WARN PullzAll SERVICE GUIDE

SERVICE GUIDE

For

WARN PULLZALL 24Vdc

P/N 885005 & 885006

 REPAIR / REPLACEMENT INSTRUCTIONS
 TROUBLE SHOOTING GUIDE

987606A1.doc Page 1 of 46

 Always

refer to the

wiring diagram

for all wiring schematics and specific details on how

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.
This guide uses NOTICE to call attention to important 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.

Caution

Moving parts entanglement hazard

Failure to observe these instructions could lead to minor or moderate injury

 Always take time to read fully and understand the instructions.
 Never operate this product if you are under 16 years of age.
 Never operate this product under the influence of drugs, alcohol or medications.

Read instructions thoroughly

Notice

Equipment damage

to wire this WARN product.

Read instructions thoroughly.

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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

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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. The PullzAll is for the tradesperson,

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 shops, garages, machine shops, home improvement, hunting, camping and more.

Cordless PullzAll 24VDC Specifications:

1. Part number 885005 (Domestic US), 885006 (International).

2. Light weight and portable.

3. Powerful 24 Volt rechargeable NiMH Battery pack (with charger and spare Battery)

4. 1,000 lbs. lifting/pulling capacity.

5. 15' of 7/32" diameter Wire Rope.

6. Variable Speed Control for precision load placement.

7. Convenient forward/reverse Switch.

8. Electronic Load Limiter with LED Indicator for operator feedback.

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1,000lbs lifting/pulling

Integrated
Swiveling
Anchor
Hook

On/Off Switch

Variable Speed Trigger Switch

Convenient Forward /
Reverse Switch

Electronic Load
Limiter with LED
Indicator for
Operator Feedback

Powerful 24volt Recharge NiMH Battery Pack

15’ of Ø7/32” Wire Rope

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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

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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

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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

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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.

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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. If liquid gets into your eyes, flush them with water for a minimum of 10

minutes and seek medical attention.

• Do not run the PullzAll

Battery Care:

When Batteries are not in tool, keep them away from the metal objects. For

example: To protect the terminals from shorting. DONOT place

Batteries in a toolbox or pocket with nails, screws, keys, etc. Fire or injury may result.

DO NOT PUT BATTERY INTO FIRE OR EXPOSURE TO HIGH HEAT. They

may explode.

Battery Disposal:

WARNING

Do not attempt to disassemble the Battery or remove any component projecting from

TM

while carrying it at your side.

the Battery terminals. Fire or injury may result. Prior to disposal protect exposed

terminal with heavy insulating tape to prevent shorting.

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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.

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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.

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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.

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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.

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