Warn A2000, Service Manual

Page 1: ...p 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...

Page 2: ...EMBLY 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 BRAK...

Page 3: ...vice 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 en...

Page 4: ...t 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...

Page 5: ...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 4...

Page 6: ...er 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 r...

Page 7: ...re 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 wr...

Page 8: ...rope or electrical tape to prevent flaring Remove motor with housing and drum support from the drum by removing the two 20x5 8 tie rod screws with the hex Allen wrench or Torque wrench If not replaci...

Page 9: ...ened 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...

Page 10: ...tor 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 br...

Page 11: ...shes in correct position Place cap on top of armature aligning index marks Drop bolts through cap holes matching up with the motor housing holes Flip unit over with weight of motor down Motor bolts wi...

Page 12: ...e the thrust washer in first with brake resting on it Replace mounting nuts flat side out Drum plate is placed on top of gear assembly with drum bushing rounded side out being placed with opening on e...

Page 13: ...ch 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 20x5...

Page 14: ...damage and gear must be replaced Check the teeth of the housing for mud sand or broken worn teeth Cam follower must be removed by prying out with screwdriver Cam follower must be removed to check all...

Page 15: ...greasing the drum sun gear Place drive shaft circle retaining ring up through all gears rotating the shaft forward and reverse to align all gears remove shaft and set aside Replace mounting nuts flat...

Page 16: ...winch into mounting Replace electrical wires to proper terminals snug only do not over tighten With winch in free spool pull out three feet of cable using hook strap Turn clutch to engage position tou...

Page 17: ...17 NOTES...

Page 18: ...it was designed Warn Industries does not offer individual replacement brake parts The complete brake assembly PN 22142 must be replaced Notice Long power out cycles under load can over heat the brake...

Page 19: ...sher Lift out the input gear and check for any fractures or breaks Remove spring by lifting out with flat blade screwdriver Check both tang ends of the spring for fractures or breaks Remove output gea...

Page 20: ...laced 3 3 Reassembly New Brake Installation To service brake clean residue and use HI TEMP Brake Slider Grease during reassembly Fill cavity of brake housing with grease Grease and replace output gear...

Page 21: ...g in put gear forwards backwards with hand restriction on planetary gears Verify thrust washer is inside motor housing and motor bolts do not extend inside motor housing cavity Re install brake to mot...

Page 22: ...and protect all Exposed wiring and electrical terminals Always install terminal boots as directed in installation instructions 4 1 Overview Of Control Operation 4 1 1 Dial Control Switch This switch...

Page 23: ...he control component Figures 4 2a b are the basic wiring diagram of the ATV winch contactor control pack Figure 4 2a Figure 4 2b 4 1 3 Solenoid Control Pack winch For the power in mode the green wire...

Page 24: ...or and connect to terminal 2 Motor terminal 1 will connect to short copper angle bracket Diode will connect to top solenoid grounding back to solenoid fastener attached with screw through plate and fa...

Page 25: ...Remote Control Plug And Wiring Schematic Inside wiring for the housing harness plug with notch of plug facing down Place wires in the back side of the plug Going clockwise green wire is opposite notc...

Page 26: ...working against the brake in the power in mode Remove all wire rope and respool in the proper direction See directional label on drum support b Load exceeds rating for winch Refer to Winch Operators...

Page 27: ...ot run at all a Ground cable is not directly attached to battery Attach ground cable to negative battery terminal b Loose connections on battery or motor terminals Be sure all connections are tight an...

Page 28: ...g Corrective Actions for problem 5 1 4 5 1 6 When remote control switch is activated only a clicking sound results and winch does not operate in either power in or power out mode a Faulty electrical g...

Page 29: ...ontrol pack is sticking or is damaged from prolonged use Replace solenoid or contactor d Also see Possible Causes and Corrective Actions for problem 5 1 4 5 1 9 Dial switch will not function or operat...

Page 30: ...30 The following Parts breakdown and parts lists are for current winch models Please refer to your WARN Winch Replacements Parts List for correct information specific to the winch being serviced...

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