Levrack Assembly Instructions

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INSTALLATION GUIDE

If you require Shipping assistance, please contact ship@levrack.com Or Direct: (402) 875-9466 If you have Assembly questions or need additional support, contact support@levrack.com Or Direct: (402) 875-9466 Ext 2 All other inquiries can be sent to info@levrack.com Visit our Levrack YouTube channel for more detailed installation videos at: www.youtube.com

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Index Section

Page

LEVRACK KIT ASSEMBLY

3-19

ACCESSORIES

20-33

WORKSTATIONS

34-38

Levrack Kits

Accessories

Workstations

Page 3

Levrack Kit Assembly

Assembly steps covered in this guide can be replicated to achieve any of the configurations below.

7ft Kits

15” 15” 15”

8ft Kits

15”

18”

10ft Kits

18”

18”

18”

18”

18”

15” 15”

12ft Kits

18”

18”

Back to Index

18”

18”

18”

18”

18”

LEVRACK KIT

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TABLE OF CONTENTS Section Tools Required

Page 4

Component Identification

5-7

Assembling Pallet Racking

8-9

Wire Deck

10

Lighting

10

Guide Wheels

11

Trolley Mounting

12

Back Panels

13-14

Upright Panels

15

Shelf Supports and Shelving

16

Handles

17

Bumpers *optional*

18

Alignment Adjustments

19

TOOLS REQUIRED Tape Measure 6’ Step Ladder 4’ or 6’ Level Anchors for Pallet Racking Ratchet with 7/16, 3/4 and 9/16 Deep and Shallow Sockets Torque Wrench 9/16 Combination Wrench Hammer and Mallet Cordless Drill with Assorted Driver Tips

LEVRACK KIT

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Part Identification P1

P2

P3

S1

Pallet Rack Upright

Pallet Rack Beam

Wire Decking

Trolley

S2

S3

S4

S5

4- Post Upright

Shelf Support

Steel Shelf

Shelf Reinforcement

LEVRACK KIT

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Part Identification A1

A2

A3

A4

Handle

Hole Plug

Back Panel

LED Light

A5

A6

Bumper

Tek Screw Pan Head

Optional (Not Required)

Optional (Not Required)

NOTE: Handle flexible Back Panel with care.

Bag Number 1012154.01

Bag Number 960213.001

LEVRACK KIT

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Part Identification H1

H2

H3

H4

Carriage Bolt 3/8 x 1

Flange Nut 3/8

Screw #10 x 1 ½

Nylon Spacer 1/2

Bag Number 1020676.01

Bag Number 93005.02

Bag Number 96004.05

Bag Number 1011993.01

H5

H6

H7

H8

Keps Nut 10-32

Hex Bolt ¼ x .5

Washer 1/4

Hex Head #10 Screw

Bag Number 93015.01

Bag Number 95002.11

Bag Number 94017.05

Bag Number 960216.001

H9 Washer #10

Bag Number 94017.03

Assembling Pallet Racking Choose your location to install the LEVRACK. P2 Install the front and rear pallet rack beams. Insert the rivets into the uppermost keyholes. You may need a dead blow hammer to properly seat the rivets.

P2 P1

Make sure the safety tab engages into the key hole on the upright to prevent the beams from dislodging.

P1

If you are installing beams onto existing pallet racking, the top of the beam will be either 84” or 96” above the floor.

The Pallet Racking frame is made up of: QTY (2) Pallet Rack Uprights (P1) QTY (2) Beam Rails (P2) Remove protective film from LEVRACK logo after beams are installed.

The pallet rack uprights and beams are heavy. Use team lifting to handle these components.

Use caution when working on ladders or performing overhead work.

LEVRACK KIT

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LEVRACK KIT

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Assembling Pallet Racking

A

B

Square the pallet rack uprights. The easiest way to accomplish this is to measure diagonally between the legs and adjust until A and B are equal.

The pallet rack beams must be level, within 1/8” left to right and front to back.

