Whelen MBFX11AA 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 Ford Explorer

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.14510A (112213)

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

Page 1

Fig. 4

ION™
LIGHTHEAD

#6 X 1 PPHSMS

#8 X 1/2"
PHILLIPS
TRUSS
SCREW

#8 SCREW
GROMMET

GASKET

BUSHING

Exits mirror

assembly

base

Mirror-Beam™

HOUSING

Position connectors between Mirror-Beam™ housing and mirror assembly housing

Exits front

of mirror

assembly

To Remove the Side Mirror Assembly:

1. Remove the triangular panel from the inside of the door that covers
the mirror assembly base (Fig. 1). This panel snaps in.

2. Remove the two nuts holding the mirror assembly on, unplug the
wiring and remove the mirror assembly from the vehicle (Fig. 2).

Preparing Mirror Assembly:

1. Remove the mirror assembly cover from the front of the mirror
assembly. The cover snaps off. Carefully push the cover forward
away from the mirror to remove it.

2. Mark off the wire hole location on the top of the cover, measuring 1-1/
2” from the rear (mirror side) and at the approximate center from left
to right (Fig. 3). The wire hole must be located over the hole in the
mirror assembly that the Mirror-Beam™ cable will exit. Drill the wire
hole through the cover using a 3/4” drill.

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. 4).

Routing Mirror-Beam™ Cable:

1. Insert the ty-wrap into the front of the
mirror assembly (Fig. 3). Remove the
small cover that snaps on and off,
covering the wiring on the mirror
neck. Continue to push the ty-wrap in
until the end of the ty-wrap sticks out
of the mirror neck (A). Pull the ty-wrap
out until slack in the cable is gone.
There should not be more than 4 - 5”
of cable sticking out of the front of the
mirror assembly.

2. Feed the ty-wrap back into the mirror
assembly neck (along the mirror
power cables path) and back out
through the hole in the mirror
assembly base that the mirror power
cable connector occupies (B & C).
You will have to cut out a small
amount of the outside of the base
gasket to accommodate the Mirror­Beam™ cable. You may have to
widen the connectors hole with a
round file if the cable doesn’t fit (B).

3. Insert the end of the cable into the
1/2” hole you drilled in the mirror
assembly cover and snap the cover
back onto the mirror assembly.

4. 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.
(see wiring diagram).

Preparing the Mirror-Beam™ cable:

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).

Fig. 4

Affixing Mirror-Beam™ Housing to Mirror Assembly:

1. Reconnect the mirror power cable and remount the mirror assembly
onto the vehicle using the original hardware. 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 and reattach the panel
covering the mirror assembly base.

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. 4).

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

Page 2

water. Dry completely.

4. Locate the two, 6” strips of double-sided adhesive tape (included).

BOLD = California Title XIII Compliant Pattern

= SYNC PatternItalic PH 1 = Phase 1 PH 2 = Phase 2

SingleFlash 75PH 2

PingPong™ 75PH 1
PingPong 75PH 2

ComAlert™ 75PH 1
ComAlert 75PH 2
LongBurst™ 75PH 1
LongBurst 75PH 2

8.

9.

10.

11.

12.

13.

14.

SingleFlash 60
SingleFlash

SingleFlash 120

SingleFlash 300
DoubleFlash 150
ComAlert™ 150
ActionFlash™ 50

90

ActionFlash™ 150
ModuFlash™
ActionScan™

Steady

15.

17.
18
1

20.

21.

16.

.

9.

22.

23.

24.

25.

SignalAlert™ 75PH 1
SignalAlert 75PH 2
CometFlash® 75PH 1
CometFlash 75PH 2

DoubleFlash 75PH 1
DoubleFlash 75PH 2
SingleFlash 75PH 1

1.

2.

3.

4.

5.

6.

7.

Flash Patterns:

Locate tape at edge of mirror cover

L

ocat

e

t

a

p

e

a

t

b

o

t

t

o

m

o

f

m

i

r

r

o

r

c

o

v

e

r

#8 X 1/2"
PHILLIPS
TRUSS
SCREW

CAUTION! DO NOT LOOK DIRECTLY AT THESE LED’S WHILE THEY ARE ON.
MOMENTARY BLINDNESS AND/OR EYE DAMAGE COULD RESULT!

IMPORTANT WARNING!

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.

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.

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 Mirror-Beam™ 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.

8. The remaining protective backing strips must now be removed. The
housing must not be in contact with the backing strips. Starting with
the strip on top, and using a small, flat blade screwdriver gently pry
the housing about 1/4” away from the mirror assembly. Carefully pull
the protective strip “tab” created in step 6, and gently remove it
completely from the tape strip. Do not allow the strip to tear while

being removed.

9. Repeat for the other tape strip on the bottom.

10. Apply pressure to the Mirror-Beam™ assembly at the tape locations.
Maintain pressure for a minimum of 20 minutes to allow the tape to
properly setup. This can be accomplished by wrapping the Mirror­Beam™/mirror assembly tightly with adhesive tape.

