hi-density spacesaving systems installation …

HI-DENSITY SPACESAVING SYSTEMSINSTALLATION INSTRUCTIONS

PROBLEMS OR QUESTIONS CALL 1-800-492-9160

FIND BACK RAIL CENTER ON ENCLOSED INSTALLATION DRAWINGS AND DEDUCT HALF THEWIDTH OF THE RAIL FROM THIS MEASUREMENT (1 7/8" FOR HD4 RAIL OR 2 1/8" FOR HD5 RAIL).MEASURE OFF THE BACK WALL AT EACH END OF SYSTEM AND MAKE A MARK THEN SNAPCHALK LINE BETWEEN THESE TWO POINTS. IF SYSTEM HAS WALLS ON BOTH ENDS CENTERBETWEEN THEM. IN THE CASE THAT ONE OR BOTH ENDS OF THE SYSTEM DO NOT END AT AWALL YOU NEED TO SQUARE THE ENDS OF THE RAIL. THE EASIEST METHOD OF DOING THIS ISTO USE A 3-4-5 TRIANGLE (SEE APPENDIX A).

ALIGN RAIL IN FRONT OF CHALK LINE. CHECK AND MAKE SURE FLOOR WILL FIT BETWEENTHE WALL AND RAIL THE ENTIRE LENGTH OF THE SYSTEM. CHECK FOR A BOW IN THE WALLAND ANY OBSTRUCTIONS, SUCH AS THERMOSTATS AND WINDOW SILLS. IF NECESSARYMOVE RAILS FORWARD.

LAY STEEL BAR IN RAIL (MAKE SURE THATALUMINUM IS FREE OF DEBRIS AND DO NOT FASTENIN AT THIS TIME UNLESS DONE AT FACTORY). IFYOUR SYSTEM HAS MORE THAN ONE PIECE OF STEELBAR PER RAIL USE THE PROVIDED 3/16" DOWEL PINSPROVIDED AT EACH JOINT.

INSERT DOWEL PIN IN HOLE IN ONE STEEL BAR ANDSLIDE BARS TOGETHER !

INSTALL LEVELING SCREWS INALL TAPPED HOLES, DO NOTRAISE RAIL AT THIS TIME.

GET THE ON CENTER DIMENSIONS FROM THE INSTALLATION DRAWING, OR MEASURE THECARRIAGES. MEASURE THE RAILS AT THE ENDS AND ALL JOINTS AND SET TO THESEDIMENSIONS. ON SYSTEMS WITH MORE THAN TWO RAILS ALWAYS MEASURE FROM THEBACK RAIL. WHEN RAILS ARE SET MARK LOCATIONS AT ALL ENDS AND JOINTS.

SET UP AND LEVEL LASER LEVEL, ORAUTOMATIC LEVEL. WHICHEVER YOUUSE. YOU SHOULD BE AT LEAST 4 FEETFROM NEAREST RAIL. MAKE SURE YOUHAVE A UN-OBSTRUCTED VIEW OF ALLRAILS.

USE TARGET OR LEVELING STICK AND FIND THE HIGHEST SPOT IN THE FLOOR. RAISE THISPOINT SO THAT YOU HAVE A MINIMUM OF 1/8" BETWEEN FLOOR AND RAIL. RAISE THE RESTOF THE RAIL TO THIS POINT. MAKE SURE RAILS ARE LEVEL NOT ONLY END TO END BUTALSO USE A TORPEDO OR BUTTON LEVEL TO MAKE SURE THAT THEY ARE LEVEL FRONTTO BACK AND THAT ALL JOINTS ARE FLUSH.

WE RECOMMEND THAT YOU LEVEL AND ANCHOR RAILS, THAN CHECK TO SEE THAT RAILSARE LEVEL AND PROPERLY ALIGNED BEFORE GROUTING. ANCHOR BACK RAIL FIRST ANDMAKE SURE IT IS ON THE CHALK LINE. CHECK THE ON CENTER MEASUREMENT, THENANCHOR THE NEXT RAIL. DO THE REST OF THE RAILS IN THE SAME MANNER, ALWAYSMEASURE FROM THE BACK RAIL.

