Installation Guide EZY 2000 PT LIFT

EZY 2000 PT
Installation Guide
LIFT
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Patent No.
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US 6,799,935 Bl
TABLE OF CONTENTS
PREPARE FOR INSTALLATION ———————————————————————————- 1
INSTALLATION SAFETY
——————————————————————————————— 2
PARTS LIST —————————————————————————————————————— 3
INSTALLATION FORD, DODGE, CHEVY, TOYOTA ————————————————— 4 - 6
CONNECTING HYDRAULIC HOSES ————————————————————————- 7
CONNECTING THE ELECTRICAL CABLES ———————————————————— 8
FINISH FRAME CONSTRUCTION / CHECK REMOTE AND HYDRAILIC FLUID
9
VIBRATION BRACKET / ARM COVER INSTALLATION ---------------------------- 10 - 11
SCHEMATICS ------------------------------------------------------------------------------------------------------ 12 - 13
INSTALLATION INSTRUCTIONS
PREPARE FOR INSTALLATION
Completely empty the truck bed. Once empty it is recommended that the bed be power washed prior to installation.
Bed Liners Spray-in bed liners provide an acceptable mounting surface for Ezy-Lift installations. However, hard
plastic drop-in bed liners must be removed from the truck bed in order to provide a solid mounting suitable
for installing Ezy-Lift.
It Takes Two. Several steps in the installation require the help of another person, for example
placing components properly, or attaching backing plates under the bed. Identify all components supplied in the installation kit and match them with the parts list. If any components are missing, contact
Ezy-Lift Tech Support at www.ezylift.com. Click on Contact Us button or call 1-800-974-3032 before beginning installation.
Park the truck on a level surface, set the parking brake and chock the
wheels for safety.
Tools Needed
Drill
5/16” -12” Long Drill Bit {Included}
Tape Measure
Drill Bit Set
Ratchet
1 7/8” Metal Hole Saw Bit
#2 Phillips Drill Bit
Saw
Standard Deep Socket Set
5 Foot 2 x 4 Lumber
Standard Hex Socket Set
Rubber Mallet
Electrical Cord
Open End Wrench Set
Extra Parts The Ezy-Lift is shipped with a few extra attaching parts i.e. screws, washers, nuts, and bolts to ensure
that there is enough to complete the installation. Having leftover attaching parts is normal.
1
Read the instructions completely before installation. It is recommended not to skip steps. We have carefully
considered the order of each step to ensure the best possible installation with the fewest possible problems.
Prior to installation, park the truck on a level surface, set the parking brake and chock the
wheels for safety.
Do not remove until
ready to operate.
Before beginning the installation remove the packing material to expose the Ezy Lift on the pallet. LEAVE BOTH
FRAMES SECURED TO THE PALLET. Carefully inventory the items identified in the illustration above. Check
the items in the hardware package against the list on page 3 of this manual. If any items are missing contact Ezy
Lift tech support at www.ezylift.com. Click on Contact Us button or call 1-800-974-3032 .
Each of the parts and quantities listed below should be on the pallet
2 - Unit Arm Frames
1 - Winch Cross Bar
1 - 90° Square
1 - Red Power Cord
2 - Access Covers
Floor Spacers; (2) long (4)
short- Use if necessary
1 - Hardware Package
1 - Unit Remote Control
2
E2202
E2203
E2211
EZ401
EZ498
EZ505
EZ552
EZ568
EZ578
EZ579
EZ596
EZ631
EZ649
EZ714
EZ735
EZ780
EZ792
EZ793
EZ806
EZ861
Description
Quantity
1
1
2
4
2
1
2
32
2
4
12
8
52
1
6
26
6
6
2
1
1
12
1
4
6
10
1
EZY2000InstallationKit
BoxSpacer(Short)
BoxSpacer(Long)
Controller,10'
Plug,Dome1‐1/4"
g
/
Nut,Nylock5/16"‐18
Plug,Square3"
Ty‐Rap,0.27"x18"
Washer,Flat1/4"S.S.
Ty‐Rap,0.14"x8"
y p
Washer,Flat5/16"S.S.
Boot,BatteryRed&BlackSet
Nut,Nylock1/4"‐20S.S.
Bolt,Hex5/16"‐18x1‐1/4"S.S.
Screw,1/4"‐20x1"S.S.
, /
Bolt,Hex5/16"‐18x3/4"S.S.
Grommet,Rub2‐5/16"O.D.x1‐5/8"I.D.
Manual,P.U./TrailerUser2000
Manual,P.U./TrailerInstall2000
Bolt,Hex5/16"‐18x4"S.S.
