Warn A2500 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 A2500 Specifications

General

Brand	Warn
Model	A2500
Category	Winches
Language	English

Summary

Getting Started

Winch Model Identification

Identify winch model and part number for accurate repair and parts ordering.

Winch Definitions and Operation

Defines key winch components and explains basic operational principles.

Disassembly and Assembly

Service Technician Repair Guidelines

Manual for authorized technicians, emphasizing proper tools and safety for repairs.

Recommended Tools for Disassembly

List of essential tools for performing winch disassembly and reassembly.

Winch Disassembly Procedure

Step-by-step instructions for safely taking apart winch components.

Brake System Service

Brake Service Tools

Tools recommended for removing and replacing the winch brake assembly.

Brake Disassembly Guide

Instructions for dismantling the winch brake system for inspection or replacement.

Brake Reassembly and Installation

Steps for correctly putting together and installing the winch brake.

Electrical Control Systems

Control System Overview

Explains winch electrical operation and types of control systems.

Dial Control Switch Wiring

Wiring diagram and instructions for the ATV winch dial control switch.

Contactor Control Pack Wiring

Wiring diagram for the ATV winch contactor control pack system.

Solenoid Control Pack Wiring

Wiring diagram for the ATV winch solenoid control pack system.

Pull Pak Solenoid Wiring

Wiring diagram for the ATV Pull Pak solenoid control pack.

3-Wire Remote Control Wiring

Wiring schematic for the 3-wire remote control plug and connections.

Winch Troubleshooting