Installation manual

6
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.
The ring terminals found in this bag will cover a wide range of wire diameters to help
connect all wires your individual installation may require to be connected to the Maxi
Fuse. For additional information on the Maxi Fuse and proper installation refer to page
8.
The larger bag contains circuit breakers for the relays, spare relays, and a
junction block to allow power distribution from the battery and maxi fuse to the fuse
block and circuit breakers. This bag also contains a fuse label for fuse identification, zip
ties, a rubber alternator boot, and heat shrink.
The parts box contains an assortment of fuses and terminals. Mounting
hardware for the junction block and circuit breakers are also located in the parts box.
TOOLS NEEDED
In addition to your regular hand tools, you will need, at least, the following tools:
 Crimping Tools*
 Wire Stripper
 Test Light or Volt Meter
 Small (10 amp or less) Battery Charger**
*We recommend that you use a quality crimper to avoid over crimping.
** see TESTING THE SYSTEM located on page 18.
FUSE BLOCK MOUNTING
Fuse Block mounting begins by locating all the necessary parts in the Painless kit
needed for proper Fuse Block Mounting. These parts are:
 Fuse Block Mounting Bracket
 4 Large Philips Head Screws
 2 of the ½” Self Tapping Screws
Begin by finding a suitable location to mount the fuse block. The location of the
Fuse Block must be easy to access, yet out of the way during operation of the vehicle.
Suitable locations for the fuse block can generally be found under the dash or on the
firewall.
The Fuse Block supplied with the Extreme Off-Road harness has a weather proof
seal; however, avoid mounting the Fuse Block where it may become in direct constant