DRILL ANCHOR HOLE DRIVE IN ANCHOR

TIGHTEN ANCHOR JUST ENOUGH ANCHOR ALL RAILS AT ENDSTO HOLD IN POSITION. DO NOT DRAW AND AT JOINTS.DOWN AS IT MAY DISTORT RAILS..

RE-CHECK TO MAKE SURE RAILS ARELEVEL AFTER ANCHORING. MIX GROUT!! MIX ONLY ENOUGH THAT CAN BE WORKED UNDER THE RAIL IN ABOUT 5MINUETS. NORMALLY USE ABOUT 1 TO 1 ½ INCHES OF WATER IN BOTTOM OF BUCKET. ADDGROUT SLOWLY AND MIX AS YOU ADD GROUT. MIX TO A THICK BATTER CONSISTENCY. (GROUT WILL NORMALLY POUR VERY SLOWLY AT THIS POINT) THIS WILL WORK FOR UP TO1/2" GAP BETWEEN RAIL AND FLOOR. THE MORE SPACE BETWEEN THE RAIL, THE THICKERYOU NEED TO MIX THE GROUT.

WORK THE GROUT UNDER THE RAIL (FOR BEST RESULTS USE A 6" DRYWALL KNIFE) UNTIL ITCOMES OUT THE OUTER SIDE. THIS WAY THE ENTIRE GAP IS FILLED. DO NOT WORK UNDERFROM BOTH SIDES. WORK UNDER AS MUCH AS YOU CAN THEN COME BACK AND CLEAN UPEXCESS.

BOTTOM VIEW INSTALL BACK FLOOR BETWEEN WALL INSTALL LEVELING SCREWS IN FLOORS BACK RAIL. YOU WILL NORMALLY HAVE 1 MAKE SURE SLOT IN SCREW IS UP. SECTION OF FLOOR THAT IS CUT. CUT END GOES TOWARDS END OF SYSTEM OR WALL.

INSTALL THE CENTER FLOORS, IF YOU HAVE PLATFORMS THE CENTER FLOOR AND STEEL BAR DONOT GO UNDER THE PLATFORM. IF YOU HAVE A 12" PLATFORM THE FLOOR AND STEEL BAR WILLSTART 12" FROM THE END

NOTE!! FLOORS ARE TONGUE AND GROOVED, BE SURE TO MATCH JOINTS.

TO FASTEN RAIL USE 3/16" DOWEL PIN, 1/4-20 INSERT DOWEL PIN INTO BLOCK AND THESELF TAPPING SCREW AND RAIL BLOCK. SLIDE INTO RAIL.

MOVE BLOCK INTO PROPER POSITION AS INSERT THE 1/4-20 SCREW AND TIGHTEN WITH INDICATED ON INSTALLATION DRAWINGS A #3 PHILIPS BIT.AND DRILL A 7/32" HOLE.REPEAT FOR OTHER END OF RAIL. MAKE SURE THAT ALL JOINTS ARE TIGHT!

FASTEN ALL FLOORS WITH 1" OR 1 1/4" FLAT HEAD TEK SCREWS PROVIDED. FASTEN AT EACH JOINTAND IN LINE WITH ALL LEVELING SCREWS. SCREWS ARE SELF DRILLING AND WILL DRILL THE PILOTHOLE. PULL IN SO HEAD IS FLUSH WITH PLYWOOD

LAY IN RAMP AND FASTEN TO RAIL IN THE SAME MANNER AS THE FLOOR.ANCHOR TAPERED END TO FLOOR WITH MASONRY ANCHORS AS REQUIRED.

