Porter 2400 Series Supplement

ASSEMBLY &OPERATION MANUAL
FLOOR COVER TRANSPORT/STORAGE SYSTEMS
No. 2400 Series
Proceed to Page 2 for Assembly Instructions
Proceed to Page 11 for General Operating Instructions
INST 00353 071
2001 PORTER ATHLETIC EQUIPMENT COMPANY. ALL RIGHTS RESERVED. 7-1-2001
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE,
AND TO ORDER REPLACEMENT PARTS

2
WARNING
READ ALL INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING TO ASSEMBLE THIS EQUIPMENT. ASSEMBLY
OF THIS EQUIPMENT MUST BE DONE ONLY BY ADULTS, WHO ARE PHYSICALLY CAPABLE OF DOING SO.
THREE (3) ADULTS WILL BE REQUIRED FOR THE ASSEMBLY PROCESS. FOUR (4) ADULTS WILL BE REQUIRED
EACH TIME A VINYL SECTION IS INSTALLED ON A BATTEN TUBE.
TOOLS REQUIRED: 7/16" Wrenches 9/16" Wrenches 3/4" Wrenches
Phillips Screwdriver Tape Measure
Power Drill with Torque (Clutch) Adjustment and a 5/16" Socket
PARTS LIST
02400
004
No.
Qty.
1 2 2
02400
005
Qty.
02400
007
02400
006 Qty.Qty.
22
02400
010
02400
009
02400
008 02400
011
Qty.
2
Qty.
22
Qty.
2
Qty.
02400
012
Qty.
2
DESCRIPTION
1112 111 1 11
4 1 1 1
222
31 111 1 1
222 2 22
711 11 11
111111
8
67 7 7
444
5
11 111111 11 11
111111 11 1111
7 777 7 7
444 4 44
13 16 16 16
6
5
414
16 12
10815
11 16 16 16
161616
12
10 2 2 2
222
9
16 161616 16 16
1211
8 9 10
72422
16 18 20
14
16 161616 16 16
161616 16 1616
2 222 2 2
222 2 22
17 32 40 48
24
201618
20
19
23 20 25 30
24
22
21
27 222
28
26
25
56 80
72
64 88 96
48
44
32 36 4028
35 504540 55 60
222 2 22
END FRAME WELDMENT
LOWER SPREADER WELDMENT
CROSS BRACE ANGLE
TOP SPREADER ANGLE
1/2" x 3" Lg. HEX HEAD CAP SCREW (Grade 5)
3/8" x 1" Lg. HEX HEAD CAP SCREW (Grade 5)
SWIVEL CASTER
BATTEN TUBE STOP
1/4" x 2
34
" Lg. RD. HEAD MACHINE SCREW
1/4" INTERNAL TOOTH LOCKWASHER
SPACER SLEEVE - 3/8" O.D. x 5/8" Lg.
ROLLER WHEEL
ROLLER PLATE - For use with batten tube stop
BATTEN TUBE ASSEMBLY
1/4" HEX NUT
CRANK ASSEMBLY
#12 x 7/8" Lg. SELF-DRILLING SCREW
1/4" LOCKING CAP NUT
1/2" x 1" Lg. HEX HEAD CAP SCREW (Grade 5)
1/2" HEX NUT
1/2" LOCKWASHER
SWIVEL CASTER With BRAKE
3/8" LOCKWASHER
3/8" HEX NUT
6
5
41211
1098
7
6
5
41211
10
9
8
7
ROLLER PLATE
12
1082422 201816
14
3/8" x 3" Lg. HEX HEAD CAP SCREW (Grade 5)
3/8" HEX NUT
3/8" LOCKWASHER
24
2016 48
44
40363228
24
2016 48
44
40363228
24
2016 48
44
40363228
24
2016 48
44
40363228
24
2016 48
44
40363228
12
810 14 16 18 20 22 24
ITEM NUMBER

3
Detail "A"
1
11
12 13
9
10 9
10
1. Check all items against Parts List on Page 2 to ensure all have been included.
ASSEMBLY OF TRANSPORT CART
2. Locate two end frame weldments (1), and
assemble swivel casters (9 & 10) to each one.
Note that each end frame will require one
swivel caster with brake (10), and one swivel
caster without brake (9). Assemble using four
3/8" x 1" lg. hex head cap screws (11), four
3/8" lockwashers (12) and four 3/8" hex nuts
(13) at each caster. Fully tighten all hardware.
See Detail "A".

