Wire Harness Installation Instructions Manual #90565 For Installing: #10144 Customizable Extreme Off-Road Harness 15 Circuit
Perfect Performance Products, LLC Painless Performance Products Division 2501 Ludelle Street Fort Worth, TX 76105-1036 800-423-9696 phone – 817-244-4024 fax Web Site: www.painlessperformance.com E-Mail: painless@painlessperformance.com If you have any questions concerning the installation of this harness or having trouble in general, 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 Friday, except holidays.
CAUTION: BEFORE THE REMOVAL OF YOUR ORIGINAL HARNESS AND/OR THE INSTALL OF YOUR NEW PAINLESS HARNESS, DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE NEGATIVE OR POSITIVE BATTERY CABLE FROM THE BATTERY.THE BATTERY IS NOT TO BE CONNECTED UNTILL THE PAINLESS HARNESS HAS BEEN INSTALLED AND TESTED. A full color copy of these instructions can be found at http://www.painlessperformance.com/InfoSearch/manuals.
Figures CONTENTS……………………………………………………………………………… FUSE BLOCK IN MOUNTING BRACKET………………………………………….. FUSE BLOCK COVER………………………………………………………………… FUSE BLOCK MOUNTED…………………………………………………………….. 5 7 7 8 ILLUSTRATIONS FUSE BLOCK ………………………………………………………………………….. 9 FUSE INPUTS………………………………………………………………………….. 10 CREATING SWITCHED 12V………………………………………………………….. 10 FUSE OUTPUTS……………………………………………………………………….. 11 RELAY INPUTS……………………………………………………………………..….. 12 RELAY 12V……………………………………………………………………..……….. 12 RELAY GROUNDS…….
INTRODUCTION The Extreme Off-Road Harness can be used to wire any non-street legal vehicle. Its 10 circuits and 4 relays will provide power to all critical and accessory components associated with your vehicle. Unlike other chassis harnesses provided by Painless, this harness only contains power Inputs and Outputs to and from the fuse block. With this harness fitting such a wide range of vehicles, these instructions will be general installation procedures.
SMALL PARTS The bagged parts, as well as the parts box, should provide you with everything you need in order to properly install the Painless Extreme Off-Road Harness. The smaller bag containing the large Maxi Fuse contains all the necessary parts to properly install an in-line fuse between the Alternator and the vehicle’s Battery.
contact with water or in a position which could be submerged in water during operation of the vehicle. Begin by installing the Fuse Block onto the Mounting bracket. The Fuse Block will slide into the bracket causing the legs to “wrap” around the Fuse block. Refer to the photo below and on the next page. Using the 4 Philips head screws, mount the fuse block to the mounting bracket. The Fuse Block cover can be mounted to the bracket by utilizing one of the Fuse Block Mounting Holes.
Using 2 of the ½” self tapping screws and the holes pre-drilled at the top of the Fuse Block mounting bracket secure the bracket to the vehicle. MAXI FUSE CAUTION: DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE NEGATIVE OR POSITIVE BATTERY CABLE FROM THE BATTERY. THE BATTERY IS NOT TO BE CONNECTED UNTILL THE PAINLESS HARNESS HAS BEEN INSTALLED AND TESTED. Begin by locating the MAXI FUSE component bag in the parts kit.
ROUTING Try to follow these basic guidelines during your install. Routing Guidelines Route the harness away from sharp edges, exhaust pipes, and hood, door, and windshield hinges. Inside edges provide protection from hazards and also provide places for tie wraps, clips and other support. Plan where harness supports will be located. Allow enough slack at places where movement could occur (body to frame, frame to engine, etc.). Use a support about every 12 inches.
Fuse Inputs The Fuse Input wires are solid color wires and are color coded to the Fuse Output wires. The 3 Fuse input wires are: PINK- ”FUSE 1-3 INPUT” ORANGE- “FUSE 4-6 INPUT” RED- “FUSE 7-10 INPUT” The power source these Input wires are connected to will determine if the Fuse Outputs will be switched 12v or battery constant. The splicing to connect each Fuse Input to the Fuse Block, seen to the left, comes pre-installed. The illustration below shows how to create switched 12 volt power.
Fuse Outputs The Fuse Output wires are all striped wires with the main color of the wire corresponding to the color found on the Fuse Input wire.
Relay Inputs The Relay Inputs are solid color wires like the Fuse Inputs. Also, like the Fuse Inputs, the color of the Relay Input wire determines the main color for the wires of the relay. The Relay Inputs are as followed: Yellow- “RELAY 1 INPUT” Blue- “RELAY 2 INPUT” Green- “RELAY 3 INPUT” White- “RELAY 4 INPUT” These Input wires will be connected to the Circuit breakers found in the parts bag. More on the Relay Input connections on page 16.
Relay Grounds The Relay Ground wires are Black striped wires. The Relay Ground wires are: Yellow/ Black- “RELAY 1 GROUND” Blue/ Black - “RELAY 2 GROUND” Green/ Black - “RELAY 3 GROUND” White/ Black - “RELAY 4 GROUND” The Relay ground wires provide a chassis ground source to the electromagnetic coil inside the relay which is used to switch, or activate, the relay. The Relay ground wire will connect to a good clean chassis ground or the negative side of the battery.
RELAY ACTIVATION METHODS 12 VOLT ACTIVATED RELAY A 12 volt activated relay is constantly grounded and will only send power out of the output side of the relay when 12 volts is applied to the relay, as the name implies. The 12 volt source can be wired directly to the relay or interrupted by a switch, as shown in the 12 VOLT SOURCE ACTIVATION drawing.
GROUND ACTIVATED RELAY A ground activated relay is just the opposite of the 12 volt activated relay, 12 volts (battery constant or switched) is supplied uninterrupted and the ground wire is switched. An example of this method is a thermostat operated fan relay. In this case however, a thermostatic switch would replace the switch in the drawing below. Like mentioned before, the ground activation method is best used when a component is operated by an unlit switch from the interior of the vehicle.
CHARGING SYSTEMS Being a “universal” style harness and with so many different charging systems from different auto manufacturers, Painless has only supplied the Output charge wire. This wire will be the larger rolled Red 6 gauge wire provided with the harness. This wire is printed “ALTERNATOR B+ TO BATTERY B+”. This wire will need to be connected to the B+ lug of the Alternator, by first installing the rubber boot and then crimping on the appropriate ring terminal.
TESTING THE SYSTEM Use a small (10 amp or less) battery charger to power up the vehicle for the first time to test the circuits. If there is a problem anywhere, the battery charger's low amperage and internal circuit breaker will provide circuit protection. Make sure the Negative Battery cable is connected to the frame or engine, and make sure there is a ground between the engine and frame, as well as the frame and the body. The Negative Battery cable should still be disconnected from the Battery.
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Painless Performance Limited Warranty and Return Policy Chassis harnesses, fuel injection harnesses and Striker ColdShot 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. Painless Performance will repair or replace defective products without charge during the first 12 months from the purchase date.
