Installation instruction – WARN ZEON CONTROL PACK RELOCATION KIT 78 User Manual
Page 8
WARN INDUSTRIES
11
89959A0
INSTALLATION INSTRUCTION
Figure 16
Figure 14
Cover Plate
Wire Terminal Housing
CONNECTING THE CONTACTOR
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.
1. Attach the wire terminal housing to the motor
terminals on the winch using terminal nuts and
lock washer previously removed. Torque nuts to
8.5-9 N-m (75-80 in. lbs.)
2. Install the cover plate and fasten with the two
supplied machine screws. Do not over tighten
screws, over tightening could damage the plastic
components.
3. Use the supplied butt splice connector and the
black extension wire to lengthen the contactor
ground wire.
4. Reconnect the ground cable and small black
wire to winch motor ground. Secure fasteners to
specified torque requirements in torque specification
chart found in these instructions.
5. Carefully inspect electrical cable routing. Is it neat
and tidy? Zip tie and secure electrical cables. Zip
ties should be snug, but not cutting into wire
insulation. Use electrical tape, pieces of rubber
hose or electrical conduit to protect electrical
cables and wire harness where needed to avoid
electrical cable insulation wear or abrasion.
6. Attach battery cables, red (positive) cable
FIRST, black (negative) second. Install boots
as appropriate to protect connections. Torque
battery terminal fasteners as directed by vehicle
service manual.
7. Make sure to plug in the winch remote and ensure
that drum is turning in the proper direction when
spooling in/out before using in the field.
8. Installation
complete.
Figure 15
OUT
IN
Ground Wire
Butt Connector