97734.A1 - 16.5TI-S Replacement Parts List
SERVICE GUIDE For WARN PULLZALL 120v AC &100v AC P/N 685000 & 685001
REPAIR / REPLACEMENT INSTRUCTIONS TROUBLE SHOOTING GUIDE
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WARNING
This guide identifies potential hazards and has important safety messages that help you and others avoid personal injury or death. WARNING and CAUTION are signal words that identify the level of hazard. These signal words mean: WARNING signals a hazard that may cause serious injury or death, if you do not follow recommendations. CAUTION signals a hazard that may cause minor to moderate injury, if you do not follow recommendations. This guide uses NOTICE to call attention to important mechanical information, and
Note: to emphasize general information worthy of special attention.
Notice
This guide has been provided for use by WARN Authorized Service Centers. Any other use is prohibited.
Caution Moving parts entanglement hazard Failure to observe these instructions could lead to minor or moderate injury Always take time to fully read and understand the Instructions. Never operate this product if you are under 16 years of age. Never operate this product when under the influence of drugs, alcohol or medications. Read instructions thoroughly
Notice Equipment damage
Always refer to the Wiring Diagram for all wiring schematics and specific details on how to wire this WARN product.
Read instructions thoroughly.
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CONTENTS
1. GENERAL DESCRIPTION
04
2. DISASSEMBLY AND ASSEMBLY
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.
Suggested Tools
06 07 11 18 24 29 33 38 39 47
Housing
Gear Train Assembly
Motor
Wire Rope Assembly
Safety Hook
Tail Hook
Drum Assembly Wiring Diagrams
2.10.
Torque Specifications
3. PULLZALL TROUBLE SHOOTING
48
4. SERVICE PART LIST
50
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1. GENERAL DESCRIPTION
The PullzAll is a powerful, lightweight, easy-to-use handheld electric tool with the ability to lift or
pull up to 1,000 lbs / 454 kg. A strong Motor and Variable Speed Trigger Switch for power in and
power out operation, Wire Rope and Clasp Hook will allow you to move heavy items into place
smoothly and precisely. These features equate to saving both time and money.
The PullzAll will help get the job done easier, faster, and with less manual labor than a come-a-
long or chain fall, making you more productive. The PullzAll is for the tradesperson, farmer /
rancher, or anyone that needs to lift or pull up to 1,000 lbs / 454 kg. This makes PullzAll ideal for
construction, pipe fitting, iron work, equipment and plant maintenance, farm and ranch use, auto
shops, garages, machine shops, home improvement, hunting, camping, and more.
PullzAll 120v AC Specifications:
1. Part number 685000 & 685001. 2. Light weight and portable. 3. Powerful 120 Volt AC Motor. 4. 1,000 lbs (454 kg) lifting / pulling capacity.
5. 15'(4.6m) of 7/32"(0.56cm) diameter Wire Rope. 6. Variable Speed Control for precision load placement. 7. Convenient forward/reverse Switch. 8. Electronic Load Limiter with LED indicator for operator feedback.
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2 DISASSEMBLY AND ASSEMBLY
2.1 SUGGESTED TOOLS
1. Hammer 2. Snap ring plier
3. Allen key set 4. Screw driver 5. Cutting plier 6. Pin remover (Punch) 7. Insulation tape 8. Gloves
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2.2 HOUSING
Before opening the Housing follow the below instructions:
Power Cord
Always unplug the product while rigging, when not in use or during maintenance and cleaning.
2.2.1 REMOVAL OF HOUSING
Remove the screws (#6 x .75), Qty 7 from Handle.
Remove the screws (#8 X 1.25), Qty 6 from the main body of the Housing.
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Keep the assembly on the work bench facing the Cover in the direction as shown in the figure.
Remove the Plastic Housing -left hand from the assembly as shown in the figure.
Remove the Main Chassis from the Plastic Housing - right hand and place it on the work bench.
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2.2.2 ASSEMBLY OF HOUSING
Install the Main Chassis in the Plastic Housing - right hand as shown in the figure.
Install the Plastic Housing -left hand on the assembly as shown in the figure.
Flip the assembly as show in the figure.
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Install the screws (#8 X 1.25), Qty 6 from the main body of the Housing.
Install the screws (#6 x .75), Qty 7 near Handle.
Note: When replacing the Housings with a Housing Service kit, be sure to affix ALL appropriate labels from the service kit onto the new housings, using the housings being replaced as a guide for placement of your new labels. Your service kit will include extra labels for other languages and markets that can be discarded after you select the ones needed for your product.
