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SERVICE MANUAL
COMPRESSOR WINCH
• REPAIR / REPLACEMENT INSTRUCTIONS
• TROUBLE SHOOTING GUIDE
As you read these instructions, you will see NOTICES, CAUTIONS and
WARNINGS. Each message has a specific purpose. A NOTICE is additional
information to help you complete a procedure. CAUTIONS are safety messages
that indicate a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. A CAUTION may also be used to alert against unsafe
practice. WARNINGS are safety messages that indicate a potentially hazardous
situation, which, if not avoided could result in serious injury. CAUTIONS and
WARNINGS identify the hazard, indicate how to avoid the hazard, and advise of
the probable consequence of not avoiding the hazard. PLEASE WORK SAFELY!
1
FOR THE
WARN
POWERPLANT
HP & HD
12V DC
Warn Industries, Inc
12900 SE Capps Road
Clackamas, OR 97015 USA
REV A
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Table of Contents
Related Manuals for Warn POWERPLANT HD
Summarization of Contents
SECTION 1 - Getting Started
Winch Model Identification
Identify winch model and part number for accurate repair and parts ordering.
Definitions and Winch Operation
Explains key winch components like motor, drum, and gear train, and their functions.
PowerPlant Operation Modes
Details how the PowerPlant operates in both compressor and winch modes for various tasks.
Remote Control and Switches Overview
Describes the remote control functionality and the operation of winch and compressor switches.
Motor Temperature Protection
Explains the thermal indicator and cutoff mechanism that prevents motor damage from overheating.
Winch/Compressor Mode Selector Guide
Instructions for correctly rotating the mode selector knob for winching or compressor functions.
SECTION 2 – Disassembly & Assembly
Service Technician Repair Guidelines
Essential advice for service technicians undertaking winch repair procedures.
Suggested Tools for Service
Lists the recommended tools required for performing disassembly and assembly tasks.
Winch Disassembly Steps
Comprehensive, step-by-step instructions for dismantling the winch for maintenance.
Winch Reassembly Steps
Detailed, step-by-step instructions for reassembling the winch after service.
SECTION 3 - Brake Removal And Replacement
Tools for Brake Service
Identifies the specific tools needed for the safe removal and installation of the brake assembly.
Brake Assembly Disassembly
Steps for removing the brake assembly from the winch drum.
New Brake Assembly Installation
Guide on installing a new brake assembly and coupling it with the motor.
SECTION 4.0 - Electric Motor & Control Pack
Contactor Operation Overview
Explains the role and function of the heavy-duty contactor in the winch's electrical system.
Motor, Contactor, Brush Removal
Instructions for safely removing the electric motor, contactor, and motor brushes.
Motor and Contactor Replacement
Procedures for installing replacement electric motor and contactor components.
Motor Brush Replacement Guide
Detailed steps for replacing worn motor brushes to ensure proper motor function.
Electrical Circuit Testing Procedures
Comprehensive guide for testing various electrical circuits and components of the winch system.
SECTION 5 – Compressor Disassembly and Reassembly
Compressor Component Identification
Diagrams illustrating and labeling the key components of the compressor assembly.
Compressor Disassembly Guide
Step-by-step instructions for taking apart the compressor unit for service.
Compressor Reassembly Guide
Procedures for correctly reassembling the compressor unit after maintenance.
SECTION 6 - Winch Trouble Shooting Guide
Winch Mode Troubleshooting
Diagnosing and resolving common issues encountered when the winch operates in Winch Mode.
Compressor Mode Troubleshooting
Diagnosing and resolving common issues encountered when the compressor operates in Compressor Mode.
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