Installation Manual for

ENGINEERING COMPANY INC. 97 Series Lighthead

ROUTE 145, WINTHROP ROAD
CHESTER, CONNECTICUT 06412-0684
TELEPHONE: (860) 526-9504
FAX: (860) 526-4078

Mounting Style #1 . . .
1. Select a mounting location. Make sure that the 97 will not interfere 6. Position the 97 components onto the mounting surface and secure
with any existing equipment. Be aware of any and all items on the to the vehicle using four #10 x 1” (#10 x 1.25” for use with flange
opposite side of the mounting surface to prevent any possible mount) sheet metal screws.
damage to existing components.
2. Using the dimensions shown on page 3, carefully remove the area
of the mounting surface where the reflector will be installed.
Mounting Style #2 . . .
Do not remove the mounting surface area where the mounting 1. Same as step 1 of Style #1.
holes are to be drilled!
2. Using the dimensions shown on page 4, carefully remove the area
3. Using a drill bit sized for a #10 sheet metal screw (and the of the mounting surface where the reflector will be installed.
thickness of the mounting surface), drill the mounting holes as Note: Mounting style #2 is designed to use Fastex® grommets
shown on Page 3. (customer supplied) to secure the 97 to its mounting surface.
4. Route the cable assembly through the wiring hole towards the
3. Same as step 4 of style #1.
necessary power supply. Be sure that both ring terminals are
grounded to the vehicle chassis ground. 4. Same as step 5 of style #1.
5. Now pass the cable through the mounting components as shown. 5. Same as step 6 of style #1 except the grommets must be inserted
Plug the 97 lighthead into the cable and plug the cable into the into the areas indicated on page 4.
power supply. Test operation of the 97 before securing it to the
vehicle.

5 6

3b
3a

2
1

WH
EL
EN
EN
G.
CO
.
PA
SAE-STI-91 DOT

T.
PE
ND
.

Wire Connection Guide

2-wire 3-wire 3-wire
SAE-WW2W5-91

(non-strobe) (non-strobe) (strobe)

MO
DE
L9
7S
Color Function Function Function
ER
IES RED +12VDC +12VDC (Tail) Anode
BLACK N/A +12VDC (Turn/Brake) Cathode
WHITE Ground Ground Trigger

IMPORTANT: The outer surfaces of this product may

be cleaned with mild soap and water. Use of any other
chemicals may void product warranty. Do not use a
pressure washer.

©2000 Whelen Engineering Company Inc.

Form No. 13537 (061300)
Page 1 of 4
 5b 6
5a

Not used with flange kit.

Shown for reference.
4

2
1

WH
EL
EN
EN
G.
CO
.
PA
SAE-STI-91 DOT

T.
PEN
D.
SAE-WW2W5-91

MO IMPORTANT: The outer surfaces of this product may

DE
L9
7S
ER
be cleaned with mild soap and water. Use of any other
IES
chemicals may void product warranty. Do not use a
pressure washer.

ITEM QTY PART NUMBER DESCRIPTION

1 4 N/A #10 x 1” P.P.H.S.M.S. (1¼” if flange mount is used)
2 A/R 68-1181349-10 LENS, AMBER
2 A/R 68-1181349-20 LENS, BLUE
2 A/R 68-1181349-30 LENS, CLEAR
2 A/R 68-1181349-40 LENS, GREEN
2 A/R 68-1181349-50 LENS, RED
2 A/R 02-0361457-13 LENS, 13° SCENELIGHT ASSY.
2 A/R 02-0361457-26 LENS, 26° SCENELIGHT ASSY.
2 A/R 68-1182293-30 LENS, 8° - 32° SCENELIGHT
2 A/R 02-0381749-( ) LENS, SPLIT
2 A/R 68-1181745L( ) LENS, ARROW
3 A/R 36-0361281-00 S30TL TWIST-IN STROBE
3a A/R 34-0041987-00 LAMP, 35H HALOGEN
3a A/R 34-0041987-01 LAMP, 50H HALOGEN
3a A/R 34-0062389-00 LAMP, STOP/TAIL INCANDESCENT (3-WIRE USAGE)
3b A/R 33-0042141-00 ASSY., LAMP HOLDER (2-WIRE/SHOWN)
3b A/R 33-0042203-00 ASSY., LAMP HOLDER (3-WIRE/NOT SHOWN)
4 A/R 68-5981389-06 REFLECTOR (METALIZED)
4 A/R 68-5981389-07 REFLECTOR (MATTE)
5 1 38-0481690-00 GASKET, REFLECTOR (NOT USED w/FLANGE KIT)
5a 1 11-783130-001 FLANGE
5b 1 38-0481440-00 GASKET, FLANGE
6 1 01-0440624-15 CABLE, 15 FT.

Page 2 of 4
 Mounting Style #1

NOTE: The dimensions shown in this illustration are shown to the third decimal place.
Although the tools capable of cutting this opening are not usually this accurate, it is
absolutely necessary to try and stay as close to these dimensions as possible.

6.831
3.416 IMPORTANT NOTE!!
6.162 The template(s) included with this manual
3.081 MAY NOT BE TO SCALE.
Before drilling, CONFIRM ALL DIMENSIONS.

3.224
2.625 2.506

Page 3 of 4
1.776

3.552 5.012
6.447 5.250

Units: Inches 3.625

Scale = NONE 7.250
4.349
8.698
 Mounting Style #2
NOTE: The dimensions shown in this illustration are shown to the
third decimal place. Although the tools capable of cutting this
opening are not usually this accurate, it is absolutely necessary to
try and stay as close to these dimensions as possible.

8.70
Units: Inches
4.35 Note orientation
Scale = NONE CL of the grommet

Optional Mounting
Template Using
Customer Supplied
Fastex ® Grommets 3.22

Page 4 of 4
Location of grommets CL
38°
1.776
6.45
2.726

.138
+.005
.275 -.000 3.082
3.728
IMPORTANT NOTE!!
The template(s) included with this manual
25° MAY NOT BE TO SCALE.
45° Before drilling, CONFIRM ALL DIMENSIONS.