Sea-Legs Demonstration Unit
Installation Guide
7922 Kerber Blvd · PO Box 111
Chanhassen, MN 55317
Phone (952) 934-7000 · Fax (952) 934-7001
Sea-Legs Demonstration Installation Guide
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revised: Dec 2004
I. PURPOSE
This document provides the procedures for the installation of the Sea-Legs product on a pontoon boat.
II. SAFETY PROCEDURES
Safety is of primary importance and must be carefully managed.
 Never work alone.
 Always wear safety glasses when drilling.
 Keep the body clear of the Sea-legs when raising or lowering the pontoon boat during and after installation.
III. CUSTOMER SATISFACTION
Our business lives and dies on our customer’s satisfaction. Our products, actions, and attitudes must be in line
with the objective of exceeding the customer’s expectations at all times.
IV. INSTALLATION FLOW
A. INSTALLATION PREPARATION
1. Prepare an installation area in a clean, dry, hard surfaced area.
2. Bring the boat into the installation area on a trailer.
3. Lay down four concrete or wooden blocks lengthwise below each of the pontoons, one under each corner.
Ideally the blocks would be 6 to 8 inches high.
4. Place a heavy cloth or piece of wood over each block to prevent damage to the pontoons.
5. Lower the boat onto the blocks, positioning the blocks as needed so the weld seam sits over the blocks.
6. Remove the trailer.
7. Lay protective tarps or cloths on the boat’s carpeting and seats in the installation area.
B. UNDER BOAT HOSE ROUTING
1. Feed the blue and green labeled hydraulic hoses from the front of the boat feeding them through the left
side pontoon brackets as viewed from the rear ending at either the transom or near the cut-out hole if doing
a corner seat install. This set of hoses controls the front module.
2. Feed the red and yellow labeled hydraulic hoses to the rear of the boat feeding them through the left side
pontoon brackets as viewed from the rear ending at either the transom or near the cut-out hole if doing a
corner seat install. This set of hoses controls the rear module.
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C. ABOVE BOAT ASSEMBLY (if you are doing a transom installation, go to section D)
1. Survey boat for best place to locate the pump assembly. The best spot is typically in the corner seat storage
area.
2. Place the pump assembly in the selected location.
3. Carefully select a spot in the immediate area near the pump assembly to drill a hole through which to run
the hydraulic hoses and the power cable wiring harness. That spot, the wiring port, should be located so as
not to puncture the pontoons.
4. Remove the pump assembly. Drill a 1/8” pilot hole to ensure proper clearance beneath the boat and above
the pontoons.
5. If the pilot hole proves satisfactory (clear of any visible obstructions), re-drill the hole using a 2” hole saw
drill bit.
6. If available, insert a rubber grommet in the hole to cover the edges.
7. Run one end of each of the four hydraulic hoses through the hole from the underside of the pontoon. Place
the pump assembly back into your selected location.
8. Connect the color coded ends of the hoses to the proper 90 degree fitting on the manifold:
a. Blue hose to fitting marked Front Extend.
b. Green hose to fitting marked Front Retract.
c. Red hose to the fitting marked Rear Extend.
d. Yellow hose to the fitting marked Rear Retract.
9. Tighten all fittings snugly.
10. Connect the black WeatherPack shroud end of the power cable wiring harness assembly to the matching
black WeatherPack connection on the pump. It will only fit in one direction. Be sure to close the
connection until it snaps.
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11. Feed the 6 gauge red and black battery cables through the wiring hole. NOTE: If the battery is in a
compartment adjacent to the compartment storing the pump assembly, drill a hole to access it directly and
run the red and black battery cables through that hole. For safety reasons, the pump and the battery cannot
occupy the same compartment.
12. Connect the red battery wire to the end of in-line power buss bar (which is connected to the Battery
Positive stud on the Trombetta Switch), using the bolt and washer already provided on the bar.
13. Connect the black battery wire to the top center stud marked Battery Negative on the Trombetta Switch.
14. Screw on the red bolt protectors to cover the positive and negative bolts on the Trombetta Switch.
15. Bolt the pump assembly to the floor using the (4) lags bolts provided. Pre-drilling is recommended.
16. Streamline the hose and wire feeds and tie off with cable ties for a secure fit with a neat appearance.
17. Clip the cable tie ends.
D. NON-INVASIVE ABOVE BOAT ASSEMBLY (if you did a transom installation, go to section E.)
1. Place a piece of plywood on the top of the transom on the stern of the boat.
2. Place the pump assembly on this board.
3. Connect the color coded ends of the hydraulic hoses to the proper 90 degree fitting on the pump manifold
(refer to photos in previous section):
a. Blue hose to fitting marked Front Extend.
b. Green hose to fitting marked Front Retract.
c. Red hose to the fitting marked Rear Extend.
d. Yellow hose to the fitting marked Rear Retract.
4. Tighten all fittings snugly.
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5. Connect the 6 gauge red battery wire to the end of in-line power buss bar (which is connected to the Battery
Positive stud on the Trombetta Switch), using the bolt and washer already provided on the bar.
6. Connect the 6 gauge black battery wire to the top center stud marked Battery Negative on the Trombetta
Switch (refer to photos in previous section).
7. Bolt the pump assembly to the plywood using the (4) lags bolts provided. Pre-drilling is recommended.
8. If necessary, feed the battery cables from the pump down through the transom to the underside of the boat.
9. Run the battery cables through the pontoon support brackets and then up into the battery compartment.
10. Connect the black WeatherPack shroud end of the remote control wiring harness to the matching black
WeatherPack connection on the pump. It will only fit in one direction. Be sure to close the connection
until it snaps
E. UNDERBOAT SEA-LEGS MODULE INSTALLATION – Rear Module
1. Place a Sea-Leg assembly module on the installation jack or floor caster jack.
2. Check the hydraulic fittings on the Sea-Leg module to make sure all are properly tightened.
3. Roll the module between the pontoons from the front of the boat toward the rear with the support pads
pointing to the front of the boat.
4. Position the rear of the module just to the rear of the rear-most full width cross member of the boat.
5. It may be necessary to first disconnect the hydraulic hoses from the cylinder tees and run them across the
top of the transom. Reconnect and properly tighten the hydraulic hoses to the cylinder tees.
6. Maintain approximately 4” of clearance between the Sea-Legs support pad and the front of the transom.
7. Connect the hydraulic hoses from the pump assembly. The red labeled hydraulic hose connects to the solid
fitting on the lift module and the yellow labeled hydraulic hose connects to the loose fitting. Tighten
snugly.
8. Raise the module so it nearly contacts the bottom side of the deck cross members. Be sure that it is not
pinching any of the hydraulic hoses or fittings.
9. Center the modules between the pontoons, checking the distances from the pontoons at each of the front
sides and rear sides of the module using a measuring tape.
10. Clamp the modules to the cross members using (3) vise-grip locking c-clamps on each side of the module.
11. Remove the lift jack.
12. Wearing safety glasses, drill 5/16” pilot holes simultaneously through the lift module flanges and the deck
cross members being careful not to damage any pre-installed electrical wires. Drill (14) holes in total, (4)
each on the two sides of the outside flanges closest to the pontoons and (3) each on the outside flanges on
the inside of the modules.
13. Use 5/16th -18 x 1 Hex Head Cap Screws and 5/16th – 18 flange lock nuts to secure the modules to the deck
cross members. Tighten snugly using an impact wrench or ½” socket wrench.
14. Release the clamps when all (14) bolts and nuts have been installed.
F. UNDERBOAT SEA-LEGS MODULE INSTALLATION – Front Module
1. Place a Sea-Leg assembly module on the installation jack or floor caster jack.
2. Check the hydraulic fittings on the Sea-Leg module to make sure all are properly tightened.
3. Roll the module between the pontoons from the front of the boat toward the rear with the support pads
pointing to the front of the boat.
4. Position the front of the module just forward of the forward-most full width cross member of the boat.
5. Maintain the recommended clearance between the rear of the front Sea-Legs module and the rear of the rear
Sea-Legs module.
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a. On a 20 foot pontoon – maintain a distance of approximately 120”.
b. On a 22 foot pontoon – maintain a distance of approximately 144”.
c. On a 24 foot pontoon – maintain a distance of approximately 168”.
d. On a 26 foot pontoon – maintain a distance of approximately 192”.
6. Connect the hydraulic hoses from the pump assembly. The blue labeled hydraulic hose connects to the
solid fitting on the lift module and the green labeled hydraulic hose connects to the loose fitting. Tighten
snugly.
7. Raise the module so it nearly contacts the bottom side of the deck cross members. Be sure that it is not
pinching any of the hydraulic hoses or fittings.
8. Center the modules between the pontoons, checking the distances from the pontoons at each of the front
sides and rear sides of the module using a measuring tape.
9. Clamp the modules to the cross members using (3) vise-grip locking c-clamps on each side of the module.
10. Remove the lift jack.
11. Wearing safety glasses, drill 5/16” pilot holes simultaneously through the lift module flanges and the deck
cross members being careful not to damage any pre-installed electrical wires. Drill (14) holes in total, (4)
each on the two sides of the outside flanges closest to the pontoons and (3) each on the outside flanges on
the inside of the modules.
12. Use 5/16th -18 x 1 Hex Head Cap Screws and 5/16th – 18 flange lock nuts to secure the modules to the deck
cross members. Tighten snugly using an impact wrench or ½” socket wrench.
13. Release the clamps when all (14) bolts and nuts have been installed.
G. FILLING THE HYDRAULIC SYSTEM AND TESTING THE SYSTEM
SAFETY NOTE: Keep the body clear of the Sea-legs when raising or lowering the pontoon boat
NOTE: While raising the pontoon, the rear will generally raise more slowly than the front. This is
because the weight of the motor makes the rear heavier. The rear will also lower faster. To compensate
for this, it may be necessary to stop pressing one button for a short period of time until the pontoon
levels out.
1. Connect the battery wires to the proper battery terminals.
a. Red wire to positive.
b. Black wire to negative.
2. A typical Sea-Legs installation requires 7 quarts of Chevron Clarity hydraulic oil.
3. Check all hoses and fittings to insure that they are tight before filling the hydraulic system.
4. Do not operate the hydraulic pumps without oil in the reservoir.
5. Disconnect one of the leads connected to the pressure switch.
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6. Fill the pump oil reservoir to within ½” of the top of the reservoir.
7. Connect the black WeatherPack shroud end of the remote control wiring harness assembly to the matching
black WeatherPack connection on the y-cable on the pump. It will only fit in one direction. Be sure to
close the connection until it snaps.
8. With the remote control transmitter in hand, simultaneously press the top 2 buttons. This is required to
activate the remote control receiver.
a. Top left button – Front of Boat up
b. Top right button – Rear of Boat up
c. Bottom left button – Front of Boat down
d. Bottom right button – Rear of Boat down
e. For safety reasons, the remote control receiver powers down after 2 minutes of inactivity.
f. Should a button stick, simply press the button again.
9. Press the FRONT UP switch (top left). This will extend the front cylinders. The oil level in the reservoir
will drop while the cylinders and the hydraulic hoses fill with oil. Add oil as needed; do not allow the
reservoir to drop below half full. Continue to press the FRONT UP switch until the pump begins to labor
or slow down. This indicates that the front cylinders and hydraulic hoses are full.
10. Press the REAR UP switch (top right). This will extend the rear cylinders. The oil level in the reservoir
will drop while the cylinders and the hydraulic hoses fill with oil. Add oil as needed; do not allow the
reservoir to drop below half full. Continue to press the REAR UP switch until the pump begins to labor or
slow down. This indicates that the rear cylinders and hydraulic hoses are full.
11. With the Sea-Legs lift modules free to travel downward, press the REAR UP switch. The oil level in the
reservoir will drop while the cylinders and the hydraulic hoses fill with oil. Add oil as needed; do not allow
the reservoir to drop below half full. Continue to press the REAR UP until the rear lift module reaches the
floor and begins to raise the rear of the pontoon. STOP.
