Warn PULLZALL 24Vdc, Service Manual

Page 1: ...987606A1 doc Page 1 of 46 SERVICE GUIDE For WARN PULLZALL 24Vdc P N 885005 885006 REPAIR REPLACEMENT INSTRUCTIONS TROUBLE SHOOTING GUIDE...

Page 2: ...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...

Page 3: ...SEMBLY 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...

Page 4: ...adesperson farmer rancher or anyone that needs to lift or pull up to 1 000 lbs This makes PullzAll ideal for construction pipe fitting iron work equipment and plant maintenance farm and ranch use auto...

Page 5: ...lling Integrated Swiveling Anchor Hook On Off Switch Powerful 24volt Recharge NiMH Battery Pack 15 of 7 32 Wire Rope Variable Speed Trigger Switch Convenient Forward Reverse Switch Electronic Load Lim...

Page 6: ...987606A1 doc Page 6 of 46 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 7: ...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 Perman...

Page 8: ...he 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 compl...

Page 9: ...ttery 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 ca...

Page 10: ...iquid gets into your eyes flush them with water for a minimum of 10 minutes and seek medical attention Do not run the PullzAllTM while carrying it at your side Battery Care When Batteries are not in t...

Page 11: ...h 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 P...

Page 12: ...f 46 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 directio...

Page 13: ...g 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 Pla...

Page 14: ...ousing 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 Switc...

Page 15: ...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 replace...

Page 16: ...r 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 Assemb...

Page 17: ...EMBLY 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 dia...

Page 18: ...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...

Page 19: ...ch 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...

Page 20: ...c Page 20 of 46 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...

Page 21: ...e 21 of 46 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 o...

Page 22: ...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 Wi...

Page 23: ...ire 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...

Page 24: ...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 fr...

Page 25: ...987606A1 doc Page 25 of 46 2 6 SAFETY HOOK 2 6 1 REMOVAL OF SAFETY HOOK To remove Safety Hook follow the Instructions...

Page 26: ...of 46 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 Safe...

Page 27: ...ety 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...

Page 28: ...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 exce...

Page 29: ...987606A1 doc Page 29 of 46 2 7 TAIL HOOK Original Tailhook Assy 2nd Generation Tailhook Assy Service Part Tailhook Assy...

Page 30: ...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 Tai...

Page 31: ...emove 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 caps...

Page 32: ...l 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 o...

Page 33: ...oc Page 33 of 46 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...

Page 34: ...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 re...

Page 35: ...987606A1 doc Page 35 of 46 2 10 WIRING DIAGRAM WIRING DIAGRAM 75824...

Page 36: ...rcuit Board through Wire guides up to Trigger Switch Route the black lead attached to male terminal support to Rocker Switch Route black lead attached to Black J4 lead at Trigger down through guides a...

Page 37: ...oc Page 37 of 46 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 Trig...

Page 38: ...38 of 46 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...

Page 39: ...06A1 doc Page 39 of 46 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 C...

Page 40: ...987606A1 doc Page 40 of 46 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...

Page 41: ...gh 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 w...

Page 42: ...ctor 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 t...

Page 43: ...987606A1 doc Page 43 of 46 2 11 TORQUE SPECIFICATIONS...

Page 44: ...n Trigger Switch Worn Brushes Motor Poor Wiring Connections Check for loaded condition whether overloaded Replace Battery Repair or Replace Switch Replace Motor Check Wiring connections Use the unit w...

Page 45: ...zAll is stalled Replace Wire harness or PullzAll Motor Assembly Poor installation caused Wire insulation to be rubbed off or cut causing direct short Replace Wire harness 1 8 PullzAll makes squeaking...

Page 46: ...or Screws 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...