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Warn 77977 Installation Instructions Manual
Warn 77977 Installation Instructions Manual

Warn 77977 Installation Instructions Manual

Dual battery control kit

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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.
you do not follow recommendations.
This guide uses NOTICE to call attention to important mechanical information, and Note: to empha-
size genera l information worthy of special attention.
Failure to observe these instructions could lead to severe injury or death.
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.
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)
RECYCLE. Consult with your local environmental or health agency to determine recycle and disposal options.
WARN INDUSTRIES
INSTALLATION INSTRUCTIONS
DUAL BATTERY CONTROL KIT
Application: Side x Side (UTV)
CAUTION signals a hazard that may cause minor to moderate injury, if
WARNING
INJURY HAZARD
WARNING
INJURY HAZARD
Read installation and operating instructions thoroughly.
NOTICE
PAGE 1
Part Number: 77977
77978A1

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Summary of Contents for Warn 77977

  • Page 1 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.
  • Page 2 CONDUIT, SHORT 13231 TIE STRAPS 74543 TERMINAL BOOT, LARGE 21841 TERMINAL BOOT, SMALL 66198 TERMINAL BOOT, DOUBLE WIRE 74466 M6 HARDWARE KIT 1/4” FLAT WASHER 1/4” LOCK WASHER 6MM NUT 6MM FLANGE NUT 6MM BOLT WARN INDUSTRIES PAGE 2 77978A1...
  • Page 3 - Center punch and hammer - Utility knife - Sandpaper/steel wool - Rubbing alcohol - Hacksaw - Torque wrench - Floor jack - Jack Stands - Wheel chocks - Electrical Tape - Work Light - Digital Volt Meter WARN INDUSTRIES PAGE 3 77978A1...
  • Page 4 V. BEFORE YOU BEGIN 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.
  • Page 5 Read installation and operating instructions thoroughly. 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. Figure 3b WARN INDUSTRIES PAGE 5 77978A1...
  • Page 6 5. Temporarily install battery and two tray clips Figure 6 to battery tray. Choose hole locations that are closest to the batter See Figure 7. Do not tighten screws. Remove battery from battery Battery tray clip tray. Battery tray clip Figure 7 WARN INDUSTRIES PAGE 6 77978A1...
  • Page 7 Figure 8a Install battery tray into battery box. See figure 8b. Figure 8b Install battery box to vehicle using four 6mm bolts, ¼” flat and lock washers, and ¼” fender washers. See figure 8c. Figure 8c WARN INDUSTRIES PAGE 7 77978A1...
  • Page 8 7. Mark and cut bolts if necessary. See Figure 9. Torque to specifications on page 3. Figure 9 Install battery into box. See Figure 10. Tighten battery tray clip screws. Figure 10 WARN INDUSTRIES PAGE 8 77978A1...
  • Page 9 (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 15 WARN INDUSTRIES PAGE 9 77978A1...
  • Page 10 Failure to observe these instructions could lead to severe injury or death. • Always verify area is clear of fuel lines, fuel tank, brake lines, electrical wires, etc. when drilling. Read installation and operating instructions thoroughly. Figure 19 WARN INDUSTRIES PAGE 10 77978A1...
  • Page 11 Figure 20 17. Use solenoid as a template to mark and center-punch mounting hole locations on vehicle. Drill holes using 1/4” drill bit. 18. Install #10 hardware and torque to specifications. See Figure 21. Figure 21 WARN INDUSTRIES PAGE 11 77978A1...
  • Page 12 Failure to observe these instructions could lead to severe injury or death. • Always route electrical wires and cables away from heat, moving parts, pinch points and sharp edges. Figure 24 Read installation and operating instructions thoroughly. WARN INDUSTRIES PAGE 12 77978A1...
  • Page 13 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. Read installation and operating instructions thoroughly. WARN INDUSTRIES PAGE 13 77978A1...
  • Page 14 NAPA item # ECH - SW158 NAPA item # ECH - SW159 NAPA item # ECH - SW160 NAPA item # ECH - SW161 43. Review control harness blue wire in diagram on page 4. WARN INDUSTRIES PAGE 14 77978A1...
  • Page 15 II. Inspect all ground and power connections. Paint, dirt, and loose connections will cause electrical resistance that can affect function. Be sure all connections are clean, tight, and free of corrosion. III. Repeat steps 1-3 above IV. Contact Warn Customer Service WARN INDUSTRIES PAGE 15 77978A1...
  • Page 16 Be sure all connections are clean, tight, and free of corrosion. III. Repeat steps 5-8 above IV. Contact Warn Customer Service VIII. MAINTENANCE/CARE NOTICE • When charging vehicle, connect battery charger to main battery. This will assure that both the main and axillary battery will be charged.
  • Page 17 A black 6 gauge cable provides a chassis ground to the auxiliary battery. Mounting and wiring hardware - Miscellaneous hardware in this kit will be used to secure various components and complete wire connections. WARN INDUSTRIES PAGE 17 77978A1...
