SERVICE MANUAL & USER GUIDE - Ezy-Lift
Contents
1. ECM 150 amps at Vehicle Battery FLUID CAPACITIES Oil Hydraulic Type from Kendall Hyken Glacial Blue Hydraulic Fluid Blue in color ConocoPhillips Lubricants NE Use Automatic Transmission Fluid ATF Red color to refill 111 514 1111111 11 10 11 1 O AE 3 85 Liters 1 U S Gallon Ulitmate Load is 4 times the Working Load Limit Ulitmate Load is 2 5 times the Working Load Limit 17 EZY 2000 LONG MAXIMUM OBJECT HIGHTH 89 OBJECT WIDTH 48 OPEN EZY 2000 SHORT OBJECT WIDTH 48 EZYZ000 FLAT BED TRAILER SS TOP EZY 2000 UTILITY Leg Supports Standard 24 25 Low Profile 20 25 2 TOP VIEW FITS IN 49 OR 54 CARGO BEDS 21 A B D E F G H WIRING DIAGRAM Part EZ508 Circuit Breaker 150 Part WG139 30 Long Controller Plug In Part EZ878 Warn Winch Solenoid Part WG132 16GA 6 Long Black Cable Solenoid to Solenoid Ground Part WG143 8GA 30 Long Black Cable Solenoid to Ground on Pump Part WG134 4GA 48 Long Black Cable Solenoid to Ground on Chassis Part WG125 8GA 170 Long Black and Red Cable Solenoid to Winch Part E2011 Warn Winch Assembly I J2. Zy Lift SERVICE MANUAL amp USER GUIDE EZY 2000 PICKUP TRUCK LIFT EZY 2000 FLAT BED TRAILER LIFT LOAD GO UNLOAD Patent No US 6 799 935 1 TABLE OF CONTENTS INTRODUC TION 1 PRODUC TIDENTIFRICATION 4 SAFETY APE AZ aa i 2 SAFETY LABELS 2 4 OPERATIONAL SAFETY 5 6 OPERATING the Ezy LiftM SYSTEM 6 7 8 Ezy Lift INSPECTION and MAINTENANCE 5 555 9 14 TROUBLESHOOTING virren anara ena 15 PARTS ce 16 QUALITY SERVICE CONTACT INFORMATION 16 5 E 17 SCHEMATICS 18 26 WARRANTY 2 OWNER REGISTRATION Ee CEA 31 INTRODUCTION PRODUCT IDENTIFICATION Using your Operator s Manual Read this entire Operator s Manual especially the Safety Information before operating This Manual is an importan
3. immediately if missing MAX LIFT CAP SINGLE LINE 1 000 LBS DOUBLE LINE 2 000 LBS OPERATIONAL SAFETY is the Owner s Operator s responsibility 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 und
4. strands not separable Segment whose diameter 15 20 less than other part of the rope Melting on one side that fuses one or more strands together e Rope that has lengthened between reference marks by more than 10 Normal Abrasion 1 2 Strand Severed Minor Snags Note It has been found that cleaners degreasers containing d Limonene citrus based cleaners can rapidly deteriorate HMPE based ropes Avoid contact with this chemical Each end user will determine through experience which signs of damage are more indicative of impending failure For example the critical damage mode of a rope that fails in service might be identified if the location of the break can be traced to damage noted in a prior inspection Plasma represent a significant technological breakthrough in high strength lifting lines however as with any synthetic fiber rope product Plasma lines have a much better chance of meeting expectations when coupled with careful maintenance and periodic Inspection 12 PLASMA 12 STRAND Plasma 12 strand ts 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 is 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 come
5. Breaker 150AMP to Winch Solenoid Part WG126 8GA Red Cable Circuit Breaker 150 to Pump Solenoid Part E2102 Utility Pump Assembly 24 ToN w gt 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 25 REMOTE CONTROL DIAGRAM 000 edu 20 9 2 26 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 mainte na
6. can best be determined by periodic inspection of the lines This guideline presents recommendations for conducting periodic inspection by the end user Conditions to be avoided in Plasma Lines There are three areas where close attention needs to be paid to Plasma lines Below are descriptions of these conditions and likely signs of their presence 1 Repeated lateral abrasion against sharp edges While HMPE 15 one of the most cut resistant polymers available metal can prove to be stronger than Plasma in a long duration abrasion event Signs of excess abrasion include strand pullouts heavy fuzzing and cut strands in a single area and localized bunching It should be noted that normal light fuzzing of the ner ee Plasma rope surface is to be expected in normal use This light fuzzing does not reduce the rated strength of the line and actually creates a protective layer on the Normal Abrasion rope that helps to prevent further damage 2 Plasma begins to lose strength above about 160 F and has a zero strength temperature around 250 C Signs of high temperature damage include melting fused strands and Typical Compression from Sheave significantly reduced diameter The fused strands should not be confused with high tension compression of the rope which might appear similar With standard urethane coatings the rope can appear melted after high tension has been applied while the rope is bent around a surface This is
7. evidence of wear or damage repair or replace as necessary e 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 14 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 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 Papa Poor elect
8. its operating personnel Owner signature Date Product serial number Company Owner Information Company Owner name Address City State Zip code Phone number Fax number E mail address Please Mail Registration to IMPAC Manufacturing Inc 41786 FM 510 Los Fresnos TX 78566 31
