SERVICE MANUAL & USER GUIDE - Ezy-Lift
Contents
1. Ezy Lift SERVICE MANUAL amp USER GUIDE EZY 2000 PICKUP TRUCK LIFT UNLOAD Patent No US 6 799 935 B1 This Page Left Blank For Printing TABLE OF CONTENTS INTRODUC TION 1 1 SAFETY 6 6 2 SAFETY LABELS cast 2 OPERATIONAL 4 OPERATING the ZAS Bidatz eu 7 C7V LIICIM INSPECTION and MAINTENANCE 9 TROUBLESHOOTING 29 dio 11 PARTS mennaan 12 QUALITY SERVICE CONTACT INFORMATION 12 13 __ _3__ _ _ 3 _ _ ____ _ _ aaa 17 WARRANTY 21 OWNER REGISTRATION 0 22 INTRODUCTION PRODUCT IDENTIFICATION Using your Operator s Manual Read this entire Operator s Manual especially the Safety Information before operating This Manual is an important part of your machine Keep all Manuals in a convenient location so they can be a2. products Unfortunately all efforts to provide safe equipment can be totally negated by a single careless act by an Installer or Operator ALWAYS WEAR SAFETY GLASSES AND USE CARE WHEN WORKING WITH POWER TOOLS Accident Prevention and Safety are dependent upon the awareness and proper training of the personnel who operate and maintain this equipment The best safety device is a careful and informed Owner Operator Taking precedence over any specific rule however is the most important rule of all SAFETY FIRST Ezy Lift model 2000LBS lift system has a rated lift capacity of 905kg 2000 Ibs Maximum Hydraulic load capacity at full extension 905kg 2000 Ibs Maximum Winch load capacity at full extension 905kg 2000 Ibs OVERLOADING YOUR VEHICLE CAN CAUSE POTENTIAL SAFETY HAZARDS Read and obey all Safety Symbols Warnings Cautionary Notes and Operating Instructions on the Ezy Lift and in this Manual Ensure that all placards are in place and legible Failure to comply with safety precautions in this Manual and on the Ezy Lift isa Safety violation that may result in serious injury death or property damage SAFETY LABELS Understanding Machine Safety Labels The unit s Safety Labels as shown in this section are placed in important areas on your Ezy Lift unit to draw attention to potential safety hazards The Safety Labels on your unit are pictorial ensuring they are most easily and universally understood Whe
3. are determined in accordance with Cordage Institute 1500 Test Methods for Fiber Rope Weights are calculated at linear density under standard preload 20000 plus 4 Specific gravity 0 98 Elongation Melting point 284 F 140 C Critical temperature 150 F 65 C a Coefficient of friction 0 09 0 12 8 sa Elongation at break 4 5 Ea Fiber water absorption 0 UV resistance moderate Wet abrasion superior 8 10 15 20 25 30 35 49 Dry abrasion superior Load of average strength _yalue based data supplied by the fiver manufacturer for new dry fiber When Replacing the Synthetic Plasma 12 Strand Rope be sure to Product insert the attaching end of the rope into the correct end of the drum hole Tie a Figure Eight Knot See Figure A and B to secure to drum Ezy Lift INSPECTION MAINTENANCE cont HYDRAULIC UNIT The Ezy Lift Hydraulic Unit is completely self contained and re quires no maintenance However periodic inspection of hydraulic cylinders hoses and fittings for any sign of leakage is recommended Periodically check the oil level in the fluid reservoir and add oil as needed to maintain full capacity ine The hydraulic pump and fluid reservoir is located directly behind the Nan cover hatch on the Driver s side of the unit With the lift cylinders fully retracted lift arms in the parked position the fluid reservoir should b
4. disconnect the wire cable s hoist hook from the load STEP 12 Depress the HOIST UP button to rewind the wire cable onto the winch spool DO NOT OVERWIND as this could damage the winch and or wire cable Apply tension to the winch cable to ensure that it winds evenly and smoothly onto the winch spool STEP 13 Return the lift arms to their parked position using the BOOM IN button STEP 14 Turn the Main Switch to the OFF position STEP 15 ALWAYS REMOVE the remote control from the power jack and store it in a clean dry location to avoid damage while transporting the load To prevent unauthorized use of the unit NEVER leave the truck unattended with the remote control inserted into the power jack PLACE THE REMOTE CONTROL IN A SAFE SECURE LOCATION WHEN NOT IN USE Ezy Lift INSPECTION amp MAINTENANCE Your Ezy Lift System is designed to give years of faultless operation However as with any mechanical product periodic inspection and maintenance is required to keep the unit in its best operating condition Here are a few tips that Owners Operators should periodically perform to keep the unit in top condition PLEASE REVIEW THIS INFORMATION II you have any questions please contact Ezy Lift during normal business hours Central Standard Time Monday through Friday excluding holidays WINCH WIRE CABLE Wire cable consists of a core strands and wires The wire cable fits and wraps onto grooves on the circumference of the
