Cellofoam PERMAPORT XPRESS Assembly, Installation And Maintenance Instructions
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- Page 1 PRESS ® PERMAPORT ASSEMBLY, INSTALLATION AND MAINTENANCE INSTRUCTIONS - 1 -...
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Page 2: Table Of Contents
It is important that these instructions are adhered to in their entirety. Please read the instructions fully before starting installation or assembly. Contents • Safety Instructions (installation) • Safety and General Instructions (Use) • Installation Considerations and Tools Required • Parts List for Permaport Xpress •... -
Page 3: Safety Instructions (Installation)
Safety Instructions (Installation) • Many of the parts of the Permaport Xpress are heavy; do not lift any parts that are beyond your capability, use additional help to maneuver parts into position. • When working near the water it may be advisable to tie a line to any parts that are liable to sink until they are attached. -
Page 4: Installation Considerations And Tools Required
• Stop the engine as soon as the Watercraft is on the Xpress; do not allow engine to run Xpress while out of the water. Do not start the engine while the watercraft is on the Refer to Watercraft owner’s manual for further details. Mounting Hardware ®... - Page 5 Xpress Parts List Ensure that all of the parts are available before starting assembly. • Xpress Hull Including 14 Fitted Rollers and 6 Void Fillers. • Two Xpress Brackets. • Two Contoured Rollers • Two Straight Rollers • Four 6” x ½” Stainless Steel Bolts •...
- Page 6 • Six ½” Brass Lock Nuts • Twenty ½” Stainless Steel Washers • Two Raised Washers and Plastic Caps • Two Pipe caps • One Lanyard • One Xpress Step™ (some models only) Other Parts Required (Not Included) • 2” Diameter Schedule 40 Galvanized Pipe (Length to suit). •...
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Page 7: Basic Assembly Instructions
Basic Assembly Applicable to all Applications Xpress It is recommended that the basic mounting kit be applied to the away from the water to avoid the possibility of loss of components. It is essential that all threads are coated with an anti-seize compound prior to assembly; failure to do so will complicate any future disassembly that may be required and will invalidate the warranty. - Page 8 Place a shock absorbing insert in both the top and bottom rectangular recesses on the selected holes. These are a tight fit, so use a mallet to tap into place home, if necessary. Bracket Preparation and Installation Assemble the two brackets as shown, ensuring that there is a pair of contoured rollers on one bracket and a pair of straight rollers on the other.
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Page 9: Attaching Dock Hardware (Front Mount)
Tighten the nuts using a ¾” wrench or Long Reach Socket. Do not over tighten the nuts, Xpress they need to be snug without causing undue compression of the . Finally, snap the plastic caps over the bolt heads onto the contoured washers. There are two different types of rollers, on a front mount application the position is unimportant. - Page 10 Xpress Alternatively, mark one line 5” from the edge of where the is to be positioned and then a second line 47 ½” from the first. Position the Dock Bracket so the center of the tube lines up with the line drawn on the dock, ensure that the bracket is firmly against the stringer, and attach to the dock using screws or bolts in the top two holes.
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Page 11: Xpress
Xpress ® Installing two Permaport ports side by side. Xpress ® When installing a pair of Permaport ports we recommend either joining them directly side by side to one another or installing them with a significant gap between them to avoid entrapment of anyone in the water. -
Page 12: Attaching Dock Hardware (Side Mount)
Side Mount Xpress Determine the position that the is to be attached and mark a line on the stringer representing the center of the forward attachment point. This MUST be a minimum of 24” from any adjoining dock at the front. There are two options for the rear attachment, the one toward the rear is the preferential Xpress position but the position in the center of the... - Page 13 Position the forward most dock Bracket so the center of the tube lines up with the line drawn on the dock, ensure that the bracket is firmly against the stringer, and attach to the dock using screws or bolts in the top two holes, (Note: If necessary, chamfer the top front edge of the dock).
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Page 14: Attaching To A Fixed Dock
Attaching to a Fixed Dock This System Must Not Be Used if There is a Possibility of the Water Level Rising to Within 15” of the Bottom of the Pipe Brackets. In this case, contact your supplier for alternative instructions. It is essential that the poles on the fixed dock are both Parallel and Upright. -
Page 15: Attaching To A Floating Dock
Attaching to a Floating Dock It will be necessary to use two lengths of 2” schedule 40 Galvanized Pipe. Measure the distance between the top of the Xpress dock and the top of the (Dim A). You will need two pieces of 2”... -
Page 16: Adjustment Of Rollers
Adjusting the Rollers Note: all of the component parts of the wheel axle assembly will sink in water; use care when removing the assembly. As supplied, the rollers are positioned such that they will accommodate the majority of Personal Watercraft (PWC’s) on the market. However, it may be necessary to change the position for use with certain PWC’s where the rollers interfere with the contours of the hull. - Page 17 Re-Assembly of Wheels Slide one end of the assembly into a recess and then using a protective piece of wood or plastic drive the other end into the opposing recess using a mallet as shown. Do not apply lubrication as an aid to insertion. - 17 -...
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Page 18: Joining Two Permaport
Xpress ® Joining Two Permaport ports Side by Side Xpress ® If two Permaport ports are to be mounted side by side it will be necessary to use a Joiner Kit, available from your dealership. The joiner Kit comprises the following components Two Plain Rubber Inserts Two threaded Rubber Inserts Two 18”... - Page 19 Joiner Kit Installation Xpress ® If you are joining two Permaport ports front mounted you will need 1 kit Xpress ® If you are joining two Permaport ports side mounted you will need 2 kits ® Xpress On a front mounted installation, mount both Permaport ports to the dock independent of each other using the hardware provided (see page 11 for requirements).
- Page 20 Xpress Drop the assembly into the insert slot. Screw the bolt into one of the threaded inserts; the end of the bolt needs to just protrude from the bottom of the insert. Xpress Repeat for all positions on both ports. (two positions on front mounted, four positions on side mounted).
- Page 21 Insert the joiner bar so that the slots wrap around the bolts. Allow the bar to drop into the slot ensuring it is still around the bolts. Allow the rubber insert and washers to drop into place Tighten the bolt, and repeat for the opposite side.
- Page 22 Xpress Step For Ease of Installation, Do Not Install the Step Until All Other Installation Is Complete! press Step™ is designed to make the complete installation more aesthetically pleasing as well affording a degree of additional protection when boarding or disembarking the Jet Ski by covering the hardware used to mount the port to the dock.
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Page 23: Xpress
Possible configurations Xpress ® Front Mounted Permaport Xpress ® Side Mounted Permaport The step can be mounted on either the front or the rear side positions, or with the addition of a second step they may be installed in both positions. Installation Instructions Simply place the step over the top of the hardware in the desired position - 23 -... - Page 24 and attach using appropriate bolts or screws. If using screws, use 3/8” diameter x 9” long screws in the front 4 positions and 3/8” x 2 ½” screws in the top 6 positions. If using bolts, use 3/8” diameter and size the length of the bolts to suit the deck it is being installed Using the step with a side by side installation...
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Page 25: Available Accessories
Accessories Rough Water Adaptor for Floating Docks Xpress is designed to be free floating and is able to rise and fall independent of the dock. This is essential on a fixed dock, but is also desirable on a floating dock. It enables the Xpress port to remain level in the water independent of the attitude of the dock. -
Page 26: Xpress Walk
Xpress Walk Xpress Walk™ enables ease of access without unduly widening the port since it can be added to just the most convenient side. It can be added to both sides, forming a 98” wide port, ideal for children or those with limited mobility. Xpress It can also be added between two ports to enable ease of access, and when... - Page 27 - 27 -...