Kubota Impac 500 Owner's Manual

IMPAC 500

IMPAC™ for Kubota ™

SAFETY, INSTALLATION, OPERATION &

MAINTENANCE

OWNER’S MANUAL

MODEL Impac 500

TABLE OF CONTENT

INTRODUCTION

...................................................................................

1

PRODUCT IDENTIFICATION

.............................................................

1

SAFETY

.................................................................................................

2

SAFETY LABELS ...........................................................................

2 - 3

OPERATIONAL SAFETY................................................................

4 - 6

INSTALLATION INSTRUCTIONS .................................................

7 - 1

4

IMPAC 500 OPERATING CONTROLS ..........................................

1

5

OPERATING THE IMPAC 500 SYSTEM......................................

..

1

6

- 1

7

IMPAC 500 INSPECTION AND MAINTENANCE.........................

..

1

8

2

1

ELECTRICAL WIRING DIAGRAM .................................................

2

2

QUALITY SERVICE / CONTACT INFORMATION .........................

2

3

CONTACT INFORMATION . ............

..................................

.............

23

WARR

A

NTY ....................................................................................

2

3

SPECIFICATIONS ..........................................................................

2

4

Notes

..

...

...........................................................................................

2

5

INTRODUCTION

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 accessed easily.

Use the Safety and Operating information in both the

IMPAC 500™ Operator’s Manual and the Machine

Operator’s Manual to operate and service the unit safely and correctly.

PRODUCT IDENTIFICATION

When contacting the IMPAC 500™ Customer

Contact Center for information on servicing, always provide the Product Serial Number (located on the control box) and Date of Purchase.

The Assembly and Installation sections of this

Manual provide information to assemble and install the IMPAC 500™ 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 IMPAC 500™ System Representative or

IMPAC™ CUSTOMER CONTACT CENTER:

1-956-233-3294

Locate the Product Serial

Number and record all relevant information in the spaces below.

DATE OF PURCHASE:

DEALER NAME:

DEALER PHONE:

PRODUCT SERIAL NUMBER:

Page 1

SAFETY

CAUTION

READ THIS ENTIRE OPERATOR’S MANUAL BEFORE BEGINNING WORK

ALWAYS WEAR SAFETY GLASSES AND USE CARE WHEN WORKING WITH POWER TOOLS

Safety is a primary concern in the design and manufacturing of IMPAC™ products. Unfortunately, all efforts to provide safe equipment can be totally negated by a single careless act by an Installer or Operator.

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

IMPAC™ Model P500™ lift system has a rated lift capacity of 227 kg (500 lbs)

Maximum Load capacity at full extension – 227 kg (500 lbs)

Maximum Winch load capacity at full extension – 227 kg (500 lbs)

Maximum Vehicle operating angle – 5 degrees

OVERLOADING YOUR VEHICLE CAN CAUSE POTENTIAL SAFETY HAZARDS!

Read and obey all Safety Symbols, Warnings, Cautionary Notes and Operating

Instructions on the IMPAC 500™ 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 IMPAC 500™ is a 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 IMPAC 500™ unit to draw attention to potential safety hazards.

The Safety Labels 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.

Page 2

SAFETY LABELS

(cont…)

CAUTION

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

BE CAREFUL

NEVER depend on the hoist or 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 rope or the rope hook.

It is recommended that leather gloves are used when rewinding the rope after use.

Page 3

OPERATIONAL SAFETY

It is the Owner’s/Operator’s responsibility to use good judgment in the operation and maintenance of the

IMPAC™ 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 IMPAC™ 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 IMPAC 500™ 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 IMPAC 500™ system. Because IMPAC 500™ has no direct involvement or control over the operation and application of the IMPAC 500™ 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 IMPAC

500™ 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 Owner’s Manual and have understood the proper operation and maintenance of the IMPAC

500™ System should be permitted to operate the IMPAC 500™ System.

General Safety Information

READ and save all instructions.

NEVER engage in any practice that will divert your attention while operating the IMPAC 500™ System. NEVER operate the IMPAC 500™ System from the Driver or Passenger seats.

ALWAYS disconnect the IMPAC 500™ 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 IMPAC 500™ System correctly.

Take time to practice so that you are comfortable with the operating system.

