Painless Trail Rocker Installation Instructions Manual Download Page 1

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Trail Rocker Installation

Instructions

4, 6, or 8-Switch Customizable Trail Rocker Switch Panel

w/ 1

∕

” & 1 ¾” Roll Bar Straps

For Installing Painless Part Number: 57102, 57105, & 57108

Manual #90635

Painless Performance Products recommends you, the installer, read this installation

manual from front to back before installing this harness.

Summary of Contents for Trail Rocker

Page 1: ...zable Trail Rocker Switch Panel w 1 5 8 1 Roll Bar Straps For Installing Painless Part Number 57102 57105 57108 Manual 90635 Painless Performance Products recommends you the installer read this installation manual from front to back before installing this harness ...

Page 2: ......

Page 3: ...ese instructions please call or email us our contact information can be found at the top of this page or online at www painlessperformance com We sincerely appreciate your business Painless Performance Products LLC shall in no event be liable in contract or tort including negligence for special indirect incidental or consequential damages such as but not limited to loss of property or any other da...

Page 4: ...AINLESS KIT 5 TOOLS NEEDED 7 INSTALLING FACTORY STYLE TERMINALS 8 SWITCH PANEL INSTALLATION 18 SWITCH WIRING 19 DOUBLE SWITCH CONTROL WIRES 22 OPTIONAL PAINLESS PART 57150 WINCH CONTROL ADD ON KIT 27 PAINLESS PERFORMANCE LIMITED WARRANTY AND RETURN POLICY ...

Page 5: ...erminated Winch Wires o 4 6 Switch Kits ONLY Additional switch wires This manual 90639 SMALL PARTS Painless harnesses include parts kits that contain the terminals fuses screws and nuts necessary for a professional installation Many of the terminals are non insulated and will require heat shrink to be applied after the terminal has been properly crimped Waterproof heat shrink has been supplied The...

Page 6: ... shrinkable and non heat shrinkable insulated terminals included in the small parts kit Another style of crimpers are Roll Over Crimpers These crimpers will crimp factory style non insulated terminals Painless offers Roll Over Crimpers such as those seen to the right under Painless part 70900 A good set of wire strippers are required to strip wire properly This style of wire stripper is ideal for ...

Page 7: ...ter is always a good tool to have on hand when installing any type of electrical component into a vehicle The most basic meters provide the two functions required to diagnose electrical issues commonly seen during a harness install voltage measurement and continuity testing Voltage measurement is the ability to read DC voltage Continuity testing allows you to test 7 Heat Gun Needed to shrink the h...

Page 8: ...at only insulation is crimped by Strap 2 The photo to the left best demonstrates this Using the appropriate jaw on the crimpers crimp Strap 1 The appropriate jaw depends on the wire gauge as well as the terminal stiffness If you are unsure which jaw to use you can always start with the biggest and work your way down until you get a tight crimp With Strap 1 crimped move onto crimping the insulation...

Page 9: ...LATION Step 1 First prepare the Switch Panel for mounting into the Switch Panel Box Step 2 Now decide which direction you want to run the Switch Panel Wires The Switch Panel Box has 3 holes through which to route the wires ...

Page 10: ...int use the loom provided to cover the Switch Panel Wires Run the loom over the wire through the grommet and into the box You can secure the end of the loom with a zip tie Note It isn t necessary to loom the entire wiring harness as you will cut these wires to length later Simply loom a few feet and make sure the end inside the base is secure ...

Page 11: ...t to close up the remaining holes Step 6 Make sure the Switch Panel Box is properly covering the back of the Switch Panel and use 4 10 32 x 3 8 button head screws and the small hex key provided in the parts kit to secure the panel to the box Remember to start each screw into the threads and tighten evenly ...

Page 12: ...ike to mount your Trail Rocker Switch Panel select the correct size Roll Bar Strap for your roll bar 1 5 8 or 1 Step 8 Locate the 4 holes on the back of the Switch Panel Box This is where you ll mount the Roll Bar Straps to the Switch Panel Box ...

