Modular Bi-File Lateral Installation Instructions 920-563-6362 E-mail: ssc@spacesaver.com Internet: www.spacesaver.com
Contents Hardware Identification..................................3 Pre-Installation........................................6 Component Identification................................7 Installation...........................................8 System Expansion....................................20 2
Hardware Identification 3
Hardware Identification 4
Hardware Identification 5
Pre-Installation Wear eye protection and other applicable safety equipment while assembling your Modular Lateral system. Know how to safely operate the required power tools before starting this project. To ensure safe and easy installation, be prepared to have an additional person on-hand to assist with certain installation steps and lifting operations. Preparation before installation: 1. Read through the entire installation procedure before you begin this project. 2. Understand all safety statements. 3. Make sure your Modular Lateral storage system will fit within the desired location. 4. Plan to assemble the Modular Lateral system where it will be used. 5. Have the necessary tools to assemble and level the system. Required tools: Power Screwdriver or Portable Hand Drill Phillips and Slotted Driver Bit 4" Long Phillips Bit Leveling Device (preferably a rotary laser level) Utility Knife Dead Blow Hammer or Rubber Mallet Hex T-Handle Wrenches: 5/32" x 6" Slotted Screwdriver (assorted sizes) Phillips Screwdriver (assorted sizes) Measuring Rule or Tape Torpedo Level Carpenters Level Apex 1/4 Square Socket 6
Component Identification NOTE: The following components will be referred to in the sections to follow. 1. Aluminum extruded rail 2. Rail tie plates under the floor 3. Stationary Base 4. Rail leveler locations 5. End stop assembly locations (2) places (In-Rail) 6. Appliance leveler 7. Stationary end piece 8. Spacer plate 9. Cover plate 10. Floor Sections 11. Splice plate (Biscuit Type) in floor See Hardware Identification page 3 12. Ramp section 13. Tension pins 14. Tapered ramp end caps 15. Floor end cover protector 16. Center flange wheel moveable carriage section 17. Flat wheel moveable carriage section 18. Moveable carriage side cover 19. Moveable carriage end cover 20. Stationary side cover 21. Stationary bracket. Hidden behind cover bumper. See Hardware Identification page 3 22. Soft cover bumper 23. Moveable bracket. Hidden behind cover bumper. See Hardware Identification page 3 24. Reinforcement block 7
Installation Assembling Rail Base 1. Arrange the aluminum extruded rail (channel side down) on the floor near the final location. Various rail lengths are provided for different system configurations. Make sure all splices line up. NOTE: To keep the rail assembly square, loosely install all self-tapping screws. Once alignment is confirmed, tighten screws in a random sequence. 2. Fasten rail tie plates (countersunk holes facing out) to the bottom side of the aluminum rail using self-tapping screws. Universal tie plates are used at both ends of the rail assembly and at all rail splices. All sixteen countersunk holes will be used to attach rail splices, eight self-tapping screws per rail. Tie plates are shifted inward when used at rail ends, only eight self-tapping screws will be required. 960181.001 Self-tapping screw #10-32 x1/2" x 8 Universal Tie Plate (2) x 16 Aluminum extruded rail (1) x 8 8
Installation Locating and Leveling Rail Base 1. Position rail channel side up in the final location. If installing the unit against a wall, place the rail assembly 2-1/2 plus the depth dimension of the stationary base away from the back wall. 2. Insert leveling screws at each rail leveler location. Use a 5/32 allen wrench to turn each leveler, until it touches the floor below. NOTE: A laser type level is recommended for the next step but not required. 3. Use the level to determine the highest point on the floor. Spot check along each rail, over the entire footprint of the rail assembly. If the high point is under a splice plate, raise the rail assembly to create a 1/8 space between the tie plate and the floor. A 1/4 space between the tie plate and the floor is required if the high point is located anywhere else. NOTE: If the unit will be expanded in the future, check for a higher point in the expansion area. If found, set the rail assembly 1/4 above the expansion area high point. Wall cross-section 2-1/2" + Depth of Stationary Base 990036.002 Socket Head Leveling Setscrew Half Dog Point 5/16" - 18 x 1-1/2" (4) Floor cross-section 9
