Installation Instructions
Contents
1. Torque Wrench 30 Ib ft capacity Zip Ties Cable Protection i e flexible electrical conduit or electrical tape Torque Specifications Please use the recommended torque specifications when assembling this product unless otherwise FASTENER SIZE FASTENER Class 8 8 TORQUE specified in the instructions FASTENER SIZE FASTENER TORQUE Grade 5 an 1 4 1 CN 3 3 4 364 Inspect all nuts and bolts on all related hardware periodically Tighten all nuts that appear to be loose Stripped fractured or bent bolts or nuts need to be replaced WARN INDUSTRIES 89969A0 5 INSTALLATION INSTRUCTION REMOVE CONTROL PACK FROM WINCH To prevent serious injury or death Always place the supplied terminal boots on wires and terminals as directed by the installation instructions To prevent serious injury or death from electrical fire lt D Never route electrical cables across sharp edges 4 Never route electrical cables near parts that get hot a tz ba ss u Small Black Never route electrical cables through or near Wire moving parts u 7 ey A A In il e A Y A fi E e i i Py 4 if e ee j AL i e gi A al r rit a E 4 a oF j f aa LA PA p r j y A AS p Lar A rs re L L AN A a lt Avoid pinch and wear abrasion points when Done ae installing all electrical cables Figure 1 Always insulate and protect all exp2. Bracket Kit je Bracket M6 Lock Washer Es 5 16 Bolt 21331 5 6 Washer 1324 31 Cable Assembly 5 16 Lock Nut 2002 Always keep wired remote control lead and power cord PIN clear ofthe drum rope and rigging Inspect for cracks C AU TI O N pinches frayed wires or loose connections Damaged ho components must be replaced before operation es 0 Bracket PIN MOVING PARTS ENTANGLEMENT HAZARD WA R N N G Failure to observe these instructions could lead to eee _ 31 Ground Extension minor or moderate injury PE gt S To avoid injury to hands or fingers Butt Splice SN ET RK gt e Never leave remote control where it can be activated as 710008 during free spooling rigging or when the winch is not a e ee OR RE N being used iO 4 Failure to observe these instructions could lead to Never leave the winch remote control plugged in 5 16 Washer 8 A Im Lock Nut 4 serious injury or death installi ina riaai ici u EL meespaoing ngging servicing ot NOTE Four 4 M6 bolts and four 4 M6 lock washers must be purchased separately in order to complete installation without Always stand clear keep hands clear keep others away when the winch is not being used Kar WARN INDUSTRIES WARN INDUSTRIES 3 89969 A0 89969A0 4 BEFORE YOU BEGIN Tools Required Torx Driver Set Ratchet Wrench Set Standard Metric Drill and Drill Bit Set Wire Cutters Wire Strippers Wire Crimps
3. ERAL SAFETY PRECAUTIONS BEFORE YOU BEGIN Please familiarize yourself with the components Warnings and Cautions Mounting Kit PN89970 Includes a mounting bracket and all needed hardware to mount your kit 4 WARNING Mounting Kit PN89965 Does not include a mounting bracket and you will need to purchase some additional hardware to complete mounting Bracket Kit PN89770 is available for purchase if you later decide to use a bracket for mounting Contact a Warn Industries customer service representative at 1 800 543 9276 As you read these instructions you will see WARNINGS CAUTIONS NOTICES and NOTES Each message has a specific purpose WARNINGS are safety messages that indicate a potentially hazardous situation which if not avoided could result in serious injury or death CAUTIONS are safety messages that indicate a potentially hazardous situation Parts List Description Qty Part Number 31 Wire Assembly Kit with 89970 Description Qty Part Number 31 Wire Assembly Kit without 89965 which if not avoided could result in minor or moderate injury Failure to observe these instructions could lead to Mounting Bracket Mounting Bracket A CAUTION may also be used to alert against unsafe practice serious injury or death 31 Cable Assembly 89663 31 Wire Assembly 89663 CAUTIONS and WARNINGS identify the hazard indicate how Always remove jewelry and wear eye protection i i i to avoid the hazard and advi
