WARN ZEON CONTROL PACK RELOCATION KIT 31 - Manual (Page 6)

WARN INDUSTRIES
7 89969A0
INSTALLATION INSTRUCTION
6. Once all four (4) control pack screws have been
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 be reinstalled.
3. Remove terminal nuts and lock washers securing
the three buss bars to the contactor (see Figure 6).
Set aside terminal nuts and lock washers, as they
will be used later on. Buss bars will not be used
for new installation.
4. Loosen the two flat head torx drive screws
securing the contactor to the contactor plate.
Only loosen. Do not remove.
5. Using the terminal nuts and lock washers
removed in previous step, connect the
labeled cables (A, F1 and F2) to corresponding
contactor terminal. Torque nuts to 8.5 - 9 N-m
(75-80 in. lb.). Refer to Figure 7.
6. Tighten the two flat head torx drive screws
and nuts used to secure the contactor to the
contactor plate. Secure fasteners to specified
torque requirements in torque specification chart
found in these instructions.
7. Once the cables have been installed, reinstall
the cover using the four (4) flat head torx drive
screws previously removed. Refer to the torque
section of this document.
Figure 6
Buss Bars
Motor Terminal Buss Bar
Insulator
Figure 4
Loosen
Screws (2x)
Figure 7
F2
F1
A
F2
A
F1
Tighten
screws (2x)
Figure 5
Remove
WARN INDUSTRIES
89969A0 8
INSTALLATION INSTRUCTION
RELOCATING THE CONTROL PACK
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.
1. (Optional) Depending on your specific
relocation kit, you can attach the shown
bracket, for easier mounting, using the supplied
hex head bolts and lock washers. If you would
like to purchase the bracket shown please
contact: WARN Industries at 1-800-543-9276 or
visit www.warn.com.
2. Find an appropriate mounting location to
mount the control pack. Make sure to check
that the cables and ground wire can be routed
to the winch and that the control pack is easily
accessible and on a solid mounting surface.
WARNING Always verify area is clear of fuel lines, fuel
tank, brake lines, electrical wires, etc., when drilling.
WARNING Never mount contactor with electrical
terminals touching metal objects.
3. If using the mounting bracket, match drill the
5/16” holes in the bracket to the mounting
surface you choose to mount your control pack
to. Be sure to check the area before you drill to
avoid hitting any electrical cables or gas lines.
If opting not to use the mounting bracket,
you can use the attached template as a guide
for drilling mounting holes. Holes should be
drilled to 6.5mm diameter.
4. Mount the bracket using the supplied 5/16”
bolts with two (2) flat washers and nylock nuts
as shown. If opting not to use the mounting
bracket, M6 screws and lock washers must
be purchased separately to complete this
installation.
Figure 8
Bracket
[Kit (89770)]
[Bracket only (89729)]
M6 Hex Head Screws
(included in kit)
[89970]
Figure 9
Nylock Nuts
2x Flat
Washers
5/16” Bolts