Parts list Instruction guide Warnings Please read carefully before assembling and using product.

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1 Parts list Instruction guide Warnings Please read carefully before assembling and using product. Jet Rail XL Part Number Tools required for assembly Hammer 9/16 Wrench 3/4 Wrench Ratchet 9/16 Socket 3/4 Socket 3/8 Socket Phillips Screwdriver Instructions #15369, Version: ,A514 TIE DOWN ENGINEERING 255 Villanova Drive SW Atlanta, GA (404) Fax (404)

2 Part # Stock # Description Qty Jet Rail Frame Tube (72 long, 3x4) Jet Rail Carriage (20 long) Jet Rail Rear Deck Mount Jet Rail Front Deck Mount 1 4a Front Brace Jet Rail Deck (47 long) Winch Mount Extension Tube (42 long, 2x3) Winch Mount Bow Stop Winch Mount Tube Carpeted Bunk, a Bunk Slicks Keel Pad 6 Long JR Winch Strap, Brake Winch, 1200 lb. 1 HARDWARE Bushing, Bushing, Winch Strap Roller /2 x 5-1/2 Rod Swivel Bracket End Cap Safety Locking Pin 1 21 BBPELLNUT500 1/2 Pal nut 12 21a BBPELLNUT625 5/8 Pal Nut Hair Cotter Pin Spool Roller Self-Tapping Screw, #10 x 3/ Self-Tapping Screw, #14 x 1-1/ z 1/2 U-Bolt /8 x 1 Hex Head Bolt BBB /8 x 4 Hex Head Bolt 7 Note: Three of the 3/8 x 4 hex head bolts are grade 5 bolts, used on page 4, section /8 x 3 Winch Bolt /2 x 5-1/2 Hex Head Bolt /2 x 7 Hex Head Bolt /2 x 8-1/2 Hex Head Bolt /2 Nyloc Nut /8 Nyloc Nut /2 Nylon Flat Washer B Nylon Bushing /2 Washers Shackle Plate /8 x 1 Carriage Bolt Stainless Steel Screws /2 x 6-1/2 rod /2 ID x 5.5 Bushing 1 TIE DOWN ENGINEERING 255 Villanova Drive SW Atlanta, GA (404) Fax (404)

3 1. Assembly of Carriage Step One Roller assemblies are installed in the top five holes of the Jet Rail Carriage. Hammer a pal nut on one end of each of the five rods. Lay carriage upside down as shown in picture 1. In bottom five holes, slide the rods through one side of the carriage. Install 2-1/2 nylon washers, the 4 nylon bushing, 2 - short nylon bushings over the 4 bushing, 2 nylon washers, through the other side of the carriage, hammer pal nut on end of rod. Repeat for the remaining four rods. (Picture 2 shows bushing/washer line up) Picture Jet Rail Carriage /2 x 5-1/2 Rod 5 21 BBBPELNUT500 Pal nut B Nylon Bushing Bushing, /2 Nylon Flat Washer 20 Step Two Install roller assemblies in two upper holes as shown in Picture 1. Use 8 bolt as shown in picture 2a to assemble the roller assemblies. Picture 1 shows finished assembly. Picture B Nylon Bushing Bushing, /2 Nylon Flat Washer End Cap /2 x 8-1/2 Hex Head Bolt /2 Nyloc Nut 2 Picture 2a Attach carriage to frame tube Place carriage onto 72 frame tube, so that the swivel tube on carriage points to the rear. Rear of frame tube has two holes together on bottom to attach rear deck mount as shown in Picture 4. (Front of tube has a single hole on each side of the tube as shown in Picture 6). 3. Assemble & Attach Rear Deck Mount Slide 1 bushings over rods on rear deck mount (Picture 4). Secure with 5/8 pal nuts. Use a hammer to attach pal nuts to rods. Using the two 3/8 x 1 hex head bolts and nyloc nuts, attach the rear deck mount to the Jet Rail Frame Tube as shown in Picture Picture Rear Deck Mount Frame Tube Bushings 2 21A BBPELNUT625 5/8 Pal nuts /8 x1 Hex Head Bolts /8 Nyloc Nuts 2 Picture TIE DOWN ENGINEERING 3

4 4. Attach Front Deck Mount to Frame Tube Attach front deck mount to front of frame tube (front of tube has a single hole on each side of the tube,picture 6). Front deck mount is mounted flush against end of the frame tube using the U-bolt, metal washers and nyloc nuts as shown in Picture Front Deck Mount Jet Rail Frame Tube Z 1/2 U-Bolt /2 Nyloc Nut /2 Flat Washers 2 4A. Attach Brace to Front Mount Mount using 3-3/8 x1 carriage bolts or 3/8 x1 hex head bolts. Brace must be positioned so that it is level with the bottom of the front brace. As shown in picture 5 4a Front brace Carriage bolt /8 Nyloc nut 3 33/nut 37/washer a Picture 5 6-Winch Mount Ext. Tube Picture 6 9- Winch Mount Tube NOTE: At this time, place frame tube/carriage with deck mounts attached, in the general area where you are planning to attach the Jet Rail to your dock. Make sure there is room for the watercraft to be winched onto the Jet Rail without obstructions. 5. Attach Winch Mount Extension Tube to Winch Mount Tube. Slide Extension Tube into front of Jet Rail Frame Tube. Cut-out in front deck mount matches the end that slides into the tube. Bolt winch mount tube to extension tube using the 3-3/8 x 4 Grade 5 hex head bolts and nyloc nuts (Picture 7a) Jet Rail Frame Tube Winch Mount Ext. Tube Winch Mount Tube 1 28 BBB /8 x 4 Hex Head Bolts /8 Nyloc Nut 3 Picture 7b Picture 7a Markings on Grade 5 Hex Head Bolts 5a. Assemble Rollers to Jet Rail Deck Insert a 6-3/4 x 1/2 roller shaft, and two 1/2 pal nuts, place the 5-1/2 long plastic bushings with three nylon bushings (Picture 7b). (NOTE: some hardware kits substitute a 1/2 x6-1/2 hex head bolt & nut for the roller shaft.) 6. Attach Jet Rail Deck To Carriage Assembly Lift Jet Rail deck assembly over carriage. Align carriage tube hole with pivot hole in deck. (Picture 8) Install 1/2 x 7 bolt with 1/2 nyloc nut. (Front of deck has two holes on each side) End with rollers goes to the rear/water side Jet Rail Deck Assembly Jet Rail Carriage Assembly /2 x 7 Hex Bolt /2 Nyloc Nut Picture 8 TIE DOWN ENGINEERING 4

5 7. Attach Bunks to Jet Rail Deck Attach one swivel bracket on each corner of the Jet Rail Deck as shown in Picture 9. There are several holes in which to adjust the width of your bunk boards to fit your watercraft. We recommend that you start with the outer most hole and adjust inward if necessary. Tighten bolts enough to allow adjustment of the bunks on your watercraft. Attach bunk boards to the swivel brackets on each side of the deck, with two 1-1/4 screws at each bracket. For easier installation predrill holes with a 1/8 bit. Bunks should be mounted with one inch of overhang on the front swivel brackets. After deciding on the permanent placement of the bunks (picture 10), tighten all four bolts holding the swivel brackets to the deck Jet Rail Deck Swivel Bracket /8 x 1 Hex Bolt /8 Nyloc Nut Carpeted Bunk /2 0 Screw 12 Picture 9 7a. Attach Keel Pads Attach a keel pad in the center of each end of the Jet Rail Deck, with the 3/4 long screws (picture 11) Keel Pad, 6 long Self Tapping Screw, 3/ Optional Bunk Slick Installation Bunk slicks provide a slippery surface that makes loading your water craft easier. Due to the slippery nature of the bunks slicks, Do Not add additional bunk slicks to the bunk boards, use only the bunk slicks provided. Picture 10 Position bunk boards evenly spaced to fit on smooth surface of the hull. Place the bunk slick so that it s flush with the rear end of the bunk board. Secure with the stainless screws provided (pict 11a). Make sure the screws arre completly set and below the bunk slick upper surface. If the screws are left higher, damage to the water craft hull could happen. 10a Bunk Slicks Stainless Screws 8 Bunk Bunk Slick Picture 11a Picture 11 TIE DOWN ENGINEERING 5

