PullzAll Installation and Operator's Guide - 84747A0

97734.A1 - 16.5TI-S Replacement Parts List

GENERAL SAFETY PRECAUTIONS SYMBOL

EXPLANATION

Read the instruction manual

Explosion/Bursting Hazard

PullzAll™ Installation and Operator’s Guide Every pulling and lifting situation has the potential for personal injury. In order to minimize that risk, we ask that you read this basic guide carefully. Please familiarize yourself with the operation of your PullzAll before using it, and be constantly safety oriented. In this guide, we will set forth many of the basic rules of safe PullzAll operation. However, because every pulling/lifting situation is different, your constant good judgment and consistent focus on safety are of great importance.

Fire and Burn Hazard

Never lift load over persons

Do not move persons

Properly seat load in throat of hook

TABLE OF CONTENTS: SAFETY

Never apply load to hook tip or latch

Symbol Index............................................................................................................... 2 General Safety Precautions .....................................................................................3-6 SPECIFICATIONS Corded 120 VAC PullzAll............................................................................................. 7 Cordless 24V DC PullzAll ............................................................................................ 8 INSTRUCTIONS Utility Pulling Introduction ............................................................................................ 9 How the PullzAll Works ........................................................................................10-12 Power Source ....................................................................................................... 13-14 Operating the PullzAll ........................................................................................... 15-18 Accessories ..............................................................................................................19 Rigging Techniques ................................................................................................... 20 Maintenance & Final Analysis ................................................................................... 21 WARN INDUSTRIES 12900 SE Capps Road Clackamas, OR 97015 USA

Always wear gloves

Finger/Fairlead Crushing Hazard

Always use supplied hookstrap

Hand Piercing/ Cutting Hazard

Hot Surface Hazard

Wind wire rope on top of drum

Do not wind wire rope on bottom of drum

Always wear hearing and eye protection

Customer Service: (800) 543 - WARN (9276) International: (503) 722-3008 Fax: (503) 722-3000

Shock Hazard

www.warn.com

Charger Plug Pinout

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GENERAL SAFETY PRECAUTIONS

GENERAL SAFETY PRECAUTIONS WARNING

Warnings and Cautions

WARNING

As you read these instructions, you will see WARNINGS, CAUTIONS, NOTICES and NOTES. Each message has a speci fi c purpose. WARNINGS are safety messages that indicate a potentially hazardous situation, which, if not avoided could result in serious injury or death. CAUTIONS are safety messages that indicate a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. A CAUTION may also be used to alert against unsafe practice. CAUTIONS and WARNINGS identify the hazard, indicate how to avoid the hazard, and advise of the probable consequence of not avoiding the hazard. NOTICES are messages to avoid property damage. NOTES are additional information to help you complete a procedure. PLEASE WORK SAFELY!

ELECTRICAL HAZARD Failure to observe these instructions could lead to serious injury or death. • Always use properly grounded single phase receptacle protected by a ground fault circuit interrupter (GFCI). • Never remove ground pin from plug. • Never route electrical cables across sharp edges. • Never route electrical cables through or near moving parts. • Never route electrical cables near parts that become hot. • Never remove electrical cover from battery charger. • Never leave the pulling tool power cord plugged in when installing, rigging, servicing or when the pulling tool is not being used. • Never disconnect ground bond. • Never operate product in a wet environment. • Always power pulling tool with only the recommended electrical system voltage. See the pulling tool speci fi cation sheet for details. • Never operate charger with damaged cord or plug. Replace them immediately. • Never operate charger if it has received a sharp blow, been dropped or otherwise damaged in any way. • Never charge battery in damp or wet environment. • Always charge battery pack in temperatures above +32 °F (0° C) and below 120 °F (49° C). This is important and will prevent serious damage to the battery. • Always store pulling tool and battery pack where temperatures will not exceed 120 °F (49 °C). • Always disconnect charger when battery is fully charged.

FALLING OR CRUSHING HAZARD Failure to observe these instructions could lead to serious injury or death. • Never attach a recovery strap to the pulling tool hook to increase the length of a pull. • Always use a hook with a latch. • Always ensure hook latch is closed and not supporting load. • Never apply load to hook tip or latch. Apply load only to the center of hook. • Never use a hook whose throat opening has increased, or whose tip is bent or twisted. • Never attempt to tow a vehicle or object with the recovery strap attached directly to the pulling tool hook. • Never use bungee straps that develop tremendous and potentially dangerous amounts of force when stretched. • Always avoid side pulls which can pile up rope at one end of the drum. This can damage rope or pulling tool. • Never hook rope back onto itself. This damages the rope. • Always use a choker chain, choker rope, or strap. • Never use pulling tool to lift or move persons. • Never use pulling tool to lift over persons • Always select an anchor point as far away as possible. This will provide the pulling tool with its greatest pulling power. • Always use suitable anchor point capable of handling load.

FALLING OR CRUSHING HAZARD Failure to observe these instructions could lead to serious injury or death. • Never use pulling tool to secure a load. • Never shock load rope. Shock load can damage, overload and break rope. • Never use the pulling tool’s rope to tow vehicle or object. Impact loading during towing can exceed rope strength. • Always be certain the anchor you select will withstand the load and the strap or chain will not slip. • Always take time to use appropriate rigging techniques for pulling/lifting. • Never spool out past the red paint on wire rope. • Never exceed pulling tool or rope capacity listed on product data sheet. Double line using a snatch block to reduce pulling tool load. • Never exceed 1000 lb. (454 kg) Maximum pulling capacity. • Always use suitable anchor point capable of handling load. • Always use factory approved mounting hardware, components, and accessories. • Always respool under tension load after use. Tightly wound rope reduces chances of “binding”, which can damage the rope. • Always spool the rope onto the drum in the direction speci fi ed by the product warning label on the product and/or documentation. • Always avoid “jogging” or “plugging” (quick on/ off cycles) with the pulling tool. This can damage motor controls and rope.

