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987606A1.doc

Page 45 of 46

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 Battery condition

Faulty Trigger Switch

Defective Motor

Check Wiring condition

Repair or replace it with new

Repair or replace Switch

Replace Motor

1.6 Electrical sparks

appear around
Motor.

Loose connection of Wires to
Motor Terminals.

Replace Motor Assembly.

1.7 Wire harness

insulation has melted

Switch held in power in
position while PullzAll 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 / high
pitch noise.

Drum Bushing not lubricated.

Grease Drum Bushings.

1.9 Full speed only, no
variable speed control

1.10 Malfunctioning

Ensure trigger is only
partially depressed

Not operating correctly.

Replace Variable Speed Trigger
switch

Cease operation. Diagnose,
Repair or Replace.

1.11 Rapid discharge of

Battery

Check for Power Switch Left
on during storage.

Check for Terminals
corrosion

Defects in charging system
such as faulty Regulator,

Always turn unit off when not in
use.

Clean and service

Check charging system

Содержание PULLZALL 24Vdc

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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