5. GER iR e A kt sean ko a a 12 Volts DC Miel Setze WING pot w det aa 12 Volts DC Amperage Syste 150 amps Amperage ale EEE Limited to 150 amps FUSES ITE GO gt 150 amps at Vehicle Battery FLUID CAPACITIES C Automatic Transmission Fluid ATF 11 FAV GRAIG IC AD AC IL 3 65 Liters 1 U S Gallon 13 EZY 2000 LONG MAXIMUM OBJECT HIGHTH 89 OBJECT WIDTH 48 OPEN TOP M se EZY 2000 SHORT OBJECT WIDTH 48 7 2000 FLAT BED TRAILER np TOP EZY 2000 UTILITY Leg Supports Standard 24 25 Low Profile 20 25 bd 4 2 142 FITS IN 49 OR 54 CARGO BEDS A B C D E F G H FULL WIRING DIAGRAM Part EZ508 Circuit Breaker 150AMP Part WG139 Controller Plug In Part WG132 16GA Black Cable Winch Solenoid to Winch Solenoid Ground Part EZ705 Winch Solenoid Part WG143 8GA Black Cable Solenoid to Pump Base Ground Part WG134 8GA Black Cable Pump Ground to Pump Base Ground Part WG125 8GA Black and Red Cab
6. System when someone is within an unsafe distance clear of moving components NEVER lift a load with a weight exceeding 905 kg 200015 Maximum Hydraulic load capacity at full extension 905 kg 2000 Ibs Maximum Winch load capacity at full extension 905 kg 2000 Ibs NEVER lift anything with the Ezy Lift System while the truck is on an incline or side of hill NEVER lift anything into the bed that will not fit cause the vehicle to be unstable when driven or that cannot be safely secured as to not move around when transported USE CAUTION keep people pets and property clear of the path of the load keep work area clear and free of obstructions DO NOT use for supporting an unattended load DO NOT use for towing other vehicles Before Operating Visually inspect the hook winch cable winch and accessories for any damage or wear Reject nylon slings with abnormal wear torn stitching broken or cut fibers or discoloration or deterioration Reject wire cable with kinking crushing bird caging or other distortions evidence of heat damage cracks deformation or worn end attachments six randomly broken wires in a single cable lay three broken wires in one strand of cable cracked hooks and hooks open more than 15 at the throat Ensure that the truck cargo bed and suspension system are in good condition i e shocks springs etc Check to see that all fasteners are secure and that the gusset screws are all tight Check for an
7. al safety hazard NEVER ATTACH a sling or chain link to the tip of the lifting hook or attempt to lift a load from the tip of the hook Make sure that the nylon sling or chain is properly seated in the saddle of the hoist hook STEP 8 With the load now attached press and hold the HOIST UP button Slowly take up slack in the wire cable until it becomes taut Keep tension on the wire cable during this process and make sure that the cable winds evenly across the drum STOP Recheck all lifting connections before proceeding to lift the load STEP 9 When sure that all the lifting connections are secure depress the HOIST UP button to slowly lift the load from the ground just high enough to clear the truck tailgate DO NOT PULL FROM ANGLES as this can damage the lift arms Continuous pulls at angles will also cause the wire cable to pile up at one end of the winch drum This can jam the wire cable and damage the winch and or cable ALWAYS MAINTAIN at least five 5 wraps of wire cable on the winch drum otherwise the wire cable drum fasteners will not withstand the load STEP 10 Press and hold the BOOM IN button to move the load onto the truck bed Use the HOIST DOWN button to keep the load low during the process Once the load is at the desired position release the BOOM IN button to stop the lift arms STEP 11 Slowly lower the load onto the truck bed by pressing and holding the HOIST DOWN button Once the load is resting safely in the truck bed