4
3. Complete assembly of transport cart by assembling spreaders and braces to end frames from Step No. 2. NOTE – This will
require three physically capable adults – one to hold each the end frame in a vertical position, one to maneuver the spreaders and
braces into place, and one to secure the hardware. See Detail "B".
4. Note – when assembled, the transport cart will have the casters with brake located in opposite corners from each other. See Detail
"B".
5. First, attach the lower spreader weldment (2) to one of the end frame weldments (1) using two 1/2" x 3" lg. hex head cap screws
(5), two 1/2" lockwashers (7) and two 1/2" hex nuts (8). Repeat to attach the lower spreader weldment to the second end frame
weldment. Ensure the two end frame weldments are oriented properly, so the casters with brake are in opposite corners. Hand-
tighten all hardware for now. See Detail "B".
6. Second, attach the top spreader angle (4) to both end frame weldments using two 1/2" x 1" lg. hex head cap screws (6), two 1/2"
lockwashers (7) and two 1/2" hex nuts (8). Hand-tighten hardware for now. See Detail "B".
7. Third, assemble the two cross brace angles (3) to the transport cart using five 1/2" x 1" lg. hex head cap screws (6), five 1/2"
lockwashers (7) and five 1/2" hex nuts (8). Notice that the center slot is not located exactly in the center of the brace angle (3).
Locate the greater space (6' 0-1/8") as shown in Detail "B". Hand-tighten hardware for now. See Detail "B".
8. Check the exploded view in Detail "B" once more to ensure each component has been assembled properly, then fully tighten all
hardware from Steps 5 thru 7.
Detail "B"
6
666
5
78
7
8
CASTER WITH BRAKE
3
4
2CASTER WITH BRAKE
6'-0
18
"
5'-9"
6'-0
18
"
5'-9"
NOTE - LOCATE LONGER
SPACE BETWEEN
SLOTS (6'-018") AS SHOWN
3

5
ASSEMBLY OF ROLLER PLATES AND BATTEN TUBE ASSEMBLIES
TO THE TRANSPORT CART
9. Determine the quantity of batten tube assemblies to be installed on your system. This quantity will dictate the location and
spacing of the roller supports for the batten tubes. See Detail "C" for locations and spacing. Hint – An easy, consistent way to
locate the roller assemblies is to measure from the end frame to the small hole for the self-drilling screw. All dimensions shown
in Detail "C" are to this hole.
Detail "C"
4 BATTEN TUBES 5 BATTEN TUBES 6 BATTEN TUBES
7 BATTEN TUBES 8 BATTEN TUBES 9 BATTEN TUBES
10 BATTEN TUBES 11 BATTEN TUBES 12 BATTEN TUBES
10"
8"
10"
8"
10"
8"
10"
8"
10"
10"
8"
10"
8"
10" 10"
10"
10"
8"
10"
10"
8"
10"
10"
8"
10"
10"
10"
8"
10"
10"
10"
8"
10"
10"
114"
814"
114"
814"
114"
814"
5"
814"
5"
814"
5"
814"
5"
814"

