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  #11  
Old 02-07-2017
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(Dan) (KJ7DAN)
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Default Re: Warn Powerplant Woes
Originally Posted by johnpa View Post
can you hone the cylinder?
I'll just replace it with a new one. The cylinder is aluminum, w/o a sleeve, so I don't think it can be honed.
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  #12  
Old 02-07-2017
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Default Re: Warn Powerplant Woes
Originally Posted by theksmith View Post
Dan, thanks for posting this info and the photos.

I hope you email or talk to Warn through your sources and find out if it's expected for nothing to have threadlocker, nylocks or lock-washers... I'm hoping yours represents a fluke or a bad batch. Otherwise it would certainly seem like a very poor design decision considering the vibrations a compressor must endure.
I'll find out in a few days and post out an update.
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  #13  
Old 02-09-2017
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Default Re: Warn Powerplant Woes
I got the replacement, and here are my (deep) thoughts:

- I was wrong about the seals: the unit (both of them) has nice seals. The ones that are inside (one on each side of the drum) are made of rubber but were covered in grease so i didn't notice them at first.
- Some bolts on the new unit still have no loctite.
- Some of the other bolts do have some white residue, but I think it's anti-seize, not a loctite. I'm adding loctite to all.
- The bolt holding the piston gasket did have red loctite and was tighten tight.
- The new unit has a new hose that's not coiled anymore. It seems like a very cheap imitation of the ARB. The connectors at the end of the hose had some teflon tape on them but were very loose. It looks like little kids assembled them. Oh wait ... The box holding the accessories has a big Made in China w/ Chinese and Taiwanese components.
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  #14  
Old 02-10-2017
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Default Re: Warn Powerplant Woes
I have been using my PowerPlant for over 6 years now with no problems. It sounds like I was just lucky when I got mine. With Dan's write up, at least I know who to call if I develop problems with it.
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  #15  
Old 02-10-2017
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Default Re: Warn Powerplant Woes
I'm not an expert on the use of loctite. I assume that Warn might have a reason for not using it - perhaps stainless steel bolts + cast iron body + loctite doesn't work well? or perhaps the white residue that I did find on some bolts is a mix of anti-seize and loctite? or maybe the sheer number of bolts they use (on piece is held by 10 bolts) is enough.

I don't know. I probably just had a bad unit. Warn after-all has a sterling reputation, they sell them by the thousands, so they must know what they're doing. I didn't hear anyone else having problems with their PowerPlants. As I mentioned, the units are built very nice - I might just be overly fixated over the loctite.
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  #16  
Old 02-12-2017
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Default Re: Warn Powerplant Woes
I'm finally done fixing the PowerPlant. I found more issues:

1. The pressure switch has super sloppy connections for a devices that's made to use offroad. It uses spade type connections that were so loose that they would've fallen off on the next trip. See pictures below. I've tighten them as well as I could and secured them with a zip tie.

IMG_0534.jpgIMG_0535.jpg

2. Upon powering the unit, sparks started to fly. The damn main battery post on the Warn contactor was so loose that it almost fallen off. Take a look at the nut and notice the burn marks:

IMG_0538.jpg

3. The boot covering the main battery post was split - I had no replacement so I've "fixed" it with electrical tape.

IMG_0536.jpg

4. Do I have to mention that none of the bolts securing the contactor, the electrical bus, and the cables were loose and had no damn split washers? This is ridiculous!!!

IMG_0537.jpg


Bottom Line: This winch/compressor could be a gem (the compressor in particular 12CFM@0PSI, 5CFM@90PSI - I don't think there's a better single unit on on the market), but the sloppiness of simple things, such as lack of split washers, lack of automotive level connectors for electrical connections, as well as the fact that the wires don't even have a protective sleeve (I've had to add that to few wires that had signs of friction - short-circuit in waiting), is stupid.

I hope this thread helps other Warn PowerPlant owners be aware of (a) how to fix their units, and (b) how to easily fix Warn's stupid assembly decisions: split-washers and wire sleeves are your friend.
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  #17  
Old 02-12-2017
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Default Re: Warn Powerplant Woes
BTW, the white stuff on some of the bolts is dielectric grease. Needless to say that Warn left those electrical bolts uncovered and at the mercy of elements...
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  #18  
Old 02-12-2017
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Default Re: Warn Powerplant Woes
If my warm winch ever starts acting up I'm calling you Dan.
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  #19  
Old 02-12-2017
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Default Re: Warn Powerplant Woes
Sure Scott
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