FASTEN RAMP AS SHOWN ABOVE. RUN ALL LEVELING SCREWS SO THEY CONTACT THE FLOOR. USEA LEVEL AND LEVEL FLOORS. IF PLYWOOD IS BOWED IT MAY BE NECESSARY TO USE MASONRYANCHORS TO BRING FLOOR DOWN LEVEL. IF YOUR FINISHED FLOOR COVERING IS 1/8" THICK THEPLYWOOD SHOULD BE 1/8" BELOW RAIL EXTRUSION AND 1/4" BELOW IF YOU HAVE 1/4" CARPET.

IF YOU HAVE SECURITY LOCK SEE PAGE 16 NOW.

TWIST AND TURN PLATFORM ANCHOR PLACE SPACER BLOCKS OVER BOLTSBOLTS INTO RAIL TO LOCK IN PLACE

SPACE ANCHOR BOLTS ANDSET PLATFORM OVER BOLTS. INSTALL NUTS AND FINGERTIGHTEN ONLY AT THIS TIME.

PLACE CARRIAGE ON RAILS, ALIGN THE PLATFORM SO IT IS EVEN WITH THE FRONT AND IS IN LINE WITH THE CARRIAGE. TIGHTEN ALL NUTS ON PLATFORM.

IF CARRIAGES ARE SPLICED MATCH UP NUMBERS. SLIDE SECTIONS TOGETHER, INSTALLCARRIAGE BOLTS AND NUTS. IT IS EASER TO SLIDE ONE SIDE TOGETHER AND INSTALL ONE BOLTAND NUT. THEN SLIDE OTHER SIDE TOGETHER. INSTALL AND TIGHTEN ALL FOUR BOLTS.

ALIGN KEYWAY IN COUPLING WITH KEY IN SHAFT AND SLIDE TOGETHER ALIGN HOLE IN SHAFT COUPLING WITH HOLE IN SHAFT . DRIVE IN ROLL PIN

IF YOU HAVE IN RAIL ANTI-TIPS YOU WILL INSTALL THEM AT THIS POINT.

HD 3 ANTI-TIP

HOOK THE ANTI-TIP IN THE RAIL BESIDE THE CARRIAGE SO IT LINES UP WITH THE HOLES IN THE WHEEL HOUSING.

THEN SLIDE ANTI-TIP IN PAST WHEEL AND LINE UP WITH THE HOLES IN THE WHEEL HOUSING.

NEXT INSERT THE BOLTS MAKING SURE THAT THE SQUARE ON THE BOLT SEATS PROPERLY IN THE SLOT AND PUT ON NUTS.

AFTER BOTH BOLTS AND NUTS ARE IN SLIDE THE ANTI-TIP AS FAR TO THE FRONT AS IT WILL GO AND THEN AS FAR OT THE BACK. THEN LOCATE THE ANTI-TIP APPROXIMATELY HALF WAY BETWEEN THESE TWO POINTS AND TIGHTEN BOLTS. AFTER THE BOLTS ARE TIGHT MOVE THE CARRIAGE AS FAR AS IT MOVES TO BOTH SIDE TO MAKE SURE ANTI-TIP DOES NOT DRAG AND ADJUST POSITION IF NECESSARY.

HD 4 & 5 ANTI-TIP

THE ANTI-TIP BRACKET TYPICALLY MOUNTED TO THE BOTTOM OF WHEEL CHANNEL. OCCASIONALLY THE SITUATION REQUIRES US TO SEND THE ANTI-TIP ASSEMBLED. IN THESE CASES USE DIRECTIONS AS FOLLOWS BUT YOU WILL INSTALL THE 3/8” BOLTS INSTEAD OF THE 1/4” BOLTS.

NEXT INSERT THE ANTI-TIP BRACKET INTO THE RAIL AS SHOWN AND FLIP UP TO ALIGN WITH BRACKET.

POSITION THE ANTI-TIP ON THE SIDE OF THE BRACKET TO THE CENTER OF THE WHEEL CHANNEL AND ALIGN HOLES.

INSERT THE 1/4-20 CARRIAGE BOLTS INTO THE HOLES AS SHOWN. MAKE SURE THAT THE SQUARE PART OF THE BOLT IS SEATED PROPERLY.

