Whelen MBCC11JJ User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Canadian Sales e-mail: [e-mail]
Customer Service e-mail: [e-mail]

Installation Guide:

Mirror-Beam™ ION™ Series™ and

ION™ V-Series™

Super-LED® Lighthead

2011 Caprice

Whelen’s emergency vehicle warning devices must be properly mounted and wired in order to be effective and safe. Read and follow all of Whelen’s
written instructions when installing or using this device. Emergency vehicles are often operated under high speed stressful conditions which must be
accounted for when installing all emergency warning devices. Controls should be placed within convenient reach of the operator so that he can operate
the system without taking his eyes off the roadway. Emergency warning devices can require high electrical voltages and/or currents. Properly protect and
use caution around live electrical connections.Grounding or shorting of electrical connections can cause high current 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 installation of any electronic device it is necessary to test all electronic equipment simultaneously to insure that they operate
free of interference from other components within the vehicle. Never power emergency warning equipment from the same circuit or share the same
grounding circuit with radio communication equipment. All devices should be mounted in accordance with the manufacturer’s instructions and securely
fastened to vehicle elements of sufficient strength to withstand the forces applied to the device. Driver and/or passenger air bags (SRS) will affect the way
equipment should be mounted. This device should be mounted by permanent installation and within the zones specified by the vehicle manufacturer, if
any. Any device mounted in the deployment area of an air bag will damage or reduce the effectiveness of the air bag and may damage or dislodge the
device. Installer must be sure that this device, its mounting hardware and electrical supply wiring does not interfere with the air bag or the SRS wiring or
sensors. Mounting the unit inside the vehicle by a method other than permanent installation is not recommended as unit may become dislodged during
swerving; sudden braking or collision. Failure to follow instructions can result in personal injury. Whelen assumes no liability for any loss resulting from the
use of this warning device. PROPER INSTALLATION COMBINED WITH OPERATOR TRAINING IN THE PROPER USE OF EMERGENCY WARNING
DEVICES IS ESSENTIAL TO INSURE THE SAFETY OF EMERGENCY PERSONNEL AND THE PUBLIC.

Warnings to Users

Warnings to Installers

Whelen’s emergency vehicle warning devices are intended to alert other operators and pedestrians to the presence and operation of emergency vehicles
and personnel. However, the use of this or any other Whelen emergency warning device does not guarantee that you will have the right-of-way or that
other drivers and pedestrians will properly heed an emergency warning signal. Never assume you have the right-of-way. It is your responsibility to proceed
safely before entering an intersection, driving against traffic, responding at a high rate of speed, or walking on or around traffic lanes. Emergency vehicle
warning devices should be tested on a daily basis to ensure that they operate properly. When in actual use, the operator must ensure that both visual and
audible warnings are not blocked by vehicle components (i.e.: open trunks or compartment doors), people, vehicles, or other obstructions. It is the user’s
responsibility to understand and obey all laws regarding emergency warning devices. The user should be familiar with all applicable laws and regulations
prior to the use of any emergency vehicle warning device. Whelen’s audible warning devices are designed to project sound in a forward direction away
from the vehicle occupants. However, because sustained periodic exposure to loud sounds can cause hearing loss, all audible warning devices should be
installed and operated in accordance with the standards established by the National Fire Protection Association.

Safety First

This document provides all the necessary information to allow your Whelen product to be properly and safely installed. Before beginning the installation
and/or operation of your new product, the installation technician and operator must read this manual completely. Important information is contained herein
that could prevent serious injury or damage.

• Proper installation of this product requires the installer to have a good understanding of automotive electronics, systems and procedures.

• Whelen Engineering recommends the use of waterproof butt splices and/or connectors if that connector could be exposed to moisture.

• Failure to use specified installation parts and/or hardware will void the product warranty.

• If mounting this product requires drilling holes, the installer MUST be sure that no vehicle components or other vital parts could be damaged
by the drilling process. Check both sides of the mounting surface before drilling begins. Also de-burr the holes and remove any metal shards
or remnants. Install grommets into all wire passage holes.

• If this manual states that this product may be mounted with suction cups, magnets, tape or Velcro®, clean the mounting surface with a 50/50
mix of isopropyl alcohol and water and dry thoroughly.

• Do not install this product or route any wires in the deployment area of your air bag. Equipment mounted or located in the air bag deployment
area will damage or reduce the effectiveness of the air bag, or become a projectile that could cause serious personal injury or death. Refer to
your vehicle owner’s manual for the air bag deployment area. The User/Installer assumes full responsibility to determine proper mounting
location, based on providing ultimate safety to all passengers inside the vehicle.

• For this product to operate at optimum efficiency, a good electrical connection to chassis ground must be made. The recommended
procedure requires the product ground wire to be connected directly to the NEGATIVE (-) battery post (this does not include products that use
cigar power cords).

• If this product uses a remote device for activation or control, make sure that this device is located in an area that allows both the vehicle and
the device to be operated safely in any driving condition.

• Do not attempt to activate or control this device in a hazardous driving situation.

• This product contains either strobe light(s), halogen light(s), high-intensity LEDs or a combination of these lights. Do not stare directly into
these lights. Momentary blindness and/or eye damage could result.

