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Page 5

System 204-D

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 “D” Remote Head

2

01-0683625AX3

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

Mounting the ISP94 Power Supply...

Your DOT system includes the Whelen Model ISP94 Power Supply. Included with your installation materials is
a templet to assist in determining the locations for the mounting holes. Use of this template will insure that the
holes are drilled in the optimum positions for your 94.There are a number of places the 94 may be mounted,
each being dependent upon the type of vehicle used. Keep in mind the following when determining a location:

The power supply is not waterproof. The mounting area 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 service purposes.

Allow a minimum of 2 inches of clearance beyond the rear of the power supply in order 
for the unit’s cooling fan to properly circulate air.

Mounting the power supply to a metal surface is recommended for optimum heat 
dissipation.

Be sure that the backside of the proposed mounting surface does not hide any wires, 
cables, fuel lines, etc., that could be damaged by drilling the mounting holes.

One of the most common places chosen is against the rear wall of the cab. This is a good choice for several
reasons, such as good air circulation and heat dissipation. If this configuration is used, follow these steps:

1.

Select a location towards the middle of the cab.

2.

Be sure that the mounting location is a minimum of 8” from the cab floor.

3.

Position the power supply in the proposed location (Keep in mind the power supply should be mounted
on as flat a surface as possible).

4.

Using the supplied drilling templet, drill four 1/8” holes in the indicated areas.

5.

Secure power supply to mounting surface with #8 x 5/8” sheet metal screws.

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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