9. periodic 3 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 The hydraulic pump and fluid reservoir is located directly behind the oO 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 be 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 F Cold Weather conditions use Kendall Hyken Glacial Blue Hydraulic Fluid Blue in color ConocoPhilips Lubricants in unit from factory Fluid can be mixed with Automatic Transmission Fluid Figure 2 MAINTENANCE INTERVALS Your Ezy Lift Lifting System should be serviced every 1 years or 200 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
10. 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 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
11. 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 If you have any questions please contact Ezy Lift during normal business hours Central Standard Time Monday through Friday excluding holidays Y 1012 Second Street Anacortes WA 98221 USA AD Puget Sound Telephone 360 293 8488 360 293 8480 www psrope com email sales psrope com Inspection Guidelines for Plasma Synthetic Ropes Puget Sound Rope Company Plasma ropes have been used extensively in numerous diverse applications for many years Over this time period particular operating conditions and hazards have been 1dentified which are more harmful to Plasma than to steel The presence of these conditions
12. the Ezy Lift System with Driver or Passenger in the vehicle OPERATIONAL SAFETY cont General Safety Information cont NEVER operate the Ezy Lift System when someone is within an unsafe distance clear of moving components NEVER lift a load with a weight exceeding 905 kg 200010 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 snatch block rope hoist and accessories for any damage or wear Reject rope or nylon slings with abnormal wear torn stitching broken or cut fibers or discoloration or deterioration Reject rope with kinking crushing bird caging cuts or other distortions evidence of heat damage deformation or worn end attachments hooks and snatch block 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
13. the gusset screws are all tight Check for any evidence of hydraulic fluid leaks WARNING NEVER MOVE THE TRUCK WITH A SUSPENDED LOAD 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 boom extension 905 kg 2000 Ibs Maximum Winch load capacity at full boom 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
14. CAUTION Safety is a primary concern in the design and manufacturing of Ezy Lift 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 VM lift system has a rated lift capacity of 905kg 2000 Ibs Maximum Hydraulic load capacity at full boom extension 905kg 2000 Ibs Maximum Winch load capacity at full boom extension 905 kg 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 5 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 La
15. K L M N Truck Battery NOT INCLUDED Part WG110 4GA 26 Long Red Cable 150Amp Fuse Box to Truck Battery Part EZ494 150Amp Fuse Box Part EZ655 150Amp Fuse Part WG140 4GA 360 Long Red Cable Circuit Breaker 150 to Winch Fuse Box Part WG127 8GA 24 Long Red Cable Circuit Breaker 150 to Winch Solenoid Part WG144 4GA 6 Long Red Cable Circuit Breaker 150 to Pump Solenoid Part E2070 Pump Assembly HYDRAULIC LINE 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 23 A B C D E F G H 7AP WIRING DIAGRAM Part EZ508 Circuit Breaker 150 Part WG124 Controller Plug In Part EZ878 Warn Winch Solenoid Part WG132 16GA Black Cable Winch Solenoid to Winch Solenoid Ground 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 1 J K M N P 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 Part WG127 8GA Red Cable Circuit
16. Re E JAA 905 kg 2000 Ibs Maximum Hydraulic load capacity at full extension 905 kg 2000 Ibs Hoist Capacity Single Line Double 452 5 kg 1000 Ibs 905 kg 2000 Ibs Maximum Hoist load capacity at full extension SL 452 5 kg 1000 Ibs DL 905 kg 2000 Ibs Swel HOOK a a 953 kg 2100 Ibs Crosby Group Snatch Block Certex CX13 0001 1 1 1 1 6 6 2000 kg 4409 55 LIFT SYSTEM AV CWC 2 x6 35mm 2 1 2 bore 41mm 16 stroke one 12 Volt Elect sect octet izka wabi z nd 11 Gauge Steel with Black Finish HOIST mettre WARN DC 1000 ELECTRICAL SYSTEM MOMS Ss SV SUC I ame 0 12 Volts INCU aa 12 Volts Amperage SV SCM 150 amps PAID OV SO WINGI wach Limited to 150 amps FUSE
17. UT 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 potential 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
18. bels on your unit are pictorial ensuring they are most easily and universally understood Where 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 CAUTION BE CAREFUL PINCH POINT PUNTO DE PELLIZCO CAUTION KEEP HANDS AWAY BE CAREFUL CAUTION STAY CLEAR PRECAUCION MANTENERSE ALEJADO This label is positioned on the lifting arms near the NEVER depend on the winch or wire rope to support pinch points where the lift arms unit frame and a lifted load linkages converge as well as on the lift arm NEVER stand or move under a lifted load hydraulic cylinders where they pass into and out of While operating the winch use a holding strap or tag line to the lift frame maneuver the load To avoid risk of serious injury it is essential to keep DO NOT grip the wire rope or the rope hook hands away from this area while the unit is in use It is recommended that leather gloves are used It is the responsibility of the Operator to advise when rewinding the wire rope after use others including bystanders of this risk NEVER remove the CAUTION label and replace
19. 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 and 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 O