8. anual and have understood the proper operation and maintenance of the Ezy Lift System should be permitted to operate the Ezy Lift System General Safety Information READ and save all instructions NEVER engage in any practice that will divert your attention while operating the Ezy Lift System NEVER operate the Ezy Lift System from the Driver or Passenger seats ALWAYS disconnect the Ezy Lift Controller and cable from the receptacle when moving the vehicle NEVER overload Overloads can cause damage and create unsafe operating conditions Ensure that the rated load capacity of any sling lifter or fitting is not exceeded Learn to use the Ezy Lift System correctly Take time to practice so that you are comfortable with the operating system Maximum Hydraulic load capacity at full extension 905 kg 2000 Ibs Maximum Winch load capacity at full extension 905 kg 2000 Ibs NEVER handle the wire winch cable with bare hands ALWAYS use leather gloves when handling the winch cable NEVER allow children or unauthorized personnel to operate the Ezy Lift System at any time NEVER use the unit for lifting supporting or transporting people NEVER stand beneath the load or Ezy Lift System lift frame or use over areas where people are present NEVER operate the Ezy Lift System with Driver or Passenger in the vehicle OPERATIONAL SAFETY cont General Safety Information cont NEVER operate the Ezy Lift
9. ccessed easily Use the Safety and Operating information in both the Ezy Lift Operator s Manual and the Machine Operator s Manual to operate and service the unit Safely and correctly II your Ezy Lift Manual has a section called Preparing the Truck it means that you may need to do something additional to your truck before you can install the Ezy Lift system The Assembly and Installation sections of this Manual provide information to assemble and install the Ezy Lift system into the cargo box of your vehicle Refer to the Service section if any adjustments are required II you have any questions or concerns with the assembly installation or operation of the unit contact your Ezy Lift System Representative or Ezy Lift CUSTOMER CONTACT CENTER 1 800 974 3032 Product Compatibility The Ezy Lift System is compatible with truck vehicles of the following makes Toyota Chevrolet GMC Dodge Ford If you need to contact the Ezy Lift Customer Contact Center for information on servicing always provide the Product Serial Number and Date of Purchase Refer to Illustration below Please locate the Product Serial Number and record all relevant information in the spaces below DATE OF PURCHASE DEALER NAME DEALER PHONE PRODUCT SERIAL NUMBER SAFETY READ THIS ENTIRE OPERATOR S MANUAL BEFORE BEGINNING WORK CAUTION Safety is a primary concern in the design and manufacturing of Ezy Lift
10. cess to handle your questions or problems should they arise to ensure that product quality continues with your Ezy Lift Parts and Service Support FOLLOW THE STEPS BELOW TO GET ANSWERS TO ANY QUESTIONS YOU MAY HAVE REGARDING YOUR EzyLift SYSTEM Ezy Lift QUALITY CONTINUES WITH QUALITY SERVICE e Refer to the appropriate Product Manual e Refer to the Product Serial Number Refer to Part Number for Parts enquiries e Contact Ezy Lift with unanswered questions USA amp Canada 1 800 974 3032 12 Ezy Lift SPECIFICATIONS MODEL Ezy Lift 2000LBS 2 Cea gi Ezy Lift Ezy Lift 2000L85 CAPACITIES _ __ _ _ 202 lt _33_ ____ _____ __ _ __ 905 kg 2000 Ibs Maximum Hydraulic load capacity at full extension aa 905 kg 2000 Ibs _ __ _ __ ___ _____ 905 kg 2000 Ibs Maximum Winch load capacity at full extension sa 905 kg 2000 Ibs WIRES WI VE FI OO Kako ea an at aa 953 kg 2100 Ibs LIFT SYSTEM EU ele legea e Meles 2 x 6 35mm 2 1 2 bore 41mm 16 stroke POWO FACK eie KEU ea 12 Volt Elect BSE a ka tk n zd a n t ka Eak 11 Gauge Steel with Black Finish WINCH Mul Galea gel AZOT ak kk ka a Mile Marker 3 5 ELECTRICAL W Ola SS Son donan
