SERVICE MANUAL
Contents
1. GO PREPARED SERVICE MANUAL FOR THE Warn Mid Frame Winches M 6000 M 8000 XD9000 12V DC Electric Winch e COMPLETE REPAIR REPLACEMENT INSTRUCTIONS e TROUBLE SHOOTING GUIDE As you read these instructions you will see NOTICES CAUTIONS and WARNINGS Each message has a specific purpose A NOTICE is additional information to help you complete a procedure CAUTIONS are safety messages that indicate a potentially hazardous situation which if not avoided may result in minor or moderate injury A CAUTION may also be used to alert against unsafe practice WARNINGS are safety messages that indicate a potentially hazardous situation which if not avoided could result in serious injury CAUTIONS and WARNINGS identify the hazard indicate how to avoid the hazard and advise of the probable consequence of not avoiding the hazard PLEASE WORK SAFELY Warn Industries Inc 12900 SE Capps Road Clackamas OR 97015 USA REV A TABLE OF CONTENTS SECTION 1 GETTING STARTED 2 1 WINCH MODELIDENTIFICA TION a 2 1 2 DEFINITIONS AND WINCH OPERATION 5 SECTION 2 DISASSEMBLY amp ASSEMBLY 6 DIOWNERJZOPEBATOR REPAIBS iuter ets 6 29 SUGGESTED TOOLS i 6 DODISASSEMPLS a M 6 AREAS SEMBE eh 10 SECTION 3 BRAKE REMOVAL2. 20 CAUTION 21 There are two ways to remove the brake assembly from the drum Number 1 Pinch the brake tangs together and lift out The friction material will be loose when the brake is removed from the drum Lock the brake tangs together with locking plyers or a clamp to revent the brake from coming unwould If the brake assembly will not slide out set the drum on end and use a steel rod drift pin or similar tool and push the brake out of the drum Number 2 Remove the brake assembly by pinching the brake tangs together then partially slide the brake out of the motor end of the drum If the brake assembly will not slide out easily set the drum on end and use a steel rod drift pin or similar tool and push the brake out of the drum To prevent the spring loaded brake assembly from unwinding use either a cardboard or steel tube with an internal diameter of 2 1 8 to hold the brake together Remove the complete brake assembly from the drum The brake unit is spring loaded Should the brake unit unwind it will be necessary to replace it with a new brake assembly Never attempt to rewind a brake unit that has come unwound 3 3 Reassembly New Brake Installation Set the drum assembly on a solid work surface and slide the brake unit through the cardboard sleeve into the drum about 6 With the brake installed in the drum insert the hex drive shaft into the brake and then install the drum with
3. powers the electric motor 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 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 drum support GEAR TRAIN Warn electric planetary winches consist of a gear train made up of three planetary gear stages The purpose of the gear train is to multiply motor torque and to reduce motor speed transmitted to the drum Warn gear trains are enclosed in a housing and are lubricated with grease FREESPOOL CLUTCH A freespool clutch is incorporated in the gear train to allow the user to pull the wire rope off the drum to the anchor point where the hook will be attached without using the winch motor This is referred to as Freespooling Drum Supports Motor s QTY UT Freespool Clutch m mmm Ee 17 Drum w Wire Rope i Gear Train Figure 1 2 Major Winch Components MOTOR CONTROLS The electric winch motor controls consist of a control pack also referred to as a solenoid pack which is 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 electr
4. the bolt located on the under side of the motor housing from the three terminals And also to the negative battery terminal 24 Figure 4 2 1s the basic wiring diagram of the 12v winch control pack The redundant solenoid system provides safety against run on from stuck shorted solenoids eec ls Ld fai ess he m qp adus i o 33 lt PS a am CONTROL ec ER SWITCH t Ter M QO Y eae _ Dn K lt omer P o SCHEMATIC DIAGRAM Figure 4 2 Control Pack and Wiring Schematic Figure 4 3 is the basic wiring diagram of the 5 wire remote control The five wire remote is designed to control both the voltage side of the circuit as well as the ground When the remote control is unplugged the ground circuit is disconnected WH VE BROWN WIRE BLACK WIRE i INSIDE USING HARNESS WIRING D I 4 Fat Figure4 3 Remote Control Plug And Wiring Schematic 25 The drawing in figure 4 4 is for routing the wires in the control pack to prevent heat damage from the bus bars in a 12 VDC control pack Armature Cable F1 Field Cable F2 Field Cable Positive Battery terminal Cable MUTUR GRUUND MOTOR GROUND
