SERVICE MANUAL MIL-9000 and MIL-12000
Contents
1. 127 INDUSTRIAL SERVICE MANUAL FOR THE MIL 9000 and MIL 12000 ELECTRIC WINCHES e COMPLETE REBUILD INSTRUCTIONS TROUBLESHOOTING GUIDE William Carpenter Warn Detroit Technical Center Livonia 734 953 9870 X 7102 P N 31303 REV BO TABLE OF CONTENTS SECTION T GETTING TED 3 1 1 WINCH MODEL IDENTIFICATION 3 1 2 DEFINITIONS AND WINCH 4 SECTION 2 DISASSEMBLY AND ASSEMBLY 6 2 GEAR TRAIN We Ole te eben ead 6 22 HLECTRIC MOTOR REPAIR 10 2 35 CONTROL PACK REPAIR 14 24 BRAKE REPAIR 16 SECTION 3 TROUBLESHOOTING GUIDE end ended 21 SECTION 4 APPENDIX OPTIONAL 0 222 221 27 4 1 MECHANICALREMOTE CLUTCH 27 4 2 WIRE ROPE TENSIONER e EE leh eh A EnS 29 CAUTION ALTHOUGH THIS MANUAL IS FOR THE WINCH OWNER SOME REPAIRS SHOULD BE DONE BY A WARN INDUSTRIAL AUTHORIZED SERVICE TECHNICIAN YOU MAY NEED SPECIALIZED TOOLS THAT MAY NOT BE READILY AVAILABLE TO THE OWNER WE HIGHLY RECOMMEND THAT YOU DO NOT ATTEMPT REPAIR OF YOUR WINCH WITHOUT THE PROPER TOOLS AND EQUIPMENT FAILURE TO CORRECTLY FOLLOW THESE INSTRUCTIONS MAY CAUSE WINCH FAILURE RESULTING IN SERIOUS BODILY INJURY O2. Install two clamps on motor Figure 2 11 Install control on motor Connect leads to terminals and secure with three nuts Figure 2 10 Secure control to motor with two clamps NOTE Lead 1 must be positioned to align with opening in cover 14 15 16 17 18 Connect lead 2 to motor and secure with lockwasher and cap screw Figure 2 9 Connect lead 1 to control and secure with nut Coat motor end of winch up to motor end drum support with plastic sealing compound Figure 2 8 NOTE Coating is generally applied by hand with a brush for service Contact Warn Industrial for coating specifications Install motor control cover on control and secure with three screws Secure lead 1 and 2 to drum supports with two clamps and screws if winch is equipped with this arrangement Figure 2 8 13 2 3 CONTROL PACK REPAIR 2 3 1 DISASSEMBLY AND ASSEMBLY NOTE REMOVAL AND REASSEMBLY OF THE CONTROL PACK ARE SHOWN IN SECTIONS 2 2 1 AND 2 2 2 Control Pack repairs are not recommended If the control assembly is defective replace it The following information is provided to the technician for diagnostic purposes only Refer to Figure 2 14 RED TO MOTOR FIELD NO 2 BLACK TO MOTOR FIELD NO 1 BLACK MOTOR ARMATURE TO MOTOR THERMAL GREEN PROTECTION SWITCH A 2 2 1 _ 6 4 3 RED LEAD OF ECL GREEN LEAD OF ECL WHITE LEAD OF RE
3. assembly later Repairs to the winch are easier and safer when it is removed from the vehicle and located on a work bench Remove two cable clamps that may connect electrical cables to your winch 2 Stand the winch on the gear housing end Figure 2 1 NOTE Plastic sealing material may have to be peeled off to access parts on the motor end of the winch Mark the three tie rod locations for easier re assembly Remove the motor end and drum by removing the three 3 8 inch tie rod bolts on the motor end If your winch is equipped with a wire rope tensioner see Appendix 4 2 for removal and re assembly SS ROD 22 24 HEX SHAFT Figure 2 1 Figure 2 2 3 Set the gear train back down in a horizontal position and remove the other three tie rod bolts and tie rods Figure 2 2 A clamp or pliers may have to be attached to the tie rods to remove the bolts Remove the hex drive shaft 4 Rotate the gear train so that the ten socket head cap screws are facing up Figure 2 3 Remove the ten cap screws Mark the housing ring gear and drum support with a marking pen in one location so they can be easily re aligned during ass
4. center hole with grease Insert loose sun gear into the first stage Figure 2 4 Fill the spaces between the teeth of the clutch ring gear with grease Figure 2 6 Place a gasket on top of the large ring gear Using a very thin screwdriver hold clutch detent pin in place while turning gear housing over onto the gears Line up marks previously made Figure 2 3 Slowly rock and rotate the gear housing until it drops down tightly on the ring gear Install ten socket head cap screws into the gear housing flange Torque to 100 120 in lb Re install the winch tie rods in the previously marked positions on the motor end and finger tighten bolts Figure 2 2 10 11 Install hex drive shaft into center of gear train With the clutch lever in the engaged position rotate the shaft several times to make sure the gears move freely Figure 2 2 Set drum into seal and bushing Insert hex drive shaft and motor coupler into drum and into engagement with coupler Figure 2 1 Install three motor end cap screws into tie rods Torque all six cap screws to 18 22 ft Ib Figure 2 1 Re attach any electrical cables to the winch that may have been removed during disassembly 2 2 ELECTRIC MOTOR REPAIR NOTE MIL 9000 and 12000 winches have electric motors and control packs sealed in a plastic material during factory assembly Repair of motors and control packs may be quite difficult due to the presence of the sealer Removal of the sealer from electr
