Warn 685000, Service Manual

Page 1: ...Click Here To View Item at www GapPower com ...

Page 2: ... 986765A2 doc Page 1 of 50 SERVICE GUIDE For WARN PULLZALL 120v AC 100v AC P N 685000 685001 REPAIR REPLACEMENT INSTRUCTIONS TROUBLE SHOOTING GUIDE ...

Page 3: ...echanical 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 p...

Page 4: ...D ASSEMBLY 2 1 Suggested Tools 06 2 2 Housing 07 2 3 Gear Train Assembly 11 2 4 Motor 18 2 5 Wire Rope Assembly 24 2 6 Safety Hook 29 2 7 Tail Hook 33 2 8 Drum Assembly 38 2 9 Wiring Diagrams 39 2 10 Torque Specifications 47 3 PULLZALL TROUBLE SHOOTING 48 4 SERVICE PART LIST 50 ...

Page 5: ...ng 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...

Page 6: ... 986765A2 doc Page 5 of 50 ...

Page 7: ... 986765A2 doc Page 6 of 50 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 ...

Page 8: ...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 ...

Page 9: ... 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 ...

Page 10: ...0 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 ...

Page 11: ...lacing 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 ...

Page 12: ...rn 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 ...

Page 13: ...0 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 ...

Page 14: ...ng 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 ...

Page 15: ...sembly 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 ...

Page 16: ...986765A1 doc Page 15 of 50 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 ...

Page 17: ...tance 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 Gea...

Page 18: ...986765A1 doc Page 17 of 50 2 4 MOTOR ...

Page 19: ... 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 ...

Page 20: ...65A1 doc Page 19 of 50 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 ...

Page 21: ...Y 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 ...

Page 22: ... 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 ...

Page 23: ...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 ...

Page 24: ...ch 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 ...

Page 25: ... Page 24 of 50 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 ...

Page 26: ...re 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 ...

Page 27: ...her 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 ...

Page 28: ...986765A1 doc Page 27 of 50 Check from the other side of the Drum whether the Wire Rope is perfectly assembled to the Drum ...

Page 29: ... 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 ...

Page 30: ...OVAL 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 ...

Page 31: ...986765A1 doc Page 30 of 50 Remove the Pin from the Hook and Rope Remove the Safety Hook from Wire Rope ...

Page 32: ... 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 ...

Page 33: ...765A1 doc Page 32 of 50 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 ...

Page 34: ...986765A1 doc Page 33 of 50 2 7 TAIL HOOK Original Tailhook Assy 2nd Generation Tailhook Assy Service Part Tailhook Assy ...

Page 35: ...EMOVAL 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 ...

Page 36: ...ge 35 of 50 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 ...

Page 37: ...e 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 ...

Page 38: ...tter 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 ...

Page 39: ...986765A1 doc Page 38 of 50 2 8 DRUM ASSEMBLY If the drum is worn or damaged the entire PullzAll must be replaced no replacement parts are available ...

Page 40: ...IAGRAMS 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 ...

Page 41: ...rough 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 Wirin...

Page 42: ... 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 ...

Page 43: ...65A1 doc Page 42 of 50 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 ...

Page 44: ...986765A1 doc Page 43 of 50 Remove the Load limiter Board Assy from Plastic Cover Check all the connections for proper contact ...

Page 45: ...Y 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 ...

Page 46: ...er 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 ...

Page 47: ...nstall 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 ...

Page 48: ...986765A1 doc Page 47 of 50 2 10 TORQUE SPECIFICATIONS ...

Page 49: ...ing action Worn Brushes Weakened brush springs Poor Wiring connections Replace Motor Assembly 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 1 2 Noise Abnormally worn ...

Page 50: ... harness 1 8 PullzAll makes squeaking high pitch noise 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 ...

Page 51: ...r 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 ...