Warn 77977 User manual

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

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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.

WARN INDUSTRIES PAGE11 77978A1
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.
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 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 20
INSTALLATION CONT.

WARN INDUSTRIES PAGE12 77978A1
Solenoid harness installation:
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 Figures 23 and 24.
INSTALLATION CONT.
Figure 22
Figure 23
Figure 24
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 and sharp edges.
•Always insulate and protect all exposed wiring and electrical
terminals.
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 and sharp edges.
*
Use terminal boots.
Double wire boot
See torque specifications.
Standard boot

WARN INDUSTRIES PAGE13 77978A1
Over-ride control harness installation:
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 gauge red cable. See Figure
25.
25. Route one red cable to the main battery
positive terminal. Route a second red cable
to the auxiliary battery positive terminal.
26. Connect each cable to the positive battery
terminal and install terminal boots.
27. Use zip ties to secure wire along routing
path.
Ground cable installation:
28. Connect one end of black 6 gauge cable to
negative terminal of auxiliary battery.
29. Route other end of black 6 gauge cable to a
chassis ground location or negative terminal
of main vehicle battery.
30. Use zip ties to secure wire along routing
path.
31. Reconnect vehicle ground cable to negative
post of main battery terminal.
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 and sharp edges.
INSTALLATION CONT.
CONDUIT
TUBING
6 GAUGE
CABLES
Figure 25
Figure 26
Figure 27

WARN INDUSTRIES PAGE14 77978A1
Figure 28
Figure 29
36. Crimp splice connector onto green control
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 insulation from black
control harness wire and crimp on ring
terminal.
41. Install ring terminal to a ground location.
42. Use zip ties to secure wire along routing
path.
Blue wire connection – 12V Indicator Lamp
(optional):
A lamp is required, with minimum
specifications to those listed below, when
connecting the blue wire to provide a visual
indication of over-ride. When lamp is
illuminated the batteries will be connected.
Lamp is not included in this kit.
Lamp Specifications:
-Incandescent lamp .25 amp max.
- If LED lamp is used, a 1000 ohm resistor .5
watt must be used in series
- Recommended lamps:
o NAPA item # ECH - SW158
o NAPA item # ECH - SW159
o NAPA item # ECH - SW160
o NAPA item # ECH - SW161
43. Review control harness blue wire in diagram
on page 4.
INSTALLATION CONT.

WARN INDUSTRIES PAGE15 77978A1
INSTALLATION CONT.
44. Select a mounting location for optional 12V
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 vehicle
start-up, a “click” should be heard and felt from the solenoid. The solenoid is now energized.
•This indicates that the control module is sensing the vehicle’s charging signal and has
determined that both batteries can be connected and charged together through the
solenoid. Both battery voltages should measure the same and be between 13.2-14.5 volts.
3. Turn off the vehicle and listen for the solenoid to “click” again (may take up to 5 minutes).
The solenoid in now de-energized.
•This indicates that the control module is no longer sensing the vehicle charging system
voltage and the batteries are no longer connected together through the solenoid.
4. If operational checks agree with the above, then the automatic control is working properly.
Go to step 6. If operational checks do not agree with the above, then follow these steps:
I. Review diagram on page 4 to be sure all wire connections are correct.
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 PAGE16 77978A1
VIII. MAINTENANCE/CARE
1. Always protect components from submersion and direct spray of high pressure water.
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-Ride Control
The procedure below assumes that the green control harness wire is connected to the winch-in circuit
on a vehicle equip with a winch. If you have chose to connect the green wire to a different accessory
than a winch, substitute activation of that accessory in the procedure below.
5. Disengage winch clutch to freespool position.
6. With vehicle engine off and key in the on position, activate the power-in function of the
winch using the rocker-switch, remote control, or wireless control. A “click” should be
heard and felt from the solenoid. The solenoid is now energized.
•This indicates that the control module is receiving an over-ride signal and is connecting
the batteries together through the solenoid.
7. Release winch switch and listen for the solenoid to “click” again. The solenoid in now de-
energized.
•This indicates that the control module is no longer receiving an over-ride signal and the
batteries are no longer connected together through the solenoid.
8. Activate the power-out function of the winch using the rocker-switch, remote control, or
wireless control.
•No “click” should be heard or felt from the solenoid.
9. If operational checks agree with the above, then the over-ride control is working properly.
If operational checks do not agree with the above, then follow these steps:
I. Review diagram on page 4 to be sure all wire connections are correct.
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 5-8 above
IV. Contact Warn Customer Service
NOTICE
•When charging vehicle, connect battery charger to main battery. This will assure that both the main and axillary battery will be
charged.