12. With the Sea-Legs lift modules free to travel downward, press the FRONT UP switch. The oil level in the
reservoir will drop while the cylinders and the hydraulic hoses fill with oil. Add oil as needed; do not allow
the reservoir to drop below half full. Continue to press the FRONT UP switch until the front lift module
reaches the floor and begins to raise the front of the pontoon. STOP.
13. Press the FRONT UP and REAR UP switches simultaneously. Remember to maintain the oil level in the
pump reservoir. Continue to press the switches until the pontoon raises off the floor. Raise the pontoon
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until it is approximately two feet off the floor. STOP. Check for clearance between the pontoon and the
ceiling while raising the pontoon.
14. Press the FRONT UP and REAR UP switches simultaneously. Remember to maintain the oil level in the
pump reservoir. Raise the pontoon, if ceiling clearance allows, as high as it will go. Add oil as needed; do
not allow the reservoir to drop below half full. Continually check for clearance between the pontoon and
the ceiling while raising the pontoon. STOP.
15. Press the FRONT DOWN and REAR DOWN (bottom 2 switches) simultaneously until the pontoon rests
on the blocks and the lift modules retract completely beneath the pontoon. You may have to release one of
the buttons to allow the boat to lower levelly.
H. FINAL HOOK UP & TESTING
1. Apply the large warning stickers visibly under the boat, one on each of the Sea-Legs modules.
2. Double check and tighten all hydraulic fittings and electrical connections above board and below the deck
3. Press the FRONT UP and REAR UP switches simultaneously (cylinder extend). Raise the pontoon, if
ceiling clearance allows, as high as it will go. Add oil as needed; do not allow the reservoir to drop below
half full.
4. Check the hydraulic connections and cylinders for leaks.
5. Cycle the pontoon up and down several times to assure that any air trapped in the cylinders and hoses is
purged out.
6. Reconnect the lead to the pressure switch that you had earlier disconnected.
7. Extend both the front and rear leg about 1 foot. Retract the front and rear legs independently to verify the
alarms are functioning when the lift modules retract completely.
8. Use cable ties to secure the hydraulic hoses under the boat.
9. Clip the cable tie ends.
10. Troubleshoot and repair any issues uncovered.
11. With the lift modules fully retracted, fill the oil reservoir to approximately 2” of the top of the reservoir
tube and install the oil filler plug.
12. Demonstrate the working unit to the Customer or Dealer Service Representative to his or her satisfaction.
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I. CLEAN UP AND DEPART (for Sea-Legs installation crews)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Fully retract the legs and lower the boat back onto the blocks.
Sweep the floor for loose hardware, metal shavings, and dirt.
Vacuum all loose debris from the top side of the boat and remove the protective tarps and cloths.
Clean up any excess hydraulic fluid from the pump compartment.
Put away all tools, spare materials, blocks, etc.
Put the boat back on the trailer.
Check out with the customer and secure payment (where possible).
Deliver a copy of the Warranty Form, Limited Warranty, and Sea-Legs Operating Instructions.
If applicable, deliver the (2) Remote Control Transmitters and the Remote Control Operating
Instructions.
Say thank you.
10.
IV: TOOLS AND MATERIALS
A. TOOLS:
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Wrench (adjustable and open end)
Drill
Hole saw drill bits
Steel drill bits
Clamps
Broom and dust pan
Shop vacuum
Small step ladder
Waste can
Concrete or wood blocks
Cloth and/or protective tarps
Wire stripper and crimper
Ratchet wrench, extension, and sockets
Automotive creeper
Shop light
Extension cords
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Sea-Legs modules (2)
Pump assembly
Bolts (28)
Nuts (28)
11” nylon tie straps (6)
7 ½” nylon tie straps (14)
Lag bolts (4)
Hydraulic hoses – (2) “short” (labeled
yellow and red)
Hydraulic hoses – (2) “long” (labeled
blue and green)
Remote control receiver w/2 transmitters
(if applicable)
Hydraulic fluid – (2) gallons
Funnel
Shop towels
Battery wire – 6 gauge – red and black
Under boat warning sticker (2)
B. MATERIALS:
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