Warn PULLZALL 24Vdc User manual

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SERVICE GUIDE
For
WARN PULLZALL 24Vdc
P/N 885005 & 885006
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.
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

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 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
Powerful 24volt Recharge NiMH Battery Pack
15’ of Ø7/32” Wire Rope
Variable Speed Trigger Switch
Convenient Forward /
Reverse Switch
Electronic Load
Limiter with LED
Indicator for
Operator Feedback

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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 PullzAllTM while carrying it at your side.
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
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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5. Keep the assembly on the work bench
facing the cover in the direction shown in
the figure.
6. Install 6 screws (#8 X 1.25) from the
main body of the Housing.
7. Install 6 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 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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2.4 MOTOR
2.4.1 REMOVAL OF MOTOR
Before removing the Motor follow the below instructions:
1. Remove the Motor 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 Assembly remove
from the Chassis assembly.
3. After removal of the Motor assembly
from the Chassis, keep the Motor
assembly on the work bench.

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2.4.2 ASSEMBLY 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 diagram (Red to M+ or
M1, Black to M- or M2).

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2.4.3 INSPECTION OF MOTOR
•Visual inspection.
•Ensure that Motor has been properly placed inside the End Housing and the screw had
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.
3. Unplug unit / remove Battery before disassembly.
Tasks:
Disassemble the Wire Rope.
1. Push the Wire in the direction of the
arrow mark as shown in the figure.

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2. Using a punch 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 snap ring plier as shown in the
figure

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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 (if
equipped).