Shim the pallet rack uprights as necessary.

If anchoring is required, use thruholes provided on footpad of each pallet rack post.

Anchor size and type will be determined by a structural engineer, local site conditions, requirements or by governing code. The pallet rack footpad has 0.625” holes.

LEVRACK KIT

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Wire Deck and Lighting P3

Place P3 Waterfall Deck on top of pallet rack beams.

Optional: Use Tek Screw H8 and Washer H9 to secure Wire Decking to the Beam.

Hang the light under the waterfall wire deck using the chain and “S” hooks provided with the light.

Hang the A4 light as tight to the deck as possible to reduce the chance of hitting it when using your LEVRACK Tie power cord to waterfall wire deck so the cord doesn’t interfere with travel of the trolleys.

A4

Failure to properly tie up the light’s power cord could result in damage to the cord and personal injury.

Guide Wheel Installation Item 1. Hex Head Cap Screw 5/16-18 x 2.75” Guide Wheel Screw P/N: 31C275HCS5Z

Item 2. Guide Wheel Item 3. Nylon Spacer P/N: 37N550SPN

Item 4. Guide Wheel Washer 5/16” P/N: 31NWSAZ

Item 5. NyLock Nut 5/16-18” P/N: 31CNNEZ

1. Insert ITEM 1 Bolt into ITEM 2 Guide Wheel.

2. Insert ITEM 3 Spacer onto bottom side of ITEM 2 Guide Wheel over ITEM 1 Bolt.

3. Install Bolt, Guide Wheel, and Spacer into open holes on top side of Trolley Bracket.

4. Fasten ITEM 1 Bolt from the bottom side of Trolley Bracket using ITEM 4 Washer and ITEM 5 Lock Nut. 5. Repeat Steps 1-4 for each of the (4) Guide Wheels.

Torque Requirements: DO NOT EXCEED 5-7 ft-lbs of Torque.

Guide Wheels should NOT compress Spacer. Guide Wheel should be secure and free to rotate without resistance. Guide Wheels are vital to keeping trolleys aligned.

Bolt Guide Wheel Spacer

Washer Lock Nut

LEVRACK KIT

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LEVRACK KIT

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Installing Trolleys

3.

2.

1. Lift S1 Trolley under pallet rack beams.

2. Set fixed wheel bracket over rail.

3. Slide adjustable wheel bracket over opposite rail.

4. Torque from the bottom.

5. Assure guide wheels stay in contact with Beam Rail as Nuts are torqued.

Check Trolley Alignment Ensure guide wheels are tight against beam angle, and the trolley is square to the beams.

Torque the adjustable guide wheel bracket to 55—60 ft/lbs.

Bottom Side of Trolley

LEVRACK KIT

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Back Panel

NOTE: Because an unsupported back panel is a very flexible item, it is recommended that they be handled with extreme care to keep from possible bends and creases.

When moving a back panel it is recommended that you carry it according to the following illustration.

Fasten the Back Panel A3 to the Trolley S1 Pass machine screw H3 through Back Panel A3.

Slide on spacer H4.

Pass machine screw H3 through Trolley S1 and install Kep Nut H5

H5

H4

H3

S1

Back Panel When installing a Levrack next to wall or obstacle be sure to allow for space/clearance for Upright Panel S2 Installation on each side of Trolley S1

Check Back Panel placement.

Back Panel placement drives the configuration moving forward.

For recommended “pod” configuration, mount Back Panels opposite one another as pictured.

LEVRACK KIT

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LEVRACK KIT

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4-Post Upright

Attach S2 Upright Panels to the trolley S1.

Use (2) each per upright: H1 Carriage Bolt H2 Flange Locking Nut Torque to 20—25 ft/lbs.

H2

H1

Shelf Installation Installation of Shelf Supports S3 will hold and lock the Back Panel into place.

Install (4) pair of S3 Shelf Supports per shelving section.

Insert rivets into keyholes and drive down with a mallet hammer until seated.

