Warn 77977 Installation Instructions Manual

WARNING INSTALLATION INSTRUCTIONS DUAL BATTERY CONTROL KIT Part Number: 77977 Application: Side x Side (UTV) ‰ Always use extreme caution when drilling on any vehicle. Make sure that all fuel lines, brake lines, electrical wires, and other objects are not punctured or damaged when / if drilling on the vehicle. Thoroughly inspect the area to be drilled (on both sides of material) prior to drilling, and relocate any objects that may be damaged. Failure to inspect the area to be drilled may result in vehi ...

Part Number Description Qty 80869 AUXILIARY BATTERY BOX 1 80111 AUXILIARY BATTERY BOX LID 1 80870 AUXILIARY BATTERY BOX MNT KIT 1 80733 BATTERY TRAY 1 80110 CONTROL MODULE 1 62810 SOLENOID 1 77954 OVERRIDE HARNESS 1 79932 SOLENOID HARNESS 1 77968 RED POWER CABLE, SHORT 1 80737 RED POWER CABLE, LONG 1 77969 BLACK POWER CABLE 1 78793 BATTERY BOX STRAP 1 80040 DOUBLE SIDED TAPE 1 79293 6MM FLANGE BOLT, BATTERY TERM. 2 1320 1/4” FLAT WASHER 4 9256 1/4” FENDER WASHER 4 62819 #10 HEX SCREW 2 62820 #10 FLANGE NUT 2 62824 STANDOFF SPACER 2 80735 RING TERMINAL 1 76406 SPLICE CONNECTOR 1 80739 Y-HARNESS, GREEN 1 ...

1 - 3/8” and 10 mm end wrench 2 - 3/8” and 10 mm socket and ratchet 3 - Wire cutters 4 - Wire strippers, crimping pliers 5 - Drill 6 - 3/16”, 1/4” and 5/16" drill bit 7 - #2 Philips screwdriver 8 - Center punch and hammer 9 - Utility knife 10 - Sandpaper/steel wool 11 - Rubbing alcohol 12 - Hacksaw 13 - Torque wrench 14 - Floor jack 15 - Jack Stands 16 - Wheel chocks 17 - Electrical Tape 18 - Work Light 19 - Digital Volt Meter III. TORQUE SPECIFICATIONS #10 15 in. lb. (1.7N-m) 1/4, M6 96 in. lb. (10.8 N-m) 5/16 35 in. lb. (4.0 N-m) 1 2 3 10 mm IPA 4 5 6 7 8 9 10 11 12 13 14 ...

• Always block vehicle after jacking/lifting vehicle and before working underneath. • Never route or secure electrical cables: - Across any sharp edges. - Through or near moving parts. - Near parts that become hot. • Always insulate and protect all exposed wiring and electrical terminals. Use electrical tape and install terminal boots as directed in installation instructions. • Never install wires under tension. Read installation and operating instructions thoroughly. V. BEFORE YOU BEGIN CAUTION Failure to observe these instru ...

Read installation and operating instructions thoroughly. • Always verify area is clear of fuel lines, fuel tank, brake lines, electrical wires, etc. when drilling. Back of buckle is facing up. Figure 3b NOTICE • Choose a location where service and maintenance of vehicle are not hindered; where the box lid can be installed and removed and where the mounting hardware will be long enough to fasten the box securely. See Figure 8 and 9 (page 8). Auxiliary Box Installation: 1. Determine auxil ...

4. Once strap is installed through battery tray, make any necessary adjustments to ensure fit around battery. See Figures 4, 5 and 6. NOTE: Adjust strap through slots in battery tray so buckle is on top of the battery. 5. Temporarily install battery and two tray clips to battery tray. Choose hole locations that are closest to the batter See Figure 7. Do not tighten screws. Remove battery from battery tray. Figure 4 Figure 5 Figure 6 Figure 7 Battery tray clip Battery tray clip ...

See figure 8a. Install battery tray into battery box. See figure 8b. Install battery box to vehicle using four 6mm bolts, ¼” flat and lock washers, and ¼” fender washers. See figure 8c. Figure 8a Figure 8b Figure 8c ...

Figure 9. Torque to specifications on page 3. Install battery into box. See Figure 10. Tighten battery tray clip screws. Figure 9 Figure 10 ...

NOTE: Double-sided tape is used to install the control module. It is necessary to prepare the control module and vehicle mounting surfaces to obtain good adhesion performance. It is important to ensure that all surfaces are clean, dry and free of any moisture. 8. Determine a location to mount the control module. Review diagram on page 4. Verify wire lengths to winch contactor and solenoid (see page 10) before finalizing control module mounting location. Temporarily install control module and wiring before applying tape. 9. Abrade the surface of the control module and mo ...

greater than 250 g/l of volatile organic compounds (VOC). Please consult your local Air Quality Regulations to be sure the cleaner is compliant. When using solvents, be sure to follow the manufacturer’s precautions and directions for use when handling such materials. 11. Remove warning tag from terminal on control module. See Figure 15. Note warning to add tie strap when mounting (reference: Figure 19). NOTE: Temperature: Tape application temperature range is 70°F to 100°F (21°C to 38°C). Full bond strength is re ...