WARNING

CHEMICAL AND FIRE HAZARD Failure to observe these instructions could lead to serious injury or death. • Always read all instructions and cautionary markings on battery charger, battery pack and cordless pulling tool. • Never operate pulling tool in an environment containing explosive or combustible material. • Never expose battery unit to high heat or fi re. • Never store Cordless PullzAll battery unit in a tool box or pocket with nails, screws, keys, etc. Shorting of battery terminal may cause fi re. • Always avoid contact with battery leakage, which may occur under extreme usage or temperature conditions. • Always remove the battery when the unit is not in use. • Always dispose or recycle battery according to local ordinances / regulations. • Always protect terminals with insulating tape, prior to disposal, to prevent shorting. • Never attempt to disassemble the battery. No user serviceable parts inside.

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GENERAL SAFETY PRECAUTIONS

CAUTION

WARNING

MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to minor or moderate injury. To avoid injury to hands or fi ngers: • Never let rope slip through your hands. • Always select an anchor point as far away as possible. This will provide the pulling tool with its greatest pulling power.

CRUSHING HAZARD Failure to observe these instructions could lead to minor or moderate injury. • The Corded 120 VAC PullzAll has some delay in the trigger control. Use the slow spooling speed and release the trigger early to prevent from spooling the hook loop into the fairlead.

MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to serious injury or death. General Safety: • Always remove jewelry and wear eye and ear protection. • Always wear gloves, eye and ear protection. • Always keep hands clear of wire rope, hook loop, hook and fairlead opening during installation, operation and when spooling in or out. • Always keep hands and clothing clear of the rope, hook and fairlead opening during operation and when spooling. • Never let rope slip through your hands. • Always Know Your Pulling Tool. Take time to fully read the Instructions and/or Operations Guide, in order to understand your pulling tool and its operations. • Never operate this pulling tool when under the in fl uence of drugs, alcohol or medication. • Never run the PullzAll while carrying it at your side. • Always be aware battery operated units are continually in an operative condition. Operational Safety: • Always wear heavy leather gloves when handling rope. • Always stand clear of rope and load and keep others away while pulling/lifting. • Always remove any element or obstacle that may interfere with safe operation of the pulling tool. • Never leave the pulling tool power cord plugged in when installing, rigging, servicing or when the pulling tool is not being used. • Always use supplied hook strap whenever spooling rope in or out, during installation and during operation. • Always use extreme caution when handling hook and rope during spooling operations. • Never operate or install a pulling tool without reading or understanding the operator’s manual. • Never operate this pulling unit if you are under 16 years of age.

MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to serious injury or death. Pulling Safety: • Always keep pulling tool and pulling/lifting load in sight during pulling/lifting operation. • Always require operators and bystanders to be aware of rope and load. • Always be aware of stability of load during pulling/ lifting, keep others away. Alert all bystanders of any unstable condition. • Never touch rope or hook while someone else is at the control switch or during pulling/lifting operation. • Never touch rope or hook while in tension or under load. • Always inspect rope, hook, and slings before operating pulling tool. Frayed, kinked or damaged wire rope must be replaced immediately. Damaged components must be replaced before operation. Protect parts from damage. • Always tightly wind wire rope onto drum after each use. During spooling in or out, rope direction can unexpectedly switch if rope is in layers on drum. Tightly wound rope reduces chance of binding. WARNING CUT AND BURN HAZARD Failure to observe these instructions could lead to serious injury or death. To avoid injury to hands and fi ngers: • Always wear gloves, eye and ear protection. • Never insert battery into charger if battery case is cracked or damaged. Battery short or fi re may result. • Never short battery terminals, because it may cause sparks or burns.

NOTICE

CAUTION

AVOID PULLZALL AND EQUIPMENT DAMAGE • Always avoid over heating the pulling tool motor. For extended pulling/lifting, stop at reasonable intervals to allow the pulling tool motor to cool down. See table for run time/duty cycle guidelines. • Always store the pulling tool in a protected, clean, dry area.

CUT AND BURN HAZARD Failure to observe these instructions could lead to minor or moderate injury. • Always be aware of possible hot surfaces at pulling tool motor or battery during or after pulling tool use. • Always charge PullzAll NiMH type battery pack only. Other types of batteries may burst causing damage and injury to person. • Always read all instructions and cautionary markings on battery charger, battery pack and cordless pulling tool.

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PULLZALL SPECIFICATIONS

PULLZALL SPECIFICATIONS The CordlessWARN ® PullzAll consists of the following features:

The Corded WARN ® PullzAll consists of the following features:

The Cordless WARN PullzAll is a powerful pulling tool. Powered by a 24 volt rechargeable battery this compact tool has a pulling capacity of 1000 pounds (454 kilos). The unit has a variable speed trigger for power-in and power-out operation, 15 ft (4.6 m) of 7/32 inch (0.56 cm) wire rope and two clasp hooks.

The Corded WARN PullzAll is a powerful pulling tool. Powered by a 120 volt AC power source this compact tool has a pulling capacity of 1000 pounds (454 kilos). The unit has a variable speed trigger for power-in and power-out operation, 15 ft (4.6 m) of 7/32 inch (0.56 cm) wire rope and two clasp hooks.

3. 3

5. 5

10.

1. Variable Speed Trigger

6. Power Cord

1. Variable Speed Trigger

6. Rechargeable Battery 7. Swiveling Anchor Hook 8. On/Off Power Switch

2. Directional Switch

7. Swiveling Anchor Hook 8. On/Off Power Switch

2. Directional Switch

3. Fairlead

4. Hook with Latch and Hook Strap

9. Wire Rope

4. Hook with Latch and Hook Strap

9. Wire Rope

5. Ready/Overload Indicator

10. Battery Release Button

Speci fi cation Data for the Corded WARN PullzAll Max Pulling Capacity 1000 lbs. (454 kg) Wire Rope Diameter 7/32 in (0.56 cm) Power Source 120 VAC Power Input 1200 W (10A)

Speci fi cation Data for the Cordless WARN PullzAll Max Pulling Capacity 1000 lbs. (454 kg) Wire Rope Diameter 7/32 in (0.56 cm) Power Source 24V DC Battery (NiMH) Power Input 720 W (30 A)

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UTILITY PULLING INTRODUCTION

HOW THE PULLZALL WORKS

So, you have your WARN PullzAll and you are ready to put it to use. This guide provides you with a basic understanding of your PullzAll and teaches you the basics of proper pulling/ lifting techniques. Before we get started, we must emphasize that the information in this guide is general in nature. Because no two situations are alike, it would be nearly impossible to review them all. We will, however, provide you with the general principles and techniques to use this tool safely and effectively. Then it is up to you to take the time to analyze the situation and apply the proper technique. Along with a little common sense, the information laid out in this guide can help you lift and pull safely. Just remember to think through each lifting or pulling situation before you act. To Go Prepared TM , the following instructions will help you understand the operation of the PullzAll.

