SERVICE GUIDE For WARN PULLZALL 24Vdc P/N 885005 & 885006 REPAIR / REPLACEMENT INSTRUCTIONS TROUBLE SHOOTING GUIDE 987606A1.
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 4 2. DISASSEMBLY AND ASSEMBLY 2.1. Suggested Tools 6 2.2. Battery 7 2.3. Housing 11 2.4. Motor 16 2.5. Wire Rope Assembly 18 2.6. Safety Hook 25 2.7. Tail Hook 29 2.8. Gear Sets 33 2.9. Drum Assembly 33 2.10. Wiring Diagrams 34 2.11. Torque Specifications 42 3. PULLZALL TROUBLE SHOOTING 43 4. SERVICE PART LIST 45 987606A1.
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. A strong Motor and Variable Speed Control allow you to move heavy items into place smoothly and precisely. These features equate to saving both time and money. The PullzAll helps in getting the job done easier, faster and with less manual labor than a come-a-long or chain fall, making you more productive.
Variable Speed Trigger Switch Convenient Forward / Reverse Switch Electronic Load Limiter with LED Indicator for Operator Feedback 1,000lbs lifting/pulling Integrated Swiveling Anchor Hook On/Off Switch Powerful 24volt Recharge NiMH Battery Pack 15’ of Ø7/32” Wire Rope 987606A1.
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 987606A1.
2.2 BATTERY 2.2.1 REMOVAL OF BATTERY Removing the Battery Pack • Verify the power switch is in the OFF position. • Push down the release button back of the Battery and slide the Battery away from the PullzAll body. • Remove the Battery when not in use. Permanent damage may occur if the unit is allowed to self-discharge in ON position 987606A1.
1. Hold the PullzAll in the position shown in figure, push down the release button at back of the Battery and slide the Battery away from the PullzAll body and pull Battery as shown direction 2. Slide away complete Battery from the PullzAll body 987606A1.
2.2.2 ASSEMBLY OF BATTERY 1. Hold the PullzAll in the position as shown in figure. Slide the Battery pack into the body as shown direction 2. Slide Battery pack completely into the PullzAll body; make sure that the latch is fully engaged. The PullzAll Battery uses NiMH technology. Generally, they can be disposed of in a municipal waste stream. However, check your local ordinances for disposal or recycling regulations. 987606A1.
2.2.3 INSPECTION OF BATTERY • Inspect the Battery is not cracked or damaged. • Inspect whether the release button in hold position or not. Safety Rules & Guidelines: • Battery tools are always in an operative condition. Be aware of the possible hazards. Always remove the Battery when the PullzAllTM is not in use. • Battery leakage may occur under extreme usage or temperature conditions. If liquid comes in contact with skin, wash quickly with soap and water, then with lemon juice or vinegar.
2.3 HOUSING Before opening the Housing follow the below instructions: Power Switch: Always turn Power switch off. Permanent battery damage may occur if the unit is allowed to self discharge in the ON position. Removing the Battery Pack: • Verify the power Switch is in the OFF position. Push down the release Button back of the Battery and slide the Battery away from the PullzAll body as shown. 987606A1.
2.3.1 REMOVAL OF HOUSING 1. Remove 6 screws (#6 x .75) from Handle 2. Remove 6 screws (#8 X 1.25) from the main body of the Housing. 3. Keep the assemblies on the work bench facing the cover in the direction shown in the figure. 987606A1.
4. Remove the Plastic Housing (left hand) from the assembly as shown in the figure. 5. Remove wiring connections of the Motor assembly from Trigger Switch (red and black wires) as shown in figure. 6. Remove the Main Chassis from the Plastic Housing. 7. Keep the Main Chassis on the work bench. 987606A1.
2.3.2 ASSEMBLY OF HOUSING 1. Keep the right hand Housing on the work bench 2. Install the Chassis assembly into the right hand Housing as shown, verify the right hand frame Bracket is fully seated into the right Housing before installing the left hand Housing. 3.Install wiring connections of the Motor assembly from Trigger Switch (red and black wires) per wiring diagram (Red to M+ or M1, Black to M- or M2). 4. Install the Plastic Housing left hand from the assembly as shown in the figure. 987606A1.
5. Keep the assembly on the work bench facing the cover in the direction shown in the figure. 6. Install 6 screws (#8 X 1.25) from the main body of the Housing. 7. Install 6 screws (#6 x .75) in 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.
2.4 MOTOR 2.4.1 REMOVAL OF MOTOR Before removing the Motor follow the below instructions: 1. Remove the Motor Assembly from the End Housing by removing the 2 screws (M5 x .8 x 12), Qty 2 from the casting securing the Motor using a 4mm Allen Wrench. 2. Tap the motor with dead blow hammer to remove the Motor Assembly remove from the Chassis assembly. 3. After removal of the Motor assembly from the Chassis, keep the Motor assembly on the work bench. 987606A1.
2.4.2 ASSEMBLY OF MOTOR 8. Install the Motor assembly in to the Chassis assembly. 9. Tighten the two CapScrews to secure Motor assembly in position. 10. Install Motor leads to top terminals of Switch per wiring diagram (Red to M+ or M1, Black to M- or M2). 987606A1.
2.4.3 INSPECTION OF MOTOR • Visual inspection. • Ensure that Motor has been properly placed inside the End Housing and the screw had been properly tightened 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 / remove Battery before disassembly. Tasks: Disassemble the 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, tap the end of the Wire Rope to push the loop back through the Drum. 3. Use the pin remover (punch) to remove the Wire Rope from the Drum. 4. Remove the Stop Button from Drum by using snap ring plier as shown in the figure 987606A1.