5. directly to the motor housing The vehicle battery is inadequate in size terminals are corroded is defective or worn out or is not fully charged Loose cable connections on battery or motor terminals The solenoid mounting plate is not attached to the winch motor or the winch mounting plate and therefore is not electrically grounded or is improperly grounded There is a short circuit in the power supply to the winch The remote control switch or cord is damaged or defective CORRECTIVE ACTION A B C D E Attach the ground cable to the threaded hole in the motor housing not to a terminal Use a fully charged conventional automotive battery with a minimum of 650 cold cranking amps rating to obtain peak performance from your winch Make sure terminals are clean and the battery is fully charged Replace battery if necessary Be sure all connections are clean and tight Attach the solenoid mounting plate to the winch motor the winch motor plate or any other location grounded to the same electrical source as the winch Check all battery and motor cable leads for loose connections worn or cracked insulation frays or any bare spots Replace cable if necessary 23 F Check the remote control switch for continuity Using a multimeter on the OHMS setting touch the test probes between two of the three terminals on the remote plug while holding down the remote control switch At least two of the terminals sho
6. of 50 feet under high loads the brake has overheated and needs a cool down cycle of approximately 30 minutes 21 CORRECTIVE ACTION A B C The wire rope must always spool onto the drum as indicated by the drum rotation label on the winch Winches are equipped with an automatic brake and WILL NOT FUNCTION if the wire rope spools in the opposite direction The wire rope spooling can accidentally be reversed by running the wire rope all the way out and re spooling in with the control switch in the power out mode Refer to the operators manual for the correct line pull rating for your winch DO NOT EXCEED THE LINE PULL RATING SHOWN ON THE IDENTIFICATION LABEL These winches are rated for intermittent duty operation only As the load is increased the duration of power out cycles must be reduced to limit the brake temperature Allow adequate time for the brake to cool between uses when performing extended power out cycles PROBLEM 3 1 3 It is difficult to spool the wire rope off the drum by hand POSSIBLE CAUSE A Bent drum flanges B Drum bushings are worn Free spool clutch is damaged inside the gear train D Wire rope is bound up on the drum E Winch is not mounted correctly causing the drum to bind CORRECTIVE ACTION A Rotate the drum while it is still on the winch to see if the drum flanges appear to be bent B C D If flanges appear to be bent the drum will have to be removed and repaired Refer
7. pulling a load won t pull load or stalls easily POSSIBLE CAUSE 24 See CAUSES for PROBLEM 3 1 5 B Check the wire rope If it is spooling onto the drum in the wrong direction it will be working against the automatic brake C Winch is mounted incorrectly causing the gear train to bind CORRECTIVE ACTION A See CORRECTIVE ACTION for PROBLEM 3 1 5 B Remove all the wire rope and respool onto the drum in the proper direction NOTE Be sure to follow the drum rotation decal sure mounting surface is flat within 020 inch Use shim stock if necessary Be sure all mounting bolts are tight PROBLEM 3 1 8 Electrical sparks appear around the motor adapter or screw heads POSSIBLE CAUSE A See CAUSES for PROBLEMS 3 1 4 and 3 1 5 B Electrical ground is not sufficient Ground wire was not installed or the battery ground wires and wire terminals are corroded CORRECTIVE ACTION A See CORRECTIVE ACTION for PROBLEMS 3 1 4 and 3 1 5 B Install a ground wire to the motor housing and attach to the negative terminal of the battery PROBLEM 3 1 9 When the remote control is activated the winch will operate only in one direction POSSIBLE CAUSE A One of the solenoids in the control pack is sticking is damaged from prolonged use B Remote control switch is damaged If winch only operates in power in direction ECL or thermal switch may have tripped CORRECTIVE ACTION 25 Replace the control