To begin, you should familiarize yourself with your PullzAll and each of its components:

Fairlead When using the PullzAll at an angle, the fairlead acts to guide the wire rope onto the top of the spooling drum. It minimizes damage to the rope while it goes through the PullzAll mount. Gear Train The reduction gears convert the PullzAll motor torque into a large pulling force. The gear train design makes it possible for the PullzAll to be light and compact. Load Limiter ( not shown ) Is a device that automatically interrupts the power whenever the circuit becomes overloaded. The ready/ overload indicator LED turns red under extreme loads and fl ashes red when maximum load has been exceeded. 5. 6.

WARNING Never operate a PullzAll without reading or understanding the operator’s manual.

Motor The motor provides torque to the gear train, which turns the PullzAll drum and winds the wire rope. Spooling Drum The PullzAll drum is the cylinder from which the wire rope winds. The drum is driven by the gear train and motor. Its direction can be changed using the directional selector switch. The wire rope unwinds off the top of the drum. Wire Rope The rope’s diameter and length are determined by the PullzAll’s load capacity and design. Wrapped around the PullzAll drum and fed through the fairlead, the rope is looped at the end to accept the hook’s clevis pin. 2. 3.

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HOW THE PULLZALL WORKS

How the PullzAll Reacts to Load The PullzAll is rated by pulling capacity. The maximum pulling torque occurs when there is only one layer of wire rope on the drum. As the layers of wire rope on the drum increase, the pulling power decreases. This is the basics of mechanical advantage.

PullzAll Mechanics

Before using your WARN PullzAll to pull or lift a load it is important to understand how it works. The major advantage of the PullzAll is its handheld convenience for performing numerous recreational and work tasks. Thinking through how you intend to use your PullzAll now could save you a big headache later. Control of Your PullzAll The PullzAll tool has an On/ Off power switch and is controlled by a directional switch and a variable speed trigger control. The directional switch provides control of the forward and reverse rotation of the spooling drum. Keep tension on the wire rope when winding in or out to prevent “bird nesting” that can bind and entangle the wire rope causing damage to it and the PullzAll. When you see the red paint on the wire rope, do not spool out any further. Doing so, can cause the wire rope to spool on the drum in the wrong direction. This can damage the wire rope and fairlead. The direction selection arrow should always match the direction of the wire rope when it is spooling in or out.

It is important to understand that the longer the pull, the more heat gets created within the motor. Spooling out the rope also generates heat. Let the motor cool between pulls because prolonged use without cooling the PullzAll will damage the motor. Run Time/Duty Cycle The PullzAll is rated for intermittent duty. It should not be operated for long periods with the motor at low RPMs. When the motor approaches stall speed a very rapid heat build up occurs which may cause motor damage. Follow the recommended run times and cooling times in the table shown. If the unit does not function after it is allowed to cool, call a Warn authorized service center.

WARNING Always keep PullzAll and pulling load in sight during pulling operation.

RUN TIME/DUTY CYCLE TABLE LOAD 500 lbs. (227 kg) 1000 lbs. (454 kg) RUN TIME 2 min 1 min COOL TIME 30 min 30 min

WARNING

Never spool out past the red paint on wire rope.

Load Limiter

Exceeding the PullzAll capacity will cause the load limiter to trip, which interrupts the power to the motor. This prevents overheating and potential motor damage. At 90% of pulling capacity the overload indicator turns red. When 100% of pulling capacity is reached the load limiter will cause the overload indicator to fl ash red and the PullzAll motor to stop. When this occurs, release the load by spooling out. Do not attempt to apply the same load if the load limiter has tripped, as this can be harmful to the unit. If the load limiter fails to reset contact an authorized service center. If the load limiter continues to trip, perform the following actions: 1) Reduce the weight of the load. 2) Increase the distance of the anchor point. 3) Rig a double line pull. For details: See “Rigging Techniques” section in this manual.

NOTICE

The PullzAll is controlled

by the variale speed trgger and direction selection switch.

The variable speed trigger switch has two general modes of operation: 1) Variable speed mode for fi ne load positioning. 2) Full speed mode for long distance.

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POWER SOURCE

The PullzAll is available in both corded and cordless models. Each model has its own bene fi ts. Ensure the power source is connected properly following these instructions: Corded 120 VAC PullzAll Properly Grounded Plug Ensure the PullzAll power cord is connected to a properly grounded, 3-prong electrical socket with a Ground Fault Circuit Interrupter (GFCI). Minimum Amperage If using an extension cord and/or generator, make sure that it is rated to handle a minimum of 15 Amps, the current required to run the PullzAll at full capacity. Cordless 24V DC PullzAll Battery Care Always turn On/Off power switch off when not in use. Permanent battery damage may occur if the unit is allowed to self- discharge in the ‘On’ position. Store battery and charger in locations where temperatures will not exceed 120ºF (49 ºC). When noticeable loss of performance is observed, replace battery pack with a fully charged battery. Avoid running the battery completely dead. This can cause permanent damage to the battery pack. Installing the Battery Pack 1) Verify the power switch is in the ‘Off’ position. 2) Slide the battery pack into the body, making sure that the latch is fully engaged. The battery release button must be in the top position. Removing the Battery Pack 1) Verify the power switch is in the ‘Off’ position. 2) Push down the battery release

button at the back of the battery and slide the battery away from the PullzAll body.