Installation Leveling Stationary Bases 1. Position a stationary base over the edge of the back rail assembly. The stationary base has a notched spacer channel that will mate with the rail edge. NOTE: The appliance leveler is completely raised in the stationary base at this point. NOTE: Use a 1/4 square Apex socket to adjust the appliance leveler. 2. Adjust the appliance leveler closest to the rail until the notch from the spacer channel begins to lift off the rail. 3. Place a torpedo level on the stationary base section and raise the opposite end until level. 4. Repeat steps 1, 2, and 3 with each stationary base section, distributing them along the rail near their final location. Notched Spacer Channel Stationary Base (3) Back Rail Adjusting Leveler Location Stationary Base (3) 960210.001 Appliance Leveler (6) 3/8-16 x 2-1/4" 10
Installation Assembling Stationary Bases NOTE: A specially designed tab and hole interlocking system is used to attach many of the following pieces. Use a rubber or dead blow mallet to assemble. 1. Using the interlocking system, attach a stationary end piece with two of the previously installed stationary bases. Tap into place with a rubber or dead blow mallet. 2. With all stationary bases assembled, set one stationary base end 1-9/16 from the rail end. 3. Connect stationary bases using a optional spacer plate and the interlocking system. Tap into place using a rubber or dead blow mallet. 4. Set the cover plate between the stationary base and rail assembly. Using self-tapping screws, fasten the cover plate to the stationary base spacer channel. 960180.001 Self-Tapping Screw #10-32 x 1/2" Cover Plate (9) 1-9/16" Interlocking System Spacer Plate (8) Stationary Base End (7) Hole Tab 11
Installation Assembling Floor and Ramp 1. Insert floor sections between the assembled rails. The under side of each floor section has a routed slot that attaches to a formed rail. A slot is also routed across the end of each floor section. Tap a biscuit type splice plate into the center of each slot. The next floor section will share this splice plate producing a stabilized joint between floor sections. 2. Use a rubber or dead blow mallet to avoid damage to the floor sections. Tap the end floor section until it is aligned with the end of the rail assembly. 3. Slide ramp section from the side onto the front rail. If space does not permit, floor section may be raised slightly allowing the ramp to slip into place from the front. 4. Ramp sections are held together at the splice using two tension pins. Tap each pin about half way into one ramp. Engage the next ramp section and tap the joint closed. 5. Fasten ramp end caps with sheet metal screws using the same openings as the tension pins. 38199.01 Biscuit Type Splice Plate (11) 1/8 x 3/4 x 6" Floor Section (10) Ramp (12) 91011.02 Tension Pin (13) Ramp End Cap (14) 96002.02 Sheet Metal Screw Pan Head Phillips #6 x 3/4" 12
Installation Assembling Moveable Carriage NOTE: The reinforcement block is attached to the first and last moveable carriages only, located on the extreme left and right of the moveable carriages directly over the back rail. The reinforcement block serves as part of the In-Rail end stop. 1. Install the reinforcement block to the movable carriage section with the center flange wheel using a machine screw. 2. Place the moveable carriage section with the flat wheel on the front rail closest to the ramp. 3. Place the moveable carriage section with center flanged wheel and reinforcement block, previously installed on the back rail, closest to the stationary bases. Center wheel flange and reinforcement block will rest in the rail slot groove. 4. Using the interlocking system, attach side cover to the moveable carriage sections. Repeat on opposite side. Moveable Carrige Section w/flat Wheel (17) Moveable Carrige Section w/center Flange Wheel (16) Moveable Carrige Side Cover (18) 96023.01 Flat Head Phillips #8-32 x 1/2" 550392.001 Reinforcement Block (24) 13
Installation Assembling Moveable Carriage (continued) 5. Moveable end covers are attached to each moveable carriage to cover the wheel mechanism. Interlock one end in place and use a slotted screwdriver to slightly pry the other end into place. Once aligned with the holes, tap the cover into place using a rubber or dead blow mallet. NOTE: Hardware field assembly is required for end stop installation. See Hardware Identification page 3. 6. The In-Rail end stop assembly slides into the rail end cavity and is secured into place by turning the setscrew. Set the end stop so the moveable carriage end is in alignment with the stationary bases end upon stopping. Repeat steps 5 & 6 for the moveable carriage on the opposite end. NOTE: This installation sequence does not cover assembling the shelving. For detail on shelving see OP-0039 4-Post and CASE Style Shelving Installation. Tighten to secure In-Rail End Stop End Stop Assembly (5) (Field Assembled) (93017.01 and 99026.01) Moveable Carriage End Cover (19) 14