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2.3 GEAR TRAIN ASSEMBLY
• If the gearsets are worn or damaged, the entire PullzAll must be replaced, no replacement
parts are available.
2.3.1 GEAR TRAIN ASSEMBLY REMOVAL
Remove Retaining Ring from Idler Gear.
Remove Wear Washer from Idler Gear.
Remove Retaining Ring from Helical Gear Press. Remove Wear Washer from Helical Gear.
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Remove Helical Gear from Gear Housing.
Remove 3 Cap Screws(#3 x .75) from Gear Housing through Left side Bracket of Chassis assembly.
Remove Gear Housing from left side Bracket of Chassis assembly.
Remove Carrier Assembly from Ring.
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Remove Ring Gear 51 T from left side Bracket P/N of Chassis assembly.
2.3.2 GEAR TRAIN REASSEMBLY
Install Gear Train assembly after installation of Motor assembly.
Insert Ring Gear 51 T on Left side Bracket of Chassis assembly as shown in the figure.
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Install Ring Gear 48T P/N 73225 and Carrier Assembly P/N 73227 in Gear Housing P/N 75077.
Install Gear Housing on Left side Bracket of Chassis assembly aligning dowel pins.
Install 3 Cap Screws (#3 x .75) in Gear Housing through Left side Bracket of Chassis assembly.
Install Helical Gear on Gear Housing as shown in the figure.
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Install Wear Washer on Helical Gear Press.
Install Retaining on Helical Gear.
Install Idler Gear on Gear Housing.
Install Wear Washer and Retaining Ring on Idler Gear.
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2.3.3 INSPECTION OF GEAR TRAIN
1. Check each Idler Gear to make sure that all teeth are present in good condition.
2. Check each Sun Gear to make sure all teeth are present and in good condition.
3. Check each side of each Sun Gear to make sure there are no grooves from wear. Replace
the Gear Set if worn.
4. Check Carrier Assembly to make sure that Planet Gears are tight. Each Gear should be able
to move a small distance when pulled from and pushed toward center of Gear Set. All
Planet Gears should have about the same amount of movement. Replace Carrier Assembly
if Planet Gears are loose.
5. Push each Planet Gear against its axle pin and rotate the Gear completely. The Gear must
turn smoothly on Pin. Replace Gear Set if Planet Gears do not turn smoothly.
6. Check the Ring Gear 48T inside the Gear Housing. All the Gear teeth must be in good
condition and they must be free of debris. The Gear Housing must be replaced if teeth have
a wear groove.
7. If the Gear sets are worn or damaged, the entire PullzAll must be replaced, no replacement
Parts are available.
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2.4 MOTOR
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2.4.1 REMOVAL OF MOTOR
Before removing the Motor follow the instructions given below:
Remove the Gear Train assembly.
Remove the 2 screws (#8 x 0.75) from Chassis assembly.
Remove the left side cap screw and nut from Hawse Fairlead assembly.
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Remove cap screw from Chassis assembly as shown in the figure.
Remove Left side Bracket from Chassis assembly.
Remove Motor assembly from Chassis assembly after removal of Wiring leads
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2.4.2 ASSEMBLY OF MOTOR
Connect all Wire leads from Motor assembly and install in to Chassis assembly as shown in the figure.
Install Left side Bracket on Chassis assembly as shown in the figure.
Install cap screw in Chassis assembly as shown in the figure.
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Install the left side cap screw and nut from Hawse Fairlead assembly.
Install 2 screws (#8 x 0.75) in Chassis assembly.
2.4.3 MOTOR INSPECTION
Visual inspection.
•
• While assembling the Motor ensure that, Motor has been properly placed inside the End Housing and the screw had been properly tightened.
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2.5 WIRE ROPE ASSEMBLY
2.5.1 REMOVAL OF WIRE ROPE
Note:
Prior to disassembly:
1. Spool out all Wire Rope. 2. Use of gloves is recommended while handling frayed or damaged Wire Rope. 3. Unplug unit before disassembly.
Tasks:
Disassemble the Drum and Wire Rope.
Push the Wire in the direction of the arrow mark as shown in the figure.
Using a punch or drift and hammer, hit the end of the Wire Rope to push the loop back through the Drum.
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Use the Pin remover (punch) to remove the Wire Rope and Stop Button from the Drum.
Straighten the bent Rope and pull the Rope out of Drum hole in the arrow direction as shown.
Remove the Hawse Fairlead from the Bracket of the Chassis.
Remove and discard Tension Plate (if equipped).
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2.5.2 ASSEMBLY OF WIRE ROPE
Assemble the Hawse Fairlead to the Bracket of the Chassis.