6 9. Assemble Bow Stop Attach 4 inch spool rollers to the bow stop using two hex head bolts, 5 x 1/2, two flat steel washers and two 1/2 nyloc nuts. The washers are used on top of the rollers. (Picture 12) Slide the bow stop over the upright winch mount tube, rubber rollers in the up position. Using the holes in the bow stop plate next to the winch mount tube,place a 4 inch x 3/8 bolt and nyloc nut. Tighten bolt so that the bow stop is about 12 inches below the top of the tube. You will adjust this later to fit your watercraft Bow Stop Spool Rollers, /2 x 5-1/2 Hex Head Bolt /2 Nyloc Nut /2 Flat Washers 2 28 BBB /8 x 4 Hex Head Bolt /8 Nyloc Nut Picture Attach Winch & Winch Mount to Winch Mount Tube Attach winch mount to winch using three - 3/8 x 1 hex bolts and nyloc nuts (picture 13). Attach winch mount & winch, to tube as shown in picture 14, using two - 3/8 x 4 hex head bolts. (Picture 14) Winch 1 28 BBB /8 x 4 Hex Head Bolt /8 Nyloc Nut Winch Mount /8 x 1 Hex Head Bolt /8 Nyloc Nut Assemble Winch Handle Picture 13 Picture 14 See NOTE on page 8 for this step Z 1/2 U-bolt /2 Nyloc Nut Shackle Plate 1 TIE DOWN ENGINEERING 6

7 Attach the winch handle to the winch. Turn clockwise until handle turns gears. Place spring in handle shaft, followed by the nyloc nut supplied with the winch. Tighten nut. 12. Attach Winch Strap to Winch Using a three inch x 1/4 hex head bolt, washer & nyloc nut, attach the winch strap to the winch as shown in pictures 15 & 16. Wind the winch strap onto the winch using the winch handle. Pull length of strap down side of tube, through the bow stop. Use a 3/8 x 4 bolt and the 3 x 3/4 strap roller in the remaining holes in the bow stop. Winch strap should be between the mounting bolt closest to the winch mount tube and the 3 x 3/4 roller. Picture JR 15 Winch Strap x 3/4 Strap Roller 1 28 BBB /8 x 4 Hex Head Bolt /8 Nyloc Nut Winch 1 Included above (13) 1/4 x 3 Hex Head Bolt 1 Included above (13) 1/4 Nyloc Nut 1 Included above (13) 1/4 washer 1 Picture 15 NOTE: If your PWC does not have a bow eye and uses a hole in the front deck, do not thread the winch strap through the bow stop. Use the strap direct from winch to PWC using the soft hook provided. Also see page 8 of these instructions. Mount Jet Rail with lag bolts or bolts through the dock floor. Check for obstructions under the dock before drilling any holes. Rear mount should be close to edge of dock where you will be hoisting the Watercraft. Picture 16 Picture 17 TIE DOWN ENGINEERING 7

