Warn Zeon Control Pack Relocation Kit Installation Manual

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 déposées de Warn Industries, Inc. (31”) ZEON CONTROL PACK RELOCATION KIT INSTALLATION GUIDE GUIDE D’INSTALLATION 89969A0 ...

12900 SE Capps Road Clackamas, OR 97015 USA Customer Service: (800) 543-9276 International Fax: (503) 722-3005 Fax: (503) 722-3000 www.warn.com WARN® and the WARN logo are registered trademarks of Warn Industries, Inc. © 2012 Warn Industries, Inc. Zeon Control Pack Relocation Kit 31” Cable Length TABLE OF CONTENTS: SAFETY Symbol Index .............................................................................................................................................................................2 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 haza ...

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� ...

removed, gently lift the control pack off of the tie plate and set aside to be further disassembled. 7. 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. 2. Gently lift the control pack cover off of the contactor plate assembly. The cover should remain wired to the contactor during this assembly process. Simply move the cover to one side or out of the way while working on the contactor. This cover will b ...

WARNING Loose or unsecured power cables can cause serious injury or death. 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. 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 ...