WARN INDUSTRIES PAGE17 77978A1
IX. SERVICE AND ACCESSORY KITS
Service Kits
Part Number Description
62871 Solenoid Kit
XI. APPENDIXA
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 wire harness power connections.
The main components of the kit and their function are as follows (see also, diagram on page 4):
Control Module - The control module monitors the two batteries individually and determines if the
batteries should be connected or disconnected through the solenoid, based on the following criteria:
1. If the control module has disconnected the batteries from each other, and the vehicle charging
system raises the main battery voltage above 13.2 volts, the control module will
automatically connect the batteries back together.
2. If the control module has connected the batteries to each other and the combined battery
voltage drops below 12.7 volts, the control module will automatically disconnect the batteries
from each other.
Solenoid - A solenoid (relay) is used as a mechanical switch that connects and disconnects one battery
from another. The solenoid gets a signal to connect or disconnect the batteries from the control
module. When the solenoid is disconnected, there is no current flow between batteries, and the
auxiliary battery does not receive a charge from the vehicle charging system. When the solenoid
reconnects the batteries, the auxiliary battery receives charge from the vehicle main battery and
charging system. Note: When the solenoid reconnects, an exhausted auxiliary battery can take a
significant amount of power from the starting battery. Always operate vehicle for 5 minutes after
demanding accessory use, especially winching, to allow batteries to recharge.
Auxiliary battery box and tray - A battery box, lid, straps and tray are included with this kit to
provide protection and a method of securing an auxiliary battery.
Wire harnesses - There are two wire harnesses included in this kit. One harness provides the user
over-ride function to connect the batteries. The second harness provides sensing and control function
between the solenoid and control module.
6 gauge cabling - Red 6 gauge battery cables are supplied for connection between the battery positive
terminals and solenoid. 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 PAGE18 77978A1
CAUTION
Unintended Winch Activation
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 conditions are met (See Over-ride Connection Conditions below). The green wire of the control
harness provides this over-ride signal to the controller. When the green wire is connected to the winch power-in circuit,
power is provided to the winch from both batteries during power-in function.
Over-ride Connection Conditions:
•Either the vehicle battery or auxiliary battery voltage needs to be above 8.5 volts, and
•the vehicle battery voltage must be greater than or equal to the auxiliary battery voltage minus .85
volts, in order for the battery over-ride to connect batteries.
•Each time the battery voltages drop below 12.7 volts and are disconnected, the batteries cannot be
reconnected for 10 seconds. Note: Rapid on/off cycling of the winch over-ride function may be
ignored by the control module resulting in batteries not being connected.
The blue wire on the control harness offers an output for an over-ride indicator lamp. If the winch power-in (green
wire) provides a signal, and the connection conditions above are met, a lamp connected to the blue wire will illuminate.
Auxiliary Battery Requirements
The auxiliary battery is not included in this kit. When purchasing an auxiliary battery, select one that is between 12 and
30 amp hour and matches the ratings of the current vehicle battery. WARN recommends a maintenance free, semi-
sealed, lead-calcium battery construction.

