Warn Industries PullzAll 885002 Service Manual Download Page 1

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987605A1 Page 1 of 49

SERVICE GUIDE

For

WARN PULLZALL 230v AC

P/N 885002, 885003 & 885004

REPAIR / REPLACEMENT INSTRUCTIONS

TROUBLE SHOOTING GUIDE

Summary of Contents for PullzAll 885002

Page 1: ...987605A1 Page 1 of 49 SERVICE GUIDE For WARN PULLZALL 230v AC P N 885002 885003 885004 REPAIR REPLACEMENT INSTRUCTIONS TROUBLE SHOOTING GUIDE...

Page 2: ...nical 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 Cauti...

Page 3: ...Suggested Tools 06 2 2 Housing 07 2 3 Gear Train Assembly 11 2 4 Motor 17 2 5 Wire Rope Assembly 22 2 6 Safety Hook 28 2 7 Tail Hook 31 2 8 Drum Assembly 36 2 9 Wiring Diagrams 37 2 10 Filter Assembl...

Page 4: ...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...

Page 5: ...Wire Rope with Industrial Grade Hook Versatile Swivel Anchor Hook Electronic Load Limiter with LED Indicator for Operator Feedback Handle with Trigger for Variable Speed Control Convenient Forward Re...

Page 6: ...987605A1 Page 6 of 49 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 7: ...w 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 R...

Page 8: ...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 Housi...

Page 9: ...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 asse...

Page 10: ...acing 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...

Page 11: ...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 Remo...

Page 12: ...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 C...

Page 13: ...Gear 51 T from left side Bracket 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 Cha...

Page 14: ...rier Assembly in Gear Housing 4 Install Gear Housing on Left side Bracket of Chassis assembly 5 Install 3 Cap Screws 3 x 75 in Gear Housing through Left side Bracket of Chassis assembly 6 Install Heli...

Page 15: ...605A1 Page 15 of 49 7 Install Wear Washer on Helical Gear Press 8 Install Retaining Ring on Helical Gear Press 9 Install Idler Gear on Gear Housing 10 Install Wear Washer and Retaining Ring on Idler G...

Page 16: ...ce 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 again...

Page 17: ...987605A1 Page 17 of 49 2 4 MOTOR...

Page 18: ...OVAL 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 n...

Page 19: ...A1 Page 19 of 49 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...

Page 20: ...OTOR 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 i...

Page 21: ...nd 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...

Page 22: ...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 a...

Page 23: ...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 as shown in fig 5 Remove the Hawse Fairlead from the Bracket of the Chassis 6...

Page 24: ...24 of 49 2 5 2 ASSEMBLY OF WIRE ROPE 1 Assemble the Hawse Fairlead to the Bracket of the Chassis 2 Tighten the cap screws with Allen key and opened end wrench 3 Keep the insulation tape to the edge of...

Page 25: ...e 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 as shown in the figure 7 Pull the Wi...

Page 26: ...n 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 rop...

Page 27: ...N 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...

Page 28: ...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 Cot...

Page 29: ...Pin from the Hook and Rope 3 Remove the Safety Hook from Wire Rope 2 6 2 ASSEMBLY OF SAFETY HOOK To Reassemble Safety Hook follow the below instructions 1 Place the Safety Hook and align the mounting...

Page 30: ...he Cotter Pin inside the hole of the Pin and bend the ends of the Cotter Pin with the help of Cutting pliers 2 6 3 INSPECTION Inspect the Hook for signs of wear and damage Hook damage examples cracks...

Page 31: ...987605A1 Page 31 of 49 2 7 TAIL HOOK Original Tail Hook Assy 2nd Generation Tail Hook Assy Service Part Tail Hook Assy...

Page 32: ...L OF TAIL HOOK To remove Tail Hook follow the below instructions 1 Remove bolt and nut from the Chassis assembly through Tail Hook 2 Loosen the cap screw with Allen key before removing the Tail Hook a...

Page 33: ...33 of 49 2 7 2 ASSEMBLY OF TAIL HOOK To Reassemble Original Tail Hook follow the below instructions 1 Tight the cap Screw after place Tail Hook and Spacer Pin between the Brackets holes 2 Assemble the...

Page 34: ...e Second Generation Tail Hook follow the instructions 1 Place Spacer Bracket in Chassis assembly with cap screw and then apply the torque 2 Take the Tail Hook and align the mounting holes with the Spa...

Page 35: ...r 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 twiste...

Page 36: ...987605A1 Page 36 of 49 2 8 DRUM ASSEMBLY If the drum is worn or damaged the entire PullzAll must be replaced no replacement parts are available...

Page 37: ...987605A1 Page 37 of 49 2 9 WIRING DIAGRAMS 1 WIRING DIAGRAMS 2 REMOVAL 3 ASSEMBLY 4 INSPECTION Wiring diagram77483...

Page 38: ...rminal from green wire from the power cord assy and Terminal from green lead to the right frame and secure underneath cap screw Route blue lead from power cord assy to the N4 filter terminal Route bla...

Page 39: ...elow instructions 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 Pow...

Page 40: ...ove the Wire leads from Trigger Switch which are inserted 5 ONLY Remove green Lead Wire from Chassis when replacing power cord 6 Remove the Load limiter Board Assy from Plastic Cover Check all the con...

Page 41: ...SEMBLY OF WIRING To reassemble the wiring follow the below instructions 1 Install PCB to Right hand Plastic Housing 2 Install LED to Right hand Plastic Housing 3 Attach green Ground Lead Wire to Chass...

Page 42: ...witch and place the Trigger Switch in 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...

Page 43: ...r and connect corresponding lead Wires Visual Inspection Ensure that Switches have assembled correctly Wiring is complete match the drawing and pin out table for corresponding switch Ensure that Wirin...

Page 44: ...SEMBLY 1 Before removal of power filter disconnect all wiring connections 2 Remove Nut and Power Filter from Power Filter assembly 3 Remove Cap Screw Tie Rod and pull the Filter Mount from Chassis ass...

Page 45: ...thru chassis Assembly and tighten with Cap Screws 2 Insert Power Filter into Mount Filter orient as shown in the Wiring Diagram and tighten the Nut securing the power Filter 3 Connect all wiring conne...

Page 46: ...987605A1 Page 46 of 49 2 11 TORQUE SPECIFICATIONS...

Page 47: ...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 rub...

Page 48: ...or Motor Assembly 1 7 PullzAll makes squeaking high pitch noise Drum Bushing not lubricated Grease Drum Bushings 1 8 Malfunctioning 1 9 Full speed only no variable speed control Not operating correctl...

Page 49: ...ESCRIPTION PART NO 1 Service Part Motor assembly 230Vac 77915 Includes Motor Plastic Housing Brushes Screws 2 Service Part Variable Speed Trigger 230Vac 77912 3 Service Part Load limiter assembly 230V...

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Warn Industries PullzAll 885002, Service Manual

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