5. the groove in the thrust washer Remove the second stage planetary gear from the gear housing AIT a iT Remove the first stage gear 2 cu y Remove the loose first stage sun gear Check for worn or chipped gear teeth Check all gears for excessive wear and replace if necessary 11 d 12 Remove the free spooling clutch handle from the gear train by removing the allen head set screw then lifting the handle out of the housing Remove the O ring seal and seal retainer inspect the O ring seal for wear Remove the sliding ring gear from the gear train end housing Check all gears for excessive wear worn or chipped gear teeth 2 4 Reassembly Apply a light coat of machine oil to the inside of the gear housing where the sliding ring gear rides CAUTION Do not apply grease to the machined surface of the gear housing This will cause difficultly in free spooling Install the sliding ring gear with the grooved end up Grease the o ring seal install the o ring seal and seal retainer onto the gear housing Then place the clutch lever into the hole in the housing Clutch lever eccentric must align with machined groove in ring gear 13 14 Secure the clutch lever with the allen head set screw Apply a light coating of machine oil to the sun gear shaft Install the sun gear into the bushing in the end of the housing Coat th
6. AND REPLACEMENTI7 SISUGGBSTED TOOLS eere 17 32 DIS SSENEDE Yee une eel ual i UE 17 JSREASSBVBEY GS B ce 18 SECTION 4 ELECTRIC MOTOR amp CONTROL PACK OVERVIEW AND WIRING 20 4 1 OVERVIEW OF CONTROL PACK OPERATION 20 SECTION 5 WINCH TROUBLE SHOOTING 23 SECTION 1 Getting Started 1 1 Winch Model Identification To ensure proper winch repair it 1s necessary to correctly identify the model and part number of your winch This makes ordering replacement parts easier and helps you obtain the necessary information from your Authorized Service Center NOTE For a part description item number and quantity refer to the Replacement Parts List in this manual for your specific winch model WINCH SERIAL NUMBER identifies when winch was manufactured and identifies individual winch e nmm WINCH NAME PLATE LABEL Identifies model designation and identifies winch configuration and winch pull rating Figure 1 1 Locations of Product Identification Nomenclature 1 2 Definitions And Winch Operation 1 2 1 Definitions Operation and service of a Warn planetary winch can be explained easier by defining a few major structural components Refer to Figure 1 2 for the following definitions MOTOR The electric winch is driven by a high speed low torque electric motor A 12 volt DC vehicle battery generally
7. d wire directly to to vehicles frame negative battery terminal See corresponding Corrective Actions for problem 5 1 4 See All possible Causes for problem 5 1 4 a Faulty electrical grounding See possible Cause a and corresponding Corrective Action for problem 5 1 4 b Faulty battery battery cable or battery cable connections See problem 5 1 4 Possible Causes b through e and corresponding Corrective Actions c Water in motor caused by submersion or improper installation of motor Replace motor See Section 2 e Worn or damaged brushes caused by damaged armature commutator or normal wear Replace motor See corresponding Corrective Action a See possible causes for 5 1 4 and 5 1 6 b Electrical ground is not sufficient Ground wire was not installed or the battery ground wires and wire terminals are corroded Install a ground wire to the motor housing and attach to the negative terminal of the battery Check remote control switch and cable Replace if necessary Check all connections inside control pack Check all pins in plug and receptacle for damage a Remote control switch is damaged b Also see Possible Causes and Corrective Actions for problem c One of the solenoids in the control pack is sticking or is damaged from prolonged use Replace solenoid 34 35
8. der load can over heat the brake and cause it to no longer hold the rated load SECTION 2 Disassembly amp Assembly 2 1 Owner Operator Repairs PLEASE READ THIS BEFORE ATTEMPTING REPAIRS THIS MANUAL IS INTENDED FOR USE BY THE WINCH OWNER AND OR OPERATOR SOME REPAIRS SHOULD BE DONE ONLY BY A WARN AUTHORIZED SERVICE TECHNICIAN IF YOU DO MAKE REPAIRS IT IS IMPORTANT THAT YOU DO NOT ATTEMPT THEM WITHOUT THE PROPER TOOLS AND EQUIPMENT IT IS ALSO IMPORTANT TO CORRECTLY FOLLOW THE INSTRUCTIONS FAILURE TO DO SO MAY CAUSE THE WINCH TO FAIL RESULTING IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE IMPORTANT NOTE OWNER REPAIRS WILL VIOD THE WARRANTY ON THE COMPONENTS BEING REPLACED OR REPAIRED 2 2 Suggested Tools The following tools are suggested for these procedures 1 5 32 HEX KEY WRENCH I 14 HEX KEY WRENCH 1 13mm 1 3 8 BOX OR OPEN END WRENCHES 1 FLAT HEAD SCREWDRIVER 1 PLIERS 1 TORQUE WRENCH 2 3 Disassembly Always disconnect all wires from the POSITIVE BATTERY TERMINAL BEFORE beginning ANY WORK on the winch FAILURE TO DO SO MAY CAUSE THE WINCH TO FAIL RESULTING IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE Q Mark electrical cables for easier assembly later Remove winch from vehicle QO Repairs are easier and safer when winch is removed from vehicle and located on a workbench Remove motor from the motor end drum support by removing the two motor bolts Visually verify that the arma