11. d become comfortable with operating the system Attaching a small load or providing tension to the winch hook when raising and lowering the wire cable will help keep the wire cable tightly wound on the drum Make sure that the wire winds evenly across the entire surface of the winch drum STEP 6 Now that you are familiar with the controls press and hold the BOOM OUT control button to raise the lift arms and position them over the object to be lifted Ensure that the winch is positioned directly above the center of the load to be lifted in order to prevent the load from swinging as it is hoisted from the ground NOTE A swinging load could cause injury and or property damage For large objects it may be necessary to remove the truck tailgate in order to correctly position the winch above the load Failure to do so may cause damage to your vehicle and or cargo box OPERATING the Ezy Lift SYSTEM OPERATING INSTRUCTIONS cont STEP 7 With the lift arm and winch now centered over the load press and hold the HOIST DOWN button to lower the wire cable s hoist hook into position for attaching to the load Keeping tension on the wire cable while it unwinds will prevent slippage of the wire cable once the load is attached NEVER WRAP THE LIFTING CABLE AROUND THE LOAD Use a nylon sling or metal chain to attach the hook to the load Wrapping the wire cable around the load and hooking it back onto itself can damage the cable and create a potenti
12. e approximately 2 3 full 25mm to 38mm 1 to 1 1 2 beneath the filler inlet See Figure 2 DO NOT OVERFILL Adding too much oil could cause the reservoir to overflow when your vehicle is in motion Use Automatic Transmission Fluid ATF with a viscosity range of 150 300 SSU at 100 gt Figure 2 MAINTENANCE INTERVALS Your Ezy Lift Lifting System should be serviced every 2 years or 400 hours of normal operation That service to include e Inspect and lubricate bearings e Check all hydraulic fittings for leaks or signs of wear tighten or replace as necessary e Inspect hydraulic power unit and reservoir for leaks or damage repair or replace as necessary Replace hydraulic fluid and inspect old fluid for signs of problems e Check cylinder for leaks and inspect cylinder rod for evidence of wear or damage repair or replace as necessary Inspect for corrosion and treat as necessary e Inspect electrical system for corrosion or damage repair or replace as necessary e Inspect all bolts including frame attachment to cargo bed frame to arm assemblies gusset and winch Tighten and or replace as necessary e Inspect winch housing and motor for any signs of wear or problems repair or replace as necessary 10 TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Boom Arms will not raise or Unit Off On switch 1s OFF Turn the switch ON lower Remote Control assembly not Remove and re insert
13. f the wire cable Replace the wire cables immediately if either condition is found When replacing the wire cable be sure to insert the attaching end of the wire cable into the correct end of the drum hole See Figure 1 Tighten the set Screws securely Always use a wire cable with minimum break strength of at least 2 540kg 5 600 Ibs NOTE Always remember to use heavy leather gloves when handling wire cable Do not allow the wire cable to slide through bare hands FROM THE MOTOR SIDE PLASMA 12 STRAND Plasma 12 strand 15 the highest strength synthetic rope available Plasma 12 strand Is manufactured from Honeywell Spectra Fiber that has been enhanced by Puget Sound Rope s patented recrystallization process This process 15 especially effective in medium to large diameter ropes where strengths are over 50 higher and creep Is significantly less than that of standard Spectra 12 strand Plasma 12 strand comes standard with a polyurethane finish and is easily spliced using a simple lockstitch type splice 4 3 2 or 5 4 3 Tuck splice Its soft torque free braided construction provides easy handling Momina Approximate Weight Minimum Tensile Strength Diameter Number PP 5 e Highest strength MM circ Kg 100m Lowest stretch A _0 05 1 25 l e Low creep a a gt e Soft hand 0 07 1 75 e Torque free Easy Splicing A N e Floats Tensile Strengths
14. ibility to use good judgment the operation and maintenance of the Ezy Lift Load Lift System PLEASE READ THIS ENTIRE OPERATOR S MANUAL BEFORE BEGINNING WORK It is the Owner s Operator s responsibility to instruct and ensure that all Operators fully understand the safe operation and maintenance of the Ezy Lift System Anyone who operates the equipment must read and fully understand this Manual prior to operating the lift system Failure to observe these instructions and safety procedures can result in serious injury and or property damage Train Ezy Lift inspection and maintenance personnel for routine and periodic inspections and maintenance Such training requirements should also provide information for compliance with any Federal State and Local Code Requirements existing Company safety rules and regulations and instructions furnished for the Ezy Lift system Because Ezy Lift Inc has no direct involvement or control over the operation and application of the Ezy Lift System once it is installed on a vehicle conforming to good safety practices is the responsibility of the Owner the User and its operating personnel Therefore it is essential that all personnel who will install inspect test maintain and operate the Ezy Lift unit read and completely understand the contents of this Owner s Manual Only those authorized and qualified personnel who have shown that they have read and understood the Own er s M
