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Painless Trail Rocker Installation Instructions Manual

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Trail Rocker Installation
Instructions
4, 6, or 8-Switch Customizable Trail Rocker Switch Panel
w/ 1
∕
" & 1 ¾" Roll Bar Straps
5
8
For Installing Painless Part Number: 57102, 57105, & 57108
Manual #90635
Painless Performance Products recommends you, the installer, read this installation
manual from front to back before installing this harness.

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Summary of Contents for Painless Trail Rocker

  • Page 1 Trail Rocker Installation Instructions 4, 6, or 8-Switch Customizable Trail Rocker Switch Panel w/ 1 ∕ ” & 1 ¾” Roll Bar Straps For Installing Painless Part Number: 57102, 57105, & 57108 Manual #90635 Painless Performance Products recommends you, the installer, read this installation...
  • Page 3 E-Mail: painless@painlessperformance.com If you have any questions concerning the installation of this product, feel free to call Painless Performance Products' tech line at 1-800-423- 9696. Calls are answered from 8am to 5pm central time, Monday thru Thursday, 8am-4:30pm Friday, except holidays.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PAGE # SECTION CONTENTS OF THE PAINLESS KIT TOOLS NEEDED INSTALLING FACTORY STYLE TERMINALS SWITCH PANEL INSTALLATION SWITCH WIRING DOUBLE SWITCH CONTROL WIRES OPTIONAL: PAINLESS PART#: 57150 - WINCH CONTROL ADD-ON KIT PAINLESS PERFORMANCE LIMITED WARRANTY AND RETURN POLICY...

  • Page 5: Contents Of The Painless Kit

    If you find that anything is missing or damaged, please contact the dealer where you obtained the kit or Painless Performance at (800) 423-9696. The Painless Trail Rocker Kit should contain the following: ...

  • Page 6: Tools Needed

    “Roll-Over Crimpers.” These crimpers will crimp factory style, non-insulated terminals. Painless offers “Roll-Over Crimpers,” such as those seen to the right, under Painless part #70900. A good set of wire strippers are required to strip wire properly. This style of wire stripper is ideal for this...
  • Page 7 In addition to these basic hand tools, you will need, at least, the following: 5. Electric Drill & Drill Bits: 1. Electric Power Drill (suggest battery powered cordless for ease and maneuverability) 2. ¼” drill bit 6. Volt/Ohm Meter: A Volt/Ohm meter is always a good tool to have on hand when installing any type of electrical component into a vehicle.

  • Page 8: Installing Factory Style Terminals

    INSTALLING FACTORY STYLE TERMINALS In the parts kit, you will see uninsulated male terminals. These terminals are for pin connector shell and require roll over crimpers.  ∕ ” Strip about of insulation off of the wire.  Insert the wire into the terminal. There are two terminal straps on the terminal.

