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MAD EasyLoad Series User Manual

MAD EasyLoad Series
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Service Manual
EasyLoad
Januari, 2018
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MAD EasyLoad Series Specifications

General IconGeneral
BrandMAD
ModelEasyLoad Series
CategoryAutomobile Accessories
LanguageEnglish

Summary

Sliding Left Right

Pin Engagement and Fixing

Ensure sliding pins are correctly inserted and fixed in their proper position for operation.

Moving In and Out Operation

Clutch Functionality Check

Verify that the clutch mechanism is functioning correctly for smooth operation.

Sealed Adjustment for Damage Prevention

Note that the clutch adjustment is sealed to prevent accidental damage.

Cleaning After Fuse Blow

Clean the mechanism if fuses blow during sliding in and out operations.

Winch Relay Function

Up and Down Switching

This relay is responsible for switching the winch motor between upward and downward movement.

Main Relay Function

Power Supply and Control

This relay manages the 12V/24V power supply, controlled by the door switch or emergency stop.

5-Pin Relays Overview

Control Functions (Up, Down, In, Out, Stop)

These 5-pin relays control the Up, Down, In, Out, and Stop functions of the winch system.

Winch Safety Switch

Cable Layer Maintenance

Ensures a minimum of one cable layer remains on the winch drum to prevent damage or malfunction.

Maximum Weight Capacity Switch

Overload Prevention Mechanism

This switch prevents the winch from lifting when the load exceeds the maximum weight capacity.

Lift Stop Switch Function

Hook Contact Safety Mechanism

Stops the winch and beam movement when the hook contacts copper stripes, indicating a limit.

Connector Grounding Issue

Fuse Locations

30A and 15A Fuse Identification

Locate the 30A and 15A fuses, which are typically found together.

Main Fuse Location

Door Switch Function

Battery Drain Prevention

The door switch prevents the system from draining the vehicle's battery when inactive.

Troubleshooting Guide

Hook Not Going Down

Troubleshooting steps for when the hook fails to move downwards.

Hook Not Going Up

Troubleshooting steps for when the hook fails to move upwards.

Copper Strip Damage Check

Connector Reseating (Left)

Inspect and reseat the left connector if the winch is not going up.

Connector Reseating (Right)

Inspect and reseat the right connector if the winch is not going up.

Copper Grounding on Inner Beam

Winch Carbon Brush Replacement

Battery Disconnection and Cable Removal

Disconnect battery power, loosen motor bolts, and remove cables before brush replacement.

Motor Cover Removal

Remove the motor cover to access the carbon brushes for inspection or replacement.

New Brush Installation

Install the new carbon brushes within their cap and then fit it back into the motor.

Motor Reassembly and Cable Reconnection

Re-secure the motor with its bolts and reconnect the cables after brush replacement.

Hoist Cable Replacement Procedure

M4 Bolt Measurement

Measure the length of the M4 bolt as part of the cable replacement process.

Spring Removal and Plate Rotation

Remove the spring and rotate the plate as instructed for cable replacement.

Winch Drum Hex Bolt Loosening

Loosen the hex bolt located within the winch drum to free the hoist cable.

Top Plate Bolt Loosening

Loosen the four bolts securing the top plate to allow access for cable replacement.

Hoist Cable Installation Check

Cable Securing in Drum

Insert the new cable into the drum, tighten the bolt, and ensure correct cable placement.