Make sure each pair of supports are level side to side and front to back.

Place (1) S5 Shelf Reinforcement on each pair of Shelf Supports NOTE: Shelf Reinforcements are not necessary for 15” shelf depths.

Place (1) S4 Steel Shelf on each pair of Shelf Supports

LEVRACK KIT

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LEVRACK KIT

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Attaching Handles

Add (1) A1 Handle to each upright.

Use (2) each: H6 Bolt H7 Washer Plug remaining handle holes.

Use (2) each: A2 Hole Plug

A2 H6 H7

A1 Handle

Bumpers

LEVRACK KIT

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*Bumpers are not required but optional. Bumpers will impact aisle width and create a gap between mobile shelving units.*

1.

Bumper Installation: 1. Pre-Drill in desired bumper location with a 3/32” Steel Bit. 2. Insert Pan Head Phillips Screw (A6) through bumper (A5).

3. Use Impact/Screw gun to drive bumper into secured position.

2.

3.

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Adjustments Check that the following items are correct for best function and aesthetics.

2

1

1. Upright Frame and Beams need to be level left to right and forward to back.

3

3. Ensure that trolley wheel brackets are square and properly torqued.

The face of trolley should be parallel to face of beam.

2. Pallet Racking should be square.

Installing wire decking before trolleys helps accomplish this.

4

4. Upright panel fasteners can be loosened and retorqued to relax tension on shelving unit.

LEVRACK KIT

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Page 20

Accessories

Back to Index

Page 21

Accessories

Page

Drawers

22

Bucket Shelf

23

Wire Basket

24

Slatwall (Internal)

25

Slatwall (External)

26

Back-Slat Bracket

27

Hanger Rail

28

Bin Rail

29

Locking Handle

30

Locking Door

31

Locking Arm

31

Receiver Hitch Bracket

32

Gator Hooks

33

ACCESSORIES

TABLE OF CONTENTS

Page 22

Drawers

1A: Install front and rear brackets opposite one another at the same height.

F = Front, R = Rear A = A side, B = B side 1B: Install self tappers to lock rear bracket into position.

Step 2.

Install rails with (3) slot spacing for 6” drawer stacking. Repeat on opposite side.

3 Slots Visible

Step 3.

3 Slots Visible

Install Drawers Front “FA”

Rear “RA”

“FB”

“RB”

Opposite

Opposite

RA Bracket FA Bracket

ACCESSORIES

Step 1.

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1. Internal Bucket Shelves nest directly into Shelving Cabinet using (2) Shelf Supports.

2. Shelf Supports should be staggered by 2 key-slots or 3 inches front to back for best fit.

3. Adjustable Dividers can be added to optimize organization.

3” Height offset in Shelf Supports.

Adjustable Dividers

ACCESSORIES

Bucket Shelving

Page 24

1. Wire Baskets nest directly into Shelving Cabinet using (2) Shelf Supports

ACCESSORIES

Wire Basket

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1. Internal Slatwall integrates directly to the 4Post Upright Key-slots using a Pressed Rivet that is pre-installed into the Slatwall.

2. It is best to start on the bottom. Additional Slatwall sections can then be inserted and stacked as needed.

Pressed Rivet

Key-Slot

ACCESSORIES

Slatwall (Internal)

Page 26

1. External Slatwall mounts on the exterior of the Levrack Kit using bolts or self-tapping screws.

2. Position and level first Slatwall section to the desired surface.

3. Use Thru-Holes on Slatwall panel and Self-Tapping Screws provided to mount.

Note: The Thru-Holes do not align with square slots in Pallet Racking Upright. The Self Tapping screw is designed to drill and position itself anywhere on the surface.