8. should operate in both directions If not continue with more trouble shooting steps D THERMAL SWITCH The motor will not run if the thermal switch is open or if its terminals are in contact with the motor case The switch should normally open when the temperature at the motor brushes reaches 400 F To check a faulting or shorting switch use an ohm meter and measure the resistance of the thermal switch between the wire cut in the previous step and the socket pin 472 of the plug which is connected to the green wire If the butt splice and switch are good the resistance should be less than 1Q across the switch If the switch is open at room temperature then it should be replaced Next check the resistance between the cut wire and the bare motor case This resistance should be greater than 1 megaohm If not the switch may be installed incorrectly and be shorting to the motor case 16 SOLENOIDS To check for bad solenoids disconnect the three cables connected to the motor on studs marked F1 F2 and A Also disconnect the red battery cable to keep the motor cables from shorting during this test Measure resistance across large studs of solenoid 1 and see if the solenoid closes 1 resistance drops when 24 vdc is supplied to the small terminal of solenoid 1 that has the wire lead attached Apply voltage to the same small stud and check the resistance change across 4 solenoid Similarly measure resistance across large studs of solen
9. the drum and remove the drum from the winch as described in Gear Train Disassembly Section 2 1 1 ii Set drum on solid working surface table bench etc Remove spacer and brake driver Figure 2 19 iv Loosen but do no remove the socket head setscrew from the center of the drum just enough so brake assembly will slide out of the motor end of the drum Figure 2 19 If assembly refuses to slide it may be necessary to insert a hex key in the shaft and tap it until assembly is dislodged NOTE Ball bearing supporting gear train end of brake assembly should be checked and replaced if necessary Figure 2 19 2 4 2 ASSEMBLY a If the winch has a hex drive shaft on the motor end 1 Slide the crush ring into the drum all the way down until it stops against the splined end wire rope retainer Figure 2 18 18 PRESS RAM PRESS RAM FIXTURE PIECE SPLINED END OF DRUM STEEL BAR BRAKE ASSEMBLY 222222222 A D CRUSH RING RUM BRAKE ASSEMBLY DRUM 1 CRUSH RING PRESS TABLE SY a Figure 2 17 Figure 2 18 2 Using a 2 3 ton press and the fixture piece provided press the brake into the crush ring until it stops against the wire rope retainer in the drum NOTE The fixture piece must be used and must be over the crush ring complete
10. the motor and gear train ends of the drive shaft it engages enough to make the load and motor run at the same speed again Since the motor continues to power out the load once again tries to overspeed the motor Again the brake engages enough to control the load This process continues repeatedly throughout the power out but at a speed so fast that it can not be detected as a stop start stop process When the remote control switch is released the brake engages and completely stops the load The Mil 9000 and Mil 12000 winches are equipped with a patented Warn Industrial Electronic Current Limiter ECL a device designed to protect the winch in case of overload The ECL monitors the electrical current input to the winch motor when powering in a load If the power in current to the winch motor exceeds a factory preset value its trip point corresponding to the winch rated load on the first layer the ECL will switch the winch motor off To reset the ECL after it trips the winch cable must be powered out for at least 1 1 2 seconds This will release the overload condition and winch operation can be resumed at a lower load SECTION 2 DISASSEMBLY AND ASSEMBLY Refer to the Replacement Parts List for your specific winch part number in the winch Operators Manual 2 1 GEAR TRAIN REPAIR 211 DISASSEMBLY 1 Disconnect winch battery cables at the vehicle battery before beginning any work the winch Mark cable connections for easier
11. to the Section 2 1 1 of this manual for drum removal To prevent the drum flanges from being bent read the Operators Manual for proper operating instructions Remove the drum from the winch Inspect the drum bushings and drum supports for wear Replace if necessary Refer to Section 2 1 1 of this manual for drum removal and inspection Remove and inspect clutch ring gear clutch lever and gear housing for burrs and rub marks Remove burrs with a file or grinding wheel or replace parts if necessary Refer to Section 2 1 1 of this manual for gear train disassembly Should the wire rope become bound onto the drum connect the hook to a load then by alternately powering in then powering out the wire rope will usually work itself free 22 In any event DO PUT YOUR HANDS ANYWHERE NEAR THE WIRE ROPE WHEN WORKING A BIND FREE Refer to the Operators Manual for proper operating instructions NOTE A roller fairlead and or wire rope tensioner will usually help prevent the wire rope from being bound onto the drum Correctly mount the winch Follow the mounting specifications as described in the Operators Manual Use shims if necessary to mount winch correctly CAUTION DISCONNECT THE CABLE AT THE POSITIVE BATTERY TERMINAL BEFORE ATTEMPTING ANY TROUBLESHOOTING OR REPAIRS PROBLEM 3 1 4 Winch lacks power or will not run at all POSSIBLE CAUSE A B C D F The ground cable is not attached