Tighten the cap screws with Allen key and opened end wrench.
Keep the insulation tape to the edge of the Wire Rope.
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Insert the Wire Rope into the Drum through the Hawse Fairlead.
Pull the wire from the other end of the Drum hole.
Bend the Wire Rope and insert in to the same hole in the direction shown in the figure.
Pull the Wire Rope from the hole as shown in the figure.
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Support one edge of the Wire and pull the other Wire as shown in the figure.
Verify Wire Rope stop button is inserted into the loop as shown before pulling the Wire Rope tight.
Hit with hammer, so that the Wire Rope will get in to the hole and tightens.
Check the Wire Rope so that it enters completely into the Drum hole.
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Check from the other side of the Drum whether the Wire Rope is perfectly assembled to the Drum.
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2.5.3 INSPECTION OF WIRE ROPE
• Inspect the Wire Rope for signs of wear or damage. Worn and damaged parts must be
replaced.
• See the Rope for damage for kinks, cuts, knots, mashed or frayed portions and broken
strands.
• Keep the Rope free from contaminants. Use a clean towel to remove the dirt and debris.
• Use of light oil on the Wire Rope can prevent corrosion.
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2.6 SAFETY HOOK
2.6.1 REMOVAL OF SAFETY HOOK
To remove Safety Hook follow the below instructions:
First straighten the bent end of the Cotter Pin by using Cutting plier and then pull out the Cotter Pin by holding head of the Cotter Pin with the help of cutting plier from the Pin.
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Remove the Pin from the Hook and Rope.
Remove the Safety Hook from Wire Rope
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2.6.2 ASSEMBLY OF SAFETY HOOK
To Reassemble Safety Hook follow the below instructions:
Place the Safety Hook and align the mounting holes with the loop of the Wire Rope
Insert the Pin through Safety Hook and Wire Rope loop.
Insert the Cotter Pin inside the hole of the Pin and bend the ends of the Cotter Pin with the help of Cutting pliers.
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2.6.3 INSPECTION
• Inspect the Hook for signs of wear and damage.
• Hook damage examples: cracks, twisted components, excessive opening, seat wear, loose or damaged safety latch or corrosion.
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2.7 TAIL HOOK
Original Tailhook Assy
2 nd Generation Tailhook Assy Service Part Tailhook Assy
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2.7.1 REMOVAL OF TAIL HOOK
To remove Tail hook follow the below instructions:
Remove bolt and nut from the Chassis assembly through Tail Hook.
Loose the cap screw with Allen key before removing the Tail Hook and Spacer Pin from Chassis assembly.
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2.7.2 ASSEMBLY OF TAIL HOOK
To reassemble the Original Tailhook follow the below instructions:
Tighten the cap screw after place Tail Hook and Spacer Pin between the Bracket holes.
Assemble the bolt and nut.
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To reassemble the Second Generation Tail Hook follow the instructions :
1. Place Spacer Bracket in Chassis assembly with capscrew and then apply the torque.
2. Take the Tail Hook and align the mounting holes with the Spacer Bracket holes and Chassis assembly.
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3. Insert the Pin through the Hook assembly.
4. Insert the Cotter Pin inside the hole of the Pin and bend the ends of the Cotter Pin with the help of pliers.
2.7.3 TAIL HOOK INSPECTION
• Inspect the Hook for signs of wear and damage
• Hook damage examples: cracks, twisted components, excessive opening, seat wear, loose or damaged safety latch or corrosion.
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2.8 DRUM ASSEMBLY
• If the drum is worn or damaged, the entire PullzAll must be replaced, no replacement parts
are available.
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2.9 WIRING DIAGRAMS
1. WIRING DIAGRAMS
2. REMOVAL
3. ASSEMBLY
4. INSPECTION
Wiring diagram 74862B0 (with Rocker switch)
Note: Older models had a circuit breaker instead of the Rocker switch. Wire Routing to the Circuit breaker is identical to the Rocker Switch.
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WIRING DETAILS
• Route black lead Wire from J3 terminal on Circuit Board through Wire guides up into handle to Trigger Switch.
• Route black lead Wire from J2 terminal on circuit board through Wire guides up to Rocker Switch.
• Route white lead Wire from J4 terminal on circuit board through Wire guides up to Trigger Switch.
Route the Motor wires as shown.
•
• Route Brush leads from Brushes up to Trigger Switch.
• Use tie strap to secure Motor Wires and Brush Wires to the right hand frame.
• Attach green Wire from Power Cord assy. to frame as shown.
• Refer Wiring diagram 74862 for installation Wiring schematic .
