Whelen FC4JJJJ User Manual

®

ENGINEERING COMPANY INC.

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

Installation Guide:

Freedom™ II

WeCan® Lightbar

Fax: [phone]
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.

• 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: Lightbars

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

©2006 Whelen Engineering Company Inc.
Form No.14012B (052110)

Page 1

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

Permanent Mounting:

1. Locate the mounting foot and mounting plate included with your
lightbar. If not already present, install the mounting plate onto the
mounting foot. When properly positioned, this plate is centered from
side-to-side on the mounting foot.

2. Flip the lightbar upside-down to expose the bottom of the extrusion
and place the mounting foot onto the extrusion.

3. Rotate the mounting foot 90° in a counter-clockwise direction. Make
sure that the edges of the mounting foot swing into position under the
extrusion mounting lip.

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

5. Position the lightbar onto the vehicle roof in the desired mounting
location. One often selected location is directly above the B-pillars.
This area is the strongest part of the roof. Refer to your lightbar
manual for cable exit location, to be sure that the lightbar is facing the
proper direction.

6. Adjust the two mounting feet outwards so that they are as close to
the edge of the roof as possible. Make sure that both mounting feet
are in full contact with the roof. Be sure that there is no less than 1/2”
clearance between the roof and the lightbar at their closest point.
When the mounting feet are in their proper position, lightly tighten the
mounting foot allen head set screws.

7. Turn the lightbar upside-down and firmly tighten all of the set screws
from step 6 (2 or 4 per side).

8. Note that on the adjustable foot, use the hole in the pad as a guide to
drill the two holes into the mounting foot at the locations shown.

Standard
Mounting

BoltBolt

Mounting
Plate

Foot

Mounting
Plate

Nut

Washer

Mounting

Pad

Washer

Nut

Adjustable
Mounting

Mounting

Pad

9. Place the lightbar in its final mounting position on the vehicle, mark
the mounting hole locations off onto the mounting surface, remove
the lightbar and drill the mounting holes.

10. Place the lightbar back onto the vehicle lined up with the mounting
holes and secure the mounting feet to the vehicle using the supplied
hardware as shown.

Foot

Strap Mounting:

1. Locate the mounting foot, mounting plate and tinnerman plate
included with your lightbar. If not already present, install the mounting
plate onto the mounting foot. When properly positioned, this plate is
centered from side-to-side on the mounting foot.

2. Flip the lightbar upside-down to expose the bottom of the extrusion
and place the mounting foot onto the extrusion.

3. Rotate the mounting foot 90° in a counter-clockwise direction. Make
sure that the edges of the mounting foot swing into position under the
extrusion mounting lip. Install a tinnerman plate onto the extrusion in
the same manner.

Page 2

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

5. Position the lightbar onto the vehicle roof in the desired mounting location.
One often selected location is directly above the B-pillars. This area is the
strongest part of the roof. Refer to your lightbar manual for cable exit
location, to be sure that the lightbar is facing the proper direction.

6. Adjust the two mounting feet outwards so that they are as close to the
edge of the roof as possible. Both mounting feet must be in full contact
with the roof. Be sure that there is no less than 1/2” clearance between
the roof and the lightbar at their closest point. When the mounting feet are
in their proper position, lightly tighten the mounting foot allen head set
screws.

7. Return the lightbar to an upside-down position. Slide each tinnerman
plate outwards until it is fully engaged with its corresponding mounting
foot. With the mounting feet and tinnerman plates in their proper positions
firmly tighten all of the set screws (2 or 4 per side). Flip the lightbar right
side-up and return it to its mounting position.

8. Open both drivers side doors. In the area directly below the mounting
foot, carefully pull the drivers side weatherstrip away from the vehicle.

Remove enough so that the area where the mounting strap will be
secured to the vehicle is exposed. Repeat procedure for passenger side.

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

10. If your mounting strap has mounting holes in the end of the strap, use
these holes as a template to drill appropriately sized pilot holes through
the strap and into the vehicle. Repeat for passenger side of the vehicle.

11. Firmly tighten the tension bolts to secure the lightbar to the vehicle.

NOTE: Model MKAJ is an adjustable mounting foot. On this model you
may loosen the screws on the rear of the foot and adjust the angle of the
lightbar. This feature can be used if the angle of the roof is not level with
the road.

IMPORTANT: To adjust the leveling screws you must use a torque wrench
set at 35 to 40 in./lbs.

Standard Mounting Foot / Model MKEZ

Mounting

Foot

Mounting
Strap

Tinnerman

Mounting

Plate

Plate

Tension

Bolt

Mounting

Mounting
Screw

Pad

5" Mounting Foot

METAL SCREW

BOLT

SHEET
METAL
SCREWS

STRAP

NOTE: The mounting straps are made to fit the contours of individual

vehicles. The strap

NOTE:

for your vehicle

NOTE:

shown here is for example only. The strap

may look different.

