Charger Base Mounting, Vehicle Wiring, and Battery Installation

Charger Base Surface and Wall Mounting

The Pelican 2460 StealthLite charging base station is engineered for fixed installation across industrial workbenches, equipment consoles, electrical panels, or facility walls. Mounting the dock securely prevents dislodgement in high-vibration industrial environments. Installers can fix the cradle using double-sided mounting tape or mechanically fasten the unit to solid vertical or horizontal surfaces using two #8 screws (screws are not included). When selecting a mounting location, maintain adequate clearance above the cradle so field personnel can smoothly insert and release the 7.00-inch (17.8 cm) high visibility yellow ABS flashlight assembly without obstruction.

Facility AC Mains Power Connection

For industrial control rooms, workshops, and inspection staging posts, the charging dock interfaces with external stepped-down power inputs. Stationary deployments utilize plug-in mains adapters, including compatible 220V transformer configurations (Pelican 2468H) or standard facility mains power transformers. Verify that input power cables are dressed neatly through strain relief pathways to avoid tension on the terminal connection. The charger cradle terminal contacts interface with the external contact points of the flashlight, delivering regulated power to replenish the internal 4.8V DC circuit within a rated 5-hour cycle.

Vehicle and Fleet 12V Direct Wiring Procedures

For deployment inside emergency response apparatus, utility maintenance trucks, and industrial fleet vehicles, the charger base supports direct 12V vehicle power integration via an accessory direct wiring rig (Pelican 6061F) or a 12V auxiliary plug-in adapter (Pelican 8056F). Professional installers must observe the following electrical integration rules:

• Ignition-Switched Line Connection: When hardwiring the charging dock via the 6061F direct wiring rig, the positive lead must be connected to an ignition-switched power circuit rather than directly to the unswitched vehicle battery. Because the fast-charge cradle draws high amperage during active cycles, direct connection to an unswitched circuit can cause parasitic drain on the vehicle battery during extended downtime.
• Polarity and Fuse Protection: Ensure circuit polarity matches vehicle chassis earth requirements and that the supply lead is protected by appropriate in-line circuit protection to guard against electrical spikes.
• Cable Routing: Fasten wiring away from sharp bulkhead edges, engine heat corridors, and steering linkages using industrial-grade wire ties.

NiMH Cell Pack Installation and Contact Alignment

The Pelican 2460 operates on a 4-cell AA NiMH pack configuration (Pelican 2469P replacement pack). Note that batteries (they are not included) are not supplied in the standard package and must be sourced separately. Prior to loading batteries (they are not included), verify the safety switch is in the discrete Off position.

1. Unthread the chemical-resistant ABS front shroud assembly counterclockwise from the body housing.
2. Inspect the internal Ethylene Propylene rubber O-ring sealing gasket for proper seated position, cleanliness, and absence of foreign grit to maintain IPX7 submersible ingress protection.
3. Check that the internal catalyst pellets on the lamp module are seated properly; these are vital for absorbing residual hydrogen gas released during NiMH cell charging.
4. Insert 4 AA NiMH batteries (they are not included) strictly observing the engraved polarity diagrams on the flashlight body: position 2 batteries (they are not included) in-line with the positive (+) terminal facing upward toward the lamp assembly, and 2 batteries (they are not included) in-line with the positive (+) terminal facing downward toward the base.
5. Confirm engagement with the stainless steel and phosphor bronze contact spring retainers.
6. Thread the shroud back onto the body firmly until fully seated against the O-ring stop.

Commissioning and Charging Diagnostic States

Before putting the Pelican 2460 into service in Class I, Division 2, Groups ABCD T4 or Class II, Division 2 hazardous environments, the manufacturer specifies an initial continuous charge cycle of 24 hours or more to properly condition new NiMH batteries (they are not included). Seat the flashlight firmly into the charging cradle until the mechanical retention latch clicks into locked position. Observe the cradle LED indicator to confirm operation: