SSV40108HAC - Hydraulic Hoist with 120 Volt Pump SSV40108HDAC - Hydraulic Hoist, Deep Water, with 120 Volt Pump SSV40108HDC - Hydraulic Hoist with 12 Volt Pump SSV40108HDDC - Hydraulic Hoist, Deep Water, with 12 Volt Pump Page 1
Bundles Required... 2 Tools Required... 2 Safety Precautions... 3 Safety Maintenance... 3 Lower Frame Drawing (Diagram A)... 4 Lower Frame Bill of Material... 5 Base Pad Assembly... 5 Lower Frame Assembly... 5 Bottom Corner Cable Brackets... 5 Platform Drawing (Diagram B)... 6 Platform Bill of Material... 7 Platform Assembly... 7/9 Drop Side Drawing/BOM (Diagram C)... 8 Drop Side Assembly... 9 Adjustable Step Drawing/BOM (Diagram D)... 9 Adjustable Step Assembly... 9 Winch Tube Drawing (Diagram E)... 10 Winch Tube Bill of Material... 11 Winch Tube Assembly... 11 Hydraulic Pump... 11 SS1204 - Control Arm Drawing... 12 SS1204 - Control Arm Drawing/BOM... 13 SS1204 - Control Arm Assembly Instructions... 13 12 Volt Pump Drawing/Assembly Instructions... 14 Table of Contents Bundles Required 12 Volt DC Pump Assembly Instructions... 15 Hydraulic Pump Drawing... 16 SS1203 - Battery Mounting Hardware Drawing/BOM... 18 SS1203 - Battery Mounting Hardware Assembly Instruct... 18 Control Pendant Operating Instructions... 19 Winch Tube Cable Diagram... 20 Connecting Lift Cables to Platform Instructions... 21 Replacement of Level Cables... 21 Bunk System Drawing/Assembly Instructions... 22 Bunk System Installation... 22 HA0001 - Motor Stop Kit Drawing/BOM... 23 HA0001 - Motor Stop Kit Assembly Instructions... 23 Hydraulic Troubleshooting Guide... 24-28 General Troubleshooting - Non-Electrical... 24 Oil Grade & Capacity... 24 Oil Change Schedule/Procedures... 25 Storage... 25 Biodegradeable Oils... 25 Troubleshooting... 26 AC Powered Hoists - General Elec Troubleshooting... 27 Wire Gauge Chart... 27 AC Powered Pumps - Troubleshooting... 27 DC Powered Pumps - Troubleshooting... 28 DC Powered Hoists - General Elec Troubleshooting... 28 SSV40108HAC Aluminum V-Frame 4000 lb. Hydraulic Hoist with AC Drive 68681 Lower Frame Bundle 66661 Leg Bundle 68124 Hyd Lift Tube Assembly 68370 Hardware Box 68682 Platform Bundle 62512 Bunk Bundle 66659 Drop Side Bundle 67115 Hydraulic Pump Assembly - AC HYD 62513 Base Pad Bundle SS1202 Adjustable Step - HYD Hoist HA0001 Hoist Motor Stop Bundle - 5 Frame 67943 Leg Bundle Controller Leg - HYD SS1204 Control Arm Assembly - HYD Hoist SS1205 Canopy Pendant Holder - HYD Hoist SSV40108HDAC Alum. V-Frame 4000 lb. Hyd. Deep Water Hoist w/ac Drive 68681 Lower Frame Bundle 67231 Leg Bundle - DW 68124 Hyd Lift Tube Assembly 68370 Hardware Box 68682 Platform Bundle 62512 Bunk Bundle 66659 Drop Side Bundle 67115 Hydraulic Pump Assembly - AC HYD 62513 Base Pad Bundle SS1202 Adjustable Step - HYD Hoist HA0001 Hoist Motor Stop Bundle - 5 Frame 67932 Leg Bundle Controller Leg - DW SS1204 Control Arm Assembly - HYD Hoist SS1205 Canopy Pendant Holder - HYD Hoist SSV40108HDC Aluminum V-Frame 4000 lb. Hydraulic Hoist with DC Drive 68681 Lower Frame Bundle 66661 Leg Bundle 68124 Hyd Lift Tube Assembly 68370 Hardware Box 68682 Platform Bundle 62512 Bunk Bundle 66659 Drop Side Bundle 66608 Hydraulic Pump Assembly - DC HYD 62513 Base Pad Bundle SS1202 Adjustable Step - HYD Hoist HA0001 Hoist Motor Stop Bundle - 5 Frame 67943 Leg Bundle Controller Leg - HYD SS1204 Control Arm Assembly - HYD Hoist SS1205 Canopy Pendant Holder - HYD Hoist Page 2 Tools Required 9/16 Socket / Wrench 3/4 Socket / Wrench 5/16 Socket / Wrench 7/16 Socket / Wrench Cable Threader SSV40108HDDC Alum. V-Frame 4000 lb. Hyd. Deep Water Hoist w/dc Drive 68681 Lower Frame Bundle 67231 Leg Bundle - DW 68124 Hyd Lift Tube Assembly 68370 Hardware Box 68682 Platform Bundle 62512 Bunk Bundle 66659 Drop Side Bundle 66608 Hydraulic Pump Assembly - DC HYD 62513 Base Pad Bundle SS1202 Adjustable Step - HYD Hoist HA0001 Hoist Motor Stop Bundle - 5 Frame 67932 Leg Bundle Controller Leg - DW SS1204 Control Arm Assembly - HYD Hoist SS1205 Canopy Pendant Holder - HYD Hoist
Post No. 2 Diagram A Post No. 1 Lower Side Frame 5x2x131 Post No. 3 Lower Frame Tube 5x2x107 Post No. 4 Bottom Corner Cable Bracket Page 4
Detail C. Slide the tube completely on until it butts against the lower corner block. Locate a 3/8 flat washer and place it on a 3/8 x 5 ½ hex bolt. (Item No. 10 in Detail B) Insert the bolt into the matching hole closest to the upright post. Secure with a 3/8 flange lock nut. Do not tighten until directed at a later time. Next place one of the 131 side frame tubes on the other lower corner block. Attach it in a similar manner just described. Post No. 2. Slide the leg of the lower corner block into the remaining end of the 107 or 119 lower frame tube just attached to Post No. 1. Secure together using the same process and hardware just described for Post No. 1. Connect the second 131 lower frame tube to the other remaining leg of the lower corner block of Post No. 2. Secure in a similar manner. Repeat this process on Post No. 3 and 4. Attaching the Bottom Corner Cable Brackets Assembly Instructions: Remove all the items from the hardware box and sort by size. Remove the hardware bags and sort all hardware items by size. Base Pad Assembly See Detail A of Diagram A. Locate the four (4) base pads, Item No. 2 and the four (4) aluminum base pad channel clamps, Item No. 3. Attach the two together as shown using 3/8 x 1 carriage bolts and 3/8 flange lock nuts. Locate the four black plastic handle grips and the four Item No. 13 leg lift rods. Slide the black plastic handle grip onto the end of the rod without the hole drilled in it. Locate the four upright hoist leg assemblies shown in Diagram A. Align the hole in the aluminum base pad channel clamp with the hole in the extension leg factory installed into the upright post. Secure the two together using the remaining end of the leg lift rod. Secure together using the hitch pin clip provided. Repeat this process on the remaining upright legs assemblies. Lower Frame Assembly Locate the two bottom corner cable brackets, Item No. 5 in Detail B Diagram A. Place a 3/8 flat washer onto a 3/8 x 6 hex bolt (Item No. 11) and drop it into the other hole of the lower frame tube that aligns with the hole in the lower corner blocks of Post No. 1 and 4. Repeat on the other leg of the lower corner blocks inserted in the 131 lower side tube on Post No. 1 and 4. Position the bottom corner cable bracket on the bottom side of the lower frames as shown, align the holes in the bracket with the bolts just installed, then insert through the bracket. Secure in place with 3/8 flange lock nuts. Note that Post No. 1 and 4 are the only posts to have the bottom corner cable brackets installed on them. Place a 3/8 flat washer on the remaining four 3/8 x 5 ½ hex bolts and insert them into the remaining hole of the lower frame tube and the lower corner blocks of Post No. 2 and 3. Check the frame for being square, then tighten the bolts just installed in the lower frame. The side of the hoist that has the bottom corner cable brackets installed on will now be the side of the hoist where the winch tube and pump will be mounted. See the drawing on the front cover of this manual. Once the base pads are attached to the upright post they will now stand in an upright position. Note that there are two posts that have the lower corner block installed creating a right hand assembly while the remaining two are installed creating a left hand assembly. Position them in their respective corners as shown in Diagram A and spaced apart the approximate distance of the lower frame tubing. The like assemblies, Post No. 1 & 3, will be located in the corners diagonally across from each other and likewise with Post No. 2 & 4. Starting with Post No.1. Locate one of the lower frame tubes (107 for a SSV10408 series or 119 for the SSV40120 series ) and slide one end of the lower frame tube over the leg of the lower corner block leg as shown. See Page 5
Diagram B Platform Assembly Platform Rail Extrusion Bunk Assemblies Cable Guide Cable End Attaches to the Drop Side Weldment Platform Assembly Cable end attaches to Bottom Corner Cable Bracket Holes for attaching platform rail extrusions to the platform. Identical hole pattern located on either side of platform. Midwest Industries, Inc. Page 6 Ida Grove, IA 51445 800.859.3028 www.shorestation.com 0003277
platform assemblies just installed as shown in Diagram B aligning the holes in the end of the platform rail extrusions with the holes in the platform assemblies. (See Detail E and Detail F in Diagram B) Place a 5/16 flat washer on a 5/16 x ¾ hex bolt and insert into one of the holes just aligned. Place a second flat washer on the bolt and secure with a 5/16 lock nut. Repeat this process until all four bolts are installed in the end of the platform rail extrusion attaching it to the platform assembly. Repeat the above process on the other end of the platform rail extrusion attaching it to the second platform assembly. Then repeat on the other platform rail extrusion attaching both platforms together at each end as shown in Diagram B. TIGHTEN THE BOLTS AT THIS TIME. Center the platform just assembled together so it is evenly spaced between the upright posts. Locate the four plastic corner guides (Item No. 35 in Detail F of Diagram B). Note that all four are identical parts. By rotating the part 180 degrees will make it a right or left hand part. They must be positioned the same direction on Posts 1 and 3. They must be rotated the 180 degrees for Posts 2 and 4. Properly position a plastic corner guide as shown and place it over Post No. 3. Align the holes in the plastic corner guide with the holes in the top of the platform end as shown in Detail F on Diagram B. Place a 3/8 flat washer on a 3/8 x 1 ½ hex bolt, then insert the bolt into the aligned holes in the plastic corner guide and the platform. Secure with a 3/8 flange lock nut but DO NOT TIGHTEN. Repeat this process on the other bolts to attach the plastic corner guide. Repeat this process on Post NO. 1. continue on Page 9 Locate the two platform assemblies. (Item No. 6 in Diagram B) Note that the cables, pulleys, etc are pre-assembled at the factory so they are identical assemblies. Position the platforms across the hoist and set them on the lower frame of the hoist so that the end of the platform that has the cable routed over the top of the pulley is on the same side of the hoist as the bottom corner cable brackets just installed. (See Detail B of Diagram A) Thread the cable down through the hole in the bottom side of the platform weldment that aligns with the groove of the pulley where the cable rides. Insert the end of the cable down through the hole in the bottom corner cable bracket installed earlier using the hole that is closest to the131 long side frame of the hoist. Secure the cable into the bottom corner cable bracket with the 5/8 hex nuts provided. Thread the first nut completely on the threads, then thread on a second nut. Thread it on until it is against the first nut. Using two wrenches, tighten the first and second nut into each other to lock them from turning loose when the hoist is used. Repeat this process on the other platform assembly. Locate the two platform rail extrusions (Item No. 5 in Diagram B). They are punched the same on both ends eliminating a right and left part. Place one of the platform rail extrusions between the two Page 7
Insert level cable in this hole. Diagram C Page 8
Rotate the next plastic corner guide 180 degrees so the topside of the plastic corner guide as described on Post No. 3 is now the bottom. Refer to the drawing of the assembled hoist on page one of this manual. Place it over Post No. 4. Repeat the attaching process just described for Post No. 3. Repeat the process used on Post No. 4 on Post No. 2. Once all of the plastic corner guides are installed, check the platform assembly again to make sure it is still centered between the posts. Once the platform is centered, position the plastic corners guides so they are centered on the posts front to rear of the hoist. The plastic corner guides should be positioned so they are as close as possible to the inner side of the posts leaving only a small amount of clearance to prevent them from rubbing on the inside of the posts as the platform is raised. When they are all positioned as described above, tighten securely into position with the bolts just installed. Drop Side Weldment Installation See Diagram C. Locate the drop side weldment that is to be attached between Post No. 2 and 3. Locate four 1 wide top clamps, four clamp shims, four 3/8 x 3 ½ hex bolts, four 3/8 flat washers, and four 3/8 flange lock nuts. Slide a top clamp down over each of Posts No. 2 and 3. Place a flat washer on a 3/8 x 3 ½ hex bolt, then insert it into the holes in each leg of the top clamp. Place on a 3/8 flange lock nut. Slide the top clamp down the post and position so that the top edge of the top clamp is located at the point of the arrow decal on the post. Tighten the bolt securing the clamp in this position. Repeat this process on the other post. Place the drop side weldment between Posts No. 2 and 3 and set it on top of the top clamps just installed. Place another top clamp over the post and slide down to the drop side weldment Slide a shim on each side of the drop side weldment between it and the top clamp. See Detail J of Diagram C. Align the top hole in the 1 top clamp, shims and drop side weldment. Then place a flat washer on a 3/8 x 3 ½ hex bolt and insert it through the aligned holes so the bolt is pointing away from the center of the hoist. Secure with a 3/8 flange lock nut. Tighten. Repeat on the top clamp on the other post. When the top clamps are installed and tightened enough to hold the drop side weldment from sliding, loosen the bolt in the bottom clamp and remove. Slide the bottom clamp up and around the shim and drop side weldment. Align the holes and re-insert the bolt just removed. Place on the flange lock nut and tighten. Both bolts should be re-tightened to make sure they won t slide down the post when a load is applied to the platform during use. Repeat this process on the other post. Locate the remaining end of the platform level cable shown in Diagram B. Insert the end of the cable up through the hole provided in the drop side weldment as shown in Detail J. Place on a 5/8 flat washer, then thread on a 5/8 hex nut. This nut will be used to level the platform across the hoist once it is fully assembled. Insert the plastic end caps provided. Assembly of the drop side is complete. Diagram D SS1202 Adjustable Step Mount the step brackets to the step bunk using four (4) 3/8 X 2-1/2 carriage bolt down through the step bunk and step brackets. Secure with 3/8 lock washers and 3/8 hex nuts. Determine the location on the drop side weldment that you that you would mount this assembly and mark. Attach the step assembly to the drop side weldment using two (2) 3/8 X 3-7/16 X 3 square u-bolts and secure with 3/8 lock washers and 3/8 hex nuts. Page 9
Winch Tube Assembly Diagram E Winch Tube Assembly Pre-drilled hole for attaching motor mount brackets. Page 10
the 2 top clamp with the holes in the winch tube assembly. Place a ½ flat washer on a ½ x 5 ½ hex bolt, then insert it through the top clamp and the winch tube assembly so that the bolt is pointing outward. Secure with a ½ flange lock nut. Repeat this process on the other post and the other end of the winch tube assembly. Tighten both clamp just installed. Once tightened, loosen and remove the bolt placed in the bottom 2 clamp. Slide the 2 clamp up around the bottom of the winch tube assembly, align the holes in the top clamp and winch tube assembly, then insert the bolt just removed. Secure with the ½ flange lock nut. Tighten securely. Mounting the Hydraulic Pump See Detail N of Diagram E. Locate the motor mount bracket in Detail N. Position the bracket so that the mounting surfaces of the bracket are as shown. Next locate the pre-drilled hole on the inside of the winch tube assembly that is approximately 16 ½ from the end of the winch tube and identified in Diagram E. Slide the motor mount bracket down over the winch tube assembly, align the hole in the bracket with the pre-drilled hole in the winch tube. Attach the motor mount bracket to the winch tube assembly using a ¼ x ½ full threaded bolt. Tighten. Place the motor assembly on the motor mount bracket as shown in Detail N. Align the holes in the center block of the motor assembly with the holes in the motor mount bracket. Attach by placing a 3/8 lock washer on a 3/8 x ¾ bolt, then inserting it through the hole provided in the motor mount bracket. Thread the bolts into the motor block. Tighten. Hydraulic Pump Winch Tube Assembly See Detail M of Diagram E. Locate the four 2 wide top clamps provided for mounting the winch tube assembly. Locate the four ½ x 5 ½ hex bolts, flat washers and flange lock nuts