Gearboss X-Cart Owner's Manual

High-density storage system
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Contents
Important User Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
General � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Manufacturer � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Intended Use � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Warranty � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Safety Precautions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
General � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
General Usage � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
Parts Lists � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Carts � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Wire-grille End Panel � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Cart Hardware Pack Components � � � � � � � � � � � � � � � � � � � � 5
Cart Hardware Pack Supplied Hardware � � � � � � � � � � � � � � � 5
Cart Knuckle Pack Components � � � � � � � � � � � � � � � � � � � � � � 6
Cart Knuckle Hardware Pack Supplied Hardware � � � � � � � � 6
Floor Track and Hardware� � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Track Stop Bracket � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Adjustable Track Lock � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Description� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
X Cart � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
Team Cart � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
Floor Track � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
Track Stop and Adjustable Track Lock � � � � � � � � � � � � � � � � � 10
Required Tools� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 11
Load Capacity � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 11
Maintenance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 11
Visit the GearBoss High-Density Storage System web page at gearboss.com for more information.
Note: Please read and understand these instructions before proceeding�
Note: If you need additional information, contact Wenger Corporation using the information below�
©Wenger Corporation 2024
Wenger Corporation, 555 Park Drive, P�O� Box 448, Owatonna, Minnesota 55060-0448
Questions? Call�����USA: (800) 4WENGER (493-6437) • Worldwide: +1-507-455-4100 • wengercorp�com
X-Cart
Printed in USA 2024-09
GearBoss
Storage System
X-Cart
Standard Floor Track Installation � � � � � � � � � � � � � � � � � � � � � � � � � 12
Before Starting the Assembly � � � � � � � � � � � � � � � � � � � � � � � � 12
Layout the Space � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12
Attach Floor Track to Floor � � � � � � � � � � � � � � � � � � � � � � � � � � 14
Track Stop Bracket Accessory Installation � � � � � � � � � � � � � � � � � � 16
Adjustable Track Lock Accessory Operation � � � � � � � � � � � � � � � � � 17
Cart Assembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 19
Attach Wheels to an X-Cart � � � � � � � � � � � � � � � � � � � � � � � � � 19
Attach Casters to a Team Cart � � � � � � � � � � � � � � � � � � � � � � � 20
Place Frame Bumpers � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21
Assemble Front End Frame � � � � � � � � � � � � � � � � � � � � � � � � � 22
Assemble Rear End Frame � � � � � � � � � � � � � � � � � � � � � � � � � � 26
Top Panel Assembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 29
Moving Carts � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 30
General � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 30
Moving Carts On and Off of a Floor Track � � � � � � � � � � � � � � 31
Replacement Parts � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32
X-Cart Chassis � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32
Team Cart Chassis � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 33
End Frame� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 34
Wire-grille End Panel � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 35
Top Panel Assembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 35
Floor Track � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
Track Stop Bracket � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
Adjustable Track Lock � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
Owner's Manual
High-Density
®
and Team Cart
Team Cart
Part #240A099-06

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Summary of Contents for Gearboss X-Cart

  • Page 1: Table Of Contents

    Track Stop Bracket � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7 X-Cart Chassis � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32 Adjustable Track Lock �...
  • Page 2: Important User Information

    The end user must exercise caution and common sense when assembling or installing Wenger Corporation products� If any questions or problems arise, call the Wenger Corporation at (800) 4WENGER (493-6437) or +1-507-455-4100 worldwide� Manufacturer The GearBoss X-Cart and Team Cart are manufactured by: ®...
  • Page 3: Safety Precautions

    Safety Precautions Throughout this document you may find cautions and warnings which are defined as follows: • WARNING: Failure to follow the instruction could result in serious injury or damage to property� • CAUTION: Failure to follow the instruction could result in minor injury or damage to property� Read all of these safety instructions before assembly, installation or use�...
  • Page 4: Parts Lists

    Front End Frame Assembly Rear End Frame Assembly Chassis Top Panel Extrusion Assembly Top Panel 48" X-Cart shown Wire-grille End Panel NOTICE Applies to both X-Carts (shown) and Team Carts in 32" (813 mm) and 48" (1219 mm) widths. Item Qty Description 48"...
  • Page 5: Cart Hardware Pack Components

    Parts Lists (continued) Cart Hardware Pack Components NOTICE Applies to the Hardware Packs supplied with both X-Carts and Team Carts. Item Description Pull Handle Long "B" Knuckle Frame Bumper Half Lock "B" Knuckle 3/8 x 1-1/4" Flat Washer 3/8-16 Acorn Nut 1/4-14 x 1"...
  • Page 6: Cart Knuckle Pack Components

    Parts Lists (continued) Cart Knuckle Pack Components NOTICE Applies to the Hardware Packs supplied with both X-Carts and Team Carts. Item Description Half "A" Knuckle Half "B" Knuckle Long "A" Knuckle Cart Knuckle Hardware Pack Supplied Hardware NOTICE Applies to the Hardware Packs supplied with both X-Carts and Team Carts. 1/4-14 x 3/4"...
  • Page 7: Floor Track And Hardware

    Parts Lists (continued) NOTICE The parts lists on this page apply to the components contained in the floor track cartons for use with the X-Carts and Team Carts. Floor Track and Hardware Item Qty Description Floor Track (Standard) Flush Mount Floor Track See Flush Track Accessory Owner's Manual 240A088 1/8 x 2"...
  • Page 8: Description

    Description X-Cart On-the-track-only storage cabinet mounted on wheels in 32" (813 mm) and 48" (1219 mm) widths. 48" (1219 mm) X-Cart is shown. Top Panel Assembly protects the stored content and can be used as a shelf Wire-grille End Panel...
  • Page 9: Team Cart

    Description (continued) Team Cart On-the-track and transport-to-the-event-location storage cabinet mounted on swiveling casters in 32" (813 mm) and 48" (1219 mm) widths 32" (813 mm) Team Cart is shown. Top Panel Assembly protects the stored content and can be used as a shelf Wire-grille End Panel provides security and a mounting surface for accessories...
  • Page 10: Floor Track

    Description Floor Track Available as Standard or Flush Mount. For flush mount track, see Flush Track Accessory Owner's Manual 240A088. Standard Floor Track Available in 8' (2438 mm) lengths Flush Mount Floor Track Available in 8' (2438 mm) lengths Track Stop and Adjustable Track Lock Available on either Standard or Flush Mount.
  • Page 11: Required Tools

    Required Tools The following tools are recommended for installation and assembly� Cart Assembly Floor Track Installation • Drill • Plumb bob • 9/16" Combination wrench • 50' Chalk line • Phillips drive bit or screwdriver • Tape measure • Mallet •...
  • Page 12: Standard Floor Track Installation

    Standard Floor Track Installation This is the procedure for installing the standard floor track. For flush mount track installation, see Flush Track Accessory Owner's Manual 240A088 Before Starting the Assembly Before installing, do the following� 1� All personnel, including temporary personnel, must read and understand these instructions� 2�...
  • Page 13 Standard Floor Track Installation (continued) Layout The Space (continued) Side Wall Rear Wall Floor Mark Strike a chalk line 78" (1981 mm) from the rear wall or obstruction Floor Mark Maintain a minimum of 1" (25 mm) clearance around Ceiling cart and accessories Tall Attic 117"...
  • Page 14: Attach Floor Track To Floor

    Standard Floor Track Installation (continued) Attach Floor Track to Floor Standard floor track sections are 8' (2438 mm) long. To achieve the required floor track length, additional sections may be joined together or trimmed as needed. The floor track (18a) is attached to the floor surface by anchoring it with the appropriate fasteners at the pilot holes in the floor track.
  • Page 15 Standard Floor Track Installation (continued) Attach Floor Track to Floor (continued) 5. Anchor additional floor track sections as needed. a. Using a mallet, drive two spring pins half way into the two floor track screw channels on the end of the anchored floor track. NOTICE Take care to not bend the spring pins when driving the track onto the pins.
  • Page 16: Track Stop Bracket Accessory Installation

    Track Stop Bracket Accessory Installation The track stop bracket is an optional accessory, skip this procedure if not installing. 1� Place the track stop bumper (23) into the channel of the installed floor track at the desired stop point for the cart�...
  • Page 17: Adjustable Track Lock Accessory Operation

    Adjustable Track Lock Accessory Operation The adjustable track lock bracket is an optional accessory, skip this procedure if not installing. NOTICE There are two versions of the adjustable track lock assembly: The track lock bracket for a standard floor track is bent to fit flush. The track lock bracket for a flush floor track is flat to fit flush.
  • Page 18 Adjustable Track Lock Accessory Operation (continued) 2� To lock the track lock: Slide the cart into the track lock and insert the track lock handle (29) into the track lock pivot weldment and rotate it clockwise to lower it onto the track follower until the cart is secure in place� NOTICE When turning the track lock pivot weldment, be sure that the track lock toggle rotates into the lock position and that the flanges are positioned under the channel in the track prior to tightening.
  • Page 19: Cart Assembly

    Cart Assembly This is the procedure for attaching wheels to an X-Cart! For attaching casters to a Team Cart, go to the following page. Attach Wheels to an X-Cart 1� Attach a wheel (33) to each corner of the chassis (14)�...
  • Page 20: Attach Casters To A Team Cart

    Cart Assembly (continued) This is the procedure for attaching casters to a Team Cart! For attaching wheel bearings to an X-Cart, go to the previous page. Attach Casters to a Team Cart 1� Attach a caster (38) to the bottom side of each corner of the chassis (14) using four 3/8-16 x 3/4"...
  • Page 21: Place Frame Bumpers

    Cart Assembly (continued) Place Frame Bumpers 1� Attach a frame bumper (3) to each of the four end frame posts on the chassis� For each frame bumper, turn the flat surface to face inside and align the pilot hole in the frame bumper with the pilot hole the chassis end frame post as shown�...
  • Page 22: Assemble Front End Frame