12. 2 Re install tension plate on tie rod previously marked 3 winch Torque tie rod bolts to 18 22 lb ft 4 Re install springs after attaching wire rope to the drum Use of a locking pliers with smooth jaws may be required to re install springs 29
13. 2 19 20 SECTION 3 TROUBLESHOOTING GUIDE PROBLEM 3 1 1 Winch does not hold the load POSSIBLE CAUSE A B C Brake inside winch drum is badly worn or broken Load exceeds rating for winch The wire rope is on the drum backwards CORRECTIVE ACTION A Replace the brake NOTE Warn Industrial does not offer replacement brake parts The complete assembly must be replaced Refer to the appropriate chapter in this manual for winch brake replacement Refer to the winch Operators Manual for proper operating instructions for the winch brake WARNING REPLACEMENT OR SERVICE OF THE BRAKE ASSEMBLY MUST BE DONE PROPERLY OR MALFUNCTION OF THE BRAKE MAY RESULT IN SERIOUS INJURY OR PROPERTY DAMAGE IF YOU HAVE ANY QUESTIONS PLEASE REFER TO THE BRAKE REPLACEMENT CHAPTER IN THIS MANUAL OR CALL THE FACTORY FOR ASSISTANCE B C Refer to the operators manual for the correct line pull rating for your winch DO NOT EXCEED THE LINE PULL RATING SHOWN ON THE IDENTIFICATION LABEL Remove all the wire rope and respool in the proper direction see directional label on drum support PROBLEM 3 1 2 Brake overheats and will not hold the load POSSIBLE CAUSE A B C The wire rope is spooled onto the drum in the wrong direction Therefore the winch is working against the brake in the power in mode Load exceeds rating for winch After a very long power out cycle in excess
14. MOTE BROWN LEAD OF ECL SWITCH REMOTE PLUG TO POSITIVE CONFIGURATION VARIES TERMINAL OF BATTERY Figure 2 14 Electrical operation of the winch control assembly consists of four heavy duty solenoids and a thermal switch located on the motor armature brush holder and an ECL Electronic Current Limiter located in the control assembly The thermal switch and the ECL are in the power in circuit When either one trips the power in circuit is opened and power in is discontinued until they reset The ECL must be reset by operating the motor in the power out mode The thermal switch is reset only by allowing the winch motor to cool adequately about 30 minutes Solenoids number 1 and 3 control current flow through the field windings and solenoids number 2 and 4 supply current to the motor armature through the thermal switch In the power out mode Figure 2 15 solenoids number 2 and 3 are energized by the remote control switch Current flows from the positive battery terminal through solenoid number 3 then through the red motor cable to the number 2 field winding to the control assembly through the black motor cable From the black motor cable current then flows through solenoid number 2 to the motor armature to ground 14 In the power in mode Figure 2 16 solenoids number 1 and 4 are energized Current again flows from the battery positive cable but this time current flows through solenoid number 1 then through the ECL t
15. R PROPERTY DAMAGE SECTION 1 GETTING STARTED 1 1 WINCH MODEL IDENTIFICATION To ensure proper winch repair it is necessary to correctly identify the model and part number of your winch This will make it easier to order replacement parts and help you obtain the proper information you need from your Authorized Service Center m WINCH NAMEPLATE LABEL y WINCH PART NUMBER LO Ww oO AO LENN 2 C WINCH DATE CODE WINCH SERIAL NUMBER Figure 1 1 See Figure 1 1 for Locations Winch Nameplate Label identifies model designation Winch Part Number identifies winch configuration Winch Date Code identifies when it was manufactured Winch Serial Number individually identifies winch 1 2 DEFINITIONS AND WINCH OPERATION 1 21 DEFINITIONS Operation and service of a Warn Industrial planetary winch can be explained easier by defining a few major structural components Refer to Figure 1 2 for the following definitions Motor The winch is driven on one end by a two direction electric motor generally run by 12 or 24 volts DC The motor is internally protected by a thermal switch that is activated when the motor gets too hot to operate efficiently The motor