as well. Slide a 2 top clamp down and around both Posts No. 1 & 4 until they are located at the arrow decal on the post. Place a ½ flat washer on a ½ x 5 ½ hex bolt, then insert it into the holes provided in the legs of the top clamp. Place on a ½ flange lock nut. Slide the 2 top clamp down so that the top of the clamp is at the point of the arrow decal on the post. Tighten in this position. Repeat on the remaining post. See Drawing on page one for reference. Raise the winch tube assembly into position between Post No. 1 and 4. Once in position rest the assembly down on top of the 2 top clamps just installed. Place a second 2 top clamp on the post and drop down and around the winch tube assembly. Align the holes in The hydraulic pump comes shipped with a solid plug in the reservoir to keep it from leaking oil. Remove this plug before operating and replace it with the breather cap that is supplied and shipped in the pump box. Page 11
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SS1204 Control Arm Assembly Locate the pendant control assembly. Insert the connector end of the wire into the end of the control arm without holes drilled through it. Push the wire into the control arm tube until the plug comes out of the other end of the control arm tube. Pull the bulk of the wire through the control arm tube for now. Attach the control arm tube to the control arm pivot weldment by aligning the holes in both parts. Insert a ¼ x 6 hex bolt into the hole in the end of the control arm, then through the hole in the control arm pivot weldment. Place on the compression spring followed by a 3/8 flat washer, ¼ flat washer and a ¼ hex nut. Tighten until the spring is slightly compressed. This can be changed to achieve the desired tension once it is being used. Place a ¼ x 2 ¼ hex bolt into the second hole in the control arm tube and the control arm pivot weldment. Secure using a ¼ hex nut. Tighten. Insert the 72 extension leg into Post No. 4 that is next to the hydraulic pump. Secure it in Post No. 4 using a ½ x 4 hex bolt and flange lock nut. Place another ½ x 4 hex bolt through the hole provided in the 72 extension leg approximately 14 from the end of the extension leg. Slide the control arm tube assembly assembled earlier over the top of the extension leg. Lower until it is resting on the ½ x 4 hex bolt installed earlier. Once it is resting on the bolt place a third ½ x 4 hex bolt in the top hole of the extension leg to keep it from coming off. Tighten. Page 13
The following are instructions for connecting the 120 volt pump only. The 12 volt system is addressed on pages15. Route the control pendant wire down the extension leg and over to the pump. Connect it to the connector plug located on the pump and identified on the drawing on page 13. Align the plugs so they will mate. Once mated turn the outside sleeve of the connector clockwise to lock the connection together. Connect the wire from the micro switch located inside the winch tube assembly to the pump by aligning the plug on the end of the micro switch wire with the connector on the pump so they will mate. The correct connector is identified below on the drawing. Once mated turn the outside sleeve of the connector clockwise to lock the connection together. Connect the hydraulic hoses from the winch tube assembly to the pump by mating the hydraulic connector male to female and female to male. Connect the electrical cord on the pump to a 120 volt power supply line that is sufficient to supply power to the pump so when it is running that there is a minimum of 109 volts. NOTE: THE POWER SUPPLY MUST A HAVE GFI PROTECTION AT THE SOURCE. CONTACT YOUR LOCAL ELECTRICIAN TO MAKE SURE YOU COMPLY WITH STATE AND LOCAL WIRING CODES. Page 14