Charger Safety Rules

If the battery does not charge properly: a. Check for voltage at the outlet by plugging in some other elec- trical device. b. Verify charger voltage is ap- proximatly 30vdc. Refer to charger plug pinout here or on charger label.

Follow these important safety instructions and review the cautionary markings on the battery charger, battery pack, and the Cordless PullzAll tool before using the Cordless PullzAll battery charger. Remove charger from power source when battery is fully charged. Use only the charger that accompanies the Cordless PullzAll or an Of fi cial WARN charger accessory. Only charge WARN Cordless PullzAll rechargeable batteries, other types of batteries may burst causing personal injury and damage. Do not charge the battery in damp or wet environment. Do not disassemble the charger. Take it to a Warn authorized service center when service is required. Important Charging Notes 1) The battery pack accepts only about 80% of its maximum capacity with its fi rst few charge cycles. However, after the fi rst few charge cycles and normal usage, the battery will charge to full capacity. 2) The charger was designed to fast charge the battery, only when the battery temperature is between 32ºF (0º C) and 120ºF (49º C). If the battery pack is too hot or too cold, the battery pack should not be charged. (This may happen if the battery pack is hot from heavy use.) Wait until the battery returns to room temperature before charging. 3) A substantial drop in operating time per charge may mean that the battery pack is nearing the end of its life and should be replaced.

Charging the Battery Pack Plug charger’s power cord into a standard power outlet, then insert the battery charging plug from the charger into the battery. The charger’s red LED indicator light will be solid, indicating charging.

WARNING Always avoid contact with battery leakage, which may occur under extreme usage or temperature conditions. Never attempt to disassemble the battery or remove any component. Always let battery cool before using in tool and before charging. Never leave the PullzAll power cord plugged in or the battery in unit when installing, servicing or storing. WARNING NOTICE WARNING

c. Check battery pack terminals for dirt. Clean with a cotton swab and alcohol if necessary. d. If you still do not get proper charging, contact Warn cus- tomer service. The PullzAll battery uses NiMH technology. Check your local ordinances/regulations for disposal or recycling regulations. Prior to disposal, protect exposed terminal with heavy insulating tape to prevent shortage. Battery Disposal

A fully discharged battery should charge in approximately two hours. Charging will automatically stop when charging is complete. For best performance, unplug the charger and allow the battery to cool to room temperature before use in the PullzAll. The battery charger indicator light signi fi es: 1) Green LED on: Fully charged 2) Red LED on: Charging 3) Red LED fl ashing: A fault condition is present. 4) Green LED fl ashing: Over temperature protection.

Chemical First Aid : If leakage from battery comes in contact with skin, wash with soap and water. If liquid gets into eyes, fl ush with water for 15 minutes.

If the red LED is fl ashing, stop charging the battery and follow the charger safety rules below. If the problem persists, contact a Warn authorized service center.

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OPERATING THE PULLZALL

Pulling or Lifting Procedure The following steps describe how to pull or lift using a single line rigging technique. Double or multiple line rigging techniques follow the same basic steps but use a snatch block to assist the process. For details, see the “Rigging Techniques” section in this manual. Step 1 : PUT ON GLOVES AND ATTACH HOOK STRAP. Ensure the hook strap is attached to the hook with latch on the wire rope, not the swiveling anchor hook.

Practice using your PullzAll before you pull or lift a load. A real situation is no time to be learning how to use your PullzAll. Knowing the proper pulling and lifting techniques can help keep you and others around you safe. And perhaps the most important part of the pulling process, regardless of the situation, is what you do before you pull. In this guide, you are shown the basic fundamentals for effective pulling/lifting. However, it is up to you to analyze the situation and make the decisions necessary for the proper use of your PullzAll. Apply your knowledge of your PullzAll and the basic fundamentals you have practiced to adjust your techniques to each unique situation. Some keys to remember when using your WARN PullzAll: 1. Always take your time to assess your situation and plan your pull or lift carefully. 2. Always take your time when using a PullzAll. 3. Use the right equipment for your situation. 4. Always wear leather gloves and do not allow the wire rope to slide through your hands.

Step 3: POWER ON THE PULLZALL. Flip the power switch to the ‘On’ position. Always leave the power switch in the ‘Off’ position when the PullzAll is not in use. Step 4 : SPOOL OUT WIRE ROPE TO LOAD. Press the directional switch to ‘spool out’. Always keep tension on the wire rope while spooling in and out. The wire rope may unwind inside the PullzAll unit causing bird nesting and binding, leading to wire rope damage.

Step 5 : ATTACH TO ANCHOR POINT. Attach the PullzAll to an anchor point using the swiveling anchor hook. That is capable of handling the load. Step 6: PLAN TO PULL. Line up your pull as straight ahead as possible. This prevents side pulls that can allow the wire rope to rub on the fairlead. Also, side pulls cause the wire rope to stack up at one end of the drum. This can damage the wire rope or the PullzAll. Step 7: SECURE TO THE LOAD. Establish a load point. Often a load does not have a secure load point. It may be necessary to secure the load with a choker chain or a load strap. Step 8: ATTACH THE CLEVIS/D- SHACKLE. Attach the shackle to the two ends of the strap or chain being careful not to over tighten the shackle (tighten and back-off 1/2 turn). Secure the shackle into the throat of the PullzAll hook. Step 9: PUT WIRE ROPE UNDER TENSION. Press the directional switch to ‘spool in’ wire rope. Use the trigger control to slowly wind the wire rope until no slack remains. Tension in the wire rope will keep it from bird nesting and binding. Once the wire rope is under tension, stand well clear, and never step over the wire rope. Step 10: CHECK YOUR LOAD. Ensure all connections are secured and free of debris before continuing with the procedure.

WARNING

Always use suitable anchor point capable of handling load.

WARNING Always use supplied hook strap to hold hook when spooling rope in or out.

WARNING Never spool out past red paint on wire rope.

WARNING

Always use properly grounded 120V AC 50/60 Hz single phase receptacle protected by a ground fault circuit interrupter (GFCI). Never remove ground pin from plug. Never operate this AC product in a wet environment. Never route electrical cables across sharp edges. Never route

WARNING

Always keep hands and clothing clear of the rope, hook and fairlead opening during operation and when spooling.