6
10. The roller supports for each batten tube must be installed identically on both end frames, to ensure the batten tube is level and
rolls properly. This will also ensure that each vinyl section rolls onto the batten tube straight and even.
11. NOTE – As with the casters with brake, the batten tube stops (19) must be located in opposite corners from each other. They
should be located in the same corners as the casters with brake. This allows the same individual to operate the caster brake and
batten tube stops from the same position. See Detail "E" on Page 7.
12. Loosely assemble the components required for each roller support assembly on the end frames, as shown in Detail "D".
13. One at a time, carefully slide each roller support assembly into position, according to the information in Detail "C". When
properly located, first tighten the two 3/8" hex head cap screws that secure the plates to the end frame. Next, tighten the two 1/4"
machine screws that secure the rollers to the plates. See Detail "D".
Detail "D"
INSTALL THIS SCREW LAST, AFTER
THE ROLLER SUPPORT ASSEMBLY
HAS BEEN CAREFULLY SLID OVER
THE TUBE ON THE END FRAME
COMPLETED
ROLLER SUPPORT ASSEMBLY
WITHOUT BATTEN TUBE STOP
SHOWN
23
20
20 18
19
17
15
24
25
26
15
22 21
23 16
16
22 21
24 25
20
20
23
ROLLER SUPPORT ASSEMBLY
WITH BATTEN TUBE STOP
17
18
ROLLER SUPPORT ASSEMBLY
WITHOUT BATTEN TUBE STOP
COMPLETED
ROLLER SUPPORT ASSEMBLY
WITH BATTEN TUBE STOP
SHOWN

7
Detail "F"
14
COLLAR
BATTEN TUBE STOP
PREVENTS ROLLING
THE COLLAR ON THE BATTEN TUBE
ASSEMBLY MUST BE LOCATED BETWEEN
THE TWO ROLLER WHEELS
PEEL-&-STICK
VELCRO HOOK
11
12
"
11
12
"
14. At the roller assemblies with the batten tube stop, snug the machine screw and locking cap nut that the batten tube stop pivots on.
Do not over-tighten – the stop (19) must be allowed to pivot freely.
15. After all roller support assemblies are properly located and securely mounted to the end frames, install the #12 x 7/8" lg. self-
drilling screws (27). One screw will be located at each roller support assembly. Using a power drill with a clutch, drive the screw
through the existing hole in the roller plate (15 or 16), into the end frame tube. This will prevent the roller support assemblies
from sliding on the end frames. See Detail "E".
16. Detail "E" shows a completed transport cart (set up for eight batten tube assemblies).
17. At this time, the batten tube
assemblies (14) can be
installed onto the transport
cart. Notice that each end of
the batten tube assembly is
different – one end has a
collar and pin, while the
other end has only an
internal pin. The end with
the collar must be located at
the end of the cart that has
the batten tube stops. This
will prevent the batten tube
assembly from sliding
sideways, and the pin
provides a means to stop the
batten tube from unrolling.
Be sure to locate the collar
between the two roller
wheels. See Detail "F".
27
Detail "E" COMPLETED TRANSPORT CART SHOWN
(For Use With 8 Batten Tube Assemblies)
CASTER WITH BRAKE, AND ROLLER SUPPORT
ASSEMBLIES WITH BATTEN TUBE STOP, LOCATED IN
OPPOSITE CORNERS OF ASSEMBLED CART
Drive self-drilling
screw through
pilot hole in roller
plate into end
frame tube - one
at each roller
support assembly

