Warn Zeon Control Pack Relocation Kit, Installation Manual

Page: 5 / 8

WARN INDUSTRIES
5 89969A0
BEFORE YOU BEGIN
Tools Required
• Torx Driver Set
• Ratchet/Wrench Set (Standard/Metric)
• Drill and Drill Bit Set
• Wire Cutters
• Wire Strippers/Wire Crimps
• Torque Wrench (30 lb. ft. capacity)
• Zip Ties
• Cable Protection (i.e., flexible electrical conduit or electrical tape)
Torque Specifi cations
Please use the recommended torque specifi cations when assembling this product unless otherwise
specifi ed in the instructions.
FASTENER SIZE
(Grade 5)
FASTENER TORQUE FASTENER SIZE
(Class 8.8)
FASTENER TORQUE
lb-ft (N.m) lb-ft (N.m)
1/4" 8 (11) M4 (2) 3
5/16" 17 (23) M5 (4.5) 6
3/8" 30 (40) M6 (7.5) 10
7/16” 48 (66) M8 (18) 25
1/2" 74 (100) M10 (37) 50
9/16” 106 (144)
5/8" 148 (200)
3/4” 269 (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 6
INSTALLATION INSTRUCTION
REMOVE CONTROL PACK FROM WINCH
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 insulate and protect all exposed wiring
and electrical terminals.
1. Disconnect the vehicle battery cables, negative
terminal first. All work with electrical wires
and cables must be completed with the battery
completely disconnected from the vehicle
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.
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 1
Figure 2
Buss Bar Cover
Control Pack
Remove
Screw
Terminal
Nuts
Small Black
Wire
Buss Bars
Disconnect Ground Wire
Remove
(4 total)
Figure 3
Control Pack