Warn Z3500 - 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

Summary

SECTION 1 - Getting Started

1.1 Winch Model Identification

Identifies winch model and part number for accurate ordering of replacement parts.

1.2 Definitions and Winch Operation

Explains major structural components, definitions, and operational principles of the winch.

SECTION 2 - Disassembly & Assembly

Service Technician Requirements, Tools, and Disassembly Overview

Covers technician requirements, suggested tools, safety warnings, and initial disassembly steps.

Motor Assembly Procedures

Details steps for motor removal, armature handling, and motor replacement procedures.

Clutch Housing Procedures

Details disassembly and reassembly steps for the winch clutch housing.

SECTION 3 - Brake Removal And Replacement

Suggested Tools and Brake Disassembly

Lists required tools and outlines steps for dismantling the winch brake system.

Brake Reassembly and Installation

Provides instructions for reassembling the brake and installing new components.

SECTION 4.0 - Control Pack Overview And Wiring Reference

Overview of Control Operation

Introduces different control pack types and their basic operation.

Contactor and Solenoid Control Wiring

Explains wiring diagrams for contactor and solenoid control packs.

SECTION 5 - Winch Trouble Shooting Guide

Load Holding and Spooling Issues

Diagnoses and resolves problems related to holding loads and wire rope spooling.

Power, Stalling, and Performance Issues

Addresses winches lacking power, stalling, or not running at all.

Operational and Wiring Faults

Troubleshoots issues like one-way operation, switch failures, and wire harness problems.

Warn Z3500 Specifications

General

Brand	Warn
Model	Z3500
Category	Winches
Language	English