THEN TIGHTEN BOLTS AND ASSURE THAT THE ANTI-TIP DOES NOT DRAG BY MOVING CARRIAGE AS FAR AS IT WILL TRAVEL TO BOTH SIDES.

TOP MOUNT END STOP EACH END STOP CONSIST OF 1 ANGLE, 2 1/4-20 FLAT HEAD SELF TAPPING SCREWS, 1 BUMPER, AND 1 #8x1” FLAT HEAD SCREW. YOU WILL NEED A DRILL, #2 PHILIPS BIT, #3 PHILLIPS BIT, AND 7/32” DRILL BIT.

FIRST ATTACH THE BUMPER TO THE ANGLE AS SHOWN WITH THE #8x1” SCREW PROVIDED. YOU MAY NEED TO PUT PRESSURE ON SCREW TO HELP IT GET STARTED AS IT IS SHORT SO IT DOES NOT TO PROTRUDE FROM THE BACK OF THE ANGLE.

THEN POSITION THE END STOP AT THE END OF THE RAIL OR AT THE POSI-TION THAT YOU WISH FOR THE CAR-RIAGE TO STOP AND CENTER ON THE EXTRUSION. DRILL ONE HOLE WITH THE 7/32” DRILL BIT AND INSERT 1/4-20 SCREW. THEN REPEAT ABOVE STEP FOR OTHER SIDE. AT THIS POINT MAKE SURE THAT ALL SCREWS ARE TIGHT AND END STOP DOES NOT MOVE.

RECESSED END STOPS

RECESSED END STOP

INSERT THE END STOP INTO THE RAIL TO THE BACK SIDE OF THE STEEL BAR IN APPROXI-MATE POSITION BEFORE YOU INSERT STEEL BAR.

LOCATE THE END STOP IN THE PROPER POSITION. IN MOST CASES IT WILL BE AT THE END OF THE RAIL BUT IF YOU HAVE BACK TO BACK LOCKING CARRIAGES IT WILL BE IN THE CENTER. THEN DRILL A #25 HOLE IN THE CENTER OF THE END STOP AND FASTEN WITH THE #8 SCREW PROVIDED.

POSITION CARRIAGE END STOP BRACKET IN BACK SLOT OF RAILS AND DRILL 7/32” HOLE. THEN FASTEN WITH 1/4” SELF TAPPING SCREW PROVIDED.

PAGE 14

BUILD YOUR SHELVING ACCORDING TO MANUFACTURERS RECOMMENDATIONS

ON MECHANICAL ASSIST CARRIAGES ON MANUAL CARRIAGES STARTSTART SHELVING 1-15/16" BACK FROM SHELVING FLUSH WITH FRONT OF CARRIAGE. PLASTIC TUBE SITS 0F CARRIAGE. END PANEL SITSON FRONT OF CARRIAGE ON THE TABS SHOWN ON BOTTOM OF CARRIAGE.

SPROCKET SET UP ON CARRIAGE SPROCKET SET UP ON CARRIAGEWITHOUT CARRIAGE SAFETY OR WITH SAFETY OR SECURITY LOCKSECURITY LOCK OR WITH IN THE FRONT SPROCKET IS FOR LOCK.RAIL SECURITY LOCK.

FOLLOWING PICTURES ARE SHOWN WITHOUT SHELVING FOR CLARITY.

REMOVE SCREW USED FOR SHIPPING. SET ONE SIDE OF THE END PANEL ON CARRIAGE, INSTALL CHAIN ON DRIVE SPROCKET.