Tighten screws

with torque wrench

set at 35 to 40 in/lbs

MOUNTING FOOT

EXTENSION

NUT

SPLIT LOCK
WASHER

TINNERMAN

NUT

FOOT

ANCHOR

PLATE

RO

VEHICLE

Plate slides into
lightbar extrusion

F

O

Mounting

Screw

SET
SCREW

Adjustable Mounting Foot / Model MKAJ

Mounting

Strap

Tension

Bolt

Adjustment

screws

Lock

Washer

Locking
Plate

Nut

Mounting
Foot

Mounting
Pad

Tinnerman
Plate

If your lightbar has a 5” mounting foot, it will assemble
differently than the standard mounting foot. It also uses an
extension to compensate for the extra height. Follow these
illustrations for assembly. Mounting to the lightbar is the
same.

IMPORTANT: For strap mounted bars, be sure you have the right sized
lightbar for your vehicle. The lightbar should be approximately the same
width as the vehicle roof. If too large or small it will not mount properly

1/2" MIN. CLEARANCE

NOTE: Unless otherwise specified, the lightbar mounting feet must be sitting as close to the edge of the roof as possible. They must also be
in full contact with the roof and not be hanging off the edge.

to the vehicle and may come loose during driving.

Page 3

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!

Routing your Lightbar Cable(s):

with

DRILLING THE CABLE ACCESS HOLE

FRONT OF LIGHTBAR

For

lightbars

cables exiting

the Driver-side

of the extrusion

For

lightbars

cables exiting

with

the Passenger-side

of the extrusion

1. To protect the headliner from damage caused by drilling the cable access
hole through the vehicle roof, allow a 5” to 7” distance between roof and
headliner by lowering the headliner before drilling.

Drill cable access hole in appropriate area

for your lightbar (see note)

2. Using a 1” hole saw, drill the cable access hole.

NOTE: There may be a roof support member that spans the distance between the driver’s and passenger’s side. DO NOT DRILL THROUGH
THIS MEMBER! Adjust the location until the hole can be drilled without contacting this support member.

3. Use a round file to smooth and de-burr the edges of the hole.

4. Install a 1” grommet (user supplied) into the cable access hole.

5. Insert the cable(s) through the cable access hole into the vehicle. Use RTV silicone to weatherproof the access hole after the cable(s) are pulled
completely into the vehicle.

Route the cable(s) one at a time to their respective destinations (power cable to vehicle battery; control cable to customer switch panel). It is left to the
installation technician's discretion to select a path for these cables that will both protect the cables from possible damage and not interfere with the
operation of any other vehicle components or equipment. Refer to the instructions included with your switches for switch wiring information.

IMPORTANT AIR BAG WARNING!Do not install this product or route any wires in the air bag deployment zone of your vehicle. Equipment
mounted or located in air bag deployment zones 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 owners manual to learn the air bag deployment zones for the vehicle. The User/Installer
assumes full responsibility to determine proper mounting location, based on providing ultimate safety to all passengers inside the vehicle.

Connecting the Power Cable:

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

1. Follow the factory wiring harness through the firewall. It may be necessary to drill a hole in the firewall. If so, be absolutely sure that there are no
components that could be damaged by drilling. After the hole has been drilled, insert a grommet to protect the cable.

2. Route the cable along the factory wiring harness towards the battery. Install a 40 amp fuse block (customer supplied) on the end of the RED wire in
the power cable. NOTE: Remove the fuse from the fuse block before connecting any wires to the battery.

3. Connect the BLACK wire to Chassis Ground.

at the battery to carry that load. DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT!

Connecting the Communication Cable:

Splice the GREEN and GREY wires from the lightbar to the GREEN
and GREY wires from the Whelen WC Controller.

Troubleshooting:

Your lightbar should now be fully operational. If it is not functioning
properly, check your connections for the following:

• The positive wire (RED) is properly connected to the battery,
by way of the user supplied fuse block.

• A working fuse of the correct amperage is installed in the
fuse block (See illustration above, for the specific fuse rating
for your lightbar).

• The ground wire (BLACK) is properly connected to the factory
ground. Be sure that the wire is fully grounded to this location.

• The two communication wires (GREEN and GREY) are properly
connected to their communication designations.

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

POWER CABLE

1. +12VDC / RED Wire / Requires a fuse, customer supplied.

2.

CHASSIS GROUND

BLACK Wire

2.

COMMUNICATIONS CABLE

1. GREEN / CAN H

2. GREY / CAN L

30 AMP Fuse: ™Freedom II

IMPORTANT WARNING!

If these connections are good, contact your Whelen representative for further assistance.

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!

Page 4