Warn Industries PullzAll 885002 User manual

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SERVICE GUIDE
For
WARN PULLZALL 230v AC
P/N 885002, 885003 & 885004
REPAIR / REPLACEMENT INSTRUCTIONS
TROUBLE SHOOTING GUIDE
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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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CONTENTS
1. GENERAL DESCRIPTION 04
2. DISASSEMBLY AND ASSEMBLY 06
2.1. 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 Assembly 45
2.11. Torque Specifications 47
3. PULLZALL TROUBLE SHOOTING 48
4. SERVICE PACK LIST 50

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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 / 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 230v AC Specifications:
1. Part number 885002 (UK), 885003 (EU) & 885004 (AUS).
2. Light weight and portable.
3. Powerful 230 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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Runs on 230v
AC Power
15’ of 7/32” Wire
Rope with Industrial
Grade Hoo
k
Versatile Swivel
Anchor Hook
Electronic Load
Limiter with LED
Indicator for Operator
Feedback
Handle with Trigger
for Variable Speed
Control
Convenient
Forward/Reverse
Switch
1000 lbs/454 Kg
Lifting/Pulling
Ca
p
acit
y

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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

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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
1. Remove the screws (#6 x .75), Qty 7
from Handle.
2. Remove the screws (#8 X 1.25), Qty 6
from the main body of the Housing

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3. Keep the assembly on 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 Housing - right hand and place it
on the work bench.

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2.2.2 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 assembly as show in the figure.

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4. Install the screws (#8 X 1.25), Qty 6
from the main body of the Housing
5. Install the screws (#6 x .75), Qty 7
near 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 replaced as a guide
for placement of your new labels. Your service kit will include extra labels for other languages
and markets that can be discarded after you select the ones needed for your product.

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2.3 GEAR TRAIN ASSEMBLY
•If the gear sets are worn 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. Remove Retaining Ring from Helical
Gear . Remove Wear Washer from
Helical Gear.

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4. Remove 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 Carrier Assembly from Ring
Gear.

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8. Remove Ring 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 Chassis assembly as shown
in the figure.

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3. Install Ring Gear 48T and Carrier
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 Helical Gear Press on Gear
Housing as shown in the figure.

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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 Gear.

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2.3.3 INSPECTION OF GEAR TRAIN
1. Check each Idler Gear to make sure that all teeth are present in good condition.
2. Check each Sun Gear to make sure all teeth are present and in good condition.
3. Check each side of each Sun Gear to make sure there are no grooves from wear. Replace
the Gear Set if worn.
4. Check Carrier Assembly to make sure that Planet Gears are tight. Each Gear should be able
to move a small distance 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 against its axle pin and rotate the Gear completely. The Gear must
turn smoothly on Pin. Replace Gear Set if Planet Gears do not turn smoothly.
6. Check the Ring Gear 48T inside the Gear Housing. All the Gear teeth must be in good
condition and they must be free of debris. The Gear Housing must be replaced if teeth have
a wear groove.
7. If the Gear sets are worn or damaged, the entire PullzAll must be replaced, no replacement
Parts are available.

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2.4 MOTOR

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2.4.1 REMOVAL 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 nut
from Hawse Fairlead assembly.

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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 leads.
.

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2.4.2 ASSEMBLY OF MOTOR
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 in Chassis assembly as
shown in the figure.