Read installation and operating instructions thoroughly. • Always verify area is clear of fuel lines, fuel tank, brake lines, electrical wires, etc. when drilling. Figure 21 Solenoid Installation: 15. Determine a location to mount the solenoid. Review diagram on page 4. Verify wire lengths to the batteries and control module (page 8) before finalizing solenoid mounting location. Temporarily install solenoid and wiring before drilling. 16. Confirm plastic clips are on both feet of the solenoid. See Figure 20. 17. Use solenoid as a ...

19. Install small terminal boots onto ring terminals of black and white wires. 20. Install large terminal boots onto ring terminals of red and green wires. 21. Connect ring terminals of black and white wires to #10 terminal posts on solenoid. Tighten to specified torque and install boots over terminals. See Figure 22. 22. Route one red 6 gauge cable end through each large terminal boot installed on red and green wires. Attach ring terminals to 5/16” (large) terminals on solenoid according to diagram on page 4. Tighten to specified torque and install boots over terminals. See also Fig ...

Green Wire Connection: 32. Review control harness green wire in diagram on page 4. 33. Plug over-ride control harness connector onto control module. See Figure 26. 34. Route green control harness wire to winch contactor and cut wire to required length. 35. Remove over-ride control harness connector from control module and strip 3/8" of wire insulation from green control harness wire and from green Y-harness. See Figure 27. Power cable installation: 23. Check to be sure battery ground cables have been disconnected. 24. Install conduit and large terminal boots to both ends of 6 gau ...

harness and green Y-harness wire. See Figure 28. 37. Reconnect override control harness connector to control module, route green wire and plug green Y-harness connector into winch contactor harness. Connection will vary depending on which winch switch options (remote, wireless, rocker) are being used. See Figure 29. 38. Use tie straps to secure green wire along routing path. Black wire connection: 39. Route black control harness wire to a chassis ground location or negative battery terminal and cut wire to required length. 40. Strip 3/8" of wire insulat ...

indicator lamp. 45. Cut/extend blue wire to required length and connect to one terminal of lamp. 46. Connect an 18 gauge wire between chassis ground and other lamp terminal. 47. Use zip ties to secure wire along routing path. VII. OPERATION CHECK Automatic Control 1. With the key in the off position, measure voltage of each battery using a volt meter. • The voltage of the each battery should be between 12-12.9 volts, if the batteries are in good condition. 2. Touch the outside surface of the solenoid and start the vehicle. Within 30 seconds of vehicl ...

2. Inspect all wire terminals and connectors prior to each use. Replace all items that appear damaged. If any terminals are corroded, disconnect both main and auxiliary battery negative cables from the battery before attempting to clean. 3. Inspect all nuts and bolts, and other related mounting hardware prior to each use. Tighten all nuts that appear to be loose. Stripped, fractured, or bent bolts or nuts need to be replaced. 4. Check all cables prior to use. Replace cables that look worn or frayed. Over-Rid ...

Service Kits Part Number Description 62871 Solenoid Kit XI. APPENDIX A Kit Contents and Functional Overview This kit is designed to manage the charge and discharge of dual batteries installed on a side x side vehicle (UTV). It is compatible with either a magneto or alternator based charging system and is designed to preserve the main vehicle battery against power demands of user installed electrical accessories. Note: For the controller to successfully preserve the main vehicle battery, all accessories must be connected to the auxiliary battery. Do not change your vehicle’s factory ...

Failure to observe these instructions could lead to minor or moderate injury, and/or equipment damage. Read installation and operating instructions thoroughly. • Connecting multiple accessories to the green control harness wire will cause unintentional winch activation. If green wire is connected to the winch power-in circuit, do not connect any other accessories to the green wire without using Warn Over-ride kit P/N 80875. Over-ride feature An optional over-ride feature is integrated into the control module design allowing the user to force the batteries to connect, if certain c ...

sécurité, nous vous avons fourni des instructions relatives à l’installation et à l’utilisation du produit ainsi que d’autres informations figurant sur des étiquettes et dans ce guide. Ces informations attirent l’attention sur les risques de danger pouvant vous affecter ainsi qu’autrui. Nous ne sommes pas en mesure de vous mettre en garde contre tous les dangers potentiels associés à ce produit. Il vous incombe par conséquent de faire preuve de jugement. TOUTE INS ...

Réf. Description Qté I. TABLE DES MATIÈRES Liste des pièces page 2 Couples de serrage page 3 Outils requis page 3 Avant de commencer page 4 Installation pages 5-15 Vérification et test du fonctionnement pages 15-16 Maintenance/entretien page 16 Kits d’entretien et d’accessoires page 17 Annexe A - Aperçu des fonctions pages 17-18 80869 BOÎTIER DE BATTERIE AUXILIAIRE 1 80111 COUVERCLE DU BOÎTIER DE BATTERIE AUXILIAIRE 1 80870 KIT DE MONTAGE DU BOÎTIER DE BATTERIE AUXILIAIRE 1 80733 PLATEAU DE BATTERIE 1 80110 MODULE DE COMMANDE 1 62810 SOLÉNOÏDE 1 77954 FAISCEAU DE CONTOURNEMENT 1 7993 ...