5-9
5-9
5-9
5-9
4
2
3
9
5
4
7
8
6
3 3
1011
5-9
5-9
5-9
MODEL: 45TA with MR11 Load Lights
2
3
DESCRIPTION
4
5
6
7
1
8
02-0484303-35
PART NUMBER
QTY
1
1
2
6
1
1
01-0269809-06
01-0669813-00
02-0342933-00
02-0386361211
02-0463931-00
46-0743112-00
1
1
1
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//--
9
6
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"
2
3
ITEM
PART NUMBER DESCRIPTION
QTY QTY
4
5
6
7
8
1
02-0484303-34
02-0484303-33
1
9
10
11
1
1
2
24
6
6
12
6
1
1
1
1
1
2
32
8
8
16
8
1
1
5
1
4
1
Page 8
32 33
34
35
23
24
19
25
17
18
22
32 33
34
35
32 33
34
35
14
26 27
28
31
31
30
30
31
30
31
16 15
30
28
29
12
3
13
4
56
12
89
7
10 11
1
1
1
1
1
1
22
2
22
44
4
444
44 444
2
111
11
2
1
2
1
22
686
13.61
2222
3
5
666
11.28 9.28 7.94
9.46
22222
1
33
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
8
A/R A/R
444444444444
77
55
8866
555
4
222
666
5
333
1
16 16
12 12 12 12
12
10 6 66
2
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
11
A/R
A/R A/R
2
22
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/
2
A/R
4
7
16.46
14.94
8
8
16
2
3
ITEM
PART NUMBER DESCRIPTION
QTYQTY QTYQTY QTY QTY QTY
11
12
13
14
15
16
20
28
17
25
21
29
18
26
22
30
19
27
23
31
24
32
4
5
6
7
8
9
10
1
33
QTYQTY QTY QTY QTY QTY
1
111
11
1
11
1111
111
1
1
1
1
1
1
111
34
35
36
1
22222222
22222222
A/RA/RA/RA/RA/RA/RA/R
4444444
4444444
11
11111
11
A/RA/RA/RA/RA/RA/RA/R
A/RA/RA/RA/RA/RA/RA/R
36
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/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
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
12
BLACK
ROTATOR
LED or
HALOGEN
12
12
BLUE
4500 SERIES WIRING
12121212121212
12
12
12 12
Length of Lightbar
ICC Light Requirements
01-0684303___
PART NUMBER KEY:
ICC LIGHT REQUIREMENTS
1= A=
R=
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
21
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Whelen Engineering Company 45KRH Installation guide

45KRH
Brand
Whelen Engineering Company
Model
45KRH
Type
Installation guide
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