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INSTALLING THE HALOGEN LIGHTING SYSTEM:
It is recommended you follow the general order of steps as
indicated below:
1.
Choose an accessible location for the halogen flasher
module, protected from the weather and abuse.
2.
Determine, on the vehicle, the desired locations of the remote
halogen light head assemblies.
3.
String interconnecting cables from halogen flasher control
module to the locations chosen to hold the remote halogen
light head assemblies.
4.
Connect the interconnecting cables to the halogen flasher
control module.
IMPORTANT:
MAKE SURE THE HALOGEN FLASHER MODULE
IS NOT CONNECTED TO POWER .
5.
Install, at the chosen locations, the halogen lightheads and
connect them to the interconnecting cables. Do not, at this
time, finalize the installation of the lightheads until the
system's final test.
6.
Install control switch and connect to halogen flasher module.
7.
Install and connect the two power cables to the power source
of the vehicle (battery), and test the halogen light system.
Note: When passing interconnecting cables through metal
surfaces, remove burrs from edges of the holes, and
use rubber grommets to protect the cables. It is
advisable to support the cables with cable ties, cable
clamps, or with any other means, to make sure that
they will not shift around or put tension on the
connectors.
MOUNTING THE HALOGEN FLASHER MODULE:
•
The unit must be mounted with the cooling fins in the
vertical plane for maximum
heat dissipation (Fig. 1).
•
Keep enough clearance, 3
inches minimum, around
the unit for proper
ventilation, and room for
easy access to the remote
halogen light head
interconnecting cable
connectors. Sufficient room
is also required to remove
or install both the module
outer cover and the internal
slide-on cover (Fig. 2).
•
Mount the halogen flasher
module on a metal surface
to enhance heat
dissipation.
INSTALLING HALOGEN LIGHT HEAD INTERCONNECTING
CABLES (customer supplied).
I
MPORTANT:
DURING THIS OPERATION MAKE SURE
HALOGEN FLASHER IS NOT CONNECTED TO POWER.
The interconnecting cables should have color coded wires. A
good installation practice is to label the opposite end of the cables
with an indelible marker with the number of the halogen connector
to which it is connected. Leave a service loop in the
interconnecting cable at the halogen flasher module location, in
case maintenance should be required at a later date. Determine
the correct wire size for the cables, depending on how you wire
the system (If you wire the lightheads individually, they will have a
different amp draw from lightheads wired in series)
Note: 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 the load.
1.
Route the interconnecting cables through the vehicle to the
location chosen for the halogen light heads. Cut the cable
length leaving an allowance for a service loop. During the
installation of the cable avoid sharp edges and chafe points.
2.
Whelen halogen lightheads are supplied with a 2 wire pigtail
to be butt spliced to the interconnecting cables. Make sure,
when butt splicing, to match the colored wires of the pigtail to
the same colored wires of the flasher module.
INSTALLING THE HALOGEN LIGHTHEADS:
After connecting the halogen lightheads (Customer Supplied) to
the interconnecting cables using the 2 wire pigtail assemblies,
install them according to their instructions. It is recommended not
to finalize the installation of the individual halogen lightheads until
the complete system has been tested, since it is possible that
minor adjustments may be needed later on.
CONNECTING THE HALOGEN FLASHER MODULE TO THE
CONTROL SWITCH:
The halogen flasher module is to be connected to a customer
supplied mode control switch. The single pole, double throw,
center off type switch, is to be installed inside the vehicle's cab. In
Mode 1, all halogen lightheads on the vehicle are flashing. In
Mode 2, only the remote halogen lightheads, located on the box of
the vehicle, will be flashing. The flashing sequence of both modes
is controlled by the halogen flasher module.
CONNECTING THE HALOGEN FLASHER MODULE TO THE
POWER SOURCE: (battery)
IMPORTANT:
DURING THIS STEP, MAKE SURE THAT
CONTROL SWITCH IS IN THE OFF POSITION.
Use an #8 AWG minimum size wire for positive and a #10 AWG
minimum size wire for negative (both customer supplied) with ring
lugs to fit the power input studs located on the halogen flasher
unit. These studs are clearly marked positive (+) and negative,
and are colored red and black respectively. Connect the positive
wire (+) directly to the battery positive post through a customer
supplied 50 amp master fuse (see wiring diagram). Install this
master fuse as close to power source as possible. Connect the
negative wire (-) directly to the battery negative post.
HI-LO INTENSITY:
Switches intensity of lighting from high to low using a customer
supplied single pole switch. This function is only active in mode 2.
(See wiring diagram)
Fig. 1