Maximum Load capacity at full extension – 227 kg (500lbs)

Maximum Winch load capacity at full extension – 227 kg (500 lbs)

Maximum vehicle operating angle – 5 degrees

NEVER handle the Hoist rope with bare hands

ALWAYS use leather gloves when handling the rope.

NEVER allow children or unauthorized personnel to operate the IMPAC 500™ System at any time. NEVER use the unit for lifting, supporting or transporting people.

NEVER stand beneath the load or IMPAC 500™ System lift frame or use over areas where people are present

NEVER operate the IMPAC 500™ System with Driver or Passenger in the vehicle.

Page 4

OPERATIONAL SAFETY

(cont…)

General Safety Information

(cont…)

NEVER operate the IMPAC 500™ System when someone is within an unsafe distance (clear of moving components).

NEVER lift a load with a weight exceeding 227 kg (500lb).

Maximum Load capacity at full extension – 227 kg (500lbs)

Maximum Winch load capacity at full extension – 227 kg (500 lbs)

NEVER lift anything with the IMPAC 500™ System while the Kubota ™ is on an incline or side of hill.

Maximum vehicle operating angle – 5 degrees

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.

ALWAYS install cargo bed locking pins before operating the IMPAC 500™ System.

Before Operating

Visually inspect the hook, synthetic rope, hoist and accessories for any damage or wear.

Reject nylon slings with abnormal wear, torn stitching, broken or cut fibers or discoloration or deterioration.

Reject synthetic rope with kinking, crushing, evidence of heat damage, cracks, deformation or worn end attachments.

Ensure that the Kubota ™ 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 to ensure that the Cargo Bed/Box is locked to the main frame with provided locking device.

NEVER MOVE Kubota ™ WITH A SUSPENDED LOAD

Page 5

OPERATIONAL SAFETY

(cont…)

Moving a Load

Center the hook over the load to keep the synthetic rope 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 synthetic rope 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 IMPAC 500™ System arms and frames.

NEVER stand in cargo bed when loading or unloading.

NEVER operate IMPAC 500™ System while the Kubota ™ is on an incline or side of a hill.

AVOID SIDE PULLS - These can cause the winch synthetic rope to slip out of the drum groove, damaging the rope or destabilizing the winch.

NEVER leave suspended loads unattended. In an emergency where the IMPAC 500™ 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 Kubota ™ and lock it so it cannot be moved.

Disclaimer

The IMPAC 500™ System is manufactured to exacting specifications and standards using high quality materials, components and workmanship.

Guidelines for load lifting and safe operation need to be observed when using/operating the IMPAC 500™ load lift system. Overall performance of the system depends on the guidelines 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.

IMPAC 500™ and/or Kubota are 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".

Page 6

INSTALLATION INSTRUCTIONS

(cont…)

BEFORE INSTALLING LIFT SYSTEM -

PARK THE

Polaris Ranger™

ON FLAT LEVEL GROUND

,

SET

PARK BRAKE AND CHOCK THE WHEELS

After the Polaris Ranger™ is securely parked, clear the

Polaris Ranger™ bed of any objects and ensure that it is clean.

INSTALLING LIFT SYSTEM

Your Polaris Ranger™ IMPAC 500™ System is shipped in a box on a pallet. Using a crane, forklift or similar, place the box/pallet on flat level ground, positioning it behind and in line with the Polaris Ranger™ . This will make the installation easier.(See Figure 2)

Before taking the next steps - lay out the following tools.

(See Figure 1)

Tools needed for installation

13)

14)

15)

1 6 )

1 7 )

9)

10)

11)

12)

5)

6)

7)

8)

1)

2)

3)

4)

Flat Head Screwdriver

Phillips Screwdriver

Utility Knife

Crescent Adjustable Wrench

7/16 inch Open End Wrench

1/2 inch Open End Wrench

9/16

17/64 inch Drill Bit

5/16 inch Drill Bit

Drill

inch Open End Wrench

Ratchet

Ratchet Extension

10mm Socket

7/16 inch Socket

1/2" inch Socket

9/16 " inch Socket

T30 Torx Wrench

Figure 1

Figure 2

Remove the top of the box.

Remove the hardware package.

Remove the hardware that is securing the Lift System to the base of the box/pallet. (See Figure 3)

Figure 3

Page 7

Step 1 – Open Tailgate

INSTALLATION INSTRUCTIONS

(cont…)

Front Bolt

Remove Bed

Tie down Hinges

Step 2 – Clear cargo bed of any objects.