,
/
Bit,Drill5/16"x12"HSS
E2024P BoxF/BPassengerSideBrace
E2025P BoxF/BDriverSideBrace
/
VibrationBracket"Ford,GMC,Dodge,OrToyota"
ItemRef# Part#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
20
2
11
15
21
16
7
12
17
5
8
18
22
3
13
19
9
14
23
Installation
Ford, Dodge, Chevy & Toyota Section
This section applies to the Boom Arm Frame installation on Ford, Dodge, Chevy and Toyota trucks only.
Foot Plate Position for ALL Models Except
Chevy
Foot Plate Position for Chevy
Step 1
Step 1
Step 1— Attach the front brackets to units.
REF I (E2098) & J (E2096)
4
Fig. A
Fig. B
Step 2—Take the unit frame that has the hydraulic pump and place it on the drivers side of the pick up
truck bed with the arm end pointing forward toward the
truck cab. Take the remaining unit frame and place it on
the truck bed on the passenger side. Be careful not to set
the unit on the hydraulic pump hoses.
Step 6— With the
units pulled back feed
RED Electrical cable
through the rubber
grommet on the
Driver Side. (As
Shown in Fig D)
Note— Depending on whether or not the truck bed has a
Fig D
bed liner or not, it may be necessary to use the bed spacers
provided to make the unit level (use where ever necessary )REF T (E2203) and U (E2202).
MOUNT THE WINCH CROSSBAR
Step 3— Align the edge of both units with the
end of the truck bed post (As Shown in Fig A&B). Once
both units are in position, on the driver’s side (pump side)
mark a center for a 1 7/8” hole for the hydraulic hoses just
under the pump plate notch so that the hoses will drop
straight down from the pump, through the truck bed floor.
REPEAT for opposite side.
Step 7— On the Driver Side run the electrical wires from
the boom arm through the cross bar and out the hole located near
the winch. Insert the crossbar on both arm brackets. The crossbar fit
into the bracket maybe extremely tight. It may be necessary to tap
it in place with the rubber mallet.
Step 8— Secure the crossbar to the unit arm brackets with
the 5/16” x 4” bolts REF S (EZ806), flat washers REF M (EZ579)
(on top and bottom) and the 5/16” nylon lock nuts REF L (EZ691).
(Do not tighten until unit is squared) (As Shown in Fig. E)
Step 4— Pull units back and drill the 1 7/8” holes
that was marked in the previous step. Insert the rubber
grommets REF E (EZ780).
Step 5— With the units pulled back feed the Hydraulic hoses down through the hole on the passenger side
of the truck and pass them under the truck bed. Do not
connect them to the pump until the units have been fastened to the truck bed. (As Shown in Fig C)
Fig. E
Step 9— Connect the wires to the appropriate terminals on
the winch. (As Shown in Fig F)
Fig. F
Fig. C
5
Squaring the Unit to Bed
Securing unit to truck bed
Step 10— Align the edge of both units with the end of the
truck bed post. (As shown in Fig G)
Step 12— Align the 5/16” drill bit through the holes
in the front foot bracket and drill through the truck bed floor.
Run the screw 5/16”-18L x 1.5ss REF R (EZ532) with
washer REF M 1/4”ss through the holes and put a washer
REF M 1/4”ss (EZ579) and nut REF L 5/16”-18ss (EZ691)
on from the underside, hand tighten only.
(As Shown in Fig. J)
Note— Depending on
whether or not the truck bed
has a bed liner or not, it may
be necessary to use the bed
spacers provided to make the
unit level (use where ever necessary )
REF T (E2203) and
U (E2202).
Fig. G
Step 11— Cut 2x4’s to the measurement acquired in the
previous step (distance between the units) to help brace the units
and keep them
square. (As shown in Fig H)
TAIL GATE
BRACE
CAB
Fig. J
Fig. K
Step 13— After placing the foot bracket loosely, drill
the pilot holes along the side of the unit {Depending on your
model drill through pilot holes that don’t interfere with the bed
seam.} After you have drilled the holes begin placing the
screws 5/16”-18L x 1.5ss REF R (EZ532) with washer REF
M 1/4”ss through the holes and put a washer REF M 1/4”ss
(EZ579) and nut REF L 5/16”-18ss (EZ691)on from the under side starting from the back of the unit and working towards the front ensuring that the unit stays square. (As Shown
in Fig. K & L)
Fig. H
Note— Be sure to maintain the same distance between units from
front to back, as well as from the edge of the truck bed. (As shown
in Fig I)
Fig. L
Step 14— Then go back and tighten the screws on
the front foot bracket. Repeat process on the other side.
Step 15— After the unit is tighten, go back and
tighten the screws on the crossbar. (As Shown in Fig. M)
Fig. I
Fig. M
6
CONNECTING THE HYDRAULIC HOSES
After securing the units to the truck bed, continue passing
the hydraulic hoses up through the driver’s side and set the
ends next to the Pump Counter Balance Valve.