16. connections and use a volt meter to verify 24 2 VDC at the bus bar connecting solenoids 1 and 3 See referenced figure Connect meter leads as follows black to ground and red to hot bus bar The black insulating coating put on some winches can sometimes contaminate electrical terminations and may need to be scraped off of contact surfaces POWER SUPPLY 24 2 VDC CURRENT AVAILABLE 100 AMPS MINIMUM FOR TEST 200 AMPS MINIMUM FOR OPERATION B GROUNDING Solenoid mounting plate should be grounded to the motor by means of a band clamp New winches also have a ground wire connecting the mounting plate with the motor ground bolt Use an ohm meter to measure resistance between mounting plate and motor case resistance should be less than 1Q C ECL The ECL electronic current limiter can be tripped when first powered so always reset by powering out the wire rope for 2 seconds to reset the limiter If the winch will power out but will not power in the ECL may be defective First check that the red wire coming from the 24 VDC charged bus bar is connected properly and that the mounting L bracket of the ECL circuit board is cleanly grounded to the solenoid plate If still no power in by pass the ECL as follows cut the wire coming from the thermal switch to the ECL near the splice on the ECL side Take the cut wire coming from the thermal switch and connect it to solenoid 4 on the same terminal that the green ECL wire is attached The winch
17. embly Remove the housing and ring gear 6 SUN GEAR FIRST STAGE SECOND STAGE THIRD STAGE SOCKET HEAD CAPSCREWS THIRD STAGE RING GEAR GEAR HOUSING GASKET GASKET MARK LINE WITH PEN MARK LINE gt WITH PEN RING GEAR DRUM SUPPORT Figure 2 3 Figure 2 4 5 Remove the three stages of planetary gears from the drum support Figure 2 4 Also remove the loose first stage sun gear 6 Remove the split plastic drum bushing and carefully pry out the drum shaft seal Figure 2 5 DRUM SUPPORT Figure 2 5 21 2 ASSEMBLY Press a new seal into the drum support Figure 2 5 Install the split plastic drum bushing With the drum support seal facing down place a gasket over the ten tapped holes and then the large ring gear on top of it Figure 2 4 Align the markings previously made during disassembly Figure 2 3 Using a grade of moly disulfide grease with good performance between 50 F 125 F Aeroshell 17 is recommended coat the inside of the ring gear teeth until all of the spaces between the teeth are filled Install the third stage carrier center spline down Figure 2 4 Completely fill the center hole in the third stage carrier between the planet gears and up to the top of the carrier plate with grease Insert the second stage carrier into the third stage Fill the second stage carrier hole with grease Insert first stage carrier Fill first stage
18. ical terminals and hardware with a needle nose pliers or other sharp instrument will be necessary to perform repairs or replacement of parts 2 21 DISASSEMBLY NOTE Tag cable and wire leads for assembly 1 Remove two screws clamps and leads 1 and 2 from motor end and gear end drum supports if winch is equipped with this wire routing arrangement Figure 2 8 REMOVE SCREWS CONTROL PACK CABLE LEADS AND CLAMPS JEE 95 96 SE SSS rai h T 55 SCREW GEAR END ps MOTOR END DRUM SUPPORT DRUM SUPPORT Figure 2 8 2 Remove three screws and plastic control cover from motor control pack 3 Remove nut and lead from control Figure 2 9 4 Remove cap screw lockwasher and lead 2 from motor 5 Remove three nuts and control leads from motor Disconnect leads Figure 2 10 DRUM SUPPORT CONTROL MOTOR Figure 2 9 Figure 2 10 6 Loosen two clamps some winches have only one clamp and remove control from motor Figure 2 11 10 DRUM SUPPORT GASKET CLAMP P moa SOCKET HEAD CAPSCREWS Figure 2 11 7 Remove clamps from motor Mark the motor motor adapter and drum support with a marking pen in one location so they can be easily re aligned during assembly 8 Place winch on end with m
19. is most often powered by a vehicle battery Motor Controls Winch motor controls consist of a control pack also referred to as a solenoid pack most often mounted to the motor and a remote control handle connected to the control pack with a cord The winch motor power source cables are connected to the control pack which in turn feeds power to the winch motor through electrical cable connections The main function of the control pack is to allow the operator to switch the winch on and off in both directions The winch control pack may also include an Electronic Current Limiter ECL to limit the pulling load of the winch Drum The winch drum is the structural component of the winch used to store wire rope and to transmit torque from the winch motor and gears to the wire rope MOTOR CONTROL PACK BRAKE ASSEMBLY Sol 6 ae O FREESPOOL 22 8 CLUTCH il See bi 1 1 MOTOR DRUM GEAR TRAIN DRUM SUPPORT DRUM SUPPORT Figure 1 2 Drum Supports Drum supports are the structural components of the winch that mount the winch to the vehicle The drum rotates while being held by the drum supports and both the motor and gear train are attached to a dru
