GearBoss Shelving System - Wenger Corporation

SAFETYThroughout this manual you will find Cautions and Warnings. They are defined as follows:• Warning; failure to follow the instruction may result in serious injury or death.• Caution; failure to follow the instruction may result in injury or damage to property.Note: Read all safety instructions before using or installing the GearBoss shelving system.GENERALCautionCautionINSTALLATIONCautionCautionCautionCautionInstallation and use of the GearBoss shelving system must comply with theinformation in the section Important End User Information, Intended Use on page 3 ofthis manual.Those using the GearBoss shelving system must observe and comply with warningsand cautions posted on the System equipment.Always wear safety glasses and safety shoes when assembling the GearBossshelving system.Make sure that anyone who helps assemble the GearBoss shelving system has readand understands this manual.Some assembly steps require that two or more persons work together. Somecomponents are difficult to handle alone.Inferior or improperly installed fasteners could cause sudden collapse of theGearBoss shelving system shelving system.GENERAL USAGECautionCautionWarning!CautionCautionNever place more than 200 lbs. on a single GearBoss shelf.Never place more than 1000 lbs. on all shelves in a single 48” section of GearBoss.Never hang from or climb on GearBoss.Always load items on GearBoss carefully, never throwing or dropping heavy items inplace.Overloading or shock-loading GearBoss could cause a collapse, resulting in propertydamage or serious injury.2

WARRANTYThe GearBoss Shelving System is guaranteed free of defects in materials and workmanship for ten fullyears.Our guarantee assures you of either a full refund, repair or replacement of the defective materials orworkmanship without charge, at the discretion of our Customer Service Department. Just call aCustomer Service Representative at 1-800-887-7145 and state the reason you are dissatisfied. If aproduct return is necessary, your representative will issue a return authorization. This is your soleremedy for breach of this warranty.Should you have a question or problem with any Wenger product, don’t hesitate to call, even if theproduct is past warranty. It’s important to us that all of our customers are satisfied.This is the sole warranty made by Wenger. Wenger disclaims all other warranties, including thewarranties of merchantability and fitness for a particular purpose, as well as all liability for incidental,consequential, special, and indirect damage. Wenger liability for direct damages shall be limited to theamount you paid for the product involved. Wenger reserves the right to make product changes withoutobligation to incorporate such changes into products previously sold.Some states do not allow the exclusion or limitation of damages or warranties, so the above may notapply to you. This warranty gives you specific legal rights. You may also have other rights which varyfrom state to state.IMPORTANT USER INFORMATIONINSTALLATION• The GearBoss Shelving System must comply with local building regulations and codes.• All personnel (including all temporary workers) installing the GearBoss shelving system must readand understand this entire manual.• Personnel installing the GearBoss Shelving System must comply with the Warnings and Cautions inthe Safety Section.INTENDED USE• The GearBoss Shelving System is intended for indoor use in normal, ambient temperature andhumidity conditions.• The GearBoss Shelving System is intended to be installed only as described in this manual.MAINTENANCE• Clean the GearBoss Shelving System with a mild detergent. Avoid using harsh or abrasive cleaningproducts.• Check wing nuts and shelf tubes periodically to ensure they have not loosened or dislodged.3

REQUIRED TOOLSThe following tools must be supplied by the installer to assemble the GearBoss shelving system.Phillips Drive BitCombination WrenchClampCordless DrillNumber 2B PencilLevelTape Rule50-foot Chalk LineMalletFASTENERSBecause materials and construction of floors and walls can vary, fasteners for attaching the GearBossshelving system to the structure are not provided. The installer must choose the appropriate fastenerand follow the manufacturer’s directions.Warning: Inferior or improperly installed fasteners could cause sudden collapse of the GearBossshelving system. Serious injury or damage to property may result.GearBoss shelving system fastener guidelines:• If the floor is wood construction, attachment should be by sheet metal or lag screws (#10minimum).• Ιf the floor is concrete, attachment should be by Concrete screw (Tapcon), or sheet metal screws(#10 minimum) into metal or plastic inserts.• Ιf the wall is wood stud-and-drywall construction, attachment should be by lag screws (1/4”minimum) into every stud.• Ιf the wall is metal stud-and-drywall construction, attachment should be by toggle bolt (1/4”minimum) into every stud.• Ιf the wall is concrete block construction, attachment should be by Concrete screw (Tapcon) ortoggle bolt (1/4” minimum), spaced no more than 16” apart.• Ιf the wall is poured concrete construction, attachment should be by Concrete screw (Tapcon) orwedge-type concrete anchors, spaced no more than 24” apart.Note:Each wall connection must be rated for a minimum of 500 lbs tension. Other fasteners may beappropriate if the tension requirement is met.4

PARTS LIST12312413591410768Item Description Item Description1 Upright Tube, 8’ 10 Marking tool Plate2 Shelf Support Bracket 11 Screw, Drill/Tap, 1/4-14 X 3/4 (not shown)3 Tube Support Bracket 12 Cap-screw, 3/8-16 X 2 3/44 48” Shelf Tube 13 Divider Wing Nut, 3/8-165 Shelf Bracket, 30 1/2”, RH 14 Shelf Plug Half6 Shelf Bracket, 30 1/2”, LH 15 Carriage Bolt, 1/4-20 X 1 1/4 (not shown)7 Shelf Bracket, 17 1/2”, RH 16 Carriage Bolt, 1/4-20 X 2 1/2 (not shown)8 Shelf Bracket, 17 1/2”, LH 17 Wing Nut, 1/4-20 (not shown)9 Shelf Extrusion Assembly5

