TRAC Outdoor Vehicle Wiring Kit

TRAC 69140 Outdoor Vehicle Wiring Kit

The TRAC 69140 Vehicle Wiring Kit has everything you need to wire your vehicle for high-current (60 amp) 12v power. This 12v high current power connection can be used for trailer winch, portable winch and any other 12v device up to 60 amps.

Kit Includes:

• TRAC 12v high-current Quick-Connect system:
• 2 Quick-Connect plugs (one for rear of vehicle and one for trailer winch or any other 12v device)
• 1½” Round Hole Adaptor (for installation on flat panel – option 1)
• U-bracket (for installation on flat surface – option 2)
• 25’ Heavy 8-gauge AWG Tin-Plated Marine-Grade Positive (red) Battery Wire
• 5’ Heavy 8-gauge AWG Tin-Plated Marine-Grade Negative (black) Battery Wire
• Corrosion resistant self-tapping grounding bolt to attach negative wire to vehicle frame
• High-current 60 amp Manual Resetting Circuit Breaker
• Cable ties to secure wires to vehicle undercarriage.

How to Install TRAC 69140 Vehicle Wiring Kit

Installation for Battery End of Harness

• Route the red positive wire along or through your vehicle from the rear of the vehicle (or the position where you choose to locate the 12v receptacle) to the battery positive terminal.
• The black negative wire will be grounded to the vehicle frame near the 12v receptacle.
• Route and position the battery wires in a safe place and secure with cable ties (zip ties). The wires should not be touching any sharp metal edge or anything that might wear the insulation off the wiring.
• The circuit breaker should be installed as close to the battery positive (+) terminal as possible and no more than 12” (30.5 cm) away from the battery positive terminal. The circuit breaker should be secured to the firewall or other surface with screws.
  • NEVER install the circuit breaker on the negative wire. Only the positive wire can be used.
• Position the red battery positive ring termination at the battery positive (+) terminal and route the wire from the terminal to the gray end cap of the circuit breaker.
  • Add an extra couple pf inches or a loop of wire to provide a little extra wire for working on the system and in case a change of location is required.
• Cut the battery positive wire so there is enough wire to run from the battery positive post, making a loop and reaching one end of the circuit breaker.
  • It does not matter which end of the circuit breaker is used.
• After the battery positive wire is cut, strip ½ (12.7mm) of the plastic insulation away from each end of battery positive wire.
• Unscrew the grey end caps on the circuit breaker and place the end cap onto each piece of wire.
• Place the red grommet in each piece of wire. Use an Allen wrench to unscrew the set screw on the circuit breaker terminals. Insert the stripped wire into the circuit breaker terminal. Tighten the set screw.
• Slide the gray end cap up to the circuit breaker and screw on. The red grommet should fit well in the gray cap as it is screwed on. Tighten finger-tight only. The red grommet and an O-ring will seal the connection. Do this on both sides of the circuit breaker.
  • NOTE: Do not connect the positive wire to the battery yet.

Installation for Rear of Vehicle

• The wiring harness should now be routed along or through your vehicle from the battery position to the rear or your chosen location for the 12v receptacle.
• Choose the type of receptacle installation that is best for your application:
  • The round hole adaptor can be used for installations through a flat panel.
  • The U-bracket can be used to install the receptacle on the side of a flat surface.
  • The receptacle (or plug) can also be unattached if desired, but make sure it is secured and not able to touch the ground or be damaged in any way.
• The wiring harness positive and negative wires can be cut to length, but can also be coiled to the access wire and secured with cable ties (zip ties).
• • U-Bracket Installation
    • The bracket will fit overt the plug, fitting in a groove on the plug. Secure to a flat surface with screws provided.
  • Round Hole Adaptor Installation
    • Drill a 1.5” hole in the flat panel. On the back side of the panel, place the plug through the round hole adaptor nut (removed from adaptor).
    • Pass the plug through the 1.5” hole. The plug must be on the back side of the panel.
    • Remove the gray plug cap by unscrewing the stainless tether where it attaches to the plug.
    • The round hole adaptor has a small screw hole on one side. The plug has a threaded hole where the stainless tether was removed. Insert the plug into the back side of the adaptor so the threaded hole is on the same side as the small screw hole.
    • The plug will snap into the adaptor. Install the small screw through the adaptor and into the plug to secure it. Pass the adaptor into the 1.5” hole and thread the nut on the backside onto the adaptor. Hand tight is tight enough.
• Install the accessory plug on the winch or whatever device you wish to power by cutting the battery wires on the winch (or other device) and stripping ½” of plastic insulation from the end of the wires.
• Insert the wires into the butt splices making sure the wires are completely inserted in the metal part of the splice.
• Crimp the splices with crimping tool. Make sure wires are connected black-to-black and red-to-red.

Information sourced from TRAC Vehicle Wiring Kit Installation Instructions

California Residents: WARNING Cancer and Reproductive Harm - P65Warnings.ca.gov