Warn 77977 Manuale utente
WARN INDUSTRIES PAGE1 77978A1
NOTICE
RECYCLE. Consult with your local environmental or health agency to determine recycle and disposal options.
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 vehicle damage, electrical shock, fire or personal injury.
Always wear safety glasses when installing this kit.
Always use extreme caution when cutting and trimming during fitting.
Always remove jewelry and wear eye protection.
Never lean over battery while making connections.
Never route electrical cables:
- Across any sharp edges.
- Through or near moving parts.
- Near parts that become hot.
- Where cables may be damaged from flying debris.
Always insulate and protect all exposed wiring and electrical terminals.
Always install terminal boots as directed in installation instructions.
Always tighten all nuts and bolts securely, per the installation and operation.
Always perform regular inspections of all components and related hardware.
INJURY HAZARD
Failure to observe these instructions could lead to severe injury or death.
WARNING
INJURY HAZARD
Failure to observe these instructions could lead to severe injury or death.
Components of this kit are designed to function with batteries rated at 12-30 amp-hr., and charging systems less than 1200
watt (100 amps @ 12 volt)
Read installation and operating instructions thoroughly.
Your safety, and the safety of others, is very important. To help you make informed decisions about
safety, we have provided installation and operating instructions and other information on labels and in
this guide. This information alerts you to potential hazards that could hurt you or others. It is not
possible to warn you about all potential hazards associated with this product, you must use your own
good judgment.
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR
EQUIPMENT DAMAGE. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND
OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.
This guide identifies potential hazards and has important safety messages that help you and others avoid
personal injury or death. WARNING and CAUTION are signal words that identify the level of hazard.
These signal words mean:
WARNING signals a hazard that could cause serious injury or death, if you do not follow
recommendations. CAUTION signals a hazard that may cause minor to moderate injury, if
you do not follow recommendations.
This guide uses NOTICE to call attention to important mechanical information, and Note: to empha-
size general information worthy of special attention.
WARN INDUSTRIES PAGE2 77978A1
II. PARTS LIST
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
80740 CONDUIT, LONG 1
80741 CONDUIT, SHORT 1
13231 TIE STRAPS 12
74543 TERMINAL BOOT, LARGE 4
21841 TERMINAL BOOT, SMALL 2
66198 TERMINAL BOOT, DOUBLE WIRE 1
74466 M6 HARDWARE KIT 1
1/4” FLAT WASHER 4
1/4” LOCK WASHER 8
6MM NUT 8
6MM FLANGE NUT 2
6MM BOLT 4
I. TABLE OF CONTENTS
Parts List page 2
Torque Specifications page 3
Tools Required page 3
Before You Begin page 4
Installation page 5-15
Operation Check and Test page 15-16
Maintenance/Care page 16
Service and Accessory Kits page 17
Appendix A- Function Overview page 17-18
WARN INDUSTRIES PAGE3 77978A1
IV. TOOLS REQUIRED
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
456
7 8 9
10 11 12
13 14 15
16 17 18
19
WARN INDUSTRIES PAGE4 77978A1
WARNING
Failure to observe these instructions could lead to severe injury or death.
•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 instructions could lead to minor or moderate injury.
Turn off vehicle/Key in off position.
Allow vehicle engine parts to cool.
Remove ground wire from negative terminal on battery.
Clean vehicle thoroughly and prepare installation area with good lighting and required tools.
Read installation and operating instructions thoroughly.
Red
Red
Red
Winch Contactor
Red
Red
Indicator lamp
output (optional)
Winch-in over ride
signal to connect
batteries only in
winch-in mode.
Do not
connect
blue wire
to ground.
Use blue
wire only with
optional lamp.
Green
Green
White
White
Solenoid
Solenoid
Harness
Control
Harness
Control
Module
Black
Black
Relocate the red 6 gauge winch power cable and all aftermarket accessory
power wires from main battery power to auxiliary battery power.
Relocation connection options:
Option 1 -or- Option 2
Blue
Green
Green
Splice
connector
Green
Green
Black
Aux
Battery
Main
Battery
Winch
remote
harness,
if equip.
Black
Black
Connector
*
*
*
**
*
*Use terminal boots.
Double wire boot
See torque specifications.
Standard boot
1. Unpack and review contents of kit. If any items are missing contact WARN Customer Service at: 1.800.543.9276
2. Review diagram below, and lengths of wires and bolts provided to determine the best location on your vehicle to
install the kit components. Verify wire lengths before finalizing component mounting locations, with a preliminary
layout of components and wiring.
WARN INDUSTRIES PAGE5 77978A1
VI. INSTALLATION
Figure 1
Figure 2
Figure 3a
WARNING
Failure to observe these instructions could lead to severe injury or death.
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 auxiliary battery box location. Be
sure to review section V, “Before You
Begin”.
2. Once box location has been determined, use
battery tray as a template to center-punch hole
pattern. Drill vehicle and battery box, using a
5/16” drill bit. See Figure 1 and 2.
3. With back of buckle facing up, install battery
strap to battery tray. Route strap through
bracket (lengthwise for larger batteries or
widthwise for smaller batteries). See Figure
3a and 3b.
WARNING
Failure to observe these instructions could lead to severe injury or death.
Read installation and operating instructions thoroughly.
•Always mount auxiliary battery box in a location that will be dry
and away from parts that become hot, moving parts and flying
debris.
WARN INDUSTRIES PAGE6 77978A1
VI. INSTALLATION CONT.
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
WARN INDUSTRIES PAGE7 77978A1
VI. INSTALLATION
6. Install battery box strap under battery box.
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
WARN INDUSTRIES PAGE8 77978A1
7. Mark and cut bolts if necessary. See
Figure 9. Torque to specifications on page 3.
Install battery into box. See Figure 10.
Tighten battery tray clip screws.
Figure 9
Figure 10
WARN INDUSTRIES PAGE9 77978A1
VI. INSTALLATION
Control Module installation:
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
mounting surface on vehicle. See Figures 11
and 12.
10. Clean the surface of the control module and
vehicle. See Figures 13 and 14.
Cleaning Recommendations:
General Cleaning: Most surfaces are best
prepared by cleaning with a 50:50 mixture of
isopropyl alcohol (IPA) and water prior to
applying tape.
Heavy Oils: A degreaser or solvent-based
cleaner may be required to remove heavy oil
or grease from a surface and should be
followed by cleaning with IPA/water.
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
WARNING
Failure to observe these instructions could lead to severe injury or death.
Read installation and operating instructions thoroughly.
•Always route electrical wires and cables away from heat, moving
parts, pinch points, sharp edges and flying debris.
WARN INDUSTRIES PAGE10 77978A1
INSTALLATION CONT.
Figure 16
Figure 17
Figure 18
Figure 19
NOTE: Cleaning solutions may contain
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 reached
after 72 hours. Do not disturb tape bond
connection once it is applied.
12. Apply tape to back of control module. See
Figure 16.
13. Take backing off tape on control module
(Figure 17) and apply control module to
prepared mounting surface on vehicle.
Pressing firmly will help insure full adhesive
contact and improve bond strength. See
Figure 18.
14. Install a tie strap around the control module
and mounting surface. If required, drill holes
using a 3/16” drill bit to route tie strap
around mounting surface. See Figure 19.
WARNING
Failure to observe these instructions could lead to severe injury or death.
Read installation and operating instructions thoroughly.
•Always verify area is clear of fuel lines, fuel tank, brake lines,
electrical wires, etc. when drilling.
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