SERVICE GUIDE For WARN PULLZALL 120Vac P/N 885000 & 885001 REPAIR / REPLACEMENT INSTRUCTIONS TROUBLE SHOOTING GUIDE 987604A2.
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.
CONTENTS 1. GENERAL DESCRIPTION 04 2. DISASSEMBLY AND ASSEMBLY 2.1. Suggested Tools 2.2. Housing 2.3. Gear Train Assembly 2.4. Motor 2.5. Wire Rope Assembly 2.6. Safety Hook Tail Hook 2.7. 2.8. Drum Assembly 2.9. Wiring Diagrams 2.10. Torque Specifications 06 07 11 18 24 29 33 38 39 47 3. PULLZALL TROUBLE SHOOTING 48 4. SERVICE PART LIST 50 987604A2.
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.
Convenient Forward/Reverse Switch Handle with Trigger for Variable Speed Control 15’ of 7/32” Wire Rope with Industrial Grade Hook Electronic Load Limiter with LED Indicator for Operator Feedback 1000 lbs/454 Kg Lifting/Pulling Capacity Versatile Swivel Anchor Hook Runs on 120v AC Power 987604A2.
2 DISASSEMBLY AND ASSEMBLY 2.1 SUGGESTED TOOLS 1. 2. 3. 4. 5. 6. 7. 8. Hammer Snap ring plier Allen key set Screw driver Cutting plier Pin remover (Punch) Insulation tape Gloves 987604A2.
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 1. Remove the screws (#6 x .75), Qty 7 from Handle. 2. Remove the screws (#8 X 1.25), Qty 6 from the main body of the Housing. 987604A1.
3. Keep the assembly on the work bench facing the Cover in the direction as shown in the figure. 4. Remove the Plastic Housing -left hand from the assembly as shown in the figure. 5. Remove the Main Chassis from the Plastic Housing - right hand and place it on the work bench. 987604A1.
2.2.2 ASSEMBLY OF HOUSING 1. Install the Main Chassis in the Plastic Housing - right hand as shown in the figure. 2. Install the Plastic Housing -left hand on the assembly as shown in the figure. 3. Flip the assembly as show in the figure. 987604A1.
4. Install the screws (#8 X 1.25), Qty 6 from the main body of the Housing. 5. 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.
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 1. Remove Retaining Ring from Idler Gear. 2. Remove Wear Washer from Idler Gear. 3. Remove Retaining Ring from Helical Gear Press. Remove Wear Washer from Helical Gear. 987604A1.
4. Remove Helical Gear from Gear Housing. 5. Remove 3 Cap Screws(#3 x .75) from Gear Housing through Left side Bracket of Chassis assembly. 6. Remove Gear Housing from left side Bracket of Chassis assembly. 7. Remove Carrier Assembly from Ring. 987604A1.
8. Remove Ring Gear 51 T from left side Bracket P/N of Chassis assembly. 2.3.2 GEAR TRAIN REASSEMBLY 1. Install Gear Train assembly after installation of Motor assembly. 2. Insert Ring Gear 51 T on Left side Bracket of Chassis assembly as shown in the figure. 987604A1.
3. Install Ring Gear 48T P/N 73225 and Carrier Assembly P/N 73227 in Gear Housing P/N 75077. 4. Install Gear Housing on Left side Bracket of Chassis assembly aligning dowel pins. 5. Install 3 Cap Screws (#3 x .75) in Gear Housing through Left side Bracket of Chassis assembly. 6. Install Helical Gear on Gear Housing as shown in the figure. 987604A1.
7. Install Wear Washer on Helical Gear Press. 8. Install Retaining on Helical Gear. 9. Install Idler Gear on Gear Housing. 10. Install Wear Washer and Retaining Ring on Idler Gear. 987604A1.
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.
2.4 MOTOR 987604A1.
2.4.1 REMOVAL OF MOTOR Before removing the Motor follow the instructions given below: 1. Remove the Gear Train assembly. 2. Remove the 2 screws (#8 x 0.75) from Chassis assembly. 3. Remove the left side cap screw and nut from Hawse Fairlead assembly. 987604A1.
4. Remove cap screw from Chassis assembly as shown in the figure. 5. Remove Left side Bracket from Chassis assembly. 6. Remove Motor assembly from Chassis assembly after removal of Wiring leads 987604A1.
2.4.2 ASSEMBLY OF MOTOR 1. Connect all Wire leads from Motor assembly and install in to Chassis assembly as shown in the figure. 2. Install Left side Bracket on Chassis assembly as shown in the figure. 3. Install cap screw in Chassis assembly as shown in the figure. 987604A1.
4. 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. 987604A1.
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. 1. Push the Wire in the direction of the arrow mark as shown in the figure. 2. Using a punch or drift and hammer, hit the end of the Wire Rope to push the loop back through the Drum. 987604A1.
3.Use the Pin remover (punch) to remove the Wire Rope and Stop Button from the Drum. 4. Straighten the bent Rope and pull the Rope out of Drum hole in the arrow direction as shown. 5. Remove the Hawse Fairlead from the Bracket of the Chassis. 6. Remove and discard Tension Plate (if equipped). 987604A1.
2.5.2 ASSEMBLY OF WIRE ROPE 1. Assemble the Hawse Fairlead to the Bracket of the Chassis. 2. Tighten the CapScrews with Allen key and opened end wrench. 3. Keep the insulation tape to the edge of the Wire Rope. 987604A1.