8
Detail "G"
SLOT IN CRANK
ASSEMBLY ENGAGES
PIN INSIDE BATTEN
TUBE
Detail "H" PIN ON BATTEN
TUBE BEARS
AGAINST BATTEN
TUBE STOP TO
PREVENT VINYL
FROM UNROLLING
28
19
DIRECTION
DURING
ROLLING
PROCESS
Detail "I"
19
DIRECTION DURING
UNROLLING PROCESS
TUBE STOP IS IN
THE UNLOCKED
POSITION
18. Clean an area on the floor that is large enough to accommodate one section of vinyl for the floor cover. Carefully open a section
of vinyl and completely unfold it on the floor. At one end, you will find the Velcro strips for securing the vinyl to the batten tube
assembly. Carefully remove the peel-&-stick Velcro hook sections from the vinyl – there are three individual pieces, each about
6" long. Apply these pieces of Velcro to the batten tube assembly, as shown in Detail "F". Be sure to space the Velcro sections
according to Detail "F", and be sure to apply them in a straight line. These will later be used to secure the vinyl section to the
batten tube.
19. Maneuver the transport cart into position, so that the first vinyl section
can be rolled onto the first batten tube assembly. Lock the brakes on both
casters, to prevent the cart from moving. NOTE – Start at the lowest
batten tubes, and work upward to the higher ones. Install a crank
assembly (28) into each end of the batten tube, making sure the slot in the
crank assembly engages the pin inside the batten tube. See Detail "G".
20. This will require four adults, and both crank assemblies. Position the
batten tube stop (19) as shown in Detail "H" (this will prevent the
material from inadvertently unrolling onto the floor during the rolling
process). Leave the batten tube stop (19) in this position. Lift the end of
the vinyl section with the Velcro strip, and attach it to the Velcro on the
batten tube. Slowly and carefully roll the vinyl section completely onto
the batten tube, making sure it feeds straight onto the tube, and does not
"walk" left to right. Pull sides of vinyl during rolling procedure as
required, to ensure a smooth, wrinkle-free roll.
21. Repeat Step No. 20 for each additional vinyl section.
22. When all vinyl sections have been installed, remove the crank
assemblies and store them in a secure location. NEVER leave
the crank assemblies on the transport cart, where they can be
used by unauthorized individuals.
23. When unrolling the vinyl sections onto the floor, the batten tube
stop (19) must be in the unlocked position as shown in Detail
"I".
24. Assembly of transport cart is now complete.

9
OPTIONAL ACCESSORIES
No. 02405-000 Power Winder – Use in place of hand crank assemblies.
Allows for effortless rolling and unrolling of vinyl sections onto
transport/storage cart. Plugs into standard 110-volt outlet.
No. 02406-200 (Hand-Held) and No. 02406-300 (Walk-Type) Tape
Applicators. Offered in two versions, as shown. Provide a convenient
way to apply tape to the vinyl section overlaps.
No. 02406-112 3" Wide Clear Tape (not shown). Tape allows vinyl
sections to be joined together. Tape is easily removable, without leaving
adhesive residue. Supplied in a case of twelve rolls (approximately 650
yards).
No. 92404-000 Storage Rack Dust Cover (not shown) – provides a one-piece cover to help keep the transport/storage cart clean
and dust-free. Available in fourteen colors.

10
WARNING
READ ALL WARNINGS THOROUGHLY BEFORE USING THIS EQUIPMENT.
FAILURE TO COMPLY WITH THE FOLLOWING INSTRUCTIONS AND WARNINGS MAY RESULT IN SERIOUS
INJURIES AND/OR PROPERTY DAMAGE.
•Never leave the crank assemblies (or optional No. 02405-000 Power Winder) unattended on the transport/storage cart.
Always keep them stored in a secure location, to prevent usage by unauthorized individuals.
•Never allow individuals to stand or climb on the transport/storage cart.
•When rolling or unrolling vinyl sections from cart, always have caster brakes engaged, to prevent cart from moving.
•It is highly recommended that the vinyl floor sections be secured to each other after being installed on the facility floor, by
applying a clear tape to the vinyl where the sections overlap. This will eliminate the possibility of individuals tripping over
uneven vinyl edges. In high-traffic areas (doorways, etc.), the vinyl floor sections may also be secured to the floor. NOTE –
Make sure the tape that is used will not leave a residue on the vinyl floor sections or on the floor when removed. Test the tape
in a hidden area of the vinyl and the floor for several days before using.
THE OWNER OF THIS EQUIPMENT IS RESPONSIBLE TO PROVIDE PROPER SUPERVISION, TO ENSURE
APPROPRIATE SAFETY AND OPERATING PROCEDURES ARE FOLLOWED, TO AVOID INJURIES OR PROPERTY
DAMAGE.
When unrolling each vinyl section from its batten tube assembly, do so SLOWLY and
carefully. As the end of the vinyl section is reached, stop the unrolling process and, by
hand, remove the vinyl section from the Velcro on the batten tube assembly.
CAUTION