WARN INDUSTRIES PAGE19 77978A1
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 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 INSTALLATION OU UTILISATION IMPRUDENTE PEUT ENTRAÎNER DES BLESSURES GRAVES OU
ENDOMMAGER L’ÉQUIPEMENT. PRENEZ SOIN DE LIRE ET DE BIEN ASSIMILER LES CONSIGNES DE SÉCURITÉ ET
D’UTILISATION DU PRODUITAVANT DE L’INSTALLER ET DE L’UTILISER.
Ce guide identifie les dangers potentiels et comporte des consignes de sécurité importantes qui permettent à vous et à autrui d’éviter les
risques de blessures graves ou de mort. Les termes AVERTISSEMENT et MISE EN GARDE sont des indicateurs du niveau de danger.
Signification des indicateurs :
Le terme AVERTISSEMENT souligne un danger potentiel qui peut entraîner des blessures graves ou la mort si vous ne suivez pas les
consignes.
Le terme MISE EN GARDE souligne un danger potentiel susceptible d’entraîner des blessures mineures ou modérées si vous ne
suivez pas les consignes.
Ce guide utilise le terme AVIS pour attirer votre attention sur des informations mécaniques importantes, et le terme Remarque : pour
souligner des informations générales qui méritent une attention particulière.
RISQUES DE BLESSURES
Le non-respect des consignes peut entraîner des blessures graves ou la mort.
AVERTISSEMENT
INSTRUCTIONS D’INSTALLATION
KIT DE COMMANDE DE BATTERIES
DOUBLES
Numéro de pièce : 77977
Application : Véhicule côte à côte (véhicule utilitaire)
Toujours faire extrêmement attention lorsqu’on perce la carrosserie d’un véhicule. Veiller à ne pas perforer ou
endommager les conduites de carburant, les conduites de frein, le câblage électrique ou tout autre objet en perçant le
véhicule. Inspecter soigneusement l’emplacement à percer (des deux côtés du matériau) avant de le faire, et déplacer tous
les objets risquant d’être endommagés. Le fait de ne pas inspecter l’emplacement peut finir par endommager le véhicule,
entraîner un choc électrique, un incendie ou des blessures.
Toujours porter des lunettes de protection lors de l’installation du kit.
Toujours faire très attention lorsqu’on découpe ou que l’on taille.
Toujours retirer les bijoux et porter des lunettes de sécurité.
Ne jamais se pencher au-dessus de la batterie en procédant aux connexions.
Ne jamais faire passer des câbles électriques :
- Sur des bords tranchants.
- Par des pièces mobiles ou à proximité.
- À proximité de pièces pouvant devenir chaudes.
- Là où ils pourraient être endommagés par une projection de débris.
Toujours isoler et protéger tous les fils et bornes électriques exposés.
Toujours installer les capuchons de borne de la manière indiquée dans les instructions d’installation.
Toujours bien serrer les écrous et les boulons conformément aux instructions d’installation et d’utilisation.
Toujours inspecter régulièrement tous les composants et le matériel connexe.
AVIS
RECYCLEZ. Consultez les organismes publics chargés de la protection de l’environnement ou de la santé pour connaître
les politiques en matière de recyclage ou de mise au rebut.
AVERTISSEMENT
RISQUES DE BLESSURES
Le non-respect des consignes peut entraînerdes blessures graves ou la mort.
Les composants de ce kit sont conçus pour fonctionner avec des batteries prévues pour 12-30 Ah et des systèmes de
charge de moins de 1200 watts (100 A à 12 volts).
Lire attentivement les instructions concernant l’installation et l’utilisation.

WARN INDUSTRIES PAGE20 77978A1
II. LISTE DES PIÈCES
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
79932 FAISCEAU DE SOLÉNOÏDE 1
77968 CÂBLE D’ALIMENTATION ROUGE, COURT 1
80737 CÂBLE D’ALIMENTATION ROUGE, LONG 1
77969 CÂBLE D’ALIMENTATION NOIR 1
78793 SANGLE DU BOÎTIER DE BATTERIE 1
80040 RUBAN DOUBLE-FACE 1
79293 BOULON À ÉPAULEMENT 6 MM, BORNE DE BATTERIE 2
1320 RONDELLE PLATE 1/4 PO 4
9256 RONDELLE DE PROTECTION 1/4 PO 4
62819 VIS À TÊTE HEXAGONALE N° 10 2
62820 ÉCROU À ÉPAULEMENT N° 10 2
62824 ESPACEUR 2
80735 COSSE ÀANNEAU 1
76406 CONNECTEUR À ÉPISSURE 1
80739 FAISCEAU EN Y, VERT 1
80740 CONDUIT, LONG 1
80741 CONDUIT, COURT 1
13231 ATTACHES 12
74543 CAPUCHON DE BORNE, GRAND 4
21841 CAPUCHON DE BORNE, PETIT 2
66198 CAPUCHON DE BORNE, FIL DOUBLE 1
74466 KIT DE MATÉRIEL M6 1
RONDELLE PLATE ¼ PO 4
RONDELLE DE BLOCAGE 1/4 PO 8
ÉCROU 6MM 8
ÉCROU À ÉPAULEMENT 6 MM 2
BOULON 6 MM 4