12 VOLT DC ELECTRICAL HYDRAULIC PUMP The 12 volt DC electrical hydraulic pump comes supplied with 4 gauge power cables with a quick connector plug so that you can connect your boat hoist to the battery in your boat. This the most economical approach and allows you the ability to charge your battery while you are boating. Connect the power cables as follows: Connecting the Power Cables to the Hydraulic Pump Attach the end fitting on the black cable to the mounting bolt holding the pump to the mounting bracket. Tighten securely. Attach the end fitting on the red cable to the large solenoid terminal for the motor. It is the post on the solenoid opposite the one that has a heavy cable attaching the solenoid to the motor windings. Installation in the Boat The power cables come equipped with end fittings that will fit the terminals on your boat battery. Simply remove the wing nuts on the battery posts, place on the end fitting of the power cable and replace the nut. Note that the Red cable is to be connected to the positive post of the battery and the black cable is to be connected to the negative post of the battery. This is standard code for battery connections. Once the connections are made the two cables can be connected together with the quick connection and you are ready to power your hydraulic pump. Page 15
MOUNTING A SEPARATE BATTERY ON YOUR HOIST A separate battery supply can be easily added to your hoist should you choose not to operate your hoist with the battery in your boat. It is attached to the winch tube assembly by using a SS1203 Battery Mounting Hardware. SS1203 Battery Mounting Hardware Place one of the motor mount brackets down over the winch tube assembly as shown. Align the holes in the bracket with the predrilled holes in the winch tube. Secure the two together with ¼ x ½ hex bolts. Repeat this process on the second motor mount bracket. Lay the battery holder bracket on top of the two motor mount brackets just installed. Align the holes, then place a 3/8 x ¾ hex bolt down through the brackets. Secure with a 3/8 flange lock nut. Repeat on the other bracket. Once all items are assembled, tighten all bolts left loose at this time. The plastic battery box is not included with the kit. However, the battery cables are supplied with the kit. The red cable is for the positive post connections while the black is for the ground. See page 14 for the instructions on how to connect your battery to the motor. Page 16
SSV40108H Winch Tube Cable Diagram Side View Lift Cable 3110364 Winch Cable 3110365 Page 18
Note: Placing a block under the platform before the cable ends are inserted into the platform will give you more length in the cable to make the connection. Insert the end of one of the lift cables through the hole in the plastic corner guide and then down into the hole in the steel gusset welded into the platform. Place on a 5/8 flat washer, then thread on a 5/8 hex nut until it is at the top of the threads. Thread on a second 5/8 hex nut until it is against the first nut just installed. Using two wrenches, tighten the two nuts into themselves to lock them so they won t work loose during the use of the hoist. Repeat this process on the other lift cable. Re-placement of the Level Cables Platform Assembly Cable Routing The level cables installed in this hoist are made of stainless steel. The platform is assembled as shown in the diagram. The cable is trained through the assembly as follows: Starting on the side that is attached to the drop side weldment, the cable comes down, then under the pulley as shown. The cable is in the pulley groove and is contained in the groove by the cable retainer Ref. No. 7. This is important so that the cable does not come out of the pulley groove when the platform is raised on the drop side weldment side of the hoist by an alternate means other than the normal lifting of the hoist winch system. Raising the platform on the winch tube side of the hoist will cause the platform to raise evenly and will keep tension on the level cables at all times. The cable is then routed under the Ref. No. 33 bushing located inside the platform tube. It must be routed under the bushing to keep the cable from rubbing on the top inside of the platform tube. Connecting the Lift Cables To The Platform Now that the hoist is operable use the control pendant to lower the lift cables. Using the operating instructions on page 16 lower the hoist. When operated in the down position the cylinder will extend causing the lift cables to be lowered out of the winch tube assembly. Lower until the cylinder is fully extended and the cables can not be extended any further. The cable is then positioned into the pulley groove on the topside of the pulley on the winch tube end of the platform tube containing it in place with a second cable retainer. Note that this retainer is mounted on the topside of the pulley while the one on the other end is on the bottom side of the pulley. The cable is then attached to the bottom corner cable bracket as indicated. NOTICE: The pulleys must turn at all times when the platform is being raised or lowered. Should you have any questions regarding the cables or pulleys, contact your local ShoreStation dealer. Page 19