• Use only soap and water to clean the outer lens. Use of other chemicals could result in premature lens cracking (crazing) and discoloration.
Lenses in this condition have significantly reduced effectiveness and should be replaced immediately. Inspect and operate this product
regularly to confirm its proper operation and mounting condition. Do not use a pressure washer to clean this product.

• It is recommended that these instructions be stored in a safe place and referred to when performing maintenance and/or reinstallation of this
product.

• FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTRUCTIONS COULD RESULT IN DAMAGE TO THE PRODUCT OR VEHICLE

Automotive: Lightheads

AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!

©2011 Whelen Engineering Company Inc.
Form No.14530A (112513)

For warranty information regarding this product, visit www.whelen.com/warranty

Page 1

Mirror Assembly Cover

Fig. 1

1”

2 1/2”

Drill 3/4 Inch

Wire Hole

Remove the Side Mirror Assemblies:

TAPE

TOP

BOTTOM

TAPE

#8 X 1/2" PHILLIPS
TRUSS SCREW

GASKET

Mirror-Beam™
HOUSING

NOTE: MIRROR ASSEMBLY SHOWN
FOR REFERENCE ONLY!

#8 SCREW
GROMMET

LIGHTHEAD

#6 X 1

PPHSMS

BUSHING

Cable

exits mirror

assembly
base here

4to5
inches
of cable

To install this product, you must remove both side mirror assemblies
from the vehicle. Following manufacturers instructions Unplug the
mirror assembly harnesses and remove both mirror assemblies.

Preparing Mirror Assembly:

1. Remove the mirror
assembly cover
and mark off the
wire hole location
onto the front of
the mirror
assembly cover
measuring 2 1/2”
from the inboard
edge of the cover
and 1” from the
bottom edge of
the cover. Drill the
wire hole using a half inch drill bit (Fig. 1).

Preparing the Mirror-Beam™ cable:

Fig. 2

3. Strongly secure the ty-wrap to the cable with electrical or similar tape.
It is important to have a sufficient length of the ty-wrap secured to the
cable (2” minimum) (Fig. 2).

Because the Mirror-Beam™ cable
must be routed through a
specific, narrow and twisting path
within the mirror assembly, it will
be necessary to temporarily
extend the length of the cable.

1. Locate the ty-wrap (included)
and cut the fastener-end off.

2. Locate the end of the cable
that has PIN-type terminals
installed on the wires. Cut off
the non-insulated wire (not
used).

Routing the Mirror-Beam™ Cable:

1. Insert the ty-wrap
into the front of the
mirror assembly
and rout the
Mirror-Beam™

cable exiting the front of the mirror assembly (Figs 3 & 4).

2. Insert the end of the cable into the hole previously drilled into the
mirror assembly cover. Now snap the cover back onto the mirror
assembly.

3. Remove the ty-wrap from the cable. Install the socket connector
(supplied) onto the end of the cable coming out of the front of the
mirror assembly (Fig. 5). (see wiring diagram).

cable into the front of the
mirror assembly where the
assembly harness enters
and exiting out the base.
You will need to cut a hole in
the base as shown, for the
cable to exit. There should
not be more than 4 - 5” of

Page 2

Fig. 5

Affixing Mirror-Beam™ Housing to Mirror Assembly:

1. Remount the mirror assembly onto the vehicle using the original
hardware and reconnect the mirror power cable. Route the Mirror­Beam™ cable through the door, along the same path as the vehicle’s
main power harness. Make sure that neither of the harness cables
are crimped or pinched. Tighten all nuts firmly, reattach the panel
covering the mirror assembly base and re-secure the door panel.

2. Mount the lighthead to the Mirror-Beam™ housing and plug the
lighthead into the connector coming from the front of the mirror
assembly. This connection will be tucked between the Mirror-Beam™
housing and the mirror assembly (Fig. 5).

3. NOTE: The following procedure requires that the mirror
assembly be no colder than 60°F (18°C). Thoroughly clean the
plastic mirror assembly and the inside surface of the Mirror-Beam™
housing using a 50/50 mixture of isopropyl (not rubbing) alcohol and
water. Dry completely.

4. Locate the two, 6” strips of double-sided adhesive tape (included).
Peel the protective strip from one side of one piece of tape and
mount it onto the top of the mirror assembly curving around the
outboard side. When properly positioned, the tape will go along the
rear (mirror side) edge of the mirror assembly cover. After the tape is
mounted, it is important to apply pressure to the protective backing
so that the tape adheres to the surface (Fig. 3).

5. Peel the protective strip from the other piece of tape. Using the
procedure outlined in the previous step, adhere it along the bottom of
the mirror assembly cover along the seam.

6. Hold the Mirror-Beam™ housing in position on the mirror assembly
and trim and remove any exposed tape. Remove the housing and
fold the protective backing strips of the tape so that 1/2” to 3/4” of
backing is extended
over the edge of the
mirror assembly.

7. Mount the Mirror­Beam™ housing
onto the mirror
assembly. The

housing must fully
engage the mirror
assembly. Press

the housing firmly
onto the exposed
tape on the mirror
assembly.