ACCESSORIES

Slatwall (External)

Page 27

Back-Slat Brackets are used to mount Slatwall or Bin Rails between Pallet Rack Uprights in a 4ft Configuration

Right Bracket Left Bracket

1. Back-Slat Brackets can be mounted to the Pallet Rack Upright Frame using a pressed Lance feature.

2. Brackets are sold as pairs, one Left and one Right.

3. Safety Bolts and Nuts are provided to ensure that the Lance Feature remains seated.

Safety Nut

Safety Bolt

Lance Feature

Bracket Pair

ACCESSORIES

Back-Slat Bracket

Page 28

• Each Hanger Rail comes with (2) Mounting Brackets • Mounting Brackets utilize Rivet-Nuts to interface with Key-slots on interior of Shelving Unit.

*Additional Hanger Rail can be used to create a parallel storage surface*

ACCESSORIES

Hanger Rail

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1. Bin Rails integrate directly into 4-Post Upright Key-slots using a Pressed Rivet.

2. Stackable Bins hang from Bin Rail *BINS NOT INCLUDED*

ACCESSORIES

Bin Rail

Page 30

1. Locking Handle Brackets mount behind the Handle using the same ¼ Hex Bolts used to mount Handle

ACCESSORIES

Locking Handle Brackets

Page 31

Left and Right-handed Locking Doors are available to close out and secure the entire system. *Additional Installation Guide available for Locking Doors*

The Locking Arm is an optional safety feature used to hold aisle spacing and prevent cabinet movement. *Additional Installation Guide available for this Locking Arm Bracket

ACCESSORIES

Locking Door

Page 32

Receiver Hitch Bracket Install Steps: 1. Attach Receiver Bracket to Pallet Racking Upright Frame at desired height.

2. The Bracket can be flip to mount on opposite side.

3. Use Carriage Bolt and Flange Nut provided to secure Bracket to the Upright Frame.

4. Only (1) Carriage bolt will be used.

Flange Nut

Receiver Mount

Carriage Bolt

5. Slide and pin Receiver Hitch accessory into place 2” Receiver Accessory *NOT INCLUDED*

ACCESSORIES

Receiver Hitch Bracket

Page 33

We’re in the business of maximizing space, which is why we collaborated with Gator Magnetics to bring you the Gator x Levrack 2.5” & 4” Hook.

Stick it anywhere and hold anything. With 25lbs of capacity and a quick release feature, these magnets are a great addition to any Levrack system. The Gator Hook is compatible with every size Levrack.

ACCESSORIES

Gator Hooks

Page 34

Workstations

Back to Index

Page 35

TABLE OF CONTENTS Page

Workstation Standard

36

Workstation PLUS

37

Workstation Mobile

38

WORKSTATIONS

Workstations

Page 36

1. Workstation Top nests directly on top of Pallet Rack Beams.

2. Apply Vinyl Foam Tape to top side of beam in all 4 corners to eliminate sliding and increase dampening.

Workstation widths available in 30”, 36”, and 48” configurations. Lengths include 4ft and 8ft.

Workstation Top

Vinyl Foam Tape

Pallet Rack Beam

Pallet Rack Upright

WORKSTATIONS

Workstation Standard

Page 37

1. Workstation Top drops in directly on top of Pallet Rack Beams between Upright Frames 2. Apply Vinyl Foam Tape to top side of beam in all 4 corners to eliminate sliding and increase dampening.

Workstation widths available in 30”, 36”, and 48” configurations. Lengths include 4ft and 8ft.

Workstation Top

Vinyl Foam Tape

Pallet Rack Beam

Pallet Rack Upright

WORKSTATIONS

Workstation Plus

Page 38

Mobile Workstation Installation Steps: 1. Install Casters to Foot plate using hardware provided.

2. Repeat for all (4) Corners and Casters.

3. Install (4) Beams into front and back side of Upright Frames.

4. Insert Wire Decking into bottom level.

5. Install Workstation top on to the top side of frame.

Top will nest onto frame with no fasteners required.

Workstation widths available in 30”, 36”, and 48” configurations. Lengths include 4ft and 8ft.

2.

1.

4.

Apply Vinyl Foam Tape to (4) corners

3.

5.

WORKSTATIONS

Workstation Mobile