Bunk Assembly Installing the Bunk System The platform can now be raised that the cables are attached to the platform. Raise the platform approximately waist high by pressing the UP button. When the platform reaches this height let the button return to its normal position and the platform will stop. Refer to the drawing on page one to familiarize yourself for the bunk installation. Then using Detail I on page 7 locate the following parts: four adjustable bunk brackets, two (2) carpeted bunk assemblies, four (4) 3/8 x 1 hex bolt, four (4) 3/8 flange lock nuts, four (4) ½ x 5 9/16 x 3 U-bolt, eight (8) ½ lock washers, and eight (8) ½ hex nuts. Place one of the ½ x 5 9/16 x 3 U-bolts around the platform tube as shown from the end of the hoist so the legs of the U-bolt are pointing inward. Position one of the adjustable bunk brackets so that the small hole on one end of the bracket is up. Align the third hole in the adjustable bunk bracket with the top leg of the U-bolt, then with the holes matched to the legs of the U-bolt slip it over the legs. Secure with ½ lock washers and ½ hex nuts. The third hole is a good starting point. The bunks may need to be adjusted in a higher position than this adjustment if your boat has a deep-v hull. Repeat this process on the adjustable bunk bracket assembly on the other platform on the other end of the hoist. Make sure that the adjustable bunk bracket is mounted on the inside of the platform tube. Place the bunk assembly on top of the two adjustable bunk brackets just installed. Align the hole in the bunk bracket already attached to the bunk assembly with the small hole in the top of the adjustable bunk bracket. Insert a 3/8 x 1 hex bolt through the holes and secure with a 3/8 flange lock nut. Repeat on the other end of the bunk assembly. Tighten the nuts on the bolts until snug but do not over tighten. The bunks must be allowed to rotate slightly so they can conform to the bottom of the boat when it is placed on the hoist. Repeat the above process on the remaining bunk assembly on the other side of the hoist. Page 20
HA0001 - Motor Stop Kit Assembly: Break the bundle and sort all parts and hardware by size. Locate the two hoist motor stop arm weldments and the hoist motor stop wood bumper. Position them together making sure the hoist motor arm weldments are positioned with the tubing bent as shown in the diagram. Using four (4) 5/16 x 2-1/4 carriage bolts, attach the hoist motor stop wood bumper to the hoist motor stop arm weldments. Secure with 5/16 lock washers and 5/16 hex nuts. Tighten. Page 21 Installation: Locate the two hoist motor stop u-bolt brackets with offset and position them as shown in the diagram on the hoist platform so they are spaced correctly to fit the hoist motor stop assembly. Place the motor stop assembly on the two hoist motor stop u-bolts brackets with offset just positioned on the platform. Drop the 3/8 x 2-7/16 x 7-1/2 over the motor stop arm weldments and down through the holes in the hoist motor stop u-bolt brackets with offset. Push the u-bolts all the way down until the tops of the u-bolts are resting on the motor stop tubes. Place a straight hoist motor stop u-bolt bracket on the u-bolts as shown. Secure in place with the 3/8 lock washers and 3/8 hex nuts provided. Repeat on the other arm. Position the hoist motor stop assembly on the hoist so it is centered side to side. Changing the motor stop location front to rear is accomplished by sliding the straight portion of the hoist motor stop arm weldments through the u-bolts. This allows you to change the motor stop location to best position your boat on the hoist. Once the assembly is in the proper position, tighten the nuts on the u-bolts. Assembly is complete.