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Warn Industries PullzAll 885002 Service Manual

Manual is about: 230v AC Winches

Summary of PullzAll 885002

  • Page 1

    987605a1 page 1 of 49 service guide for warn pullzall 230v ac p/n 885002, 885003 & 885004 ƒ repair / replacement instructions ƒ trouble shooting guide.

  • Page 2

    987605a1 page 2 of 49 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 se...

  • Page 3: Contents

    987605a1 page 3 of 49 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 assemb...

  • Page 4: 1. General Description

    987605a1 page 4 of 49 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 all...

  • Page 5

    987605a1 page 5 of 49 runs on 230v ac power 15’ of 7/32” wire rope with industrial grade hook 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...

  • Page 6: 2.1 Suggested Tools

    987605a1 page 6 of 49 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.

  • Page 7: 2.2  Housing

    987605a1 page 7 of 49 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 ...

  • Page 8

    987605a1 page 8 of 49 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..

  • Page 9: 2.2.2 Assembly Of Housing

    987605a1 page 9 of 49 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..

  • Page 10

    987605a1 page 10 of 49 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, usin...

  • Page 11: 2.3 Gear Train Assembly

    987605a1 page 11 of 49 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 f...

  • Page 12

    987605a1 page 12 of 49 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..

  • Page 13

    987605a1 page 13 of 49 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..

  • Page 14

    987605a1 page 14 of 49 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 ...

  • Page 15

    987605a1 page 15 of 49 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..

  • Page 16

    987605a1 page 16 of 49 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. ...

  • Page 17: 2.4 Motor

    987605a1 page 17 of 49 2.4 motor.

  • Page 18: 2.4.1   Removal Of Motor

    987605a1 page 18 of 49 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..

  • Page 19

    987605a1 page 19 of 49 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. ..

  • Page 20: 2.4.2   Assembly Of Motor

    987605a1 page 20 of 49 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..

  • Page 21: 2.4.3 Motor   Inspection

    987605a1 page 21 of 49 4. Install the left side cap screw and nut from hawse fairlead assembly. Install 2 screws (#8 x 0.75) in chassis assembly. 2.4.3 motor inspection • visual inspection. • while assembling the motor ensure that, motor has been properly placed inside the end housing and the screw ...

  • Page 22: 2.5 Wire Rope Assembly

    987605a1 page 22 of 49 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 before disassembly. Tasks: disassemble the drum and wire rope. 1. Push the wire ...

  • Page 23

    987605a1 page 23 of 49 3.Use the pin remover (punch) to remove the wire rope and stop button from the drum. 4. Straighten the bent rope and pull the rope out of drum hole as shown in fig. 5. Remove the hawse fairlead from the bracket of the chassis. 6. Remove and discard tension plate (if equipped)..

  • Page 24

    987605a1 page 24 of 49 2.5.2 assembly of wire rope 1. Assemble the hawse fairlead to the bracket of the chassis. 2.Tighten the cap screws with allen key and opened end wrench. 3. Keep the insulation tape to the edge of the wire rope..

  • Page 25

    987605a1 page 25 of 49 4. Insert the wire rope into the drum through the hawse fairlead. 5. Pull the wire from the other end of the drum hole. 6. Bend the wire rope and insert in to the same hole in the direction as shown in the figure. 7. Pull the wire rope from the hole as shown in the figure..

  • Page 26

    987605a1 page 26 of 49 8. Support one edge of the wire and pull the other wire as shown in the figure. 9. Verify wire rope stop button is inserted into the loop as shown before pulling the wire rope tight 10. Hit wire rope loop with a hammer, so that the wire rope will be pushed in to the rope reten...

  • Page 27

    987605a1 page 27 of 49 12. Check from the other side of the drum whether the wire rope is perfectly assembled to the drum. 2.5.3 inspection of wire rope • inspect the wire rope for signs of wear or damage. Worn and damaged parts must be replaced. • see the rope for damage for kinks, cuts, knots, mas...

  • Page 28: 2.6 Safety Hook

    987605a1 page 28 of 49 2.6 safety hook 2.6.1 removal of safety hook to remove safety hook follow the below instructions: 1. First straighten the bent end of the cotter pin by using cutting plier and then pull out the cotter pin by holding head of the cotter pin with the help of cutting plier from th...

  • Page 29

    987605a1 page 29 of 49 2. Remove the pin from the hook and rope. 3. Remove the safety hook from wire rope 2.6.2 assembly of safety hook to reassemble safety hook follow the below instructions: 1.Place the safety hook and align the mounting holes with the loop of the wire rope.

  • Page 30: 2.6.3 Inspection

    987605a1 page 30 of 49 2. Insert the pin through safety hook and wire rope loop. 3. Insert the cotter pin inside the hole of the pin and bend the ends of the cotter pin with the help of cutting pliers. 2.6.3 inspection • inspect the hook for signs of wear and damage. • hook damage examples: cracks, ...

  • Page 31: 2.7 Tail Hook

    987605a1 page 31 of 49 2.7 tail hook original tail hook assy 2 nd generation tail hook assy service part tail hook assy.