20. erstand 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 Manual 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 boom extension 905 kg 2000 Ibs Maximum Winch load capacity at full boom 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
21. nce 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 27 Notes 28 05 06 2013 John Winsauer john impacmfg com 713 471 3994 www impacmfg com www ezylift com Ezy Lift EZY 2000 OILFIELD AND LTL DELIVERY SERVICES q John Winsauer johnQimpacmfg com 713 471 3994 www impacmfg com www ezylift com COMPLETE TRUCK BED amp HOIST 30 Owner Registration 1 have read and fully understand the safety content 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 I 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
22. normally not melting and can be worked out with little effort The rope strength is not affected 3 Plasma lines can lose strength if overstrained This can be the result of exceeding the recommended design factor for an extended time period or by instantaneous peak loads during dynamic loading events A typical design factor is 5 1 but this should be determined in conjunction with the application engineer Signs of overstraining can be subtle but include localized thinning and elongation and loss in flexibility for example the rope becomes rigid Inspection Guidelines for Plasma Rope Below are some suggestions for inspecting Plasma for the above damage conditions Each end user should develop their own method of routinely inspecting these lines for damage prior to heavy use The method and frequency of inspection will depend on the end users experience and usage level 1 Lay rope out under hand tension so the entire length can easily viewed 2 Visually inspect the entire length of rope for signs of abrasion heavy fuzzing stiff regions fused or melted regions or thinned areas Make note of any damaged areas 10 Moderate Abrasion 3 Relate any damage to service over hardware for possible situation remedies 4 Monitor for overloading To accomplish this put a small less than 10 of break load but repeatable load on the line In subsequent inspections a similar load should be applied again so determine a method that
23. rical connection Check all wire connections FEE Vehicle battery charge is 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 15 PARTS We recommend Ezy Lift authorized replacement Parts available by contacting e 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 process 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 e Refer to Part Item Number for Parts enquiries e Contact Ezy Lift with unanswered questions USA amp Canada 1 800 974 3032 16 Ezy Lift SPECIFICATIONS EZY 2000 2000 Ib LIFTING SYSTEM aaa eerste Ezy Lift Model se ZEE Ezy Lift 2000LBS CAPACITIES HCA DACI eee ree ete ORA
24. s 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 y g Nominal Size Approximate Weight Minimum Tensile Strength Diameter Number Highest strength circ Lowest stretch Low creep Soft hand Torque free Easy Splicing Floats lt 1 Tensile Strengths are determined in accordance with Cordage Institute 1500 Test Methods for Fiber Rope Weights are calculated at linear density under standard preload 20006 plus 4 Specific gravity 0 98 Elongation Melting point 284 F 140 Critical temperature 150 F 65 C a Coefficient of friction 0 09 0 12 8 Elongation at break 4 5 Fiber water absorption 0 UV resistance moderate Wet abrasion Superior 8 10 15 20 25 30 85 40 Dry abrasion superior Load of average strength _value based on 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 13 Ezy Lift INSPECTION amp MAINTENANCE cont HYDRAULIC UNIT The Ezy Lift Hydraulic Unit is completely self contained and re quires no maintenance However
25. t part of your machine Keep all Manuals in a convenient location so they can be accessed 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 If 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 If 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
26. will give approximately the same load each time Put a bright mark on the line at a point just beyond the tail of the splice one suggestion is to use a bright colored ribbon through one or two strands of he rope Put another bright colored mark or ribbon approximately 20 feet down rope from first mark These marks will be a reference for future measurements and should be located securely While under reference tension using a flexible tape measure measure the length between reference marks Write down this reference length and compare it to previous or subsequent measurements re Abrasion 5 Keep a detailed record of the line reference length as well as any damage areas and their approximate locations relative to one or both reference marks Future inspections should be used to monitor minor damage areas for signs of growth Inspection Frequency The end user should determine the frequency of rope inspections For heavy use the rope should be carefully inspected prior to each day s use The user should also perform a quick visual inspection without length measurement prior to any use of the rope 11 Rope Replacement Ropes that show severe damage should be replaced repaired damaged areas cut out and re spliced or down rated to other applications Examples of severe damage in Plasma rope include but are not limited to a More than 2 strands severed within a 2 foot segment b Fused segment that is no longer flexible
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