Step 3 – Remove the the 4 Bed Tie down Hinges.

Also remove the bolt in front of b ed tie down hinge.

Step 4 – Place side Mounting wall onto the cargo bed.

(Repeat on Driver/Passenger Side)

Step 5 – Use a 1/2 ” & 9/16" socket/wrench to bolt support bolts. Insert the Use the 5/16" x 3/4" with washers t o bolt the top wall bracket and the 3/8 " x 3 " with lock washer to bolt the wall bracket to the cargo bed.

(Repeat on Driver/Passenger Side)

Step 6 – Use a 1/2 ” socket/wrench to bolt support bolts. Use the 5/16" x 1" with washers to bolt the Mount wall to the cargo bed.

(Repeat on Driver/Passenger Side)

Step 7 – Place Passenger side of the Impac 500 Unit on top of the Wall Mount u se a 1/2 ” socket/wrench to bolt the 5/16" x 1 " on the front and 5/16" x 3/4"bolts with washers on the rear side.

(Repeat on Driver/Passenger Side)

Step 8 –– Place the winch rail into the arm on the passenger side and connect the driver side power connector. Then place winch rail into arm and bolt down with EZ806 – 5/16”-18 x 4” with EZ579 – 5/16” flat washer and EZ691 – 5/16”-18 nylock nuts.

Page 8

INSTALLATION INSTRUCTIONS

(cont…)

Step 9 – Install the 12V DC 103 HPU Starter 4-Pole Solenoid Part# EZ502 inside battery storage compartment located under the c argo bed . You will need to drill two 1/4” holes to mount Starter Solenoid to the inside of the battery storage compartment .

{Use 2pcs – Part# EZ872 Hexagon Head Cap Screw S.S. (1/4”-20 x 1/2” Long) and 2pcs –

Part# EZ631 Nylon Nut (1/4”-20)}

Step 10 – Place the Fuse Block next to the 4-Pole

Solenoid way about 2” mark the holes on the Fuse

Block onto the battery storage compartment.

Step 11 - Drill the mark holes with a 1/4" drill bit. Mount the resetting fuse Part # EZ677.

{Use 2pcs – Part# EZ609 Phillips Head Cap Screw S.S. (#10-32 x 3/4” Long) and 2pcs – Part# EZ661

Nylon Nut (#10-32).} {As shown above}

Step 1 2 – Install the Wire Part# WG160

6 inch Power Red Wire to the silver colored

#10 post on the Block Fuse 50 Amp and run it to the 5/16” post on the 4-Pole

Solenoid.

Step 1 3 – Install the Wire Part# WG1 63 12 inch Ground Green Wire to Batteries

Ground terminal and run it to the #10 post on the 4-Pole Solenoid by pushing it in through the existing wiring going into the center storage compartment under the seat. {As shown above}

Step 1 4 – Install the Wire Part# WG1 62 24 inch Red Power Wire to the

Batteries Power terminal and run to the copper colored #10 post on the

Block Fuse 50 Amp by pushing it in through the existing wiring going into the center storage compartment under the seat.

Step 1 5 – Open the Kubota cargo bed outward to connect the Wire Part# WG16 4 72 inch Ignition

Power Wire to the ignition terminal cable to the #10 post on the 4-Pole Solenoid. Run it over the engine make sure you are not on any hot spots touching the wire.

Page 9

INSTALLATION INSTRUCTIONS

(cont…)

Step 16 – Install the Wire Part# WG1 61 12 0 inch Red and Black Quick Connect Wires by running it under the cargo bed and above the cargo bed brace bars . By following the existing wiring on the chassis going into the battery storage compartment. Connecting the Red cable to the 5/16” post on the 4-Pole Solenoid and the Black cable to the Batteries Ground Terminal.

{As Shown Below}

Step 17 – Drill 1/4" holes front side of the cargo bed to support the actuator cable and the Red plug power cable.

(Use the 1/4"-20 screws and the Nylock 1/4"-20 Nut and the hose clamps provide.) After Installed connect the power to the unit.

{As Shown Below}

Page 1 0

INSTALLATION INSTRUCTIONS

(cont…)

Step 18 – Insert Actuator Cable through the top hole of the control box and connect it to the Actuator Control PEM Box. Push remanding cable into box and close the box with the cover. Use the existing holes clamp to secure the actutor cable to the control box.