Remove the hose plugs with a 9/16 and a 1/2 inch open end wrenches.
Have a cloth or shop towel ready. Some fluid will drip out of the
hoses. Place the 9/16 wrench on the hose end and the 1/2 wrench on
the hose cap and turn in opposite directions.
Use a 9/16 and 5/8 open end wrench to secure the
hose ends to the fittings on the pump. Each of the
two fittings are different, one male and one female.
It is not possible to hook them up incorrectly.
After the hoses are securely connected to the pump pull the slack
back through the feed holes towards the passenger side frame.
Roll the extra length of the hoses and use the smaller tie wraps to
secure the coil.
7
Connecting the Electrical Cables
Disconnect the Fuse box off the Long Red Cable. Run the Long Red Cable under the truck bed and attach it to
the chassis with the supplied tie wraps. Pass the long end up into the engine compartment and reconnect it to the
Fuse Terminal.
Connect the Short Red Cable with the fuse to the battery and place the fuse in a clear area of the truck’s engine
compartment firewall. Mount the Fuse Box to the firewall in this area.
VERY IMPORTANT
Run the Ground line down through the same hole and mount it to the truck frame. Insure that the
terminal attaching points are clean to bare metal for the best ground contact.
8
Finish Frame Construction
It will probably be necessary
to tap in the cross bar end caps
with the rubber mallet.
Attach the Side Access Panels to both sides of
the Unit Arm Frames.
Do not remove until
ready to operate.
Finally, cut the shipping straps band off the
arms. Before operating.
Check the Remote Control and the Hydraulic Fluid in the Lift Pump
Plug the female fitting into the receptacle on the rear of the pump side frame. Depress and hold the “Boom Out”
As the arms come out, the hydraulic fluid level in the pump reservoir will drop
towards the bottom indentation in the reservoir (indicated by the red line in the
illustration). Allowing the fluid level to drop below the bottom indentation may
lead to air entering the system. As the level approaches the bottom indentation release the “Boom Out” button to stop the arms. Add transmission fluid
to the reservoir up to the level of the top reservoir indentation indicated by the
black line in the illustration.
9
VibrationBracket
FIG. 2 FIG. 1 Step 1 – Alien bracket to bolt. Loose fit. (FIG. 1) Step 2 – Alien bracket with bed rail. Clamp and Drill. (FIG. 2) Step 3 – Install bolts tight, then tighten lower bumper bolt. This bracket is used for damping rough road vibration to prevent lower bed cracking around mount bolts. Fasten with three bolts provided to truck‐bed side wall. (NOT INTENDED FOR LIFTING LEVERAGE) 10
Arm Cover Installation
Repeat Step on Other Side
Place cover over Arm and Bolt Down
DETAIL B
SCALE 1 / 4
B
DETAIL A
SCALE 1 / 4
A
11
EZY2000
HYDRAULIC LINE ASSEMBLY
A
B
D
E
C
F
A.
B.
C.
D.
E.
F.
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
12
EZY2000
WIRING DIAGRAM
A
O
20AMP
FUSE
B
P
C
I
E
D
G
F
H
J
A)
B)
C)
D)
E)
F)
G)
H)
K
Part# EZ508 Circuit Breaker 150AMP
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
L
I)
J)
Truck Battery {NOT INCLUDED}
Part# WG110 4GA. 26” Long Red Cable
(150Amp Fuse Box to Truck Battery)
K) Part# EZ494 150Amp Fuse Box
L) Part# EZ655 150Amp Fuse
M) Part# WG140 4GA. 360” Long Red Cable
(Circuit Breaker 150AMP to Winch Fuse Box)
N) Part# WG127 8GA. 24” Long Red Cable
(Circuit Breaker 150AMP to Winch Solenoid)
O) Part# WG144 4GA. 6” Long Red Cable
(Circuit Breaker 150AMP to Pump Solenoid)
P) Part# E2070 Pump Assembly
13
M
N
Ezy 2000 Installation Help Sheet
Place spreader bars with 4 (2 x 6 x 12 pieces of wood) in bed to square the unit.
When installing Power Cord drill hole before setting unit all the way to left side of bed. Run power line through
hole and set unit with spreaders next to left bed wall.
When installing unit you may have to improvise when mounting support nuts and bolts through bed. If squared
unit lines up on bed seam make sure to drill holes to outside of seam. You will sometimes have to use a cone drill
bit at an angle (see
Photos) to increase size of hole and then re-drill at an angle to be on the outside of the bed seam.
After unit is square secure with front and back nuts and bolts .
14
Notes
04/17/2013