Warn 685000 User manual

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986765A2.doc Page 1 of 50

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SERVICE GUIDE

For

WARN PULLZALL 120v AC &100v AC

P/N 685000 & 685001

REPAIR / REPLACEMENT INSTRUCTIONS

TROUBLE SHOOTING GUIDE

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986765A2.doc Page 2 of 50

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.

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Notice

This guide has been provided for use by WARN Authorized Service Centers. Any

other use is prohibited.

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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 product if you are under 16 years of age.

Never operate this product when under the influence of drugs, alcohol or medications.

Read instructions thoroughly

Notice

Equipment damage

Always refer to the Wiring Diagram for all wiring schematics and specific details on how

to wire this WARN product.

Read instructions thoroughly.

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986765A2.doc Page 3 of 50

CONTENTS

1. GENERAL DESCRIPTION 04

2. DISASSEMBLY AND 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

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986765A2.doc Page 4 of 50

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 / 454 kg. A strong Motor and Variable Speed Trigger Switch for power in and

power out operation, Wire Rope and Clasp Hook will allow you to move heavy items into place

smoothly and precisely. These features equate to saving both time and money.

The PullzAll will help get 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 / 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 & 685001.

2. Light weight and portable.

3. Powerful 120 Volt AC Motor.

4. 1,000 lbs (454 kg) lifting / pulling capacity.

5. 15'(4.6m) of 7/32"(0.56cm) 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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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

986765A1.doc Page 7 of 50

2.2 HOUSING

Before opening the Housing 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.

986765A1.doc Page 8 of 50

Keep the assembly 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.

986765A1.doc Page 9 of 50

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.

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