Step 2 : CONNECT TO POWER SOURCE. Corded 120 VAC PullzAll 1) Connect the PullzAll power cord to a properly grounded, 3-prong electrical socket. 2) Verify that power cords and extension cords are positioned so that the wire rope or mov- ing load will not damage the cords. 3) Verify that extension cords are rated for 15 Amps. Cordless 24V DC PullzAll 1) Ensure the battery pack is fully charged. 2) Verify the power switch is in the ‘Off’ position. 3) Slide battery pack into the body, making sure that the latch is fully engaged. The battery release button must be in the top position.

Spooling Alone : Attach the hook with latch to an anchor point and walk the PullzAll away from the load. Spooling with an Assistant : Have the person handling the rope hold the hook strap and walk the wire rope away from the PullzAll while spooling out the wire rope. NEVER spool the wire rope out past the red paint on the wire rope. The red paint is visible when 13 ft. (3.9 m) of wire rope is unwound. Doing so can cause the wire rope to spool on the drum in the wrong direction. This can damage the wire rope and fairlead.

WARNING

Never hook wire rope back onto itself. This damages the rope. CAUTION The Corded 120 VAC PullzAll has some delay in the trigger control use the slow spooling speed and release the trigger early to

electrical cables through or near moving parts. Never route electrical cables near parts that become hot.

5. Only one person should operate the PullzAll while pulling a load. 6. Think safety at all times. 7. Practice. Practice and practice the steps.

prevent from spooling the hook loop into the fairlead.

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OPERATING THE PULLZALL

Begin Pulling or Lifting the Load

Step 12: MAKE YOUR INTENTIONS CLEAR. Be sure that everyone in the immediate vicinity surrounding the pulling operation is completely aware of your intention before you pull or lift. Declare where the spectators should not stand—never behind, in front of, or under the load and never near the wire rope or snatch block. Your situation may have other “no people” zones.

Step 13: BEGIN PULLING/ LIFTING. Press the directional switch to ‘spool in’ wire rope. With light tension already on the wire rope, begin spooling in slowly and steadily. What to look for under load The rope must always be spooled onto the drum. As you spool in, make sure the rope winds evenly and tightly on the drum. This prevents the outer wire wraps from drawing into the inner wraps, “bird nesting” and binding can damage the wire rope and PullzAll. During side pulls the wire Step 14: SECURE LOAD. Once movement of the load is complete, be sure to secure the load completely. Only then should you release tension in the wire rope. Step 15 : DISCONNECT WIRE ROPE. Reverse directional switch and spool out a short length of wire rope. Disconnect hook with latch from the load whenever possible. Step 16: DISCONNECT FROM ANCHOR. Disconnect the swiveling anchor hook from the anchor point. rope tends to stack up at one end of the drum. To prevent stacking the wire rope on one side of the drum, line up the pull as straight ahead as possible.

Step 17: REWIND WIRE ROPE . Reverse directional switch to ‘spool in’ wire rope. Be sure any wire rope already on the spooling drum is wound tightly. Arrange the wire rope so it will not kink or tangle when spooled. Always keep the wire rope under tension when spooling the wire rope back onto the drum. Do not let the wire rope slide through your hand. If alone, attach the hook with latch to an anchor point, apply light tension to the wire rope and slowly walk the PullzAll towards anchor point as wire rope winds on drum. If a person is handling the rope, keeping tension, they should walk the wire rope in, using the hook strap. If you do not have the hook strap, use a length of cord or something similar. To prevent serious injury, NEVER put your fi ngers inside the hook area as you are spooling in. DO NOT use the load limiter to stop the hook against the fairlead; the hook should not spool into the unit. . Step 18: TURN OFF THE PullzAll Flip the power switch to the ‘Off’ position. Store the PullzAll in a clean and dry place. Pulling operations are now complete.

NOTICE

The following steps describe how to operate the PullzAll after it has been properly rigged.

Avoid over heating the

PullzAll motor. For extended pulling, stop at reasonable intervals to allow the PullzAll motor to cool down. See table for run time guidelines. CAUTION The Corded 120 VAC PullzAll has some delay in the trigger control. Use the slow spooling speed and release the trigger early to prevent from spooling the hook loop into the fairlead.

Step 11: LAY SOMETHING OVER THE WIRE ROPE. In the interest of safety consider hanging a dense fabric midway between the PullzAll and the load point to absorb energy should the wire rope or load point snap loose. For example use a heavy blanket, heavy jacket, chain or a back pack.

WARNING Never use pulling tool to lift or move persons. Never use pulling tool to lift over persons.

Establish “no people” zones

NOTICE

Troubleshooting

Always avoid side pulls which can pile up rope at one end of the drum. This can damage wire rope or PullzAll. Always keep hands and clothing clear of the rope, hook and fairlead opening during operation and when spooling. WARNING

If the PullzAll will not spool in or out, ensure that the On/ Off power switch is in the ‘On’ position. Verify that the overload indicator is not fl ashing and the green power indicating light is on. On the Corded PullzAll unit, ensure that the power cord is plugged in and the circuit has power. On the Cordless PullzAll unit ensure that the battery is charged. Then try spooling the rope. If this does not solve the problem, contact a Warn authorized service center.

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RIGGING TECHNIQUES

ACCESSORIES

Start by spooling out the wire rope. Attach the hook to an anchor and run the rope through a snatch block. Using the snatch block, spool out enough wire rope to reach your load point. DO NOT spool out past the red wire rope. Doing so can cause the wire rope to spool on the drum in the wrong direction. This can damage wire rope and fairlead. Secure to the load point with a strap or choker chain. Attach the clevis/shackle. Attach the shackle to the two ends of the strap/chain, being careful not to over tighten (tighten and back-off 1/2 turn).