4. Warn Industries Inc 12900 S E Capps Road Clackamas OR USA 97015 8903 1 503 722 1200 FAX 1 503 722 3000 www warn com Customer Service Service Clients 1 800 543 9276 International Sales Support Les Ventes internationales Soutiennent 1 503 722 3005 2012 Warn Industries Inc WARN the WARN logo are registered trade marks of Warn Industries Inc WARN et le logo WARN sont des marques d pos es de Warn Industries Inc CE 89969A0 317 ZEON CONTROL PACK RELOCATION KIT INSTALLATION GUIDE GUIDE D INSTALLATION o oo ee are ORIGINAL INSTRUCTIONS SYMBOL INDEX SYMBOL EXPLANATION SYMBOL EXPLANATION Read All Product Always Wear Leather Literature Gloves Zeon Control Pack Relocation Kit 31 u Cable Length Am Wear gene N Do Not Move People Eye Protection Every winching situation has the potential for personal injury In order to minimize that risk it is important to read this guide and The Basic Guide to Winching Techniques carefully Please familiarize yourself with the operation of your winch before using it and be constantly safety oriented In this guide we provide important safety information and instructions on how to install your Control Pack Relocation Kit Please read the Basic Guide to Winching Techniques for information on how to properly use your winch and proper rigging techniques Never Use Winch as a Always Use Supplied Hoist Hook Strap Please keep this manual and other product liter
5. arts that get hot Never route electrical cables through or near moving parts Avoid pinch and wear abrasion points when installing all electrical cables 1 Optional Depending on your specific relocation kit you can attach the shown bracket for easier mounting using the supplied hex head bolts and lock washers If you would like to purchase the bracket shown please contact WARN Industries at 1 800 543 9276 or visit www warn com 2 Find an appropriate mounting location to mount the control pack Make sure to check that the cables and ground wire can be routed to the winch and that the control pack is easily accessible and on a solid mounting surface Always verify area is clear of fuel lines fuel tank brake lines electrical wires etc when drilling Never mount contactor with electrical terminals touching metal objects 3 If using the mounting bracket match drill the 5 16 holes in the bracket to the mounting surface you choose to mount your control pack to Be sure to check the area before you drill to avoid hitting any electrical cables or gas lines If opting not to use the mounting bracket you can use the attached template as a guide for drilling mounting holes Holes should be drilled to 6 5mm diameter 4 Mount the bracket using the supplied 5 16 bolts with two 2 flat washers and nylock nuts as shown If opting not to use the mounting bracket M6 screws and lock washers must be purchased s
6. ature found in this kit for future reference Should you be missing any of the necessary instructions please visit www warn com or contact us at the number below Finger Fairlead Crushing Fairlead Pinch Point Hazard TABLE OF CONTENTS SAFETY A E and Piercing Cutting UNO UT ee ae 2 Hazard 2 Hot Surface Hazard General Safety PrecautiOns ccscsssssssssssssssssscsessssssssssssscsecssssssssssssessssssssessssassecsesssssesassassecsessucsesssssssecsessecsessssassecaeesscseass 3 INSTRUCTIONS Explosion Burstin p 9 Fire and Burn Hazard Be ORE A sanieren oe 4 gt Hazard Pe SUNS EEE 4 Tools Required A 5 Never Route Electrical Never Route Electrical TORUSSPEE CAMION retenida ac 5 Cables through Sharp Cables through or near Edges Hazard Moving Parts Hazard Installation NStTUCTIONS ea 6 9 Remove Control Pack From WINE oi aa 6 7 Installing Relocation Cables 7 Avoid Installing Electrical Exposed Wiring Hazard ai Nun Cables around Pinch and Insulate Exposed Wiring Relocating the Control Paca 8 Wear Abrasion Points and Terminals Connecting the Contactor aaa 9 Mounting Hole Dril Template nd 10 Never Hook Back on Rope Warn Industries Inc 12900 SE Capps Road Clackamas OR 97015 USA Customer Service 800 543 9276 International Fax 503 722 3005 WARN and the WARN logo are registered trademarks of Warn Industries Inc Fax 503 722 3000 O 2012 Warn Industries Inc www warn com WARN INDUSTRIES WARN INDUSTRIES 1 89969A0 2 GEN
7. cal 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 Figure 12 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 TE OUT IN JD 8 Installation complete WARN INDUSTRIES WARN INDUSTRIES 9 89969A0 89969A0 10
8. eparately to complete this installation WARN INDUSTRIES 89969A0 8 Bracket Kit 89770 Bracket only 89729 included in kit 89970 Figure 8 5 16 Bolts Nylock Nuts Figure 9 INSTALLATION INSTRUCTION INSTALLATION INSTRUCTION CONNECTING THE CONTROL PACK AK WARNING Loose or unsecured power cables can cause Lo Plate serious injury or death HS Mounting Hole Drill Template Wire Terminal Housing 1 Attach the wire terminal housing to the motor terminals on the winch using terminal nuts and lock washer previously removed 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 Template NOT to scale 3 Use the supplied butt splice connector and the black extension wire to lengthen the contactor ground wire see Figure 11 4 Reconnect the ground cable and small black wire to winch motor ground Ensure the ground wire is securely fastened Secure fasteners to specified torque requirements in torque specification chart found in these instructions Ground Wire Butt Connector Figure 11 5 Carefully inspect electrical cable routing Is itneat 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 electri
