Table of Contents
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SERVICE GUIDE
ATV and Utility Winches
A2000, A2500, T2500, U2500,
P2500, Z3500, Pull Pack
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
1
FOR THE
WARN
12V DC
Electric Winch
Warn Industries, Inc
12900 SE Capps Road
Clackamas, OR 97015 USA
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Table of Contents
Related Manuals for Warn U2500
Summarization of Contents
SECTION 1 - Getting Started
Winch Model Identification
Details on identifying winch model and part number for correct repair and parts ordering.
Definitions And Winch Operation
Explains major structural components and basic winch operation principles.
Winch Operation
Outlines the operational capacity and power flow for ATV and Utility winches.
SECTION 2 – Disassembly & Assembly
Service Technician Repairs
Emphasizes the manual's intended use by authorized technicians and the importance of proper tools.
Suggested Tools
Lists the necessary tools for disassembly and assembly procedures.
Disassembly
Provides safety warnings and essential steps before starting winch disassembly.
SECTION 3 - Brake Removal And Replacement For ATV & Utility Winches
Suggested Tools
Lists the recommended tools for brake removal and replacement procedures.
Brake Disassembly
Details the steps involved in disassembling the winch brake system.
Reassembly/ New Brake Installation
Guides through the process of reassembling the brake or installing a new brake assembly.
SECTION 4.0 - Control Pack Overview And Wiring Reference
Overview Of Control Operation
Explains the electrical operation of winch control systems, including dial, contactor, and solenoid types.
SECTION 5 – Winch Trouble Shooting Guide
Winch does not hold load
Identifies possible causes and corrective actions when the winch fails to hold a load.
Brake over heats and will not hold load.
Addresses issues related to brake overheating and loss of holding capability.
Difficulty in spooling wire rope OFF drum by hand.
Provides solutions for problems encountered when manually spooling wire rope off the drum.
Winch lacks power, pulls slowly, stalls or will not run at all.
Lists causes and fixes for a winch exhibiting low power or failure to operate.
Winch does not have the same pulling power as when it was new.
Explains why pulling power might decrease and how to address it.
When remote control switch is activated, only a "clicking sound" results and winch does not operate in either power-in or power-out mode.
Diagnoses issues causing a clicking sound without winch operation.
Electrical sparks appear around the motor or motor end housing.
Addresses the causes and solutions for electrical sparking near the motor.
When the remote control is activated, winch operates in only one direction.
Guides troubleshooting for winches operating in only one direction.
Dial switch will not function or operate winch
Solutions for when the dial switch fails to operate the winch.
Switch is burned
Identifies and resolves issues related to a burned switch.
Wire harness melted insulation
Addresses problems caused by melted wire harness insulation.
Wire rope is behind drum flange
Provides corrective actions for wire rope being improperly positioned behind the drum flange.
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