WARNING: The tape adhesive used in this procedure is fully bonded
after 72 hours @ 70°F (21°C). During this period, do not expose the
Mirror-Beam™ to any unnecessary force, such as the high-pressure
water from a car wash.

WARNING: 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.

11. Locate the factory-drilled hole in the Mirror-Beam™ housing. Using a
.125” drill bit and the housing as a template, drill a hole into the mirror
assembly. Using the #8 x 1/2” black oxide phillips truss screw,
(included) secure the Mirror-Beam™ housing to the mirror assembly.

Connecting the Mirror-Beam™ to Power:

1. Re-connect the mirror assembly to it’s main power cable. Route the
Mirror-Beam™ cable through the door, along the same path as the
vehicle’s main power cable and connect to power.

2. Cut the non-insulated wire off the Mirror-Beam™ cable. After the
connections are complete, confirm proper operation.

WARNING: 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
load. DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT!

Scan-Lock™ (WHT/VIO) - With the light on: To advance to the next
flash pattern, apply +VDC to the WHT/VIO wire for less than 1 second.
To cycle backwards, apply +VDC to the WHT/VIO wire for more than 1

second. To reset to the factory default pattern, turn off power to the
lighthead. While applying +VDC to the WHT/VIO wire, turn the lighthead
back on. Continue to apply voltage for 5 seconds.

SYNC (GREY) - Lights configured to display the Phase 1 mode of a
pattern will flash simultaneously. Lights configured to display the Phase 2
mode will alternate with any Phase 1 lights with the same pattern.

To sync two lights, configure both lights to display the same Phase 1
pattern. With the power off, connect the GREY wires from each light
together. When the lights are activated, their patterns will be
synchronized. To configure the two lights to alternate their patterns,
advance the pattern of either lights to Phase 2 of the current pattern.

IMPORTANT: It is the responsibility of the installation technician to
make sure that the installation and operation of this product will not
interfere with or compromise the operation or efficiency of any
vehicle equipment!

at the battery to carry that

Page 3

LED COLOR

SIDE

0 1 - 0 6 8 7 0 4 6 1 _ _

D = RED/WHT
E =
F =
H =
J =

BLU/WHT

AMB/WHT

WHT/GRN

BLU/RED

AMB/RED
GRN/RED
AMB/BLU
BLU/GRN
AMB/GRN

K =
L=
M =
N =
P=

LED COLOR
1 =
2 =
3 =
4 =
5 =

AMB
BLU
WHT
GRN
RED

AMB/AMB
BLU/BLU
WHT/WHT

GRN/GRN

RED/RED

A=
B =
C =
G =
R =

SIDE
D =P=DRIVER

PASSENGER

4

5

3

8

7

12

6

10

9

ITEM

PART NUMBER

DESCRIPTION

QTY

11-487045-R01

11-487045-L01

01-06870461__

01-0415532-00

46-0742172-15

15-081C1B-081

15-061416-160

21-0200237080

01-026D363-_0

38-0444165-00

21-12080905-1

MIRROR-BEAM ION SERIES 2011 EXPLORER

HOUSING, MIRROR-BEAM PASSENGER 2011 EXPLORER

HOUSING, MIRROR-BEAM DRIVER 2011 EXPLORER

SCREW, 8 X 1/2 PHIL TRUSS SS, BLACK OXIDE

KIT, CABLE INSTALLATION

ASSY, CABLE 3/C 18 GA 15'

SCREW, #6 X 1" PPHSMS TYPE A SS

SUB ASSY, SURFACE MOUNT ION

SCREW GROMMET, #8

BUSHING

GASKET

A/R

2

A/R

1

2

1

2

1

1

1

2

8

10

9

7

4

6

5

3

1

LED COLOR
1 =
2 =
3 =
5 =

AMB
BLU
WHT
RED

SIDE
D =P=DRIVER

PASSENGER

4

5

3

8

12

6

10

9

ITEM

PART NUMBER

DESCRIPTION

QTY

11-487045-R01

11-487045-L01

01-06876411__

01-0447089-00

46-0747089-15

15-081C1B-081

15-061416-160

21-0200237080

01-026E782-*0

38-0444165-00

21-12080905-1

MIRROR-BEAM ION V-LIGHT SERIES 2011 EXPLORER

HOUSING, MIRROR-BEAM PASSENGER 2011 EXPLORER

HOUSING, MIRROR-BEAM DRIVER 2011 EXPLORER

SCREW, 8 X 1/2 PHIL TRUSS SS, BLACK OXIDE

KIT, CABLE INSTALLATION

ASSY, CABLE 3/C 18 GA 15'

SCREW, #6 X 1" PPHSMS TYPE A SS

SUB ASSY, SURFACE MOUNT ION V-SERIES

SCREW GROMMET, #8

BUSHING

GASKET

A/R

2

A/R

1

2

1

2

1

1

1

2

8

10

9

7

4

6

5

3

1

7

LED COLOR

SIDE

0 1 - 0 6 8 7 6 4 1 1 _ _

PARTS KEY

Page 4