9. ly process Simply move the cover to one side or out of the way while working on the contactor This cover will be reinstalled Remove terminal nuts and lock washers securing the three buss bars to the contactor see Figure 6 Set aside terminal nuts and lock washers as they will be used later on Buss bars will not be used for new installation Loosen the two flat head torx drive screws securing the contactor to the contactor plate Only loosen Do not remove Using the terminal nuts and lock washers removed in previous step connect the labeled cables A F1 and F2 to corresponding contactor terminal Torque nuts to 8 5 9 N m 75 80 in Ib Refer to Figure 7 Tighten the two flat head torx drive screws and nuts used to secure the contactor to the contactor plate Secure fasteners to specified torque requirements in torque specification chart found in these instructions Once the cables have been installed reinstall the cover using the four 4 flat head torx drive screws previously removed Refer to the torque section of this document INSTALLATION INSTRUCTION Motor Terminal Buss Bar Buss Bars Loosen Screws 2x Tighten screws 2x Figure 7 WARN INDUSTRIES 89969A0 INSTALLATION INSTRUCTION RELOCATING THE CONTROL PACK AX WARNING To prevent serious injury or death from electrical fire lt Never route electrical cables across sharp edges Never route electrical cables near p
10. osed wiring and electrical terminals 1 Disconnect the vehicle battery cables negative Remove terminal first All work with electrical wires s and cables must be completed with the battery crew Jj Buss Bar Cover completely disconnected from the vehicle EN er SA Control Pack wiring 2 Disconnect the ground cable on the under side of the winch see Figure 1 Make sure the small black wire that connects to the control pack is disconnected and hanging freely 3 Remove the top buss bar cover by unscrewing the fastener holding it in place Retain fastener for later use Figure 2 4 Remove the three motor terminal nuts and lock washers that secure the buss bars to the motor Retain the terminal nuts and lock washers for future step 5 Remove the four 4 flat head torx drive screws located on the underside of the tie plate NOTE Rope may need to be spooled out to complete this step Figure 3 WARN INDUSTRIES 89969A0 6 Once all four 4 control pack screws have been removed gently lift the control pack off of the tie plate and set aside to be further disassembled Remove the motor terminal buss bar insulator after control pack has been removed INSTALLING RELOCATION CABLES 1 Disassemble the control pack by removing the four 4 flat head torx drive screws Gently lift the control pack cover off of the contactor plate assembly The cover should remain wired to the contactor during this assemb
11. se of the probable consequence Never route electrical cables across sharp edges Wire housing top 89372 Wire housing top 89372 of not avoiding the hazard NOTICES are messages to avoid Never route electrical cables near parts that get hot 64503 M4 screw 64503 31 ground extension 89963 M6 bolt needed NOT INCLUDED IN KIT M6 lock washer needed NOT INCLUDED IN KIT CHEMICAL AND FIRE HAZARD you complete a procedure PLEASE WORK SAFELY parts Always place the supplied terminal boots on wires and terminals as directed by the installation instructions Never lean over battery while making connections Never route electrical cables over battery terminals Never short battery terminals with metal objects Always verify area is clear of fuel lines fuel tank MOVING PARTS ENTANGLEMENT HAZARD brake lines electrical wires etc when drilling Always consult operator s manual for proper wiring Failure to observe these instructions could lead to details serious injury or death Always insulate and protect all exposed wiring and General Safety electrical terminals Always Know Your Winch Take time to fully read the Never mount contactor with electrical terminals Instructions and or Operations Guide and or Basic touching metal objects Guide to Winching Techniques in order to understand your winch and its operations 31 ground extension 89963 Bracket M6 bolt M bot newn fe fun OPTIONAL BRACKET KIT SOLD SEPARATELY
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