  • Page 9: Switch Panel Installation

    SWITCH PANEL INSTALLATION Step 1: First, prepare the Switch Panel for mounting into the Switch Panel Box. Step 2: Now, decide which direction you want to run the Switch Panel Wires. The Switch Panel Box has 3 holes through which to route the wires.
  • Page 10 Step 3: Run the Switch Panel Wires through one of the 3 openings and then through the rubber grommet found in the parts kit. Step 4: At this point, use the loom provided to cover the Switch Panel Wires. Run the loom over the wire, through the grommet, and into the box.
  • Page 11 Step 5: Place the rubber grommet into the opening. Then, use the plastic plugs provided in the parts kit, to close up the remaining holes. Step 6: Make sure the Switch Panel Box is properly covering the back of the Switch Panel, and use (4) 10 –...
  • Page 12 Step 7: Once you’ve selected where you’d like to mount your Trail Rocker Switch Panel, select the correct size Roll Bar Strap for your roll bar: ∕ ” ¾”. Step 8: Locate the 4 holes on the back of the Switch Panel Box. This is where you’ll mount the Roll Bar Straps to the Switch Panel Box.
  • Page 13 ∕ ” button head screws and the small hex key provided in order to mount the Switch Panel. Step 10: Once, you’ve selected a spot to mount your Trail Rocker Switch Panel, use the hardware to mount the switch panel.
  • Page 14 Step 11: Route the Switch Panel Wires to the Switch Control Wires coming from your Trail Rocker Fuse/Relay Center*. A 12-pin connector housing and terminals are provided in the parts kit in order to connect to these wires. *Trail Rocker...
  • Page 15 Step 14: Strip each of the Switch Panel Wires ∕ ”, and install a male pin terminal from the parts kit onto the end of each wire. See page 7 for detailed instructions of how to properly crimp these terminals. We recommend Painless #70900 Roll-Over Crimpers.
  • Page 16 Step 15: Locate the 12-pin connector housing included in the parts kit. Note the locating tab for orientation. Step 16: Insert the newly pinned wires into the 12-pin connector housing. Make sure, while inserting the pins, that once connected the wire color matches the one across from it. The diagram on page 13 illustrates the pinout of the...
  • Page 17 Step 17: Once completed, the connector should appear as it does below. The 2 empty cavities are for optional wench wires (see page 21). Step 18: Link the two connectors and join the wiring harness from the Fuse/Relay Center to the Switch Panel. Use zip-ties to secure the wires up under the dash and out of the way.

  • Page 18: Switch Wiring

    SWITCH WIRING The lighted rocker switches included in your kit are wired as shown in the diagram below.

  • Page 19: Double Switch Control Wires

    DOUBLING SWITCH CONTROL WIRES The Trail Rocker Fuse/Relay Center is capable of supporting 8 different accessories. Those who purchased a 4 or 6-switch panel may wish to control multiple accessories with a single switch. Steps 19-22 are optional and only for those who wish to control multiple functions for one switch.
  • Page 20 Step 20: With the Switch Panel wire removed from the switch, cut off the terminal, and strip the wire ∕ ”.
  • Page 21 Step 21: Take the Switch Panel wire you just stripped and one of the additional Switch Panel wires included in the kit; then slide them together into a 16-14 ga. terminal provided in the included parts kit. Step 22: With both wires inside, crimp the terminal, and reconnect the doubled Switch Panel wires to the switch.

  • Page 22: Optional: Painless Part#: 57150 - Winch Control Add-On Kit

    57150, available online at www.painlessperformance.com). Steps 23 - 28 show you how to install a Winch Control Add-on Kit to your Trail Rocker Switch Panel and connect the control wires to the switch. The SPDT Wiring diagram on page 23 will show how to connect to a standard SPDT switch.
  • Page 23 Step 23: Remove the switch panel faceplate, power, and ground wires from the switch you are replacing with the Winch Control Add-on Switch. Then, locate the tabs located at the top and bottom of the switch. Step 24: These tabs lock the switch in place. To remove the switch, squeeze the tabs in and slide it out of the bracket.
  • Page 24 Step 26: Before connecting the wires to the Winch Control Add-on Switch, take time to familiarize yourself with the wiring diagram below.
  • Page 25 Step 27: Reconnect the power, ground, and Switch Panel wires to the Winch Control Add-on Switch as seen below.
  • Page 26 Step 28: Strip and terminate the other ends of the wire as you did in Steps 14 – 16. And insert the WHITE/RED into slot of the pin connector shell and the BROWN/WHITE into slot #10.
  • Page 27 Painless Performance Products LLC Limited Warranty and Return Policy Chassis harnesses, fuel injection harnesses, and Trail Rocker units are covered under a lifetime warranty. All other products manufactured and/or sold by Painless Performance are warranted to the original purchaser to be free from defects in material and workmanship under normal use.
  • Page 28 Painless Performance Products LLC 2501 Ludelle Street Fort Worth, TX 76105 Phone (817) 244-6212...