20. led Figure 4 1 Re install the detent spacer spring and ball in housing Follow step 3 of Section 2 1 2 Re install the splined lever to the clutch shaft Be sure to line up the marks made during disassembly Rotate the clutch ring gear by hand and check engaged and disengaged positions of the splined lever The lever should rotate 135 from engaged to disengaged positions If it rotates less than 135 the shaft is incorrectly installed Pull back the ball spring and detent spacer and rotate the clutch shaft 180 Re align the splined lever and re install ball spring and detent spacer Recheck for 135 rotation Continue with steps 4 14 of Section 2 1 2 28 4 2 WIRE ROPE TENSIONER If your winch is equipped with a wire rope tensioner use this section for removal and installation 4 21 DISASSEMBLY 1 Mark the tie rod on which the tension plate pivots and the tie rod the spring anchors are attached to This will aid re assembly Figure 4 2 2 Unhook the springs from the tensioner Use of a locking pliers with smooth jaws may be required to remove springs 3 Follow step 2 of Section 2 1 1 Then remove the tension plate 4 Remove spring anchors from the other tie rod TENSION PLATE TIE ROD SPRING Figure 4 2 4 2 2 ASSEMBLY 1 the spring anchors on previously marked tie rod NOTE Anchors must be on the outboard side of the drum support or tensioner will not function properly Figure 4 2
21. led out by hand with the freespool clutch disengaged 1 2 2 WINCH OPERATION A Warn Industrial electric winch is a compact device used to pull large loads over long distances Refer to Figure 1 2 when reading the following section The power for pulling is generated in the vehicle battery and charging system Power is fed from the vehicle into the winch control pack At the push of a remote control switch from the operator the power then proceeds from the control pack into the winch motor The winch motor turns the electrical energy into mechanical torque The motor shaft turns the drive coupling and hex drive shaft which in turn drives the brake On power in operation the brake simply rotates and drives the planetary gears starting with the gear carrier stage furthest from the winch drum first stage carrier The first stage carrier in turn drives the second stage which in turn drives the third stage The third stage is directly coupled to the drum and drives the drum Since the wire rope is connected to the drum it winds around the drum as the drum turns causing the load to move On power out operation the motor is reversed and the wire rope moves in the opposite direction All the winch components operate in the same manner as when powered in except the brake During power out operation the load tries to overspeed the motor make the motor turn faster than it would under its own power When the brake senses a difference in speed between
22. ly Figure 2 18 3 hex drive shafts and winch as in section 2 1 b If the winch has no input hex shaft on the motor end 1 Slide the new brake assembly into the drum IMPORTANT The brake assembly must be completely seated in the drum the distance from the end of the drum to the end of the assembly inside the drum must be no less than 1 9 16 Tighten the socket head set screw in the center of the drum Torque to 120 130 in lbs iii Install the drum assembly into the gear train end of the winch insuring that the hex drive shaft extending from the gear train aligns with the brake hex on the brake assembly iv Install the brake driver and spacer on the other end of the opposite end of the brake assembly v Install the motor and drum support assembly aligning the motor shaft to the brake driver vi Reinstall drum into winch and reattach wire rope IMPORTANT All brakes used in the Mil 9000 and 12000 electric winches operate in one direction ONLY The wire MUST be installed the proper direction to insure proper brake operation 19 7 BRAKE DRIVER ye DISK BRAKE ASSEMBLY SETSCREW NOTE DU NOT REMOVE SETSCREW BACK 1 2 TURNS ONLY TO REMOVE BRAKE ma TOLERANCE RING BEARING Figure
