Warn Zeon Control Pack Relocation Kit, Installation Manual

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WARN INDUSTRIES
3 89969A0
GENERAL SAFETY PRECAUTIONS
As you read these instructions, you will see WARNINGS,
CAUTIONS, NOTICES and NOTES. Each message has a specifi c
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
which, if not avoided, could result in minor or moderate injury.
A CAUTION may also be used to alert against unsafe practice.
CAUTIONS and WARNINGS identify the hazard, indicate how
to avoid the hazard, and advise of the probable consequence
of not avoiding the hazard. NOTICES are messages to avoid
property damage. NOTES are additional information to help
you complete a procedure.
PLEASE WORK SAFELY!
Warnings and Cautions
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to
serious injury or death.
General Safety:
• Always Know Your Winch. Take time to fully read the
Instructions and/or Operations Guide, and/or Basic
Guide to Winching Techniques, in order to understand
your winch and its operations.
• Always keep wired remote control lead and power cord
clear of the drum, rope, and rigging. Inspect for cracks,
pinches, frayed wires or loose connections. Damaged
components must be replaced before operation.
WARNING
FALLING OR CRUSHING HAZARD
Failure to observe these instructions could lead to
serious injury or death.
• Always stand clear, keep hands clear, keep others away.
WARNING
CHEMICAL AND FIRE HAZARD
Failure to observe these instructions could lead to
serious injury or death.
• Always remove jewelry and wear eye protection.
• 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.
• 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,
brake lines, electrical wires, etc., when drilling.
• Always consult operator’s manual for proper wiring
details.
• Always insulate and protect all exposed wiring and
electrical terminals.
• Never mount contactor with electrical terminals
touching metal objects.
WARNING
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to
minor or moderate injury.
To avoid injury to hands or fi ngers:
• Never leave remote control where it can be activated
during free spooling, rigging, or when the winch is not
being used.
• Never leave the winch remote control plugged in
when installing, freespooling, rigging, servicing or
when the winch is not being used.
CAUTION
WARN INDUSTRIES
89969A0 4
BEFORE YOU BEGIN
Please familiarize yourself with the components.
• Mounting Kit PN89970: Includes a mounting bracket and all needed hardware to mount your kit.
• 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.
Parts List
Description Qty Part Number Description Qty Part Number
31” Wire Assembly Kit with
Mounting Bracket 89970 31” Wire Assembly Kit without
Mounting Bracket* 89965
31” Cable Assembly 1 89663 31” Wire Assembly 1 89663
Wire housing top 1 89372 Wire housing top 1 89372
M4 screw 2 64503 M4 screw 2 64503
Butt splice 1 85978 Butt splice (18 AWG) 1 85978
31” ground extension 1 89963 31” ground extension 1 89963
Bracket 1 89729 *M6 bolt needed 4 NOT INCLUDED IN KIT
M6 bolt 4 86346 *M6 lock washer needed 4 NOT INCLUDED IN KIT
M6 lock washer 4 77009
5/16” bolt 4 21331 OPTIONAL BRACKET KIT - - SOLD SEPARATELY
5/16” washer 8 1324 Bracket Kit 89770
5/16” lock nut 4 2002 Bracket 1 89729
M6 Bolt 4 86346
M6 Lock Washer 4 77009
5/16” Bolt 4 21331
5/6” Washer 8 1324
5/16” Lock Nut 4 2002
* NOTE: Four (4) M6 bolts and four (4) M6 lock washers must be purchased separately in order to complete installation without
use of bracket.
31” Cable Assembly
M4 Screws (2)
Wire Housing Top
Butt Splice
5/16” Washer (8)
M6 Bolt (4)
5/16” Lock Nut (4)
M6 Lock Washer (4)
5/16” Bolt (4)
31” Ground Extension
Bracket