9. e inside of the ring gear teeth with grease until all spaces between the teeth are filled Use a grade of moly disulfide grease with good performance between 50 F 45 5 C and 125 F 51 7 C Aeroshell 17 is recommended Completely fill the teeth of the first stage and second stage carrier assemblies with grease and place into the gear housing Use light grade machine oil on the three planetary gear bushings inside the carrier assembly It may help to align all the planetary gear teeth 1f you install the hex drive shaft into the first stage sun gear and rotate slightly as you slide the gears into place Install the second stages rotating the shaft to align the teeth O Remove the shaft to allow for installation of the drum support Apply a light coating of grease to the thrust washer and install on the gear housing CAUTION The thrust washer must be installed with the grove facing up for proper operation Install the gasket material on to the gear housing Line up the holes in the gasket with those in the housing Grease and install the third stage planetary gear set on to the second stage assembly and trust washer CAUTION Make sure that the splined end of the third stage planetary is facing up 15 Install the third stage ring gear on to the third stage planetary gear set and the housing Make sure to line up the index marks that were made during the disassembly proc
10. emoval instructions Remove drum from winch Section 2 3 Inspect drum bushings and drum support for wear PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION c Free spool clutch inside gear train is damaged 5 1 4 Winch lacks power pulls slowly stalls or will not run at all d Wire rope is bound up on the drum e Winch is not mounted correctly which causes winch to bind f Internal corrosion on ring gear will not allow ring gear to rotate smoothly g End housing has grease between ring gear and inside machined surface not allowing the ring gear to rotate easily a Ground cable is not directly attached to motor housing or is an incorrect size Remove and inspect clutch ring gear clutch shaft and gear housing for burrs or damage Remove burrs with file Replace parts if necessary See section 2 3 for gear train disassembly By connecting the hook to a load and alternately powering in and powering out the wire rope will usually work itself free IMPORTANT DO NOT PUT YOUR HANDS NEAR THE WIRE ROPE OR FAIRLEAD WHEN ATTEMPTING TO FREE A BOUND ROPE Check mounting hole dimensions Follow mounting specifications and procedures as described in the operator s manual Be sure mounting surface is flat to with in 0 020 inch Be sure all mounting bolts are tight Disassemble gear train inspect and clean sliding ring gear replace if necessary Remove gear train Clean all grease from machined sur
11. ess when reassembling Insert the drive spline into the third stage carrier Apply the second gasket to the ring gear making sure you line up the holes in the gasket and those in the ring gear Install the gear train onto the end support by lining up the index marks you made during disassembly Attach the gear train to the end housing using 10 allen head screws Reinstall the tie rods if they have been removed during disassembly K bh TU Reo Apply a light coating of grease to the inside of the drum bushing and install into the drum support CAUTION For the bushing to fit properly the slot in the bushing must fit over the index tab in the drum support NOTICE With the brake installed in the drum insert the hex drive shaft into the brake and then install the drum with the shaft onto the gear train assembly You may need to spin the hex shaft to line it up with the sun gear in the gear housing CAUTION If the brake has been removed from the drum go to section 3 BRAKE REMOVAL AND REPLACEMENT for brake installation proceedures Brake will not function properly if the coupler tangs are not positioned properly Install the aluminum motor coupler over the brake assembly with the internal tangs on the motor coupler at a 90 degree angle to the tangs on the cam follower of the brake assembly a Follower tang 17 Apply a light coating of
12. face of gear housing and ring gear Apply light oil on machined surfaces Attach ground cable to threaded hole in motor housing not to a terminal b Loose connections on battery Be sure all connections are tight or motor terminals and clean c Vehicle battery not fully Charge battery charged d Battery terminals are Clean terminals corroded e Battery is too small or defective f Solenoid ground cable disconnected Replace with conventional automotive battery with minimum of 650 cold cranking amps rating Check solenoid ground cable for damage connect to threaded 22 hole in motor housing PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 5 1 5 Winch does not have the same pulling power as when it Was new 5 1 6 When remote control switch is activated only a clicking sound results and winch does not operate in either power in or power out mode 5 1 7 Electrical sparks appear around the motor or motor end housing 5 1 8 When the remote control is activated winch operates in only one direction g Short circuit in winch power supply or wiring Check battery cables and motor cable leads for loose connections worn or cracked insulation and fraying or bare spots Replace cable if necessary h Remote control switch or cord is damaged Test winch operation with replacement remote control Replace remote control if defective i Battery ground wire connected Connect groun