{As Shown Below}

Page 1 1

INSTALLATION INSTRUCTIONS

(cont…)

Step 18 - (

A) Installing Open Cab Bed Lock System

Open the cargo bed to bump position. Next remove the 12mm bolt on the back of the cab wall place the

E5164PB Driver Side Bracket using the 12mm-1.25x35mm bolt provided. Repeat the same using E5165PB

Passenger Side Bracket .((As shown in Fig. A and B)) Reference to Open Cab Diagram Page 13.

Next remove the two top bolt of the cargo bed wall and reuse them to install the E5168PB Driver and

E5169PB Passenger Side Brackets. ((As shown in Fig. C)) Reference to Open Cab Diagram Page 13.

Some adjustment may be required.

(B) Installing Closed Cab Bed Lock System

Open the Cargo Bed to Bump position. Next remove the 10mm bolt on the back of the cab wall. Secure the

E5166PB Bridge Bracket to the E5164PB Driver Side Bracket with EZ735 Hexagon Head Bolt, 5/16"-18x3/4",

EZ579 Washer, Flat 5/16" S.S. and EZ691 Nut, Nylock 5/16"-18 S.S.. Then place the Driver Side Bracket

E5164PB using the 10mm-1.25x40mm bolt provided and the E5167PB Spacer on the back to support the bracket. Use the E5166PB Bridge Bracket Painted to provided support to the Driver Side Bracket E5164PB by using the self drilling screw to secure bridge to cab back wall. Repeat the same without use the E5166PB

Bridge Bracket on the Passenger Side as the Kubota has on welded in place and u se E5165PB Passenger Side

Bracket.

On the welded Bridge Bracket on the passenger side use the EZ475 Hexagon Head Bolt, Metric

M8-1.25x20mm Zinc. to bolt down.

((As shown in Fig. A and B)) Reference to Closed Cab Diagram Page 14.

Next remove the two top bolt of the cargo bed wall and reuse them to install the E5168PB Driver and

E5169PB Passenger Side Brackets. ((As shown in Fig. C)) Reference to Open Cab Diagram Page 14. Some adjustment may be required.

12mm Bolt

12mm Bolt

Fig. A

10mm Bolt

8mm Bolt

Fig. B

10mm Bolt

Fig. C

Page 1 2

Fig. D

Page 1 3

Kubota Closed Cab Bed Lock System

Page ŗŚ

IMPAC 500

™

OPERATING CONTROLS

OPERATING HAND CONTROLLER

STEP 1: Plug the controller cable plug into the receptacle. (See Figure 1)

STEP 3: Use the hand controller to lift and load.

(See Figure 3)

Figure 3

Figure 1

STEP 2: Turn the key in the ignition switch, on the

Kubota to get power to the P500 unit

STEP 4: Using the Hand Controller

The TOP ROCKER SWITCH operates the “Boom.”

Push the switch toward “OUT” to extend the lift arms.

Push the switch toward “IN” to retract the lift arms.

(See Figures 4a & 4b)

Figure 4a Figure 4b

The BOTTOM ROCKER SWITCH operates the Winch wire rope. Push the switch towards “DOWN” to lower the hook/load. Push the switch towards “UP” to raise the hook/load. (See Figures 4c & 4d)

Figure 2

ON

Figure 4c

OM EZJDPG

C-2011

Page 1 5

Figure 4d

OPERATING the IMPAC 500

™

SYSTEM

Your IMPAC 500™ System operates from the Kubota ™ 12-volt battery, which provides power to the winch and actuators.

Actuators provide the lift and rotation necessary to extend and retract the lift arms via the hand-held remote control.

OPERATING INSTRUCTIONS

STEP 1: Position your Kubota ™ to allow the entire loading or unloading operation to be performed without having to move the vehicle. Ideally the Kubota ™ 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 – 227kg (500 lbs)

Maximum Winch load capacity at full extension – 227 kg (500 lbs)

Maximum vehicle operating angle – 5 degrees

STEP 2: Set the Kubota ™ parking brake and leave the engine running to keep the battery charged. STEP

3: Make sure locking pin is inserted locking into locking bracket hole.

STEP 4: In some instances if is prefered to leave tail gate up.

STEP 5: Plug the remote control assembly into the power/control jack. It is located on the Driver’s side.

