Warn A2000 User manual

SERVICE GUIDE

FOR THE

WARN

ATV and Utility Winches

A2000, A2500, T2500, U2500,

P2500, Z3500, Pull Pack

12V DC

Electric Winch

REPAIR / REPLACEMENT INSTRUCTIONS

TROUBLE SHOOTING GUIDE

This guide has been provided for use by Warn Authorized Service Centers. Any other

use is prohibited.

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 emphasize general information worthy of special attention

Warn Industries, Inc

12900 SE Capps Road

Clackamas, OR 97015 USA

TABLE OF CONTENTS

SECTION 1 - GETTING STARTED--------------------------------3

1.1 WINCH MODEL IDENTIFICATION--------------------------------------------------------3

1.2 DEFINITIONS AND WINCH OPERATION------------------------------------------------4

SECTION 2 –DISASSEMBLY & REASSEMBLY--------------7

2.1 SERVICE TECHNICIAN REPAIRS ---------------------------------------------------------7

2.2 SUGGESTED TOOLS --------------------------------------------------------------------------7

2.3 DISASSEMBLY/REASSEMBLY-------------------------------------------------------------7

SECTION 3 –BRAKE REMOVAL AND REPLACEMENT--18

3.1 SUGGESTED TOOLS ------------------------------------------------------------------------ 18

3.2 DISASSEMBLY ------------------------------------------------------------------------------- 18

3.3 REASSEMBLY/ NEW BRAKE INSTALLATION -------------------------------------- 20

SECTION 4 –CONTROL PACK OVERVIEW AND WIRING

REFERENCE----------------------------------------------------------- 22

4.1 OVERVIEW OF CONTROL OPERATION---------------------------------------------- 21

SECTION 5 –WINCH TROUBLE SHOOTING--------------- 26

SECTION 1 - Getting Started

1.1Winch Model Identification

To ensure proper winch repair it is necessary to correctly identify the model and part number of

your winch. This makes ordering replacement parts easier, and helps you obtain the necessary

information from your Authorized Service Center. NOTE: For a part description, item

number and quantity, refer to the Replacement Parts List in this manual for your

specific winch model.

WINCH IDENTIFICATION: label is located on the clutch end housing; this information

covers the winch and the pull rating.

WINCH BUILD DATE: build date of the winch is located on the cable protectors, motor end or

clutch housing end. The date code, (ex.) 3201A- gives the week, year, 32nd week of 2001 line A.

Figure 1.1 Locations of Product Build Date

1.2 Definitions And Winch Operation

1.2.1 Definitions

Operation and service of a Warn planetary winch can be explained easier by defining a few major

structural components. Refer to Figure 1.2 for the following definitions:

MOTOR: The winch motor is a permanent magnet motor. A 12-volt DC battery powers the

electric motor.

DRUM: The winch drum is the structural component of the winch used to store wire rope and

to transmit torque from the winch motor and gears to the wire rope.

DRUM SUPPORT: Drum supports (covered by housing) are the structural components of the

winch that mount the winch to the vehicle. The drum rotates while being held by the drum

supports and both the motor and gear train are attached to a drum support.

GEAR TRAIN: Warn electric planetary winches consist of a gear train made up of three

planetary gear stages. The purpose of the gear train is to multiply motor torque and to reduce

motor speed transmitted to the drum. Warn gear trains are enclosed in a housing and are

lubricated with grease.

FREESPOOL CLUTCH: A freespool clutch is incorporated in the gear train to allow the user

to pull the wire rope off the drum to the anchor point where the hook will be attached, without

using the winch motor. This is referred to as "Free spooling".

Figure 1.2 Major Winch Components

Drum Support

Motor

Free spool Clutch

Drum w/ Wire Rope

Gear Train

MOTOR CONTROLS: The electric winch motor is controlled by a control pack (contactor),

ATV switch, or a rocker switch. The 12-volt battery power source feeds the electric cables that

are connected to these controllers. The main function is to allow the winch to function in both

directions.

POWER-IN and POWER-OUT - Terms used to describe winch operation. When the wire rope

is reeled in under motor power, it is being "powered in". When the wire rope is reeled out

under motor power it is being "powered out". (This is different than when the winch is

"freespooled out", which refers to the wire rope being pulled out by hand with the freespool

clutch disengaged.)