5. Straighten the bent Rope and pull the Rope out of Drum hole in the shown direction. 6. Remove the hawse fairlead from the Bracket of the Chassis. 7. Remove and discard the Tension Plate (if equipped). 987606A1.
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. 987606A1.
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. 987606A1.
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. 987606A1.
11. Check the Wire Rope so that it enters completely into the Drum hole. 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.
2.6 SAFETY HOOK 2.6.1 REMOVAL OF SAFETY HOOK To remove Safety Hook, follow the Instructions: 987606A1.
1. First straighten the bent end of the Cotter Pin by using pliers, and then pull away the Cotter Pin by holding head of the Pin with the help of pliers from the Pin. 2. Remove the Pin from the Safety Hook and Wire Rope. 987606A1.
3. Remove the Safety Hook from Wire Rope. 2.6.2 ASSEMBLY OF SAFETY HOOK To reassemble Safety Hook follow the 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. 987606A1.
3. Insert the Cotter Pin inside the hole of the Pin and bend the ends of the Cotter Pin with the help of pliers. 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. 987606A1.
2.7 TAIL HOOK Original Tailhook Assy 2nd Generation Tailhook Assy Service Part Tailhook Assy 987606A1.
2.7.1 REMOVAL OF TAIL HOOK To remove Tail Hook, follow the instructions below: 1. First straighten the bent end of the Cotter Pin, and then pull out. 2. Remove the Pin from the Hook assembly. 3. Remove the Tail Hook from Chassis assembly. 987606A1.
4. Remove Spacer Bracket from Chassis assembly while loosening the capscrew. 2.7.2 ASSEMBLY OF TAIL HOOK To reassemble Tail Hook follow the instructions: 1. Place Spacer Bracket in Chassis assembly with capscrew and then apply the torque. 987606A1.
2. Take the Tail Hook and align the mounting holes with the Spacer Bracket holes and Chassis assembly. 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. 987606A1.
2.7.3 INSPECTION OF TAIL 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. 987606A1.
2.8 GEARSETS • If the gearsets are worn or damaged, the entire PullzAll must be replaced, no replacement parts are available. 2.9 DRUM • If the drum is worn or damaged, the entire PullzAll must be replaced, no replacement parts are available. 987606A1.
2.10 WIRING DIAGRAM WIRING DIAGRAM - 75824 987606A1.
2.10.1 WIRING DETAILS • Route Red Lead Wire from J3 Terminal on Circuit Board through Wire guides up into handle to Trigger Switch. • Route Red Lead Wire (soldered to Male Terminal Support) from J2 Terminal on Circuit Board through Wire guides up to where the male Terminal support is mounted. • Route Black Lead Wire from J4 Terminal on Circuit Board through Wire guides up to Trigger Switch. • Route the black lead attached to male terminal support to Rocker Switch.
Switch Pin-out Table Manufacturer name is embossed on switch. 2.10.2 REMOVAL OF WIRING 1. Remove the leads from Battery Terminals if required. Trigger Switch: 2. Remove the Wires from Trigger Switch. 987606A1.
3. Remove the leads from Rocker Switch if required. 4. Take out Load limiter Board Assy from right Plastic Cover after unscrewing all the screws. 5. Remove the 3 leads from out Load limiter Board Assy if required. 987606A1.
2.10.3 ASSEMBLY OF WIRING 1. Install Load limiter Board Assy to right Plastic Cover. 2. Install the two screws at Load limiter Board Assy with the help screw driver right Plastic Cover. 987606A1.
Electronic Load Limiter 3. Push the Plastic Retainers out that secure the LED display 4. Install Battery Terminal into Right Hand Housing using Screws (6 x 0.50), Qty 2. 987606A1.
5. Route Red Lead Wire (soldered to Male Terminal Support) from J2 Terminal on Circuit Board through wire guides up to rear of Housing to where the Male Terminal support is mounted. Trigger Switch 6. Route Red Lead Wire from load limiter circuit board J3 and black wire from load limiter J4 through wire guides up in to handle to Trigger Switch (Red to B+, Black to B-) Black wire is connected to black wire from rocker switch. 987606A1.
7. Install leads to Rocker Switch 2.10.4 INSPECTION OF WIRING 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.
2.11 TORQUE SPECIFICATIONS 987606A1.
3. PULLZALL TROUBLE SHOOTING PROBLEM 1.1 PullzAll does not power in or pulls slowly. 1.2 Noise POSSIBLE CAUSE CORRECTIVE ACTION Battery is not fully charged. Charge Battery Loose connection on Battery or 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. Battery voltage too low due to Battery deterioration. Replace Battery. Worn Trigger Switch Repair or Replace Switch.
1.3 Motor running but not pulling Damaged Geartrain Replace PullzAll 1.4 Motor does not run. Check Battery Condition visually (any short circuit ) Check Wiring condition Check Battery condition Repair or replace it with new Faulty Trigger Switch Repair or replace Switch Defective Motor Replace Motor Loose connection of Wires to Motor Terminals. Replace Motor Assembly. 1.6 Electrical sparks appear around Motor. 1.
loose Terminals, etc... Damaged Wiring. Check Electrical Circuits 4. SERVICE PART LIST Description Part Number 1. Service Part -Motor Assembly 24vdc (Includes Motor & Screws) 77916 2. Service Part - Variable Speed Trigger, 24vdc 77913 3. Service Part - Load Limiter Assembly, 24vdc 86355 (Includes LED Bezel, Screws and LED Retention Pins) 4. Service Part - Wire Rope Assembly, PullzAll (Includes Fairlead) 76065 5. Service Part - Rapid Charger-120v 77922 6.