  • Page 18 • 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.
  • Page 19 KIT DE COMMANDE DE BATTERIES DOUBLES Numéro de pièce : 77977 Application : Véhicule côte à côte (véhicule utilitaire) Votre sécurité et celle des autres est très importante. Afin de vous permettre de prendre des décisions éclairées dans le domaine de la sécurité, nous vous avons fourni des instructions relatives à...
  • Page 20 CAPUCHON DE BORNE, PETIT 66198 CAPUCHON DE BORNE, FIL DOUBLE 74466 KIT DE MATÉRIEL M6 RONDELLE PLATE ¼ PO RONDELLE DE BLOCAGE 1/4 PO ÉCROU 6MM 8 ÉCROU À ÉPAULEMENT 6 MM BOULON 6 MM WARN INDUSTRIES PAGE 20 77978A1...
  • Page 21 11 - Alcool à friction 12 - Scie à métaux 13 - Clef dynamométrique 14 - Cric rouleur 15 - Chandelles 16 - Cales de roue 17 - Ruban isolant 18 - Lampe de travail 19 - Voltmètre numérique WARN INDUSTRIES PAGE 21 77978A1...
  • Page 22 1. Déballez et examinez le contenu du kit. S’il manque des éléments, communiquez avec le service à la clientèle WARN à ce numéro : 1.800.543.9276 2. Examinez le schéma ci-dessous ainsi que les longueurs de fil et les boulons fournis afin de déterminer le meilleur emplacement sur le véhicule pour l’installation des éléments du kit.
  • Page 23 Acheminez la sangle par le support (dans le sens de la longueur pour les batteries grand format ou de la largeur pour des batteries plus petites). Voir figures 3a et 3b. Figure 3b WARN INDUSTRIES PAGE 23 77978A1...
  • Page 24 Choisissez les trous les plus proches de la batterie. Voir figure 7. Ne serrez pas les vis. Clip de plateau de batterie Retirez la batterie du plateau de batterie. Clip de plateau de batterie Figure 7 WARN INDUSTRIES PAGE 24 77978A1...
  • Page 25 Figure 8b Fixez le boîtier de batterie au véhicule à l’aide de quatre boulons 6 mm, de rondelles plates et de blocage 1/4 po et de rondelles de protection 1/4 po. Voir figure 8c. Figure 8c WARN INDUSTRIES PAGE 25 77978A1...
  • Page 26 Voir figure 9. Serrez selon les couples de serrage de la page 3. Figure 9 Installez la batterie dans le boîtier. Voir figure 10. Serrez les vis de clip du plateau de batterie. Figure 10 WARN INDUSTRIES PAGE 26 77978A1...
  • Page 27 à base de solvant pour éliminer toute trace d’huile ou de graisse épaisse de la surface avant de nettoyer avec de l’alcool isopropylique et de l’eau. Figure 15 WARN INDUSTRIES PAGE 27 77978A1...
  • Page 28 • Avant de percer, toujours s’assurer que la zone ne contient pas de conduites de carburant, de réservoir de carburant, de conduites de frein, de câblage électrique, etc. Lire attentivement les instructions concernant l’installation et l’utilisation. Figure 19 WARN INDUSTRIES PAGE 28 77978A1...
  • Page 29 Percez les trous à l’aide d’une mèche de 1/4 po. 18. Installez le matériel n° 10 et serrez selon les couples de serrage. Voir figure 21. Figure 21 WARN INDUSTRIES PAGE 29 77978A1...
  • Page 30 • Toujours acheminer les fils électriques et les câbles loin de la chaleur, des pièces mobiles, des points de pincement, des bords tranchants et de toute projection de débris éventuelle. Figure 24 Lire attentivement les instructions concernant l’installation et l’utilisation. WARN INDUSTRIES PAGE 30 77978A1...
  • Page 31 3/8 po de l’isolation du fil vert du faisceau de commande et du fil vert du faisceau en Y. Voir figure 27. Lire attentivement les instructions concernant l’installation et l’utilisation. WARN INDUSTRIES PAGE 31 77978A1...
  • Page 32 1000 ohm 0,5 watt en série - Lampes recommandées : o NAPA article n° ECH - SW158 o NAPA article n° ECH - SW159 o NAPA article n° ECH - SW160 o NAPA article n° ECH - SW161 WARN INDUSTRIES PAGE 32 77978A1...
  • Page 33 électrique susceptible d’affecter le fonctionnement. Assurez-vous que toutes les connexions sont propres, bien serrées et non corrodées. III. Répétez les étapes 1 à 3 ci-dessus. IV. Communiquez avec le service à la clientèle WARN WARN INDUSTRIES PAGE 33 77978A1...
  • Page 34 Assurez-vous que toutes les connexions sont propres, bien serrées et non corrodées. III. Répétez les étapes 5 à 8 ci-dessus. IV. Communiquez avec le service à la clientèle WARN VIII. MAINTENANCE/ENTRETIEN AVIS • Lors de la charge du véhicule, connecter le chargeur de batterie à la batterie principale. Ceci assurera que les batteries principale et auxiliaire seront chargées.
  • Page 35 Un câble noir calibre 6 fournit une masse de châssis à la batterie auxiliaire. Matériel de montage et de câblage - Diverses pièces de ce kit servent à sécuriser certains composants et compléter les connexions de fils. WARN INDUSTRIES PAGE 35 77978A1...
  • Page 36 • Connecter plusieurs accessoires au fil vert du faisceau de commande entraînera une activation involontaire du treuil. Si le fil vert est connecté au circuit d’enroulement du treuil, ne pas connecter d’autres accessoires au fil vert sans utiliser le kit de contournement WARN (réf.