13. grease to the inside of the drum bushing and install it into the drum support CAUTION For the bushing to fit properly the slot in the bushing must fit over the index tab in the drum support Install the motor end drum support on to the drum and attach the tie rods with the two allen head cap screws Torque the cap screws to 18 22 ft Ib 24 4 29 8 Nm Install the motor on to the drum support making sure that the index pin in the motor housing seats into the index hole in the end support You may need to rotate the motor back and forth to get the splines on the motor to line up with those in the motor coupler Q Secure the motor with the two motor bolts Torque the bolts to 5 7 ft 1b 6 8 9 5 Nm 18 Reattach the electrical cables from the control pack to the motor NOTES 19 SECTION 3 Brake Removal And Replacement For MID Frame Winches NOTICE Warn Industries does not offer individual replacement brake parts The complete brake assembly must be replaced 3 1 Suggested Tools These tools are suggested for the following procedures 7 32 Hex Key Wrench Rubber Mallet 3 2 Disassembly Remove the wire from the drum or secure it on the drum for ease of working O Remove the drum from the winch as described in winch disassembly section 2 3 Q Set drum on solid working surface table bench etc then remove the aluminum motor coupler from the drum tube
14. ia BC GREEN WIRE BLACK WIRE BROWN WIRE BROWN WIRE WHITE WIRE INOW NEU INA MON E o BLACK WIRE A GREEN WIRE N Figure 4 4 12v Winch Control Pack Wiring Diagram 26 42 Electric Motor Removal and Motor Brush Replacement Always disconnect all wires from the POSITIVE BATTERY TERMINAL BEFORE beginning ANY WORK on the winch FAILURE TO DO SO MAY CAUSE THE WINCH TO FAIL RESULTING IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE Mark electrical cables for easier assembly later Remove winch from vehicle QO Repairs are easier and safer when winch 15 removed from vehicle and located on a workbench Disconnect cables from the control pack and disconnect the battery ground cable O Remove motor from the motor end drum i support by removing the two motor bolts g7 ewm ae i Vi EE Remove motor end cap from motor housing Plastic brush holder and brushes will be visible 24 Q Note the location of the armature bearing in the brush holder 4 plastic lock tabs secure the bearing Remove screw from copper strap This will allow the release of the brush holder from the motor housing Q Pull armature firmly to remove from motor housing and brush holder CAUTION Remove armature carefully to prevent breaking of lock tabs that secure armature bearing to brush holder a Remove the brush holder from the motor housing Ins
15. ical cable connections The main function of the control pack is to allow the operator to switch the winch on and off in both directions Positive Battery Cable Remote Socket Q Control Pack w Cover Fl Cable Green Label F2 Cable Blue Label Armature Cable Yellow Label Control Pack Ground Cable BRAKE All planetary winches are equipped with a directional sensitive automatic brake The brake requires that the wire rope be wound onto the drum in the correct direction to operate properly A Drum rotation label is located on the motor end drum support to help identify proper rotation When the wire rope 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 Q Motor Coupler Direct Drive Cone Brake Drive Shaft Figure 1 4 Internal Winch Brake POWER IN 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 it 1s being powered out This is different than when the winch is freespooled out which refers to the wire rope being pulled out by hand with the freespool clutch disengaged 1 2 2 Winch Operation A Warn winch is a compact device used to pu
16. ll heavy loads over short distances up to 100 Refer to Figure 1 2 when reading the following section The vehicle battery and charging system generates the power for pulling the load Power feeds from the battery power source into the winch control pack At the push of a remote control switch the power flows to the winch motor The winch motor turns the electrical energy into mechanical energy The motor shaft turns the motor coupler 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 farthest from the winch drum the first stage carrier The first stage carrier in turn drives the second stage carrier which then drives the third stage carrier The third stage directly drives the drum Since the wire rope is connected to the drum the rope winds around the drum causing the load to be drawn in On power out operation the motor is reversed and the winch drum is rotated in the opposite direction All winch components operate in the same manner as during power in except the brake During power out the load tries to over speed the motor make the motor turn faster than it would under its own power When the brake detects this over speed it engages just enough to make the load and motor run at the same speed and slow the load When the remote control switch is released the brake engages and completely stops the load Long power out cycles un