DESCRIPTIONGEARBOSS SHELVING SYSTEMUpright TubeShelf Bracket, 30 1/2”, RHShelf Support Bracket48” Shelf TubeWallExtrusion AssemblyTube Support BracketFloorINSTALLATIONBEFORE STARTING THE ASSEMBLYBefore installing the GearBoss, do the following.1. All personnel, including temporary personnel, must read and understand this entire manual.2. Inventory the cartons and make sure the tube support brackets and all required components arepresent.3. Determine which floor and wall fasteners are needed (see page 4) and purchase them.4. Before beginning the installation, move the cartons near the location where the GearBoss Shelvingsystem will be installed. Refer to any architectural drawings supplied by Wenger or a contractor.5 Make sure the area is free of any obstacles or obstructions.Warning:Warning:Warning:Personal injury or damage to property may result if the instructions in this manualare not followed.Some components are awkward to handle. Serious injury or property damage mayresult if only one person attempts the installation.Always wear safety glasses and safety shoes when installing the GearBoss shelvingsystem.6

INSTALLATION (CONTINUED)LAYOUT AND TUBE SUPPORT BRACKET ATTACHMENT6. Based on the architectural drawings, layout the location of the tube support brackets. Place thetube support brackets tight with the back wall and side wall when starting in the corner.(Detail A provides measurement guidelines.)7. Mark holes of the tube support brackets on the floor.8. Secure the tube support brackets to the floor.48” (122 cm)Back WallSideWall48” (122 cm)Top ViewDetail A7

INSTALLATION CONTINUEDINSTALLING THE SHELF SUPPORT BRACKET9. To determine the location of the shelf support bracket, placethe upright tube onto the tube support bracket and position uprightagainst the wall.10. Using the marking tool plate, mark the wall at the bottom edge of themarking tool plate (Detail B).11. Continue previous step until all upright tubes have beenmarked.MARKHEREDetail B12. Snap a chalk line across the two highest marks.Note: If there is more than 1” discrepancy between the chalk line and the lowest mark, contactWenger Corporation for further instructions.Note: If the wall is stud construction, mark the location of each stud along the chalk line.Stud LocationsChalk LineWallFloor8

INSTALLATION (CONTINUED)INSTALLING THE SHELF SUPPORT BRACKET (CONTINUED)13. Place the first upright tube on it’s support bracket. Using a level to keep the upright tubevertical, make a V-mark on the chalk line 1 1/4” to the left of the upright tube.1 1/4”Chalk LineV-MarkUpright TubeWallRemove the upright tube from it’s support bracket.14. Hold the shelf support bracket with it’s bottom edge on the chalk line and it’s left end atthe V-mark.If the wall is masonry construction, locate the first shelf support bracket here, referring tothe fastener guidelines on page 4.If the wall is stud construction, it may be necessary to (1) move the shelf support bracketto the left until the punched holes align with the studs or (2) drill holes in the shelfsupport bracket to align with the studs.Warning: With stud wall construction, a fastener must be installed in every stud. Refer tothe fastener guidelines on page 4.Chalk LineMove shelf support bracket if necessary.V-MarkFastenersShelf Support BracketEach additional shelf support bracket must overlap the previous one so the end holesalign. If the last shelf support bracket is too long, it may be cut off 1” past the last uprighttube.Shelf Support BracketOverlap & Align Holes9

INSTALLATION (CONTINUED)INSTALLING THE UPRIGHT TUBE15. Place the tube support bracket at the top of the upright tube.Tube Support BracketUpright Tube16. Position the upright tube onto the tube support bracket anchored to the floor (Detail C) and tip theupright tube under the shelf support bracket.17. Using a level, make sure the upright tube is vertical in both directions.18. Clamp the tube support bracket onto the shelf support bracket. (Detail D)19. With self tapping screws (item 11), screw the tube support bracket to the shelf support bracket.Detail DClampLevelDetail C20. Repeat steps 15-19 until all upright tubes have been installed.10

SHELF ASSEMBLY/INSTALLATIONTo Assemble the shelf:21. Determine the desired location of the shelf on the upright tube.22. Position the shelf bracket on the inside of the upright tube.23. Insert the cap-screw (item 12) through the upright tube and shelf bracket, and secure it using thedivider wing nut (item 13).24. Repeat on the opposite upright tube. Make sure the shelf brackets are even, to ensure a level shelf.The best way to determine the exact location is to count the number of holes in the upright tube.25. Line up the shelf extrusion assembly to the end of the shelf brackets. Lightly tap the shelf extrusionassembly ends with a mallet until they snap into place. Make sure the shelf extrusion assembly tabis locked into place on the shelf bracket. (Detail E)26. Using carriage bolt (item 15) and wing nut (item 17), fasten the shelf extrusion assembly to the shelfbracket. (Detail F)Note: If shelves are located side by side on the upright tube, refer to page 12 for fasteninginstructions.Detail F12513151769Detail E11