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:

STEP 6: 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 raise from their parked position and rotate out approximately 120°over the Kubota ™ 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 hook, and become comfortable with operating the system. Attaching a small load or providing tension to the winch hook when raising and lowering 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 7: 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 Kubota ™ 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.

Page 1 6

OPERATING the IMPAC 500

™

SYSTEM

(cont…)

OPERATING INSTRUCTIONS

(cont…)

STEP 8: With the lift arm and winch now centered over the load, press and hold the HOIST DOWN button to lower the rope cable’s hoist hook into position for attaching the load. Keeping tension on the rope cable while it unwinds will prevent slippage of the rope 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 rope 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 9: With the load now attached, press and hold the HOIST UP button. Slowly take up slack in the rope cable until it becomes taut. Keep tension on the rope 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 10: 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 Kubota ™ tailgate.

DO NOT PULL FROM ANGLES as this can damage the lift arms. Continuous pulls at angles will also cause the rope cable to pile up at one end of the winch drum.

This can jam the rope cable and damage the winch and/or cable.

ALWAYS MAINTAIN at least five (5) wraps of rope cable on the winch drum, otherwise the rope cable drum fasteners will not withstand the load.

STEP 11: Press and hold the BOOM IN button to move the load onto the Kubota ™ 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 12: Slowly lower the load onto the Kubota ™ bed by pressing and holding the HOIST DOWN button.

Once the load is resting safely in the Kubota ™ bed, disconnect the rope cable’s hoist hook from the load.

STEP 13: Depress the HOIST UP button to rewind the ropecable onto the winch spool.

DO NOT OVERWIND as this could damage the winch and/or rope cable.

Apply tension to the winch cable to ensure that it winds evenly and smoothly onto the winch spool.

STEP 14: Return the lift arms to their parked position using the BOOM IN button.

STEP 15: Turn the Main Switch to the OFF position.

STEP 16: 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 Kubota ™ unattended with the remote control inserted into the power jack.

PLACE THE REMOTE CONTROL IN A SAFE, SECURE LOCATION WHEN NOT IN USE

Page 1 7

IMPAC 500

™

INSPECTION & MAINTENANCE

Your IMPAC 500™ 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 IMPAC 500™ during normal business hours, Central Standard

Time, Monday through Friday - excluding holidays.

Synthetic Rope

Page 1 8

1012 Second Street

Anacortes, WA 98221

USA Telephone:

360-293-8488 Fax:

360-293-8480 www.psrope.com

email: [email protected]

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 identified which are more harmful to Plasma than to steel. The presence of these conditions 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 is one of the most cutresistant polymers available, metal can prove to be stronger than Plasma in a longduration 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

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 rope that helps to prevent further damage.

2. Plasma begins to lose strength above about 160 ºF, and has a zero-strength temperature around 250 ºC. Signs of high temperature damage include, melting, fused strands, and 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 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).

Page 1 9

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.

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 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.

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.

Page 20

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 (strands not separable) c. Segment whose diameter is 20% less than other part of the rope d. Melting on one side that fuses one or more strands together e. Rope that has lengthened (between reference marks) by more than 10%

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.

Page 21

Kubota Installation

Wiring Diagram

Start your Loom 8" away from Red Quick

C onnect Plug

Part# WG1

61

Kubota Quick Connect Wire

(Quick Connect to Battery and 4-Pole Solenoid)

EZ549- 2pcs Terminal Ring #8 x 5/16" Stud

EZ476- 1pcs Red Quick Connect Plug

EZ172- 120in Auto Black 8GA Wire

EZ173- 120in Auto Red 8GA Wire

EZ182- 2in Tubing, Shrink 3/8" Black

EZ150- 108in Loom, 3/8" Black for Wire

Part# WG16

4

Kubota

Ignition Power Wire

(4-Pole Solenoid to (Key) Ignition Terminal)

EZ289-

72 in Red 14GA Wire

EZ796- 1pcs Termianl, Ring #14 x 10mm Stud

EZ820- 1pcs Male Bullet 14Ga Connector

Ground On Battery

Part# EZ502

Solenoid, 12V DC 103

HPU Starter 4-Pole

Connect to Ignition

Power Wire

Positive On Battery

Part# WG

162

Kubota Power Wire to Fuse Block

(Battery to 4-Pole Solenoid)