15. le Solenoid to Winch Part E2052 Winch Assembly 1 J K L M N 0 P Truck Battery NOT INCLUDED Part WG110 4GA Red Cable Winch Fuse Box to Truck Battery Part EZ494 Winch Fuse Box Part EZ655 150AMP Fuse Part WG140 4GA Red Cable Circuit Breaker 150AMP to Winch Fuse Box Part WG141 8GA Red Cable Circuit Breaker 150AMP to Winch Solenoid Part WG144 4GA Red Cable Circuit Breaker 150AMP to Pump Solenoid Part E2070 Pump Assembly Part E2069 Cylinder Assembly Part EZ584 Hose 3 16 x 45 Part EZ585 Hose 3 16 x 36 Part EZ587 Hose 3 16 x 138 Part EZ586 Hose 3 16 x 126 Part E2070 Pump Assembly HYDRAULIC LINE ASSEMBLY 8 C D E F G H APU WIRING DIAGRAM Part EZ508 Circuit Breaker 150AMP Part WG124 Controller Plug In Part EZ878 Warn Winch Solenoid Part WG133 8GA Black Cable Winch Solenoid to Pump Ground Part WG145 4GA Black Cable Winch Solenoid to Ground on Truck Part WG125 8GA Black and Red Cable Winch Solenoid to Winch Part E2011 Warn Winch Assembly l J K Part WG132 16GA Black Cable Winch Solenoid to Winch Solenoid Ground L M N P Page 10 Truck Battery NOT INCLUDED Part WG110 4GA Red Cable 150Amp Fuse Box to Truck Battery Part EZ494 150Amp Fuse Box Part EZ655 150Amp Fuse Part WG146 4GA Red Cable Circuit Breaker 150AMP to Winch Fuse Box Part WG127 8GA Red Cable Circ
16. nte nance or repair unauthorized alteration or use of the product beyond the range of normal usage To obtain warranty service contact Ezy Lift at 1 800 974 3032 during business hours Central Standard Time 8 00 am 5 00 pm Monday through Friday excluding holidays Be prepared to provide 1 Name Address and Phone Number 2 Proof of Purchase 3 Unit Serial Number and 4 Explanation of the Problem This Warranty is the only Warranty made by Ezy Lift and it cannot be amended or amplified by any party Please fill out the form on the following page with your company or personal information after reading this manual 21 Owner Registration 1 have read and fully understand the safety content and procedures of the EZY LIFT 2000 owner s manual Only designated personnel that have shown adequate knowledge of this product will be permitted to use it 1 understand that Impac Manufacturing Inc has no direct involvement or control over the EZY LIFT 2000 operation and application once it has left the facility and conforming to good safety practices is the responsibility of myself the owner the user and its operating personnel Owner signature Date Product serial number Company Owner Information Company Owner name Address City State Zip code Phone number _i s Fax number E mail address Please Mail Registration to IMPAC Manufacturing Inc 41786 FM 510 Los Fresnos TX 78566 22
17. re necessary the Operator s Manual explains any potential safety hazards in special safety messages identified with the words CAUTION or BE CAREFUL and incorporate the Safety Alert symbols shown below AVOID INJURY Only trained personnel should be allowed to ser vice or maintain the unit Improper service or maintenance can lead to potential unit failure and injury while in use SAFETY LABELS cont PINCH POINT _ PUNTO DE _ PELLIZCO CAUTION KEEP HANDS AWAY This label is positioned on the lifting arms near the pinch points where the lift arms unit frame and linkages converge as well as on the lift arm hydraulic cylinders where they pass into and out of the lift frame To avoid risk of serious injury it is essential to keep hands away from this area while the unit is in use It is the responsibility of the Operator to advise others including bystanders of this risk NEVER remove the CAUTION label and replace immediately if missing BE CAREFUL CAUTION STAY CLEAR PRECAUCION MANTENERSE ALEJADO BE CAREFUL NEVER depend on the winch or wire rope to support a lifted load NEVER stand or move under a lifted load While operating the winch use the holding strap to maneuver the load DO NOT grip the wire rope or the rope hook IL is recommended that leather gloves are used when rewinding the wire rope after use OPERATIONAL SAFETY is the Owner s Operator s respons