Various pulling situations will require application of other pulling techniques. These could range from too little distance to achieve maximum pull/lift using straight line rigging, increasing pulling power, or maintaining a straight line pulling situation. You will have to assess what technique is correct for you situation. Think “safety” at all times. Think through each situation before you act. Increasing Pulling Power & Duration In some cases, you may fi nd yourself needing more pulling power. The use of snatch blocks increases mechanical advantage and increases your pulling power:

Snatch Block: Used properly, the multi-purpose snatch block allows you to: (1) increase your PullzAll’s pulling power, and (2) change your pulling direction without damaging the wire rope. Proper use of the snatch block is covered in the “Rigging Techniques”.

The PullzAll is a convenient handheld pulling tool. Some of the following accessories are vital to the safe operation of the PullzAll, while others offer added versatility and convenience. Gloves: Wire rope, through use, will develop “barbs” which can slice skin. It is extremely important to wear protective gloves while operating the PullzAll or handling the wire rope. Avoid loose fi tting clothes or anything that could become entangled in the wire rope and other moving parts.

WARNING Never spool out past red paint on wire rope.

CAUTION

Never attach a recovery strap to the PullzAll hook to increase the length of a pull. Never use bungee straps that develop tremendous and potentially dangerous amounts of force when stretched.

Clevis/D-Shackles: The D-Shackle is a safe means for connecting the looped ends of straps and snatch blocks. The shackle’s pin is threaded to allow

Pallet Pulling Example:

Hook Strap: Used to hold the hook and keep fi ngers away from the fairlead as the rope is being spooled in and out. Pulling tools develop tremendous forces and can easily remove fi ngers and limbs that are placed in pinch points. Put the hook into the loop and hold the strap between the thumb and fore fi ngers.

Lifting

easy removal. Strap: Typically made of tough, high-quality nylon, it provides the operator an attachment method for connecting the PullzAll wire rope to a load or anchoring point.

Anchor the PullzAll so that it is offset and not inline with object to be lifted. Do not attempt to lift an off-center load, this can cause the load to swing dangerously. Never allow the load to swing or twist.

Single line

WARNING Never use pulling tool to lift or move persons. Never use pulling tool to lift over persons.

Double line

Double Line

Because pulling power decreases with the number of layers of rope on the PullzAll drum, you can use a snatch block to double line out more rope. This decreases the number of layers of rope on the drum, and increases pulling power.

Choker Chain: Can be used to hook-up a load.

Accessory kits are available for the PullzAll. Contact Warn customer service to learn more.

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WARN INDUSTRIES * THE BASIC GUIDE TO UTILITY PULLING 20

MAINTENANCE AND FINAL ANALYSIS

Maintenance

Final Comment

Inspect the wire rope and hooks for signs of wear or damage before and after each operation. Worn and damaged parts must be replaced. Do not attempt to lengthen the wire rope or repair a damaged rope. Keep the wire rope and hooks free from contaminants. Use a clean towel to remove dirt & debris. Using light oil on the wire rope and hooks can prevent corrosion from forming. When cleaning the Cordless PullzAll tool be sure to keep clear of electrical terminals on battery pack and verify that the battery is not cracked or otherwise damaged. Any hook that has twisted components or excessive opening may indicate over-loading of the product. Contact a Warn authorized service center for repairs, replacement parts or accessories. Examples of Wire Rope Damage : Kinks, cuts, knots, mashed or frayed portions, and broken strands. Examples of Hook Damage : Cracks, twisted components, excessive opening, seat wear, loose or unclosed latch, and corrosion.

This guide to proper pulling techniques cannot cover all the possible situations in which you may need to use a PullzAll. In the fi nal analysis, the decisions you make will determine the fi nal outcome. So think through each situation and each step of use. Always be mindful of your own safety and the safety of others. Pay attention and you’ll have fun.

WARNING

Never leave the PullzAll power cord plugged in or the battery in unit when installing, servicing or storing.

PullzAll™ Guide d’installation et manuel de l’utilisateur Chaque situation de traction et levage peut potentiellement occasionner des blessures. Pour minimiser ce risque, il est important que vous lisiez ce guide de base avec attention, que vous vous familiarisiez avec le maniement du PullzAll avant de l’utiliser et que vous vous préoccupiez avant tout de la sécurité. Nous exposons dans ce guide de nombreuses règles de sécurité fondamentales pour le maniement du PullzAll. Toutefois, comme chaque situation de traction/levage est différente, votre bon sens et votre attachement constant aux principes de sécurité sont d’une importance primordiale. Index des symboles................................................................................................... 23 Mesures générales de sécurité ............................................................................24-27 SPÉCIFICATIONS PullzAll 120 V c.a. avec fi l ......................................................................................... 28 PullzAll 24 V c.c. sans fi l ...........................................................................................29 INSTRUCTIONS TABLE DES MATIÈRES: SÉCURITÉ Introduction à la traction utilitaire............................................................................... 30 Principes de fonctionnement du PullzAll ..............................................................31-33 Source d’alimentation ........................................................................................... 34-35 Utilisation du PullzAll ............................................................................................ 36-39 Accessoires ............................................................................................................... 40 Techniques de câblage.............................................................................................. 41 Entretien et derniers commentaires ..........................................................................42 WARN INDUSTRIES 12900 SE Capps Road Clackamas, OR 97015 États-Unis Service à la clientèle : (800) 543 - WARN (9276)

WARNING Always use Warn Industries Replacement Parts when the product needs to be serviced. Contact the Warn Customer Service department to fi nd the proper replacement part numbers (contact information listed

in Warranty information).

International : (503) 722-3008 Télécopie : (503) 722-3000

www.warn.com

WARN INDUSTRIES * THE BASIC GUIDE TO UTILITY PULLING 21

MESURES GÉNÉRALES DE SÉCURITÉ

MESURES GÉNÉRALES DE SÉCURITÉ Avertissements et mises en garde

SYMBOLE

EXPLICATION

AVERTISSEMENT

Lire le manuel d’utilisation

Risque d’explosion/rupture

Les directives suivantes comprennent des indications intitulées AVERTISSEMENT, MISE EN GARDE, AVIS et REMARQUE. Chacune a un objectif bien précis : AVERTISSEMENT présente des consignes de sécurité soulignant un danger potentiel qui, s’il n’est pas évité, peut entraîner des blessures graves ou la mort. MISE EN GARDE comprend des consignes de sécurité signalant un danger potentiel qui, s’il n’est pas évité, peut entraîner des blessures légères ou modérées. MISE EN GARDE sert aussi à signaler une utilisation dangereuse. MISE EN GARDE et AVERTISSEMENT identi fi ent un danger, indiquent comment l’éviter et montrent ses conséquences possibles si on l’ignore. AVIS présente des consignes visant à éviter les dommages matériels. REMARQUE donne des renseignements additionnels qui aident à accomplir une procédure. TRAVAILLEZ PRUDEMMENT!

