Warn A2000 User Manual

1
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

Warn A2000 Specifications

General

Fairlead	Roller
Gear Train Type	Planetary
Rated Line Pull	2000 lbs
Remote Control	Hand-held remote
Motor Type	Permanent magnet

Summary

Getting Started with Warn Winches

Winch Model Identification

Identifies the model and part number of your winch for easier ordering of replacement parts.

Definitions and Winch Operation

Defines major structural components and explains winch operation for service and understanding.

Winch Disassembly and Reassembly

Service Technician Repairs

Manual is for WARN authorized service technicians; emphasizes correct tools, equipment, and following instructions.

Suggested Tools for Disassembly

Lists suggested tools for disassembly and assembly procedures, including wrenches, sockets, and pliers.

Disassembly and Reassembly Process

Details safety warnings and steps for disassembling and reassembling winch components.

Brake Removal and Replacement

Suggested Tools for Brake Service

Lists suggested tools for brake removal and installation procedures, including ring pliers and screwdrivers.

Brake Disassembly Steps

Outlines the steps and checks for disassembling the winch brake assembly to identify worn or broken parts.

Reassembly and New Brake Installation

Provides instructions for reassembling the brake assembly with proper greasing and component placement.