1.2.2 Winch Operation

The ATV winch is designed to pull loads in length to approx.48.5 ft. The Utility winch will

pull up to approx. 58.5ft.

(Refer to Figure 1.2 when reading the following section). The vehicle battery and charging

system generates the power for pulling the load.

Power feeds from the battery power source into the winch control pack. At the push of a

control switch the power flows to the winch motor.

Motor Cable (Yellow /#1)

Positive Battery Cable

Motor Cable (Blue/#2)

Control Pack Ground Cable

Remote Socket Wiring

Motor Cable (Blue/#2)

Positive Battery Cable

Motor Cable (Yellow/ #1)

Control Pack Ground Cable

The winch motor turns the electrical energy into mechanical energy. The motor shaft powers

the gears, which in turn pulls the load. For the winches with a brake, it will hold the load if

user must stop.

On power-in operation, the drive shaft rotates and drives the planetary gears, starting with the

gear carrier stage farthest from the winch drum (the first stage carrier.) The first stage carrier,

in turn, drives the second stage carrier, which then drives the third stage carrier. The third

stage directly drives the drum. Since the wire rope is connected to the drum, the rope winds

around the drum, causing the load to be drawn in.

On power-out operation, the motor is reversed and the winch drum is rotated in the opposite

direction. All winch components operate in the same manner as during power-in.

In stopped position, the switch activates the “dynamic braking” effect of the motor , resisting

additional turning of the wire rope drum.

NOTES:

SECTION 2 –Disassembly & Assembly

2.1 Service Technician Repairs

WARNING

Personal Injury

Failure to observe these instructions could lead to severe injury or death.

READ THIS BEFORE BEGINNING REPAIRS

This manual is intended for use by a WARN authorized service technician. It is

important that you make repairs with the proper tools and equipment. It is also

important to correctly follow the instructions. Failure to do so, may cause the winch

to fail.

2.2 Suggested Tools

The following tools are suggested for these procedures: Hex 3/16 Allen wrench,

Torque wrench, 1/2, 7/16, 3/8, and 5/16 sockets, 3/8 & 7/16 box end wrench, needle

nose pliers, and one flat blade screwdriver.

2.3 Disassembly

WARNING

Personal Injury

Failure to observe these instructions could lead to severe injury or death.

Never lean over battery while making connections

Always disconnect all wires from battery, before beginning work.

Always disconnect negative terminal first and reconnect negative terminal last.

Always remove jewelry and wear eye protection.

MOTOR REMOVAL:

Note the motor placement for correct

replacement before any removal, also

checking and marking any wires that

will be removed.

Repairs are easier and safer when

winch is removed from vehicle and

located on a workbench.

Secure wire rope with rope or electrical

tape to prevent flaring.

Remove motor with housing and drum

support from the drum by removing the

two ¼-20x5/8 tie rod screws with the hex

Allen wrench or Torque wrench.

If “not” replacing the armature, the

cap assembly must be taped to the

body of the motor case to prevent

springs pushing cap off and allowing

brushes to become dislodged.

Motor is removed from motor housing by

removing the two motor bolts located on

top of the motor cap.

At this time the cap assembly may be

removed, and checked for wear, corrosion,

and electrical terminals that may have

been damaged or over-tightened.

ARMATURE REMOVAL:

Placing shaft end on the bench and

pushing case down, pulling the armature

out at the top will remove the armature.

Check the armature for broken wires,

burned, or excessive wear on the

commutator.

If any of these problems are present the

armature must be replaced, also the case

must be cleaned with alcohol or similar

cleaner.

ARMATURE REPLACEMENT:

To replace the armature, it is slid in from

the bottom of the casing, which is

identified by the magnets closer to one end

of the case. If there is resistance to the

armature placement, it is the wrong

direction.

Inspect housing closely, as some motor

housings can be damaged by excessive

heat or damaged from a hit.

MOTOR REPLACEMENT:

Motor cannot be installed until the drum

support plate is removed and 1st stage

planetary gear with sun gear, or brake.

The two motor bolt nuts will be found

inside the housing.

Inspect housing, as some housings can be

damaged by excessive dirt/mud or

damaged from a hit.

Check that the brass bushing and thin

washer are in place, position the motor

shaft through the bushing and washer.

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