(IF YOU HAVE SAFETY LOCKS MAKE SURE THATTHEY ARE IN UNLOCKED POSITION) (IF YOU HAVEIN THE RAIL SECURITY LOCK CLIP THE LOCKCABLE TO THE SPRING ON THE LOCK ARM). RAISETHE OTHER SIDE OF THE PANEL. SET ON CARRIAGE.CHECK TO MAKE SURE THAT CHAIN IS ON THE TOPDRIVE SPROCKET AND THE TENSIONER SPROCKET. IF THE PANEL TUBE DOES NOT ALIGN WITH THE SHELVING UPRIGHT USE A LEVEL TO CHECK THE PLUMB OF THE SHELVING AND THE PANEL. NEXT USE SHIMSTO ADJUST THE ONE THAT IS OUT OF PLUMB (IT IS TYPICALLY THE SHELVING). THEN FASTEN THE END PANELS WITH 1" HEX HEAD TECH SCREWS PROVIDED. USE AT LEAST 3 SCREWS PER SIDE AND BE EXTREMELY CAREFUL NOT TO STRIP OUT THREADSIN PLASTIC TUBES!! TAKE A SLOTTED SCREW DRIVER AND TIGHTEN THECHAIN TENSIONER. TIGHTEN JUST ENOUGH TO TAKETHE PLAY OF THE HAND CRANK. DO NOT OVERTIGHTEN AS IT WILL MAKE THE UNIT TURN HARD. POSITION TWO BUMPERS PER AISLE ONE AT EACH ENDOF THE CARRIAGE (LONG CARRIAGES WILL HAVEMORE). ATTACH TOWARD THE TOP BY DRILLING A #25HOLE AND INSERTING SCREWS PROVIDED.

REMOVE PROTECTIVE CAP. HUBS ARE SHIPPED WITH SET SCREWS IN TWO HOLES. THE HOLE WITHOUT THE SET

SCREW IS FOR THE THREADED ROD WITH THE TIP.

INSTALL THE THREADED ROD WITH THE TIP FIRST. BE SURE TO ALIGN SO THE TIP WILL GO INTOTHE KEYWAY IN THE SHAFT. TAKE A PAIR OF CHANNEL LOCKS AND TIGHTEN THIS ROD. THEN TAKEA ALLEN WRENCH AND TIGHTEN THE SET SCREWS IN THE OTHER HOLES. THEN INSTALL AND TIGHTENTHE OTHER THREADED RODS. NEXT SLIDE PAINTED TUBES OVER THREADED ROD AND INSTALL KNOBS.MAKE SURE THAT KNOBS ARE AS TIGHT AS POSSIBLE. WE ALSO RECOMMEND USING LOCTITE ONTHE KNOBS TO KEEP THEM FROM BACKING OUT.

ERGONOMIC CRANK INSTALLATION INSTRUCTIONS:REMOVE PROTECTIVE TIP FROM CRANK SHAFT.

ALIGN KEY WAY IN SHAFT WITH KEY WAY IN CRANK.SLID ON UNTIL IT STOPS.

TAKE A LONG 1/8" ALLEN WRENCH AND TIGHTENSCREWS:

THERE ARE TWO SET SCREWS TO TIGHTEN, MAKE SURETHEY ARE TIGHT, AND MAKE SURE THE CRANK WILL NOTMOVE IN OR OUT.

SECURITY LOCK BAR INSTALLATION INSTRUCTIONSINSTALL LOCK BAR ON HD4 RAIL FROM THE END OF RAILBEFORE INSTALLING RAIL AS SHOWN. IF SYSTEM HAS, APLATFORM IT CAN BE INSTALLED PRIOR TO INSTALLINGPLATFORM. ON HD5 RAIL IT WILL DROP IN FROM THE TOP ATANY TIME. BE SURE LOCK BAR IS ON RAMP SIDE OF RAIL!DO NOT FASTEN BAR AT THIS TIME. WHEN SYSTEM ISCOMPLETE ROLL ALL CARRIAGES INTO CLOSED POSITIONEXCEPT FOR THE LOCKING CARRIAGE. NOW SLIDE BARUNDER LOCK ON CARRIAGE TURN KNOB TO LOCK POSITIONSO LOCK ENGAGES SECOND OR THIRD NOTCH CLOSEST TOTHE OTHER CARRIAGES, WITH LOCK IN LOCK POSITION ROLLCARRIAGE TO OTHER CARRIAGES WHEN IN POSITIONUNLOCK AND MOVE LOCKING CARRIAGE TO OPEN THE ISLE.