18. the properly plugged in Remote Control assembly Poor electrical connection Check all wire connections with pump Hydraulic pump solenoid failure If motor runs cycle manual solenoid override button in amp out several times to free valve test with boom in or out button on pendent Boom may be stowed by moving manual solenoid override button in or out and depressing boom button on pendent simultaneously Winch will not operate or it Remote Control assembly not Remove and re insert the runs in one direction properly plugged in Remote Control assembly Poor electrical connection Check all wire connections leading up to the winch Boom Arms and Winch will Fuse at vehicle battery blown Replace fuse not operate Fuse at pendent 15 blown Replace fuse located 18 pump hous ing Poor electrical connection Check all wire connections FEE Vehicle battery charge 15 low Recharge or replace battery Remove the dome plug to access the valve If motor runs cycle manual solenoid override stem located on the front of the unit button in amp out several times to free valve test with boom in or out button on pendent Note Remove the load if any before retracting the boom 11 PARTS We recommend Ezy Lift authorized replacement Parts available by contacting USA amp Canada 1 800 974 3032 e Or visit www Ezylift com for your internet connection to Parts ordering and Information Ezy Lift provides a pro
19. uidelines and safe operation information in the OM being observed in conjunction with conditions on the day Examples of conditions on the day could be temperature variations including highs and lows hot dry cold raining as well as size and type of load being lifted Ezy Lift is not able to control your working environment or safe operating practices at any given time and are therefore not liable for variations in performance or injury resulting from misuse or variations in conditions on the day OPERATING the Ezy Lift SYSTEM Your Ezy Lift System operates from the truck s 12 volt battery which provides power to the winch and the hydraulic power unit The hydraulic unit is completely self contained with a DC motor gear pump reservoir load hold check valves and relief valves to prevent overloading Flow from the pump to a pair of double acting cylinders provides the lift and rotation necessary to extend and retract the lift arms via the hand held remote control USING THE UNIT UNDER LOW VOLTAGE CONDITIONS CAN REDUCE LIFE OF THE HYDRAULIC PUMP AND WINCH OPERATING INSTRUCTIONS STEP 1 Position your truck to allow the entire loading or unloading operation to be performed without having to move the vehicle Ideally the truck will be on solid level ground Ensure that there is adequate overhead clearance for the lift arms to operate and extend fully Maximum Hydraulic load capacity at full extension 905 kg 2000 Ibs Ma
20. uit Breaker 150AMP to Winch Solenoid Part WG126 8GA Red Cable Circuit Breaker 150AMP to Pump Solenoid Part E2102 Utility Pump Assembly 7AP HYDRAULIC LINE ASSEMBLY Part E2069 Cylinder Assembly Part EZ585 Hose 3 16 x 36 Part EZ584 Hose 3 16 x 45 Part EZ659 Hose 3 16 x 156 Part EZ660 Hose 3 16 x 176 Part E2102 Utility Pump Assembly Page 11 REMOTE CONTROL DIAGRAM 000V edu 10 1IVL L9263 LL gt A gt N WARRANTY Ezy Lift warrants the Ezy Lift product to the original Buyer against defective materials and parts for one 1 year Winch thirty 30 days from the date of purchase Ezy Lift s sole and exclusive liability and the Buyer s sole and exclusive remedy under this War ranty is the repair or replacement of any materials or parts determined to be defective by Ezy Lift In no event shall Ezy Lift be liable for incidental or consequential damages including but not limited to inspection or transportation cost cost of cover loss of profits loss of use and damages or inju ry of any kind based upon claim for breach of Warranty This Warranty does not cover breaking or fraying of the winch rope cost of labor for field repairs transportation charges in connection with replacement or repairs of defective parts or any damage as a result of misuse neglect overloading accident improper installation mai