EZ173- 24in Red 8GA Wire

EZ819- 1 Ring Terminal 8Ga x 10mm Stud

EZ549- 1pcs Terminal, Ring #8 x 5/16" Stud

EZ182- 2in Tubing, Shrink 3/8" Black

Part# WG1

63

Kubota

Ground Wire

(Battery Ground to 4-Pole Solenoid Ground)

EZ134- 12in Green 14GA Wire

EZ796- 1pcs Termainal, Ring 14GA x 10mm Stud

EZ833- 1pcs Terminal Ring 14Ga x 3/8" Stud

EZ157- 2in Tubing, Shrink 1/4" Black

EZ6

77

-

Circuit Breaker

50 AMP

Self Resetting Fuse

Part# WG160

Polaris

/Kubota

Fuse Block to 4-Pole Solenoid

EZ173- 6in Red 8GA Wire

EZ819- 1pcs Terminal, Ring #8 x 10mm Stud

EZ549- 1pcs Terminal, Ring #8 x 5/16" Stud

EZ182- 2in Tubing, Shrink 3/8" Black

QUALITY SERVICE - CONTACTS

SERVICE LITERATURE

If you would like a copy of the Parts Catalog or Technical Manual for this machine, please contact:

• USA & Canada: 1-956-233-3294

• Or visit “www.Ezylift.com”

PARTS

We recommend IMPAC 500™ authorized replacement parts USA and Canada : 1-956-233-3294

IMPAC 500

™

QUALITY CONTINUES WITH QUALITY SERVICE

IMPAC 500™ provides a process to handle your questions or problems, should they arise, to ensure that product quality continues with your IMPAC 500™ Parts and Service Support.

FOLLOW THE STEPS BELOW TO GET ANSWERS TO ANY QUESTIONS YOU MAY HAVE REGARDING YOUR I MPAC 500 ™

SYSTEM

•

•

•

•

Refer to the appropriate Product Manual

Refer to the Product Serial Number

Refer to Part Item Number for Parts enquiries

Contact IMPAC MANUFACTURING with unanswered questions

WARRANTY

IMPAC 500™ warrants the IMPAC 500™ product to the original Buyer against defective materials and parts for six (6) months from the date of purchase.

IMPAC MFG's sole and exclusive liability and the Buyer’s sole and exclusive remedy, under this Warranty, is the repair or replacement of any materials or parts determined to be defective by IMPAC 500™ .

In no event shall IMPAC 500™ 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, damages or injury of any kind based upon claim for breach of Warranty.

This Warranty does not cover breaking or fraying of the winch rope cable, 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, maintenance or repair, unauthorized alteration, or use of the product beyond the range of normal usage.

To obtain warranty service, contact IMPAC MANUFACTURING at 1-956-233-3294 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 IMPAC MANUFACTURING and it cannot be amended or amplified by any party.

OM EZJDPG C-2011

Page 24

IMPAC 500

™

SPECIFICATIONS

MODEL (IMPAC 500™ System for Kubota ™ )

Manufacturer ……………………………………………………………………….……………....……….……..….…...…… IMPAC MFG™

Model Number ……………………………………………………………………………..…………..……….........….……. IMPAC 500™

CAPACITIES

Lift Capacity ……………………………………………………………………………………………..……….………....... 277 kg (500 lbs)

Maximum Hydraulic load capacity at full extension ……………………………………………………....…. 277 kg (500 lbs)

Winch Capacity ………………………………………………………………………..………………...……...…......….. 277 kg (500 lbs)

Maximum Winch load capacity at full extension …………………………………………..…………....……. 277 kg (500 lbs)

Winch Hook …………………………………………………………………..……......…...…. 2.7 MT (3 Tons) Eye Hoist with Latch

Maximum vehicle operating angle ……………………………………………………………………………………....…….. 5 degrees

LIFT SYSTEM

LINAK ACTUATORS

WINCH

WARN …………………………………………....…………………………..……………..................……………..…..… DC 1000

ELECTRICAL

Voltage - System ……………………………………………………………………...……..……………………………...… 12 Volts DC

Voltage - Winch ………………………………………………………………………..………………………….....…..……..…. 12 Volts DC

WEIGHT ......................................................................................................................................................140 lbs

DIMENSIONS

Overall Length …………………………………………………………………………………….……………………......…1600 mm (63”)

Overall Width …………………………………………………………………………………….…………....…...….. 1264 mm (49-3/4”)

Page 25

IMPAC 500

™

NOTES

Page 26