WARN ZEON CONTROL PACK RELOCATION KIT 78 - Manual (Page 7)

WARN INDUSTRIES
9 89959A0
INSTALLATION INSTRUCTION
DETERMINE CONTACTOR
MOUNTING LOCATION AND CABLE
ROUTING PATH
To determine the contactor mounting location
it is recommended that the contactor be mounted
on a solid mounting surface and easily accessible.
Contactor should be in a location that is as clean
and dry as possible. Ensure the contactor mounting
location selected provides sufficient clearance
from all metal structures. Exact location will vary
depending on the vehicle.
To determine the winch motor cable assembly
and ground wire routing path, verify the path will
allow the winch motor cable assembly and ground
wire to be routed avoiding sharp edges, parts that
get hot and moving parts. Consider chassis flex
and vibration which might damage cable.
MOUNTING THE CONTACTOR
WARNING To prevent serious injury or death. Always
place the supplied terminal boots on wires and terminals as
directed by the installation instructions.
WARNING To prevent serious injury or death from
electrical fi re:
Never route electrical cables across sharp edges.
Never route electrical cables near parts that get
hot.
Never route electrical cables through or near
moving parts.
Avoid pinch and wear/abrasion points when
installing all electrical cables.
WARNING Always verify area is clear of fuel lines, fuel
tank, brake lines, electrical wires, etc., when drilling.
WARNING Never mount contactor with electrical
terminals touching metal objects.
After determining contactor mounting location,
you are ready to mount your contactor.
1. Use the contactor as a template to drill the
holes needed to mount the contactor.
2. Drill the holes to 6.5mm diameter. WARNING! Be
sure to check the area before you drill to avoid hitting
any electrical cables or gas lines.
3. Install the contactor using the supplied bolts,
rectangular washers and lock nuts.
Figure 10
Contactor Mounting Location Example
WARN INDUSTRIES
10 89959A0
INSTALLATION INSTRUCTION
Figure 12
Contactor Terminal
Separator Red Wire with Ring
Terminal
A
F2
(+)
F1
Terminal Nuts
(torque 8.5-9 N-m)
Lock
Washers
Figure 11
NOTE: Before making any connections, you will be
routing the winch motor cable assembly and ground
extension wire only.
4. Once you have determined your winch motor
cable assembly and ground wire path, route
the cable assembly and the ground extension
wire from the winch to the contactor. Loosely
secure in place using zip ties.
5. Confirm cables are protected from sharp edges,
heat and moving parts. Consider chassis flex
and vibration which might damage cable.
6. Locate and install the relcoation kit contactor
terminal separator (included in kit).
7. Install the red wire (with ring terminal) from the
remote socket wire bundle to the positive (+)
contactor terminal.
WARNING Always insulate and protect all exposed wiring
and electrical terminals.
8. Install protective electrical boots on each of the
cables.
9. Connect cables to contactor using the terminal
nuts and lock washers previously removed.
Connect the labeled cables (A, F1 and F2) to
corresponding terminal. Torque nuts to 8.5-9 N-m
(75-80 in. lbs.). Refer to Figure 12 for Final Cable
Assembly.
10. Reconnect the winch remote socket wires back
onto the contactor’s spade terminals. The
white wire gets connected to spade terminal 1,
brown wire to spade terminal 2, and green wire
to spade terminal 3.
11. Using zip ties or purchased hardware, secure
the remote socket into place near the contactor.
If you require greater socket location flexibility,
order Warn PN 86605.
Figure 13
1
2
3