  • Page 32: 2.7.1 Removal Of Tail Hook

    987605a1 page 32 of 49 2.7.1 removal of tail hook to remove tail hook follow the below instructions: 1.Remove bolt and nut from the chassis assembly through tail hook. 2.Loosen the cap screw with allen key before removing the tail hook and spacer pin from chassis assembly..

  • Page 33

    987605a1 page 33 of 49 2.7.2 assembly of tail hook to reassemble original tail hook follow the below instructions: 1.Tight the cap screw after place tail hook and spacer pin between the brackets holes. 2.Assemble the bolt and nut..

  • Page 34

    987605a1 page 34 of 49 to reassemble the second generation tail hook follow the instructions : 1.Place spacer bracket in chassis assembly with cap screw and then apply the torque. 2.Take the tail hook and align the mounting holes with the spacer bracket holes and chassis assembly..

  • Page 35: 2.7.3 Tail Hook Inspection

    987605a1 page 35 of 49 3.Insert the pin through the hook assembly. 4.Insert the cotter pin inside the hole of the pin and bend the ends of the cotter pin with the help of pliers. 2.7.3 tail hook inspection • inspect the hook for signs of wear and damage • hook damage examples: cracks, twisted compon...

  • Page 36: 2.8 Drum Assembly

    987605a1 page 36 of 49 2.8 drum assembly • if the drum is worn or damaged, the entire pullzall must be replaced, no replacement parts are available..

  • Page 37: 2.9 Wiring Diagrams

    987605a1 page 37 of 49 2.9 wiring diagrams 1. Wiring diagrams 2. Removal 3. Assembly 4. Inspection wiring diagram77483.

  • Page 38: Wiring Details:

    987605a1 page 38 of 49 wiring details: • route black lead wire from j3 terminal on circuit board through wire guides up into handle to trigger switch. • route white lead wire from j4 terminal on circuit board through wire guides up to trigger switch. • route the motor wires as shown. • route brush l...

  • Page 39: 2.9.1 Removal Of Wiring

    987605a1 page 39 of 49 2.9.1 removal of wiring to remove the wiring follow the below instructions: 1. Remove rocker switch from plastic housing right hand and remove corresponding lead wires. 2. Remove 2 retaining rings using a large flat bladed screw driver. This will release the power cord as show...

  • Page 40

    987605a1 page 40 of 49 4. Remove the wire leads from trigger switch, which are inserted. 5. Only remove green lead wire from chassis when replacing power cord . 6. Remove the load limiter board assy from plastic cover. Check all the connections for proper contact ..

  • Page 41: 2.9.2 Assembly Of Wiring

    987605a1 page 41 of 49 2.9.2 assembly of wiring to reassemble the wiring follow the below instructions: 1. Install pcb to right hand plastic housing. 2. Install led to right hand plastic housing. 3.Attach green ground lead wire to chassis. Tighten cap screw and nut to..

  • Page 42

    987605a1 page 42 of 49 4. Connect lead wires to correct locations on the trigger switch and place the trigger switch in the right hand plastic housing. 5. Install direction switch slider properly into the housing slot related to the trigger switch. 6. Make sure that all lead wires are routed correct...

  • Page 43: 2.9.3 Inspection of Wiring

    987605a1 page 43 of 49 8. Use 2 retaining rings to lock power cord with the plastic housing in opposite direction. 9. Install rocker switch to right plastic cover and connect corresponding lead wires. • visual inspection • ensure that switches have assembled correctly. Wiring is complete match the d...

  • Page 44: 2.10  Filter  Assembly

    987605a1 page 44 of 49 2.10 filter assembly 1. Before removal of power filter disconnect all wiring connections. 2. Remove nut and power filter from power filter assembly. 3. Remove cap screw, tie rod and pull the filter mount from chassis assembly. 2.10.1 removal of power filter.

  • Page 45

    987605a1 page 45 of 49 1. Insert tie rod into filter mount thru chassis assembly and tighten with cap screws. 2. Insert power filter into mount filter, orient as shown in the wiring diagram and tighten the nut, securing the power filter. 3. Connect all wiring connections to the power filter. 2.10.2 ...

  • Page 46: 2.11 Torque Specifications

    987605a1 page 46 of 49 2.11 torque specifications.

  • Page 47

    987605a1 page 47 of 49 3. Pullzall trouble shooting problem possible cause corrective action 1.1 pullzall does not power in or pulls slowly. Loose connection on motor terminals. Be sure all connections are tight and clean. Do not let bottom nut or stud turn while tightening. Check the speed mode sel...

  • Page 48: Inspection

    987605a1 page 48 of 49 1.4 motor does not run. Faulty trigger switch defective motor repair or replace switch replace motor loose connection of the wires to the motor terminals. Secure the motor terminal and wires. 1.5 electrical sparks appear around motor. Switch held in power in position while pul...

  • Page 49: 4.   Service Part List

    987605a1 page 49 of 49 • while using a tester for checking continuity or measuring voltage, be sure to insert the tester probe from the wire harness side. 4. Service part list item no. Description part no. 1. Service part -motor assembly 230vac 77915 (includes motor, plastic housing, brushes & screw...