Warn 685000 Service Manual

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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 import ...

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 ...

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- lo ...

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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 ...

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. ...

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. ...

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. ...

Install the screws (#8 X 1.25), Qty 6 from the main body of the Housing. 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. ...

2.3 GEAR TRAIN ASSEMBLY • If the gearsets are worn or damaged, the entire PullzAll must be replaced, no replacement parts are available. 2.3.1 GEAR TRAIN ASSEMBLY REMOVAL Remove Retaining Ring from Idler Gear. Remove Wear Washer from Idler Gear. Remove Retaining Ring from Helical Gear Press. Remove Wear Washer from Helical Gear. ...

Remove Helical Gear from Gear Housing. Remove 3 Cap Screws(#3 x .75) from Gear Housing through Left side Bracket of Chassis assembly. Remove Gear Housing from left side Bracket of Chassis assembly. Remove Carrier Assembly from Ring. ...

Remove Ring Gear 51 T from left side Bracket P/N of Chassis assembly. 2.3.2 GEAR TRAIN REASSEMBLY Install Gear Train assembly after installation of Motor assembly. Insert Ring Gear 51 T on Left side Bracket of Chassis assembly as shown in the figure. ...

Install Ring Gear 48T P/N 73225 and Carrier Assembly P/N 73227 in Gear Housing P/N 75077. Install Gear Housing on Left side Bracket of Chassis assembly aligning dowel pins. Install 3 Cap Screws (#3 x .75) in Gear Housing through Left side Bracket of Chassis assembly. Install Helical Gear on Gear Housing as shown in the figure. ...

Install Wear Washer on Helical Gear Press. Install Retaining on Helical Gear. Install Idler Gear on Gear Housing. Install Wear Washer and Retaining Ring on Idler Gear. ...

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 ...

2.4.1 REMOVAL OF MOTOR Before removing the Motor follow the instructions given below: Remove the Gear Train assembly. Remove the 2 screws (#8 x 0.75) from Chassis assembly. Remove the left side cap screw and nut from Hawse Fairlead assembly. ...

Remove cap screw from Chassis assembly as shown in the figure. Remove Left side Bracket from Chassis assembly. Remove Motor assembly from Chassis assembly after removal of Wiring leads ...