Cellofoam PERMAPORT XPRESS Assembly, Installation And Maintenance Instructions
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- Page 1 XPRESS ® PERMAPORT ASSEMBLY, INSTALLATION AND MAINTENANCE INSTRUCTIONS October 12 2020...
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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 • Stop the engine as soon as the Watercraft is on the Xpress ; do not allow engine to run while out of the water. Do not start the engine while the watercraft is on the Xpress . Refer to Watercraft owner’s manual for further details. Mounting Hardware Xpress ®...
- 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 • 2 Stainless steel Channels • Two ½” x 14” Stainless Steel Bolts • Ten ½” Brass Lock Nuts • Twenty Six ½” Stainless Steel Washers • Two Raised Washers and Plastic Caps • Two Pipe caps • One Lanyard •...
- Page 7 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 Note: If installation is for a floating dock front mount, do not attach the rollers. 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.
- Page 9 Insert a 14” long x ½” stainless steel bolt through the assembly and attach the ½” Brass Lock nut and washer on the bottom. 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 .
- Page 10 Front Mount Note: The dimension shown below as “A: is nominally 47 ½” but due to manufacturing tolerances may be slightly different, check the dimension and use the actual dimension for installation. Xpress Determine the position that the is to be attached and mark a line on the stringer Xpress representing the center of the .
- Page 11 Xpress ® Installing two Permaport ports side by side Without Permaport Walk between. 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 Xpress ® Installing two Permaport ports side by side With Xpress Walk between. Xpress Xpress If an Walk is being installed between two Ports then a space needs to be Xpress left between the Dock hardware to allow for the Walk.
- Page 13 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 14 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 15: Attaching To A Fixed Dock
Attaching to a Fixed Dock These instructions are applicable to both side and front mount fixed dock installations. 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. -
Page 16: Attaching To A Floating Dock
Attaching to a Floating dock (Front Mount Only) There are two C channels in the hardware kit, attach both of these to the dock Bracket as shown using four ½” x 1 ½” bolts, washers and brass locknuts. Xpress Move the into position, ensure that the Xpress brackets are able to wrap around the... - Page 17 October 12 2020...
- Page 18 Attaching to a Floating Dock (side mount) It will be necessary to use two lengths of 2” schedule 40 Galvanized Pipe. Measure the distance between the top of the dock and the top of Xpress (Dim A). You will need two pieces of 2” diameter, schedule 40 galvanized pipe that is at least 36”...
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- Page 20 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 21 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. October 12 2020...
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Page 22: Joining Two Permaport
Xpress ® Joining Two Permaport ports Side by Side Xpress’s ® It is only possible to join two Permaport together when front mounted. 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 is supplied pre-assembled Joiner Kit Installation ®... - Page 23 Prior to assembly carry out an inspection on the joiner as follows: - When the parts are assembled during manufacture, grease is applied to the threads inside the joiner to ensure free movement, the bolt should be able to freely turn in the captive nut inside the joiner assembly, ensure this is the case prior to assembly, the nut must remain stationary.
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Page 24: Xpress Step
Xpress Step For Ease of Installation, Do Not Install the Step Until All Other Installation Is Complete. Xpress 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. - Page 25 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. October 12 2020...
- Page 26 Installation Instructions Simply place the step over the top of the hardware in the desired position 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”...
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Page 27: 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 28 October 12 2020...