Installation Assembling Stationary Shelving 1. Set shelving on top of the stationary bases. Attach the stationary side cover by interlocking one end in place and use a slotted screwdriver to slightly pry the other end in to place. Once aligned with the holes, tap the cover in place using a rubber or dead blow mallet. NOTE: The stationary side cover prevents the shelving from moving side to side. 2. The optional filler channel must be bent 90 degrees. The long side of the filler channel fits between the stationary shelving sections at the front. The short side of the channel fits between the stationary shelving sections across the top. Always align the channel with the top of the shelving. The channel may have to be trimmed on the long side for special height shelving. 3. Attach a filler channel between each static section of shelving. Fasten filler channel in three locations on each side of shelving and twice at the top side using Tek screws. 4. Attach the stationary bracket to hold the shelving in place from front to back. Fasten one bracket on each side of the stationary base using pan head screws. Located inside Stationary Shelving Filler Channel Stationary Shelving 960216.001 #10 x 5/8" Hex Head Tek Screw Stationary Side Cover (20) 96116.02 #10-24 x 1/2" Pan Head Phillips Stationary Bracket (21) 550366.001 15
Installation Assembling Stationary Shelving (continued) 5. Secure the shelving in place using Tek screws at each bracket location. 6. Place the soft cover bumper over the stationary bracket rivet and slide down into place. Secure cover at the bottom using pan head screw. 7. Secure the shelving to the stationary base at each rear corner using Tek screws. NOTE: Floor end cover protectors are specific to the right and left floor sides. 8. Fasten the center of the floor end cover protector to the floor section with a wood screw. Secure floor end cover to rail assembly using self-tapping screws at the four outside holes of the floor end cover. Check the fit. Repeat on opposite side. 960216.001 #10 x 5/8" Hex Head Tek Screw Stationary Bracket (21) 550366.001 Soft Cover Bumper (22) 960216.001 #10 x 5/8" Hex Head Tek Screw 96116.02 #10-24 x 1/2" Pan Head Phillips 960180.001 Self-Tapping Screw #10-32 x 1/2" Floor End Cover Protector (15) 96047.02 Wood Screw Pan Head Phillips #8 x 3/4" 16
Installation Assembling Moveable Carriage Bracket NOTE: Each moveable carriage requires two stationary brackets and two moveable brackets. All four corners of a moveable carriage will require brackets. The stationary brackets prevent the shelving from moving side to side and serve as an In-Rail anti-tip device. 1. Slide the moveable bracket into the rail groove, turn it 90 degrees and then fasten it to the center flange wheel section using pan head screws. Fasten the stationary bracket using a pan head screw. Repeat on opposite side. 2. Secure the shelving using Tek screw at one of the top two holes in the stationary and moveable brackets. 3. Attach the soft cover bumper over the stationary bracket rivet and then slide down into place. Use a pan head screw to fasten the cover at the bottom. 960216.001 #10 x 5/8" Hex Head Tek Screw Moveable Shelving Moveable Bracket (23) Stationary 550363.001 Bracket (21) 550366.001 960216.001 #10 x 5/8" Hex Head Tek Screw 96116.02 #10-24 x 1/2" Pan Head Phillips Soft Cover Bumper (22) Step 2 Step 1 17
Installation Assembling Bi-File and Tri-File Overhead Anti-Tip NOTE: Angle brackets and field assembled hardware from page 4 (Bi-File ) and 5 (Tri- File ) are installed as part of an overhead anti-tip device. When moveable shelving reaches a certain height an overhead Anti-tip device must be incorporated. The field assembled bracket bridges the space between the moveable shelving carriage and the stationary shelving. 1. Using Stationary Hardware from page 4, attach angle brackets to an open channel section designed to accommodate both Bi-File and Tri-File overhead anti-tip systems. The opening in the angle bracket is slotted for adjustment. 2. The channel and bracket assembly attaches to the shelving by sliding into the opening at the top of the shelving upright. The lower side of the channel always faces front. 3. Once the brackets are fully seated into the shelving uprights, secure them into place. Each bracket contains multiple threaded screw holes. Select the hole which lines up nearest the bottom of the upright keyhole and fasten at this location with a pan head screw and washer. Angle Bracket 401198-001 Open Channel Section 94017.05 1/4" Washer 93015.02 Keps Nut 1/4-20 95016.03 Carriage Bolt #1/4-20 x 1/2" 94017.03 #10 Flat Washer 96004.02 Pan Head Phillips #10-32 x 3/8" 18
