Mount The Contactor; Electrical Connections; Install Wiring - Warn Provantage 2500 Guide D’installation

Section 6 - Mount the Contactor :
To prevent serious injury or death.
WARNING
Always place the supplied terminal boots on wires and
terminals as directed by the installation instructions.
To prevent serious injury or death from
WARNING
electrical 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.
Never mount contactor with electrical
WARNING
terminals touching metal objects.
After determining contactor mounting
location in Section 2 and mounting your
switch option, you are ready to mount your
contactor.
1. Confirm power is disconnected.
2. Make sure to check that the cables and
ground wire can be routed to the winch
and that the desired contactor location is
easily accessible.
NOTE: You may need to adjust your
original desired contactor mounting
location, due to speci c wiring lengths.
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MOUNTING
Always verify area is clear of fuel lines,
WARNING
fuel tank, brake lines, electrical wires, etc., when
drilling.
3. Use the contactor as a template to drill the
holes needed to mount the contactor. Be
sure to check the area before you drill to
avoid hitting any electrical cables or gas
lines.
4. Mount the bracket using the supplied
bolts with the nylock nuts.
6. Proceed to Section 6 - Install Wiring for
complete wiring installation instructions.
Figure 16 - Mount Contactor
WARN INDUSTRIES
13

ELECTRICAL CONNECTIONS

Section 7 - Install Wiring
To prevent serious injury or death. Always
WARNING
place the supplied terminal boots on wires and terminals as
directed by the installation instructions. All wires must be
attached to the contactor before mounting the contactor to
the ATV/UTV.
To prevent serious injury or death from
WARNING
electrical 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.
Always insulate and protect all exposed
WARNING
wiring and electrical terminals.
1. Confirm power is disconnected. All work with
electrical wires and cables must be completed
with the battery completely disconnected from
the vehicle wiring.
2. Slip terminal boots on both ends of yellow and
blue cables. See Figure 18 on following page.
3. Attach the yellow and blue electrical cables to
the motor terminals on the winch. Yellow is
marked #1 and blue is marked #2 on the motor.
Torque the terminal nuts on the motor to 5.7
N-m (50 lb-in). Seat boots over terminal.
4. Route the yellow and blue electrical cables
back to the contactor. Place boots over ring
terminals. Place ring terminals on color coded
contactor posts (yellow cable to yellow post,
blue cable to blue post). Install and finger
tighten nuts to retain ring terminals on
contactor posts. Do NOT tighten nuts or seat
boots at this time.
5. Install boots on ring terminal ends of red
and black cables. Place ring terminals on
color coded contactor posts (red cable to red
post, black cable to black post). Install and
finger tighten nuts to retain ring terminals on
contactor posts. Do NOT tighten nuts or seat
boots at this time. Route red and black cables
to battery. Do NOT connect cables to battery at
this time.
6. Adjust cables to facilitate orderly and straight
routing of the cables from the contactor. Avoid
kinks or sharp bends in cables. Avoid crossing
cables over each other for at least the first 6"
(152mm) of cable starting from the contactor
post. Torque the contactor terminal nuts to 4.5
N-m or 45 lb-in. Seat boots over ring terminals
and posts.
7. Connect the winch remote switch wires to the
contactor's spade terminals following the color
codes on spade terminals and wires (green wire
to green spade connector, brown wire to brown
connector, etc.)
Black Terminal
(negative -) Blue Terminal
(negative -)
Red Terminal
(positive +)
Green Spade Connector
Brown Spade Connector
Black Spade Connector
Figure 17
8. Carefully inspect battery and winch electrical
cable routing. Is it neat and tidy? WARNING!
Always route and secure electrical cables
away from sharp edges, away from moving
parts and away from sources of heat. Zip tie
and secure electrical cables and wiring harness.
Zip ties should be snug, but not cutting into
wire insulation. Use electrical tape, pieces of
rubber hose or electrical conduit to protect
electrical cables and wire harness where
needed to avoid electrical cable insulation wear
or abrasion.
9. Attach battery cables, red (positive) cables
FIRST, black (negative) second. Install boots
as appropriate to protect connection. Torque
battery terminal fastener as directed by vehicle
service manual.
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14
Yellow
Terminal
(positive +)
Mounting
Bracket
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