23. m support Gear Train Warn Industrial electric planetary winches consist of a gear train made up of three planetary gear stages The gear ratios range from 156 1 to 315 1 The purpose of the gear train is to multiply motor torque and to reduce motor speed transmitted to the drum Warn Industrial gear trains are enclosed in a housing and are lubricated with grease Freespool Clutch A freespool clutch is included in the gear train to allow the user to pull the wire rope out to the point where the hook will be attached without using the winch motor This feature is essential for speeding up the time it takes to hook up and make a pull e Brake planetary winches are equipped with an automatic brake When the wire is reeled in the brake is not activated When reeling out under load however the brake slows the winch drum to an acceptable speed and holds the load when the winch is shut off The brake is usually located inside the winch drum and dissipates heat through the drum and wire rope The brake requires that the wire rope be wound onto the drum in the correct direction to operate properly Power and Power Out Terms used to describe winch operation When the wire rope is reeled in under motor power it is being powered in When the wire rope is reeled out under motor power generally under load it is being powered out this is different than when the winch is freespooled out which refers to the wire rope being pul
24. o the black motor cable to field winding number 1 Current then flows through field winding number 2 to the red motor cable to the control assembly Current flowing in the reverse direction through the field windings cause the motor to turn in the opposite direction From the red motor cable current then flows through solenoid number 4 to the black cable going to the motor armature to ground RED MOTOR FIELD NO 2 FROM MOTOR FIELD NO 2 BLACK FROM MOTOR FIELD NO 1 1 p BLACK TO MOTOR FIELD NO 1 i ot p BLACK TO MOTOR ARMATURE BLACK TO MOTOR ARMATURE Ww WE NE 55 SSS WE WSS SS 55555 WK WN 555 SSS WS NN BSS WE 55555 SS NIN h A a FA 1 IRZ 524 Nai mi 2 Loy Ce POWER OUT _ E POWER IN SOLENOIDS 2 AND 3 SOLENOIDS 1 AND 4 TOPOSITIVE SWITCH ENERGIZED TO POSITIVE x SWITCH ENERGIZED TERMINAL OF BATTERY TERMINAL OF BATTERY Figure 2 15 Figure 2 16 15 2 3 2 DETERMINING THE DEFECTIVE ELECTRICAL COMPONENT Refer to drawing 982624 for illustration and schematic CAUTION DISCONNECT THE CABLE AT THE POSITIVE BATTERY TERMINAL BEFORE ATTEMPTING ANY TROUBLESHOOTING OR REPAIRS A POWER SUPPLY Check for tight fit of all
25. oid 2 while applying 24 vdc to the small terminal of solenoid 2 that has the wire lead attached Measure the resistance change across the 3 studs when applying 24vdc to same 2 small stud If the resistance across the solenoid does not go from open to closed megaohms to tenths then the solenoid 15 bad D MOTOR If the motor is suspected to be failing check these While the motor is disconnected from the control pack measure the resistance between F1 and F2 and between A and ground Resistance should be less than 19 The motor brushes could be worn and should be replaced the internal wiring could be burned and the motor should be replaced 17 2 4 BRAKE REPAIR NOTE Warn Industrial does not offer replacement brake parts The complete brake assembly must be replaced There were two distinct models of brakes installed in Mil 9000 and 12000 winches at different times Refer to the winch to determine the type used 2 41 DISASSEMBLY 1 Remove the drum from the winch as in the Gear Train Disassembly Section 2 1 1 2 If the winch has a hex drive shaft on the motor end Place the drum in a 2 3 ton press Insert a 6 8 inch long piece of steel bar into the splined end Press on the bar with the press until the brake assembly drops to the bottom of the drum Remove brake and crush ring from drum crush ring may be up against the splined drum end b If the winch has no input hex shaft on the motor end 1 Remove all the wire rope from
26. otor end up and remove ten socket head screws from motor end drum support 9 Remove motor and gasket from drum support assembly Figure 2 12 SPACER MOTOR HOUSING ELECTRIC THERMAL SWITCH LEADS GASKET ELECTRIC THERMAL SWITCH Figure 2 12 10 Remove two bolt assemblies motor adapter spacer rear cover and spacer from motor housing NOTE Perform Steps 12 through 15 only if replacing brush assembly 11 Remove electric thermal switch from two electric thermal switch leads 11 12 13 14 15 Remove armature assembly from brush assembly Figure 2 13 ARMATURE ASSEMBLY SPACER NG BRUSH ASSEMBLY POWER STUD MOTOR HOUSING BRUSH ASSEMBLY Figure 2 13 Remove nut lockwasher washer and insulator securing brush assembly power stud to motor housing Remove three nuts screws and brush assembly from motor housing Remove spacer insulator and washer from brush assembly power stud 2 2 2 ASSEMBLY NOTE Do not apply coating to any electrical contacts of the armature assembly Perform Steps 1 through 4 only if replacing brush assembly 1 2 Install washer insulator and spacer on brush assembly power stud Install brush assembly in motor housing and secure with three screws and nuts Figure 2 13 Secure brush assembly power stud to motor housing with insulator washer lockwasher and nut Coat inside diameter of the bushing in the rear cover Install armat
