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.