21. winch drum that transmits motion to the wire cable Wire cable sizes are stated as the diameter of a circle that would enclose the wire cable strands i e 8mm 9 5mm 5 16 3 8 etc Each wire cable size is available in various cable constructions and materials e Routinely check that the winch wire cable has not become loosely wound Under load a loosely wound Spool allows the wire cable to work its way down into the layers of wire cable on the drum This can cause the wire cable to become wedged within the body of the windings on the spool and damage the wire cable Keep tension on the wire cable during unwinding and rewinding A good practice is to inspect and rewind the wire cable under tension after each use e Routinely check to see that the wire cable is evenly wound on the drum and not bunched to one side of the winch drum During winding of the wire cable check to see that the cable is winding evenly on the drum If necessary rewind the wire cable under tension making sure that the cable is evenly placed across the width of the winch drum e Routinely check the wire cable for evidence of kinking or damage Replace any cable found to have evidence of kinking or damage Loosely wound spool or cable wound at one end of the winch drum allowing it to become wedged can damage the wire cable and could cause it to break under load resulting in the potential for both property damage and injury Fraying and kinking reduces the load capacity o
22. ximum Winch load capacity at full extension 905 kg 2000 Ibs STEP 2 Set the truck parking brake and leave the engine running so as not to discharge the battery STEP 3 Open the truck tailgate very important to prevent damage to the truck s tailgate In some instances it is preferable to remove the tailgate prior to loading cargo STEP 4 Plug the remote control assembly into the power control jack that is located on the Driver s side near the base of the tailgate opening STEP 5 Turn the Main Switch to the ON position THE UNIT IS NOW READY FOR OPERATION The Remote Control unit has two rocker buttons one for the boom and one for the hoist Each button is double acting with the following commands BOOM IN BOOM OUT HOIST DOWN and HOIST UP To activate the lift arms press and hold the BOOM OUT control button This will cause the arms to rise from their parked position and rotate out approximately 150 over the truck bed To reverse the process and return the lift arms to their parked down position press and hold the BOOM IN control button until the arms are fully down Similarly to activate the crane winch press and hold the HOIST DOWN control button to lower unwind the wire hook and the HOIST UP control button to raise wind the wire hook Both the lift arms and the crane winch can be stopped in any position by simply releasing the control button Practice moving the arms in and out raising and lowering the wire cable an
23. y evidence of hydraulic fluid leaks A WARNING NEVER MOVE THE TRUCK WITH A SUSPENDED LOAD OPERATIONAL SAFETY cont Moving a Load Center the hook over the load to keep the cable from slipping out of the drum grooves and overlapping and to prevent the load from swinging when it is lifted Inspect the drum to verify that the cable is in the grooves Lift the load only high enough to clear the tailgate or rear of the cargo bed Keep fingers and arms well clear of the pinch points between the Ezy Lift System arms and frames NEVER stand in cargo bed when loading or unloading NEVER operate Ezy Lift System while the truck is on an incline or side of a hill AVOID SIDE PULLS These can cause the winch cable to slip out of the drum groove damaging the wire or destabilizing the winch NEVER leave suspended loads unattended In an emergency where the Ezy Lift System has become inoperative or if a load must be left suspended for any length of time barricade and post signs under the load and on all three sides Turn off the truck and set the parking brake it so it cannot be moved Disclaimer The Ezy Lift System Model 2000L85 is manufactured to exacting specifications and standards using high qual ity materials components and workmanship Guidelines for load lifting and safe operation need to be observed when using operating the Ezy Lift Model 2000L855 load lift system Overall performance of the system depends on the g
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