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Introduction...

The material contained in this manual provides the information necessary for proper installation of Whelen
Engineering’s DOT3

®

 Lighting System. This includes all wiring and mounting information for models 104 &

204. However, because the DOT3

®

 System is designed to be versatile enough to meet any and all needs,

customized system configurations are common. This should not significantly effect the installation procedure
to a great extent. Be sure to read this manual 

thoroughly

. There are important warnings and notes included

that  will  ensure  a  fast  and  efficient  installation.  They  will  also  prevent  system  damage  due  to  installation
errors.

Parts List...

The following table lists all of the parts included with each of our standard-configuration systems. Customized
systems will have components that may not be reflected in this list:

System 104-A

Description

Qty.

Part Number

Model “A” Remote Head

2

01-0683776-A0

DOT 9 Connector Flex Tube Kit (Contains 2 Assemblies)

1

01-0416222-00

ISP94 Intelligent Strobe Power Supply, w/Diagnostix™

1

01-0668156-00

3 Connector DOT Waterproof Cable (30 Foot) (with install kit) 2

01-0442208-30

Dual Switch Assembly 

1

02-0341880-00

DOT Power Connector

1

46-0725612-00

System 104-B

Description

Qty.

Part Number

Model “B” Remote Head

2

01-0683776-AX

DOT 11 Connector Flex Tube Kit (Contains 2 Assemblies)

1

01-0416222-01

DOT 9 Connector Cable Kit (DOT Harness Kit Included, Qty. 2) 1

01-0462508-00

ISP94 Intelligent Strobe Power Supply, w/Diagnostix™

1

01-0668156-00

9 Connector DOT Waterproof Cable (Driver Side/30 Foot)

1

02-0262508-00

9 Connector DOT Waterproof Cable (Passenger Side/30 Foot) 1

02-0262508-01

Dual Switch Assembly 

1

02-0341880-00

DOT Power Connector

1

46-0725612-00

System 104-D

Description

Qty

Part Number

Model “D” Remote Head

2

01-0683776AX8

DOT 11 Connector Flex Tube Kit (Contains 2 Assemblies)

1

01-0416222-01

DOT 9 Connector Cable Kit (DOT Harness Kit Included, Qty. 2) 1

01-0462508-00

ISP94 Intelligent Strobe Power Supply, w/Diagnostix™

1

01-0668156-00

9 Connector DOT Waterproof Cable (Driver Side/30 Foot)

1

02-0262508-00

9 Connector DOT Waterproof Cable (Passenger Side/30 Foot) 1

02-0262508-01

Dual Switch Assembly 

1

02-0341880-00

DOT Power Connector

1

46-0725612-00

System 204-A

Description

Qty.

Part Number

DOT 3 Connector Flex Tube Kit (Contains 2 Assemblies)

1

01-0416224-00

Model DOT-52 “A” Remote Head

2

01-0683625-A0

ISP94 Intelligent Strobe Power Supply, w/Diagnostix™

1

01-0668156-00

3 Connector DOT Waterproof Cable (30 Foot)(with install kit)

2

01-0442208-30

Dual Switch Assembly 

1

02-0341880-00

DOT Power Connector

1

46-0725612-00

System 204-B

Description

Qty.

Part Number

DOT 9 Connector Flex Tube Kit (Contains 2 Assemblies)

1

01-0416222-00

DOT 9 Connector Cable Kit (DOT Harness Kit Included, Qty. 2) 1

01-0462508-00

Model DOT-52 “B” Remote Head 

2

01-0683625-AX

ISP94 Intelligent Strobe Power Supply, w/Diagnostix™

1

01-0668156-00

9 Connector DOT Waterproof Cable (Driver Side/30 Foot)

1

02-0262508-00

9 Connector DOT Waterproof Cable (Passenger Side/30 Foot) 1

02-0262508-01

Dual Switch Assembly 

1

02-0341880-00

DOT Power Connector

1

46-0725612-00

Summary of Contents for DOT3 System 104 Series

Page 1: ...arcing which can cause personal injury and or vehicle damage including fire Many electronic devices used in emergency vehicles can create or be affected by electromagnetic interference Therefore after...

Page 2: ...IT IS A VIOLATION OF THE FEDERAL MOTOR VEHICLE SAFETY STANDARD FOR THE THIRD BRAKE LIGHT AS WELL AS REAR BRAKE LIGHTS FUNCTIONS THAT BLACK OUT THE REAR BRAKE LIGHTS SOMETIMES CALLED BRAKE LIGHT CUT OU...

Page 3: ...page 6 Wiring the Remote Head Assembly page 6 Systems 104 A and 204 A page 6 Systems 104 B and 204 B page 7 Systems 104 D 104 H or 204 D page 9 Mounting Wiring the Dual Switch Assembly page 10 Illust...

Page 4: ...t Strobe Power Supply w Diagnostix 1 01 0668156 00 9 Connector DOT Waterproof Cable Driver Side 30 Foot 1 02 0262508 00 9 Connector DOT Waterproof Cable Passenger Side 30 Foot 1 02 0262508 01 Dual Swi...

Page 5: ...must be dry and free from elements that could damage the unit road salt sand snow The power supply should not be exposed to excessive heat The mounting area should be easily accessible for wiring and...

Page 6: ...t with other vehicles or equipment that may damage the remote head The remote head was designed to be mounted vertically The mounting surface must be able to tolerate welding Be aware of all of the fu...

Page 7: ...river Side End of cable towards Power Supply RED wire Connect with Set Screw Connectors to RED wire on Harness Kit Insert other end of RED Harness Kit wire into Position 1 of connector BLACK wire Conn...

Page 8: ...ness Kit wire into Position 3 of connector Connect pin housing to OUTLET 3 NOTE The remaining wires are to be connected as follows If a wire is designated for a specific lamp ex Driver Side Tail Light...

Page 9: ...ousing to OUTLET 1 NOTE The remaining wires are to be connected as follows If a wire is designated for a specific lamp ex Driver Side Tail Light that wire must be connected to the existing factory cir...

Page 10: ...or pinch the wires The factory harness may depending on vehicle design include a service loop that will keep the wires from being damaged or broken by the movement of the dump body Mounting and wiring...

Page 11: ...4 A SYSTEM ILLUSTRATION FOR REAR DRIVER S SIDE REMOTE HEAD BLACK GREEN WHITE INLINE SPLICE 3 CONNECTOR DOT WATERPROOF CABLE 30 FOOT 1 2 3 1 2 3 BLACK WHITE GREEN BLACK WHITE GREEN WHITE GREEN BLACK 5...

Page 12: ...BROWN GREEN YELLOW AUX WIRE ORANGE STROBE LIGHT NO CONNECTION BRAKE TAIL TURN SIGNAL LIGHT A B C A B C A B C NO CONNECTION STROBE LIGHT BRAKE TAIL TURN SIGNAL LIGHT AUX WIRE VIOLET GREEN BROWN BLUE O...

Page 13: ...IVER S SIDE REMOTE HEAD BLACK RED WHITE BLUE VIOLET BROWN GREEN YELLOW AUX WIRE ORANGE STROBE LIGHT BACK UP LIGHT BRAKE TAIL TURN SIGNAL LIGHT A B C A B C A B C BROWN GREEN BLUE ORANGE YELLOW BLACK RE...

Page 14: ...14 6 25 5 10 0 218 7 32 dia POWER SUPPLY OUTLINE DRILLING TEMPLATE FOR ISP94 POWER SUPPLY The template s included with this manual MAY NOT BE TO SCALE CONFIRM ALL DIMENSIONS Before drilling IMPORTANT...

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