RISQUE ÉLECTRIQUE Le non-respect des consignes peut entraîner des blessures graves ou la mort. • Toujours utiliser une prise correctement mise à la terre conçue pour fonctionner avec un courant monophasé et protégée par un disjoncteur différentiel. • Ne jamais enlever la broche de terre de la fi che. • Ne jamais faire passer les câbles électriques par- dessus des bords tranchants. • Ne jamais faire passer les câbles électriques à travers des pièces mobiles ou à proximité. • Ne jamais faire passer les câbles électriques à proximité de pièces pouvant devenir chaudes. • Ne jamais retirer le couvercle électrique du chargeur de batterie. • Ne jamais laisser le cordon d’alimentation de l’outil de traction branché durant l’installation, le câblage, l’entretien ou quand l’outil de traction n’est pas utilisé. • Ne jamais débrancher la liaison de mise à la terre. • Ne jamais faire fonctionner l’appareil dans un environnement humide. • Toujours alimenter l’outil de traction uniquement avec un circuit électrique possédant la tension recommandée. Voir la fi che technique de l’outil de traction pour plus de détails. • Ne jamais utiliser le chargeur avec un cordon ou une prise endommagé. Les remplacer immédiatement. • Ne jamais faire fonctionner le chargeur s’il a subit un coup dur ou une chute, ou a été endommagé. • Ne jamais charger la batterie dans un environnement humide ou mouillé. • Toujours charger la batterie à des températures supérieures à 0 °C et inférieures à 49 °C. Ceci est important et permettra d’éviter de graves dommages à la batterie. • Toujours ranger l’outil de traction et la batterie dans un lieu où la température ne dépasse pas 49 °C. • Toujours débrancher le chargeur lorsque la batterie est complètement chargée.

Risque d’incendie et de brûlure

Ne jamais soulever de charge au-dessus de personnes

Ne pas déplacer des personnes

Positionner correctement la charge dans la gorge du crochet

Ne jamais appliquer la charge sur l’extrémité ou le loquet du crochet

AVERTISSEMENT

Toujours porter des gants

Danger d’écrasement des doigts dans le guide-câble

RISQUES ASSOCIÉS AUX PRODUITS CHIMIQUES ET RISQUE D’INCENDIE Le non-respect des consignes peut entraîner des blessures graves ou la mort. • Toujours lire toutes les instructions et les avertissements sur le chargeur de batterie, la batterie et l’outil de traction sans fi l. • Ne jamais faire fonctionner l’outil de traction dans un environnement contenant des matériaux explosifs ou combustibles. • Ne jamais exposer la batterie à une forte chaleur ou un feu. • Ne jamais ranger la batterie du PullzAll sans fi l dans une boîte ou poche à outils avec des clous, vis, clés, etc. Le court-circuitage des bornes de la batterie peut provoquer un incendie. • Toujours éviter tout contact avec une fuite de la batterie, ce qui peut se produire en cas d’utilisation ou de température extrême. • Toujours retirer la batterie lorsque l’appareil n’est pas utilisé. • Toujours éliminer ou recycler la batterie conformément aux règlements en vigueur. • Toujours protéger les bornes avec du ruban isolant avant leur élimination pour empêcher tout court-circuit. • Ne jamais tenter de démonter la batterie. Elle ne contient aucune pièce réparable par l’utilisateur.

Toujours utiliser la sangle de crochet fournie

Risque de percement/coupure des mains

Risque de surface chaude

Enrouler le câble sur le dessus du tambour

Ne pas enrouler le câble sur le dessous du tambour

Toujours porter un dispositif de protection auditive et oculaire

Risque de choc électrique

Brochage de prise de chargeur

WARN INDUSTRIES * LE MANUEL DE BASE DES TECHNIQUES DE TREUILLAGE UTILITAIRE 23

WARN INDUSTRIES * LE MANUEL DE BASE DES TECHNIQUES DE TREUILLAGE UTILITAIRE 24

MESURES GÉNÉRALES DE SÉCURITÉ

AVERTISSEMENT

DANGER DE HAPPEMENT PAR DES PIÈCES MOBILES Le non-respect des consignes peut entraîner des blessures graves ou la mort. Consignes de sécurité générales : • Toujours retirer les bijoux et porter des lunettes de sécurité et des protège-oreilles. • Toujours porter des gants, des lunettes de sécurité et des protège-oreilles. • Toujours garder les mains éloignées du câble, de la boucle du crochet, du crochet et de l’ouverture du guide-câble durant l’installation et l’utilisation de l’appareil et l’enroulement ou le déroulement du câble. • Toujours garder les mains et les vêtements éloignés du câble, du crochet et de l’ouverture du guide- câble pendant le fonctionnement de l’appareil et l’enroulement ou le déroulement du câble. • Ne jamais laisser le câble glisser dans les mains. • Toujours se familiariser avec l’outil de traction. Prendre le temps de bien lire le manuel d’utilisation a fi n de comprendre l’outil de traction et son fonctionnement. • Ne jamais faire fonctionner l’outil de traction sous l’effet de drogues, de l’alcool ou de médicaments. • Ne jamais faire fonctionner le PullzAll en le portant sur le côté. • Toujours garder à l’esprit que les appareils à batterie sont continuellement opérationnels. Consignes de sécurité relatives au fonctionnement : • Toujours porter des gants de cuir épais durant la manipulation du câble d’acier. • Toujours se tenir à l’écart du câble et de la charge et ne jamais laisser personne s’approcher durant les opérations de traction ou de levage. • Toujours s’assurer que tout objet ou obstacle pouvant gêner la bonne utilisation de l’outil de traction est écarté. • Ne jamais laisser le cordon d’alimentation de l’outil de traction branché durant l’installation, le câblage, l’entretien ou quand l’outil de traction n’est pas utilisé. • Toujours utiliser la sangle de crochet fournie pour enrouler ou dérouler le câble, durant l’installation ou l’utilisation. • Toujours faire très attention en manipulant le crochet et le câble pendant les manœuvres de déroulement. • Ne jamais installer et faire fonctionner un outil de traction sans avoir lu et compris le manuel de l’utilisateur. • Ne jamais faire fonctionner cet appareil de traction si l’on a moins de 16 ans.