Page 13: ... 4 10 flat washers and 4 10 32 x 3 8 button head screws and the small hex key provided in order to mount the Switch Panel Step 10 Once you ve selected a spot to mount your Trail Rocker Switch Panel use the hardware to mount the switch panel ...

Page 14: ...erminals are provided in the parts kit in order to connect to these wires Step 12 It may help to familiarize yourself with the wiring diagram below before connecting the wires from the Switch Panel to the 12 pin connector housing in Step 16 Trail Rocker Fuse Relay Center Part Numbers 1 Universal 57100 2 Jeep CJ 57024 3 Jeep TJ 57042 4 Jeep JK 57005 ...

Page 15: ...cure the end of the loom with a zip tie provided or a large piece of heat shrink not provided Step 14 Strip each of the Switch Panel Wires 3 16 and install a male pin terminal from the parts kit onto the end of each wire See page 7 for detailed instructions of how to properly crimp these terminals We recommend Painless 70900 Roll Over Crimpers ...

Page 16: ...g tab for orientation Step 16 Insert the newly pinned wires into the 12 pin connector housing Make sure while inserting the pins that once connected the wire color matches the one across from it The diagram on page 13 illustrates the pinout of the 12 pin connector housing from the wire side ...

Page 17: ...as it does below The 2 empty cavities are for optional wench wires see page 21 Step 18 Link the two connectors and join the wiring harness from the Fuse Relay Center to the Switch Panel Use zip ties to secure the wires up under the dash and out of the way ...

Page 18: ...14 SWITCH WIRING The lighted rocker switches included in your kit are wired as shown in the diagram below ...

Page 19: ... with a single switch Steps 19 22 are optional and only for those who wish to control multiple functions for one switch Provided in the kit are extra Switch Panel wires and some 16ga 14ga terminals similar to those shown below Step 19 Choose which switch you want to control multiple functions with and disconnect the existing Switch Panel wire from the terminal on the bottom of the switch terminal ...

Page 20: ...16 Step 20 With the Switch Panel wire removed from the switch cut off the terminal and strip the wire 3 8 ...

Page 21: ...and one of the additional Switch Panel wires included in the kit then slide them together into a 16 14 ga terminal provided in the included parts kit Step 22 With both wires inside crimp the terminal and reconnect the doubled Switch Panel wires to the switch ...

Page 22: ...res can be connected to a on off on momentary contact SPDT switch or a winch switch not provided in the kit If you do not have a winch switch Painless offers a Winch Control Add on Kit Painless Part 57150 available online at www painlessperformance com Steps 23 28 show you how to install a Winch Control Add on Kit to your Trail Rocker Switch Panel and connect the control wires to the switch The SP...

Page 23: ... with the Winch Control Add on Switch Then locate the tabs located at the top and bottom of the switch Step 24 These tabs lock the switch in place To remove the switch squeeze the tabs in and slide it out of the bracket Step 25 Insert the Winch Control Add on Switch into the empty socket of the bracket ...

Page 24: ...20 Step 26 Before connecting the wires to the Winch Control Add on Switch take time to familiarize yourself with the wiring diagram below ...

Page 25: ...21 Step 27 Reconnect the power ground and Switch Panel wires to the Winch Control Add on Switch as seen below ...

Page 26: ...22 Step 28 Strip and terminate the other ends of the wire as you did in Steps 14 16 And insert the WHITE RED into slot 9 of the 12 pin connector shell and the BROWN WHITE into slot 10 ...

Page 27: ...d to the original purchaser to be free from defects in material and workmanship under normal use Painless Performance will repair or replace defective products without charge during the first 12 months from the purchase date No products will be considered for warranty without a copy of the purchase receipt showing the sellers name address and date of purchase You must return the product to the dea...

Page 28: ...Painless Performance Products LLC 2501 Ludelle Street Fort Worth TX 76105 Phone 817 244 6212 ...

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