    Cart Assembly (continued) Assemble Front End Frame NOTICE The only difference between the front and rear end frame assemblies is that the caution decal is located on the front end frame post (see below). 1. Lay the front end frame assembly (12) flat with the top ledge facing up and the decal side facing down� 2�...
  • Page 23 Cart Assembly (continued) Assemble Front End Frame (continued) 4� Turn the front end frame assembly over� 5� With the horizontal wires facing up, position the wire-grille end panel (17) to fit onto the attached "a" knuckles (41) and approximately 1/4" (6 mm) below the end frame horizontal tube� NOTICE The top wire of the wire-grille should be approx.
  • Page 24 Cart Assembly (continued) Assemble Front End Frame (continued) 6� Attach half "b" knuckles to the top pair of installed half "a" knuckles� a� Engage the slot of a half "b" knuckle (42) with the post of an attached half "a" knuckle� c�...
  • Page 25 Cart Assembly (continued) Assemble Front End Frame (continued) 8� Attach long "b" knuckles and pull handles to the middle pair of installed half "a" knuckles� a� Engage the slot of a long "b" knuckle (2) with the post of an attached long "a" knuckle� c�...
  • Page 26: Assemble Rear End Frame

    Cart Assembly (continued) Assemble Rear End Frame 1. Lay the rear end frame assembly (13) flat with the top ledge facing up� 2� Attach a half "a" knuckle (41) toward the top and bottom of each rear end frame post using a 1/4-14 x 3/4"...
  • Page 27 Cart Assembly (continued) Assemble Rear End Frame (continued) 3� Turn the rear end frame assembly over� 4� With the horizontal wires facing up, position the wire-grille end panel (17) to fit onto the attached "a" knuckles (41) and approximately 1/4" (6 mm) below the end frame horizontal tube� NOTICE The top wire of the wire-grille should be approx.
  • Page 28 Cart Assembly (continued) Assemble Rear End Frame (continued) 5� Attach half "b" knuckles to the installed half "a" knuckles� a� Engage the slot of a half "b" knuckle (42) with the post of an attached half "a" knuckle� c� While maintaining the 1/4" (6 mm) wire-grille space at the top and aligning the horizontal wires to clear the open pilot holes in the...
  • Page 29: Top Panel Assembly

    Cart Assembly (continued) Top Panel Assembly 1. Lay the top panel flat with the black side facing upward. NOTICE To prevent scratching the top panel, use a table or cardboard packaging as a work surface. Top Panel 2� Attach the top panel extrusions (15) to Extrusions both sides of the top panel (16) using two (15)
  • Page 30: Moving Carts

    2� Release the track follower by pulling the locking lever away from the follower� See the following page for moving carts on and off a floor track. X-Cart engaged with a floor track Track Follower Team Cart engaged Retracted...
  • Page 31: Moving Carts On And Off Of A Floor Track

    3� To remove a Team Cart from the track, retract both track followers by pulling each one upward until it locks in place� Release the track follower by pulling the locking lever away from the follower� X-Cart engaged with a...
  • Page 32: Replacement Parts

    Applies to both 32" (813 mm) and 48" (1219 mm) widths, specify width when ordering. Item Description Frame Bumper 1/4-14 x 1" Self-drilling Screw X Cart Chassis Track Follower Shoulder Bolt Roller Plunger 3/4" Poly Wheel Axle Pin 1/4-14 x 3/4" Self-drilling Screw GearBoss Decal 48" X-Cart shown...
  • Page 33: Team Cart Chassis

    3/8-16 Acorn Nut 1/4-14 x 1" Self-drilling Screw Team Cart Chassis Shoulder Bolt Track Follower Plunger Shaft GearBoss Decal 3/8-16 Lock Nut 6" Dia Swivel Caster 3/8-16 x 3/4" Button Head Screw Plunger Clip Backer Plunger Clip 32" Team Cart shown...
  • Page 34: End Frame

    Replacement Parts (continued) End Frame NOTICE Applies to both 32" (813 mm) and 48" (1219 mm) widths, specify width when ordering. Item Description Pull Handle Long "B" Knuckle Half Lock "B" Knuckle 3/8-16 Acorn Nut 1/4-14 x 1" Self-drilling Screw 3/8-16 x 1-1/4"...
  • Page 35: Wire-Grille End Panel

    Replacement Parts (continued) Wire-grille End Panel NOTICE Applies to both X-Carts (shown) and Team Carts in 32" (813 mm) and 48" (1219 mm) widths, specify both when ordering. Item Description 48" Wire-grille Wire-grille End Panel End Panel 32" Wire-grille End Panel Top Panel Assembly NOTICE Applies to both X-Carts (shown) and Team Carts in 32"...
  • Page 36: Floor Track

    Replacement Parts (continued) Floor Track Item Description Standard Floor Track 1/8 x 2" Spring Pin 8-18 x 3/4" Self-drilling Screw Floor Track End Cap Track Stop Bracket Item Description Track Stop Bracket Track Stop Bumper 1/4-14 x 3/4" Self-drilling Screw Adjustable Track Lock Item Qty Description...

This manual is also suitable for:

Team cart

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