NOW WITH LOCK BAR EXPOSED USING #25 DRILL BITDRILL TWO HOLES AND INSERT SCREWS SUPPLIED.

APPENDIX A3-4-5 RULE

IF SYSTEM IS OPEN TO ROOM ON ONE END. (FIGURE 1) FIRST FIND MEASUREMENT A THIS IS THE BACK RAIL CENTER ON YOUR INSTALLATIONDRAWING AND SUBTRACT HALF THE WIDTH OF THE RAIL SAME AS IF YOU HAD A WALL ON EACHEND. MAKE YOUR MARKS AND POP A CHALK LINE. THEN MEASURE FROM THE WALL YOU AREENDING ON ALONG THE CHALK LINE THE LENGTH OF THE RAIL AND MAKE A MARK ACROSS CHALKLINE (THIS IS POINT 1 ON THE DRAWING). NEXT ON THE CHART FIND THE LARGEST SIZE OF AREATHAT WILL FIT INTO YOUR SYSTEM (EXAMPLE: YOUR SYSTEM IS 14'X19' YOU USE THEMEASUREMENTS FOR 12X16) ON THE CHALK LINE MEASURE FROM POINT 1 AND MAKE A MARK (IFYOU RAIL LENGTH IS LONGER THAN YOUR CARRIAGE LENGTH USE SIDE B FROM THE CHART, IF IT ISSHORTER USE SIDE C). NEXT MEASURE FROM POINT 1 PERPENDICULAR TO THE LINE AND MAKE ANARC THAT PASSES THROUGH THE POINT THAT YOU ESTIMATE IS SQUARE (IF YOU USED SIDE B ONTHE BACK USE SIDE C, IF YOU USED SIDE C USE SIDE B). NEXT MEASURE FROM THE MARK YOUMADE ON THE LINE TO THE ARC YOU MADE ON THE END AND MAKE A MARK WHERE THEYINTERSECT (THIS DISTANCE IS SIDE D). NOW SIMPLY POP A LINE FROM POINT 1 ACROSS THATINTERSECTION. THIS LINE IS SQUARE. IF ONE RAIL HITS THE END WALL AND EXTENDS PAST YOURLINE THE END WALL IS OUT OF SQUARE SO JUST MOVE THE OTHER RAILS SO THAT THEYEXTEND PAST THE SAME AMOUNT.

IF SYSTEM IS OPEN TO ROOM ONBOTH ENDS. FOLLOW THE DIRECTIONS FOR ONEEND ONLY YOU LOCATE POINT 1 BYMEASURING FROM A KNOWN POINT ONTHE END OF SYSTEM (EXAMPLE: SYSTEMSTARTS 3' FROM A WALL, COLUMN, ORDESK).

IF SYSTEM IS IN MIDDLE OFROOM (FIGURE 2). FIRST DETERMINE MEASUREMENT AAND POP YOUR CHALK LINE. EXAMPLE:YOU KNOW THAT IT IS 48" TO THE FACEPANELS AND YOU HAVE A STANDARDFRONT (20" FROM CENTER OF WHEELTO END OF EXTRUSION) THEN ADD 19"AND THAT IS MEASUREMENT A (67"). TOTHE HANDLES ADD 4" MORE. THENLOCATE POINT 1 JUST AS YOU WOULDFOR A SYSTEM OPEN ON BOTH ENDS.

YOU CAN CHECK YOUR SQUARE ONCEYOU HAVE THE RAILS LAID OUT BYMEASURING DIAGONALLY FROM THELEFT END OF THE BACK RAIL TO THERIGHT END OF THE FRONT RAIL ANDTHEN THE LEFT END OF THE FRONTRAIL TO THE RIGHT END OF THE BACKRAIL THESE MEASUREMENTS SHOULDBE THE SAME.

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