Installation Assembling Bi-File and Tri-file Overhead Anti-Tip (continued) 4. The field assembled anti-tip (angle bracket with bearing) is attached to the moveable shelving carriage in similar fashion as in the previous three steps. Align the bracket and roller guide as shown below. 5. The Tri-File field assembled anti-tip hardware detailed on Page 5 is attached in the same way as steps 2-4. Orient the bracket and roller guide as shown below. Tri-File Feild Assembled Anti-Tip Hook Assembly Bi-File Feild Assembled Anti-Tip Hook Assembly 94017.03 #10 Flat Washer 96004.02 Pan Head Phillips #10-32 x 3/8" 19
System Expansion Expansion installation NOTE: The following information deals only with the additional steps required for adding moveable carriages to either the length or depth of an existing system. Customers may expand their systems in either way. A basic Bi-File system will begin with two stationary bases and one moveable carriage. This system may be expanded to any practical length, as long as there is one fewer moveable carriages than stationary bases. Systems are also available in a Tri-File configuration. Tri-File places an additional rail assembly and row of moveable carriages in front of the existing Bi-File. NOTE: The universal strap shown is used in a variety of different applications. Expanding Bi-File Length 1. Assemble the rail expansion sections to be used. Refer back to Rail Assembly, pages 8 & 9. 2. Place two universal straps as shown. Align expansion rail and existing rail assemblies so that the ends butt up next to each other. Fasten them to the end of the existing rail assembly using self-tapping screws. 3. Elevate the Bi-File rail assembly to match the existing rails. Placing a carpenters level across both rail assemblies, level the expansion rails to the same elevation as the existing rail assemblies. Universal Strap 960180.007 Self-Tapping Screw #10 x 3/8" Existing Rail Expansion Rail 20
System Expansion Expanding Bi-File to Tri-File NOTE: In all cases leave screws loose until alignment is confirmed. Once alignment is confirmed, tighten screws in a random sequence. The following configuration is done at each end of rail assemblies. 1. Assemble the rail expansion sections to be used. Refer back to Rail Assembly, pages 8 & 9. 2. Place two universal straps as shown. One universal strap on the existing rail assembly and one on the expansion rail assembly. Insert self-tapping screws in the holes nearest the end of the rail assemblies. 3. Elevate the Tri-File rail assembly to match the existing rails. Placing a carpenters level across both rail assemblies, level the expansion rails to the same elevation as the existing rail assemblies. 4. Place a third universal strap to span between the rail assemblies. Fasten strap to the underside of the previously installed universal straps using self-tapping screws. Considerable pressure must be applied when threading the screws into the universal straps. Use shim stock of some sort to hold the lower strap in place. 5. Set the decorative channel into place between the two rail assemblies. 6. Once alignment is confirmed, tighten all screws to secure rail assemblies together. Existing Rail Decorative Channel Universal Strap 960180.007 Self-Tapping Screw #10 x 3/8" Expansion Rail 21
System Expansion Expanding Tri-File Length NOTE: In all cases leave screws loose until alignment is confirmed. Once confirmed, tighten them in a random sequence. The following configuration is done at each end of rail assemblies. 1. Assemble the rail expansion sections to be used. Refer back to Rail Assembly, pages 8 & 9. 2. Place three universal straps as shown. Fasten them to the existing rail assembly using self-tapping screws. Align expansion rail and existing rail assemblies so that the ends butt up next to each other. 3. Placing a carpenters level across both rail assemblies, level the expansion rails to the same elevation as the existing rail assemblies. 4. Place a forth universal strap to span between the rail assemblies. Fasten strap to the underside of the previously installed universal straps using self-tapping screws. Considerable pressure must be applied when threading the screws into the universal straps below. Use shim stock of some sort to hold the lower strap in place. 5. Once alignment is confirmed, tighten all screws to secure rail assemblies together. Existing Rail Decorative Channel Universal Strap 960180.007 Self-Tapping Screw #10 x 3/8" Expansion Rail 22
Note Section 23
Note Section Spacesaver Corporation a division of KI U.S.A.: 1450 Janesville Avenue, Fort Atkinson, WI 53538-2798, (920) 563-6362, 1-800-492-3434, FAX: (920) 563-2702 CANADA: 266 King Street East, Toronto, Ontario M5A 4L5, (416) 360-1022, 1-800-544-3679, FAX: (416) 360-7290 UK: Commonwealth House, 148-153 High Holborn, London WC1V 6PJ, (020) 7404-7441, FAX: (020) 7404-7442 WEBSITE: www.spacesaver.com E-MAIL: ssc@spacesaver.com Copyright 2001, Spacesaver Corporation. All rights reserved. 24 OP-0304