27. pack Plastic sealing material may make it very difficult to replace B C parts Check the remote control switch and cable replace if necessary See CORRECTIVE ACTION for PROBLEM 3 1 4 Check all connections inside the control pack Make sure they are clean and tight Power out winch for at least 1 1 2 seconds If ECL was tripped winch should now operate in power in mode If winch still doesn t power in the thermal switch may have tripped Let motor cool for at least 30 minutes then try to power in again 26 SECTION 4 APPENDIX OPTIONAL EQUIPMENT 4 1 MECHANICAL REMOTE CLUTCH If your winch is equipped with a mechanical remote clutch use this section instead of the standard clutch lever disassembly instructions found in Section 2 1 1 411 DISASSEMBLY Mark the position of the splined clutch lever on the winch so it can be easily re aligned during assembly 2 Remove the spherical rod end and splined clutch lever from the clutch shaft Figure 4 1 3 Follow steps 1 7 of Section 2 1 1 4 Remove the detent spacer spring and ball from a hole in the flange of the gear housing Pull the clutch lever out of the housing SPHERICAL ROD END CLUTCH SHAFT es DETENT SPACER STEEL BALL GEAR HOUSING Figure 4 1 27 41 2 ASSEMBLY Re install the clutch shaft in housing in exactly the same position it was removed Apply a light coating of oil or grease to hole where the clutch shaft is instal
28. uld show a zero meter reading Repeat for the other switch direction If there is a reading much above zero the switch may have a short circuit or broken wire and should be replaced PROBLEM 3 1 5 When the remote control switch is activated there 15 only a clicking sound and the winch does not operate in either power or power out modes POSSIBLE CAUSE The battery is not fully charged terminals are corroded battery is defective or worn out B The electrical grounding wire is not attached to the motor housing C The motor armature is damaged or shorted possibly from incorrect wiring of the control pack to the motor or overheating of the motor D Water in the motor caused by submersion or improper installation of the motor or the motor vent fitting was not hooked up causing an electrical short E Worn or damaged brushes caused by a damaged armature commutator or normal wear CORRECTIVE ACTION Recharge the battery If the battery will not take a full charge replace it or check the charging source Clean the battery terminals and wire terminals B Attach the electrical ground wire to the motor housing C Replace the motor armature See Section 2 2 D Replace the motor See Section 2 2 E Replace the motor brushes See Section 2 2 PROBLEM 3 1 6 Winch does not have the same pulling power as when it was new See CAUSES and CORRECTIVE ACTION for PROBLEM 3 1 5 PROBLEM 3 1 7 Winch runs slowly and lacks power when
29. ure into brush assembly Pull brushes back first with screwdriver or other pointed tool Connect thermal switch to two electric thermal switch leads Figure 2 12 IMPORTANT Always check for a short circuit after replacing the thermal switch Touch one multimeter probe to a thermal switch terminal and the other probe to the motor case Use the OHM setting on the meter If there is a reading on the meter then there is a short circuit Check the connections making sure that bare connections are not touching the motor housing Insulate these connections with a small amount of silicone RTV or other insulating material Re check with the meter If there is no reading the circuit is OK 12 Position spacer on inside of motor adapter and rear cover and install motor adapter and rear cover on motor housing and secure with two bolt assemblies Install gasket on motor drum support assembly Install motor on drum support assembly making sure motor shaft is engaged into motor shaft coupling Be careful armature doesn t fall out of brushes when tipping motor over or brushes may be damaged Secure motor to motor end drum support with ten hex socket head screws Tighten socket head screws to 30 40 Figure 2 11 NOTE If motor or control have been precoated with sealing compound remove compound from between motor and control mounting spline contact area Failure to do so may cause improper grounding or control 10 11 12 13
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