17. oled onto the drum in the wrong direction b Load exceeds winch rating c Brake inside winch drum is badly worn or broken a Wire rope is spooled onto drum in the wrong direction Winch is working against the brake in the power in mode b Load exceeds rating for winch c After a very long power out cycle over 30 feet under heavy load brake has overheated a Bent drum flange b Worn drum bushings Remove all wire rope from drum and respool in the proper direction see directional label on drum support Refer to the Winch Operators Manual for the correct line pull rating for your winch DO NOT EXCEED THE LINE PULL RATING SHOWN ON THE IDENTIFICATION LABEL Replace brake Entire brake assembly must be replaced Refer to this manual for winch brake replacement Remove all wire rope and respool in the proper direction See directional label on drum support Refer to Winch Operators Manual for the line pull rating for your winch DO NOT EXCEED LINE PULL RATING SHOWN ON IDENTIFICATION LABEL Let brake cool for approximately 30 minutes 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 brake temperature Allow adequate time for brake to cool between extended power out cycles Rotate drum on winch and inspect for bent drum flanges A bent drum must be removed and replaced See Section 2 3 drum r
18. pect brushes replace brushes if they measure less then 1 2 inch in length Q Note the location position of the slot the brass strap slides through Secure the four brushes Pull the brush outward and angle them down so they stay secured in the bracket The brushes must be secured before the armature can be installed 28 E 29 Align brush holder slot with motor housing strap so it lines up with screw hole Carefully install armature into motor housing Place brush holder on flat surface gently align motor housing armature and brush holder Snap armature bearing into brush holder clips Secure motor housing strap to brush holder Inspect all electrical connections to ensure they are tight Inspect cable insulation for damage and make sure cables are not being pinched Reinstall motor cap assembly 30 Install the motor on to the drum support making sure that the index pin in the motor housing seats into the index hole in the end support You may need to rotate the motor back and forth to get the splines on the motor to line up with those in the motor coupler Secure the motor to the drum support with the two motor bolts SECTION 5 Winch Trouble Shooting Guide PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 5 1 1 Winch does not hold load 5 1 2 Brake over heats and will not hold load 5 1 3 Difficulty in spooling wire rope OFF drum by hand 3l a Wire Rope is spo
19. the shaft on to the gear train assembly You may need to spin the hex shaft to line it up with the sun gear in the gear housing CAUTION 22 Install the aluminum motor coupler over the brake assembly in the drum with the internal tangs on the coupler at a 90 degree angle to the tangs on the cam follower of the brake assembly Cam Follower tang Brake will not function if the motor coupler tangs are not positioned properly Q Install the aluminum Motor coupler over the brake assembly in the drum with the internal tangs on the coupler at a 90 degree angle to the cams on the brake assembly a Reinstall drum support and motor as outlined in the winch basic assembly instruction in section 2 4 23 SECTION 4 0 Electric Motor amp Control Pack Overview And Wiring Reference i 1 cof RN Figure 4 1 4 1 Overview Of Control Pack Operation Electrical operation of the winch control assembly consists of four heavy duty solenoids In the power out mode the black wire and the white wire are triggered by the remote control switch to energize solenoids number 2 and 3 see figure 4 2 In the power in mode the green wire and the white wire are triggered by the remote control switch to energize solenoids numbers 1 and 4 Because of the large amounts of current needed to pull loads at the higher capacities we recommend CAUTION Ede temet pte The ground cable should be attached directly to
20. ture shaft 15 moving out with the motor housing Use a screwdriver if needed to move armature with motor Caution if the armature falls out of the motor the motor brushes will need to be reset to allow reinstallation Stand winch on gear housing end O Remove the two tie rod bolts A second wrench or pliers attached to the tie rods may be required to remove the bolts Remove the split plastic drum bushing Check the drum bushing and drum support for excessive wear a Remove the motor side drum support and the aluminum motor coupler from the drum assembly If brake removal is required go to SECTION 3 BRAKE REMOVAL AND N O TI C REPLACEMENT for brake removal procedures Remove the drum assembly from the gear train end of the winch Remove the drive shaft from the gear train end of the winch Mark the housing ring gear and drum support with a marking pen in one location so they can be easily realigned during assembly Remove the ten allen head cap screws Remove the drum support from the ring gear Remove complete gear train from drum support Remove the drive spline from the third stage carrier Remove the ring gear from the end housing 10 Note that the splined end of the third stage gear is facing up Remove the third stage carrier Q After removing the third stage gear you will see the second stage gear Note the position of
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