Warn U2500 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 U2500 Specifications

General

Model	U2500
Finish	Black Powder Coat
Rated Line Pull	2500 lbs
Motor Power	1.1 hp (0.8 kW)
Rope	50 ft x 3/16 in
Fairlead	Roller
Recommended Battery	12V
Remote Control	Hand-held remote

Summary

SECTION 1 - GETTING STARTED

1.1 WINCH MODEL IDENTIFICATION

Identifies winch model and part number for accurate repairs and part ordering.

1.2 DEFINITIONS AND WINCH OPERATION

Defines major winch components and explains basic operation of Warn planetary winches.

SECTION 2 – DISASSEMBLY & REASSEMBLY

2.1 SERVICE TECHNICIAN REPAIRS

Guide for authorized technicians, stressing proper tools and instructions for safe and correct winch repairs.

2.2 SUGGESTED TOOLS

Lists essential tools recommended for performing winch disassembly and reassembly procedures.

2.3 DISASSEMBLY & REASSEMBLY

Comprehensive procedures for disassembling and reassembling winch components like motor, armature, clutch, and housing.

SECTION 3 - BRAKE REMOVAL AND REPLACEMENT

3.1 SUGGESTED TOOLS

Lists recommended tools for performing brake removal and replacement on the winch.

3.2 BRAKE DISASSEMBLY

Step-by-step instructions for safely disassembling the winch's mechanical brake assembly.

3.3 REASSEMBLY/ NEW BRAKE INSTALLATION

Procedures for reassembling or installing a new brake assembly, including greasing and component checks.

SECTION 4.0 - CONTROL PACK OVERVIEW AND WIRING REFERENCE

4.1 OVERVIEW OF CONTROL OPERATION

Explains winch control system operations, detailing dial, contactor, and solenoid types with wiring diagrams.

SECTION 5 - WINCH TROUBLE SHOOTING GUIDE