Whelen MKEZ83 User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Fax: [phone]

2011 Ford Explorer / MKEZ83

(Models without roof rack)

Installation Guide:

Lightbar Strap Mount

Internet: www.whelen.com
Sales e-mail: [e-mail]
Canadian Sales e-mail: [e-mail]
Customer Service e-mail: [e-mail]

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.

• 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 any 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.

• If this product uses a remote device to activate or control this product, make sure that this control is located in
an area that allows both the vehicle and the control 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 AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!

Automotive: Lightheads

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

©2011 Whelen Engineering Company Inc.
Form No.14491 (042811)

Page 1

IMPORTANT! The lightbar should be located a minimum of 16"
from any radio antennas!

Installation:

Be sure you have the right sized lightbar for your vehicle. The lightbar
should be approximately the same width as the vehicle's roof. If the lightbar
is too large or small it may shift or come loose during driving.

1. Locate the mounting foot, anchor plate and locking plate included with
your lightbar. If not already present, loosely install the locking plate
onto the mounting foot using the supplied allen set screws.

Anchor

Mounting

Strap

Tension

Bolt

Mounting
Foot

Locking
Plate

Plate

Tinnerman
Nut

3. Repeat this procedure for the remaining mounting foot and anchor
plate and return the lightbar to its right side-up position.

4. Position the lightbar on the vehicle roof and adjust the two mounting
feet outwards so that the mounting pads are resting inside of the
channel near the edge of the roof (Fig. 1). You must also center the
lightbar so that the mounting strap is centered exactly between the
front and rear doors (Fig. 2). Make sure that both mounting feet are in
full contact with the roof. When properly positioned, tighten the allen
screws to hold the foot in place. Repeat this procedure for the
remaining foot. (Refer to your lightbar manual for cable exit location,
to be sure that your lightbar is facing the proper direction.)

Mounting
Screw

2. Flip the lightbar upside-down and place the mounting foot onto the
extrusion (See illustrations below). Rotate the foot 90° counter­clockwise. Make sure that the edges of the foot slide under the
extrusion mounting lip. Install an anchor plate (with allen screws) onto
the extrusion in the same manner.

Insert foot into extrusion with locking
plate attached.

ANCHOR
PLATE

Twist mounting foot
into position

Loosely secure foot and locking plate.

5. Insert the mounting strap onto the mounting foot as shown. Be sure
that the strap fits flush against the vehicle where it will be secured.
Insert the tension bolt through the mounting strap, through the anchor
plate and into the tinnerman nut. Tighten slightly with a long-shafted,
Phillips screwdriver. Repeat procedure
for the passenger’s side.

Tinnerman

6. Use the
two holes
in the end
of the strap as
a template to drill the

Nut

Anchor

Plate

Mounting

Strap

Roof Surface

Tension
Bolt

Groove

pilot holes for the sheet metal screws
through the strap and into the vehicle. Repeat
this for passenger’s side of the vehicle.

7. Screw the sheet metal screws into the holes you
drilled in step 6 and tighten firmly. Repeat for

Mounting
Screws (2)

passenger’s side of the vehicle.

8. Now firmly tighten the tension bolt to secure the lightbar to the vehicle.

Page 2