4. Insert the Wire Rope into the Drum through the Hawse Fairlead. 5. Pull the wire from the other end of the Drum hole. 6. Bend the Wire Rope and insert in to the same hole in the direction shown in the figure. 7. Pull the Wire Rope from the hole as shown in the figure. 987604A1.
8. Support one edge of the Wire and pull the other Wire as shown in the figure. 9. Verify Wire Rope stop button is inserted into the loop as shown before pulling the Wire Rope tight. 10. Hit wire rope loop with a hammer, so that the Wire Rope will be pushed in to the rope retention hole. 11. Check the Wire Rope so that it enters completely into the Drum hole. 987604A1.
12. Check from the other side of the Drum whether the Wire Rope is perfectly assembled to the Drum. 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. 987604A1.
2.6 SAFETY HOOK 2.6.1 REMOVAL OF SAFETY HOOK To remove Safety Hook follow the below instructions: 1. 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. 987604A1.
2. Remove the Pin from the Hook and Rope. 3. Remove the Safety Hook from Wire Rope 987604A1.
2.6.2 ASSEMBLY OF SAFETY HOOK To Reassemble Safety Hook follow the below instructions: 1. Place the Safety Hook and align the mounting holes with the loop of the Wire Rope 2. Insert the Pin through Safety Hook and Wire Rope loop. 3. Insert the Cotter Pin inside the hole of the Pin and bend the ends of the Cotter Pin with the help of Cutting pliers. 987604A1.
2.6.3 INSPECTION OF SAFETY HOOK • • 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. 987604A1.
2.7 TAIL HOOK Original Tailhook Assy 2nd Generation Tailhook Assy Service Part Tailhook Assy 987604A1.
2.7.1 REMOVAL OF TAIL HOOK To remove Tail hook follow the below instructions: 1.Remove bolt and nut from the Chassis assembly through Tail Hook. 2.Loose the cap screw with Allen key before removing the Tail Hook and Spacer Pin from Chassis assembly. 987604A1.
2.7.2 ASSEMBLY OF TAIL HOOK To reassemble the Original Tailhook follow the below instructions: 1.Tighten the cap screw after place Tail Hook and Spacer Pin between the Bracket holes. 2.Assemble the bolt and nut. 987604A1.
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. 987604A1.
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. 987604A1.
2.8 DRUM ASSEMBLY • If the drum is worn or damaged, the entire PullzAll must be replaced, no replacement parts are available. 987604A1.
2.9 WIRING DIAGRAMS 1. WIRING DIAGRAMS 2. REMOVAL 3. ASSEMBLY 4. INSPECTION Wiring diagram 74862 Note: Older models had a circuit breaker instead of the Rocker switch. Wire Routing to the Circuit breaker is identical to the Rocker Switch. 987604A1.
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.
2.9.1 REMOVAL OF WIRING To remove the wiring follow instructions below: 1. Remove Rocker Switch from Plastic Housing right hand and remove corresponding lead Wires. 2. Remove 2 Retaining Rings using a large flat bladed screw driver. This will release the Power Cord as shown in figure. 3. Remove Power Cord assembly from the Plastic Housing. 987604A1.
4. Remove the Wire leads from Trigger Switch. 5. ONLY Remove green Ground Lead Wire from Chassis when replacing power cord. 6. Remove the Load limiter Board Assy from Plastic Cover. Check all the connections for proper contact. 987604A1.
2.9.2 ASSEMBLY OF WIRING To reassemble the wiring follow the below instructions: 1. Install Load limiter Board Assy to Right hand Plastic Housing. 2. Install LED to Right hand Plastic Housing. 3.Attach green Ground Lead Wire to Chassis. Tighten cap screw and nut. 987604A1.
4. Connect lead Wires to correct locations on the Trigger Switch and place the Trigger Switch into the Right hand Plastic Housing. 5. Install direction Switch slider properly into the Housing slot related to the Trigger Switch. 6. Make sure that all lead Wires are routed correctly and connected to Switch correctly. 7. Install Power Cord assembly. 987604A1.
8. Use 2 Retaining Rings to lock Power Cord with the Plastic Housing in opposite direction. 9. Install 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 and pin-out table for corresponding switch. • Ensure that Wiring has not jammed in Housing. Direction Switches slider assembled correctly.
2.10 TORQUE SPECIFICATIONS 987604A1.
3. PULLZALL TROUBLE SHOOTING PROBLEM 1.1 PullzAll does not power in or pulls slowly. POSSIBLE CAUSE CORRECTIVE ACTION 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.
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 Wire harness or Motor Assembly. 1.7 Wiring harness insulation has melted. Poor installation caused Wire insulation to be rubbed off or cut, causing direct short. Replace Wiring harness. 1.
4. SERVICE PART LIST ITEM NO. DESCRIPTION PART NO. 1. Service Part -Motor assembly 120Vac (Includes Motor, Plastic Housing, Brushes & Screws) 77914 2. Service Part - Variable Speed Trigger,120Vac 77911 3. Service Part - Load limiter assembly, 120Vac (Includes bi-color LED) 86354 4. Service Part - Wire rope assembly, PullzAll (Includes fair lead) 76065 5. Service Part - Tail hook assembly 77930 6. Service Part - Front Hook assembly 78052 987604A1.