8 Instructions For Use To load watercraft onto Jet Rail, slide deck back to rear of Jet Rail. Tilt deck into water. Jet Rail extends to the length of the watercraft. Use pin provided to lock winch tube in place before using lift. Also make sure the bow stop is tightened approximately at bow level. This may need to be adjusted to fit your watercraft. Pull enough strap out to reach watercraft. Hook to watercraft and turn winch handle to pull watercraft out of water. Winch until watercraft meets bow stop. To unload watercraft, slowly release strap by turning winch handle counter clockwise. Push watercraft backwards allowing Jet Rail deck to roll and tilt into the water. Jet Rail may be shortened by pulling pin and sliding extension tube into frame tube when not used to store watercraft. NOTE: TO BALANCE WATERCRAFT ON JET RAIL, an extra U-bolt and plate is included to use as a stop for the rolling carriage on the frame tube. Some watercraft will not slide on the bunk rails as it is being winched up, causing an unbalanced mount. The U-bolt can be mounted on the frame tube to stop the carriage from moving forward, if your watercraft experiences this imbalance. A starting point would be 22 inches from the front mounting plate. Adjust accordingly after using your Jet Rail. SEE PICTURE ON PAGE 6. A soft hook (1 x 18 nylon strap stitched in a loop) is provided for watercraft that do not have a bow eye. Place the soft hook through the front deck hole and place the hook from the winch strap through the end of the loop to winch watercraft on and off of the Jet Rail. If you use this method, you may use the winch strap straight from the winch to the PWC and not go through the bow stop WARNING JET RAIL WILL FALL INTO WATER IF NOT BOLTED TO THE DOCK WHEN WINCHING ON OR OFF A WATERCRAFT. THE LIFT IS NOT DESIGNED FOR LIFTING HUMANS. DO NOT ALLOW ANYONE TO SIT OR STAND ON WATERCRAFT WHEN IT IS BEING PUT ON OR OFF THE LIFT OR IS BEING STORED ON THE JET RAIL. TIE DOWN ENGINEERING 8

9 One person launch n load Easy assembly Nothing else to buy Small footprint, takes up less room on dock The Jet Rail is an all galvanized steel PWC lift designed for easy one person launch and load. The small foot print under the ski allows easy walk around while the watercraft is stored on the dock or seawall. The 1200 lb. brake winch and mount adjusts to any size watercraft and slides inside the lift when not in use, saving even more precious dock space. Carpeted bunk boards and all hardware are included. All you add is your PWC! Model: Jet Rail XL Part Number: Capacities Weight of PWC: Length of PWC: lb (or capacity of dock, whichever is less) NOTE: Gas and oil capacities must be added to the Factory Dry Weight to get a true weight of your PWC. Example dry wt. 600 lbs, 15 gallons gas gallons of oil = 16.6 x 8 lbs= bls. 600 lbs lbs. = lbs. 22" 5' 6' Closed = 7'-1" Extended = 10'-8" 36" Specifications (3/21/2003) Weight without PWC 175 lbs Length with extension in 7 1 Length with full extension 10 8 Width without PWC 22 Width of dock mounting hdw. 18 Length between dock mounting hdw 6 Winch capacity 1200 lbs Winch strap length 15 Height without PWC at winch 36 Height without PWC at bunk rail 19 Maximum space between edge of dock and rear dock mount 2.5 Bunk Length 5 Max. ht. from water to dock mount 22 Assembly Time: Approximately 90 minutes Tools required: Hammer, 9/16 Wrench, 3/4 Wrench, Ratchet, 9/16 Socket, 3/4 Socket, 3/8 Socket, Phillips Screw Driver The Jet Rail was not designed for alterations such as electric winches, roller bunks or modifications to the existing parts Shipping Boxes: Box 1: Dimensions 43 x 50 x 7-1/4, wt. 73 lbs. Box 2: Dimensions 8-1/2 x 4-1/2 x 74 wt. 50 lbs. Box 3: Dimensions 22-1/4 x 8 x 48-1/4, wt. 58 lbs ,514 TIE DOWN ENGINEERING 255 Villanova Drive SW Atlanta, GA (404) Fax (404)

10 102308, # Part # Description Qty Jet Rail Frame Tube Jet Rail Carriage Jet Rail Rear Deck Mount Jet Rail Front Deck Mount 1 4a Front Brace Jet Rail Deck (47" long) Winch Mount Extension Tube Winch Mount # Part # Description Qty Bow Stop Winch Mount Tube Carpeted Bunk, 5' 2 10a Bunk Slicks Keel Pad 6" Long Brake Winch, 1200 lb Swivel Bracket Spool Roller 4" 2 4a 4 9 TIE DOWN ENGINEERING 255 Villanova Drive SW Atlanta, GA (404) Fax (404)

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