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2.9.1 REMOVAL OF WIRING
To remove the wiring follow the below instructions:
Remove Circuit Breaker or Rocker Switch from Plastic Housing (right hand) and remove corresponding lead Wires. Circuit Breaker Shown. Rocker Switch replaced the Circuit Breaker on later models.
Remove 2 Retaining Rings P/N 73742 to unlock Power Cord as shown in figure.
Remove Power Cord assembly from the Plastic Housing.
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Remove the Wire leads from Trigger Switch.
Remove green lead Wire from Chassis . Ensure that all Wires are properly Connected.
Push the Plastic Retainers out that secures the LED display.
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Remove the Load limiter Board Assy from Plastic Cover. Check all the connections for proper contact .
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2.9.2 ASSEMBLY OF WIRING
To reassemble the wiring follow the below instructions:
Install Load limiter Board Assy to Right hand Plastic Housing.
Install LED to Right hand Plastic Housing.
Bolt green lead Wire as a ground to Chassis with the help of Allen key.
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Connect lead Wires to correct locations on the Trigger Switch and place the Trigger Switch into the Right hand Plastic Housing.
Install direction Switch slider properly into the Housing slot related to the Trigger Switch.
Make sure that all lead Wires are routed correctly and connected to Switch correctly.
Install Power Cord assembly.
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Use 2 Retaining Rings to lock Power Cord with the Plastic Housing in opposite direction.
Install Circuit Breaker or Rocker Switch to Right Plastic Cover and connect corresponding lead Wires.
2.9.3 INSPECTION OF WIRING
Visual Inspection.
•
• Ensure that Switches have assembled correctly. Wiring is complete match the drawing.
• Ensure that Wiring has not jammed in Housing. Direction Switches slider assembled correctly.
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2.10 TORQUE SPECIFICATIONS
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3. PULLZALL TROUBLE SHOOTING
PROBLEM
POSSIBLE CAUSE
CORRECTIVE ACTION
1.1 PullzAll does not power in or pulls slowly.
Loose connection on Motor terminals.
Be sure all connections are tight and clean. Do not let bottom nut or stud turn while tightening.
Check the speed mode selected.
Change mode as required.
Burnt main contact point, or poor contacting action.
Worn Brushes.
Replace Motor Assembly
Weakened brush springs.
Poor Wiring connections.
Rope is interfacing with Tie Rod or other part of PullzAll.
Rewind Rope on Drum, so that it is level and not rubbing on other parts of PullzAll.
Motor is hot.
Allow PullzAll Motor to cool for at least 10 minutes between short pulls. Increase cooling time for heavy loads or long pulls.
Abnormally worn Bushing.
Replace PullzAll.
1.2 Noise
Worn or Broken Gearset.
Replace PullzAll
Motor malfunctioning.
Replace Motor.
1.3 Motor is running but not pulling.
Damaged Geartrain
Replace PullzAll
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Motor does not run. Faulty Trigger Switch
Repair or replace Switch
Defective Motor
Replace Motor
Loose connection of the Wires to be Motor terminals.
Secure the Motor terminal and Wires.
1.6 Electrical sparks appear around Motor.
Switch held in power-in position while PullzAll is stalled.
Replace Wiring harness PullzAll Motor.
1.7 Wiring harness insulation has melted. 1.8 PullzAll makes squeaking / high pitch noise.
Poor installation caused Wire insulation to be rubbed off or cut, causing direct short.
Replace Wiring harness.
Drum Bushing not lubricated. Grease Drum Bushings.
1.10 Malfunctioning
Not operating correctly.
Cease operation. Diagnose, Repair or Replace.
INSPECTION
VISUAL INSPECTION:
• While disconnecting the connectors, never pull the wiring Harnesses. Unlock the connector first and then pull them apart by holding connectors themselves.
• While connecting connectors, also hold connectors and put them together until they lock securely (a click is heard).
• While Installing the Wiring Harness, fix it with clamps so that no slack is left.
• While using a tester for checking continuity or measuring voltage, be sure to insert the tester probe from the wire harness side.
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4. SERVICE PART LIST
ITEM NO.
DESCRIPTION
PART NO.
1.
Service Part -Motor assembly 120v AC
77914
(Includes Motor, Plastic Housing, Brushes & Screws)
2.
Service Part - Variable Speed Trigger,120v AC
77911
3.
Service Part - Load limiter assembly, 120v AC
86354
(Includes LED Bezel, Screws and LED Retention Pins)
4.
Service Part - Wire rope assembly, PullzAll
76065
(Includes fair lead)
5.
Service Part - Tail hook assembly
77930
6.
Service Part - Front Hook assembly
78052
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