DANGER DE HAPPEMENT PAR DES PIÈCES MOBILES Le non-respect des consignes peut entraîner des blessures graves ou la mort. Consignes de sécurité relatives à la traction : • Toujours garder l’outil de traction et la charge à tracter/soulever en vue lors des opérations de traction/levage. • Toujours exiger de l’opérateur et des personnes présentes d’être conscients du câble et de la charge. • Toujours être conscient de la stabilité de la charge durant la traction/le levage. Veiller à ce que personne ne s’approche. Alerter toutes les personnes alentour en cas d’instabilité. • Ne jamais toucher le câble ou le crochet lorsqu’une autre personne manipule l’interrupteur de commande ou durant les opérations de traction/levage. • Ne jamais toucher le câble ou le crochet lorsque le câble est tendu ou sous charge. • Toujours inspecter le câble, le crochet et les élingues avant de faire fonctionner l’outil de traction. Tout câble ef fi loché, tordu ou endommagé doit être remplacé immédiatement. Tous les composants endommagés doivent être remplacés avant d’utiliser le produit. Protéger toutes les pièces contre le risque de dommages. • Toujours enrouler le câble sur le tambour de façon serrée après chaque utilisation. Durant l’enroulement ou le déroulement, le câble peut changer de sens inopinément s’il s’enchevêtre et se coince sur le tambour. Un câble enroulé de manière serrée réduit le risque qu’il coince.

DANGER DE CHUTE OU D’ÉCRASEMENT Le non-respect des consignes peut entraîner des blessures graves ou la mort. • Ne jamais attacher une sangle de dépannage au crochet de l’outil de traction pour augmenter la longueur d’un treuillage. • Toujours utiliser un crochet muni d’un loquet. • Toujours s’assurer que le loquet du crochet est fermé et qu’il ne soutient aucune charge. • Ne jamais appliquer la charge sur l’extrémité ou le loquet du crochet. Appliquer la charge uniquement au centre du crochet. • Ne jamais utiliser un crochet dont l’ouverture de la gorge a augmenté ou dont l’extrémité est courbée ou tordue. • Ne jamais essayer de remorquer un véhicule ou un objet avec la sangle de dépannage directement attachée au crochet de l’outil de traction. • Ne jamais utiliser des sangles élastiques car elles développent une force énorme en tension et sont potentiellement dangereuses. • Toujours éviter de tirer sur le côté, ce qui a pour effet d’empiler le câble sur l’une des extrémités du tambour. Cela peut endommager le câble ou l’outil de traction. • Ne jamais accrocher le câble à lui-même. Cela l’endommagerait. • Toujours utiliser une élingue, un câble à nœud coulant ou une sangle. • Ne jamais utiliser l’outil de traction pour soulever ou transporter des personnes. • Ne jamais se servir de l’outil de traction pour soulever une charge au-dessous de personnes. • Toujours choisir un point d’ancrage aussi distant que possible. Cela assure à l’outil de traction une puissance de traction maximum. • Toujours utiliser un point d’ancrage approprié capable de supporter la charge.

DANGER DE CHUTE OU D’ÉCRASEMENT Le non-respect des consignes peut entraîner des blessures graves ou la mort. • Ne jamais se servir de l’outil de traction pour maintenir une charge. • Ne jamais secouer le câble sous charge. Cela peut endommager, surcharger et casser le câble. • Ne jamais utiliser le câble de l’outil de traction pour remorquer un véhicule ou objet. La charge d’impact durant le remorquage peut excéder la résistance du câble. • Toujours s’assurer que le point d’ancrage choisi peut supporter la charge et que la sangle ou la chaîne ne glisse pas. • Toujours prendre le temps d’utiliser des techniques de câblage adaptées pour tirer/soulever. • Ne jamais débobiner au-delà de la peinture rouge sur le câble. • Ne jamais dépasser la capacité de l’outil de traction ou du câble indiquée sur la fi che technique du produit. Un câblage double avec poulie ouvrante permet de réduire la charge subie par l’outil de traction. • Ne jamais dépasser la capacité de traction maximale de 454 kg. • Toujours utiliser un point d’ancrage approprié capable de supporter la charge. • Toujours utiliser un matériel de montage, des composants et des accessoires homologués par le fabricant. • Toujours rembobiner sous tension de charge après chaque utilisation. Un câble enroulé de manière serrée réduit le risque qu’il coince et soit endommagé. • Toujours enrouler le câble sur le tambour dans le sens spéci fi é par l’étiquette d’avertissement apposée sur l’appareil ou fi gurant dans sa documentation. • Toujours éviter de faire marcher et d’arrêter l’outil de traction rapidement de façon répétée (avec la commande ou la prise). Cela peut endommager les commandes du moteur ou le câble.

AVERTISSEMENT

RISQUE DE COUPURE ET DE BRÛLURE Le non-respect des consignes peut entraîner des blessures graves ou la mort. To avoid injury to hands and fi ngers: • Always wear gloves, eye and ear protection. • Never insert battery into charger if battery case is cracked or damaged. Battery short or fi re may result. • Never short battery terminals, because it may cause sparks or burns.

WARN INDUSTRIES * LE MANUEL DE BASE DES TECHNIQUES DE TREUILLAGE UTILITAIRE 25

WARN INDUSTRIES * LE MANUEL DE BASE DES TECHNIQUES DE TREUILLAGE UTILITAIRE 26

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