WEATHER GUARD 110-SM User Manual [en, es, fr]

INSTALLATION MANUAL

STEEL & ALUMINUM SIDE BOX

TRUCK STORAGE SOLUTIONS

SECURING YOUR REPUTATION

ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS

BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT.

Model# ________________ Serial#__________________

PRODUCT REGISTRATION

MODELS 164-X-01 THRU 186-X-01

WWW.WEATHERGUARD.COM

Purchased Date:

For your convenience, place product registration tear-off sticker here.

______________________ Place of purchase: ______________________ Key Code: ______________________

DANGER

Danger of explosion. Do not use this product for storing or transporting ammables, explosives, hazardous materials, or hazardous waste, such as containers of gasoline, solvents, gun powder, dynamite, propane tanks, acetylene tanks and cutting torches. This product is only intended and safe for use in storing and transporting small tools, equipment and other similar materials. Any modications made to, or unintended use of this product, could create a hazardous condition that can cause death, serious personal injury or property damage.

WARNING

To keep debris out of your eyes when checking the underside of the vehicle, or when drilling, always wear eyewear. Prior to drilling, so as not to cut or puncture fuel tanks, fuel lines, brake lines, electric wires, etc., check under vehicle for locations. All oor mounting bolts near the gas tank area should be installed from the underside of the vehicle, to guard against the gas tank being punctured in the event of a collision. This would mean not using Blind Fastener in this area. Holes drilled in this area should be 3/8”.

CAUTION

Before marking the leg mounting holes, check inside the box for location of gas spring housing and components that may obstruct

safe drilling.

To keep debris out of your eyes when checking the underside of the vehicle, or when drilling, always wear eyewear.

INSTALLATION TIME

Approximate installation time:48 minutes per unit (0.8 hours) depending on truck equipment installation experience.

- NOTICE -

Any modication or unintended use of this product shall immediately void all manufacturers warranties. Manufacturer disclaims all liability for injuries to persons or property resulting from any modication to, or unintended use of this product.

*24-0199*

Part No. 24-0199 REV. C ECN 5305 04/13

(1) Side Box

(1) Small Parts Tray

(2) Legs

(2) Rubber Mounting Pads

(1) Side to Cross Box

Mounting Angle

(2) Keys

(10) 5/16” Flat Washers

(8) 5/16” Lock Washers

(8) 5/16”–18 Blind Fasteners

(1) Installation Tool

(1) 5/16”–18 x 2 1⁄4” Black

Oxide Hex

Head Bolt

(1) 3⁄4” Round Cap Plug

(8) 5/16”–18 x 1 1⁄4 “ Hex

Head Bolts

(1) 5/16”–18 Nylon Lock Nut

(1) Retaining Washer

(2) 5/16”–18 x 2 1⁄4” Hex

Head Bolt

(2) Fender Washers

(2) Mounting Clamps

(1) “J” Bolt

Note: The rubber mounting pad comes as a single piece and must be separated into two pieces, one for each side of the truck.

TOOLS REQUIRED

• 1⁄2” deep well ratchet wrench

• 1⁄2” open or box end wrench

• 9/16” open or box end wrench

• Drill with 3/16”, 3/8”, and 1⁄2” drill bit

• Carpenter’s square

PARTS LIST

Note:

• If your pickup is tted with a plastic drop-in bed liner, it may need to be drilled, trimmed, or cut for proper installation of truck box.

• Truck box cover may not properly latch until box is fully bolted to truck bed.

• Periodically check tightness of mounting bolts to insure proper attachment.

• Use touch-up paint on any drill holes to prevent oxidation.

• Install boxes with vehicle parked on level ground.

Step 1: LOCATE BOX IN TRUCK BED

• Mount Saddle/Cross Box rst (if applicable).

• Place rubber mounting pads on bed rails.

• Place box into position on top of mounting

pads.

• Support box with blocking until mounted.

• Square box to bed and level box so top is horizontal when viewed from rear.

• Leave 1/8” gap between side box and saddle/ cross box (if applicable).

• Make sure cover opens fully without

interference.

Note: Fasten leg mounting feet directly to bed oor, not bed liners or mats.

INSTALLATION INSTRUCTIONS

Figure 1

5/16" Flat Washer

Hex Head Bolt

Mounting Clamp

5/16" Flat Washer

Hex Head Bolt

Mounting Clamp

5/16" Flat Washer

Figure 1

1/8"

SIDE BOX

CROSS BOX

Figure 2

Hex Head Bolt

Mounting Clamp

5/16" Flat Washer

Figure 1

Step 2: MARK AND DRILL MOUNTING HOLES

• Position rear leg as shown in Figure 1. Use square to ensure vertical orientation.

• Mark both holes at top of leg and both holes in truck bed oor. Note: To maintain full oor width between wheel wells, legs should be aligned with the inside edge of wheel wells. The

foot of the leg must be squarely mounted on or between the tops of oor ribs.

• Repeat leg placement and marking process for other leg. If installing side boxes with a saddle or cross box, the front leg can be replaced with an angle bracket (see Figure 2).

• Remove box from truck

• Drill all marks on box and truck with 3/16” drill bit. Redrill all holes with 1⁄2” drill bit.

• Install all Blind Fasteners (see Figure 1, 2 and 4).

Figure 2

1/8"

SIDE BOX

CROSS BOX

Step 3: ATTACH BOX TO TRUCK BED Note: If you encounter interference with the mounting clamp and a stake pocket in the truck bed, it may be

necessary to drill a 1⁄2” hole in the truck box and use the “J” bolt instead of mounting clamp. Note: It is recommended that all fasteners be tightened hand tight rst to ensure t, then go back and fasten

securely with wrench.

• Place box back in original position.

• Install all bolts in leg mounting feet as shown in Figure 3.

• Insert the two mounting clamps as shown in Figure 3.

• Snap Cap Plug into bottom hole. Note: Mounting clamp bolt may be difcult to turn due to the “lock nut” feature. Apply a small amount of grease to

bolt threads prior to installation to ease assembly.

End Panel Slot

Mounting Pad

Bed Lip

Figure 3

Fender Washer

Mounting Clamp

INSTALLATION INSTRUCTIONS USING BLIND FASTENERS

Blind Fastener

Note: Make sure there is enough hole depth before installing the Blind Fastener.

Note: Black Oxide Bolt, Flat Washer, and Installation Tool are only used to install Blind Fasteners.

• Install Blind Fastener using Figure 4 as a guide.

• Place a drop of oil on black oxide bolt for lubrication.

• Insert Blind Fastener in the hole.

• Hold the “Installation Tool” with a 9/16” wrench while turning the “Black Oxide Bolt” with a 1/2” wrench until fully seated.

• Turning “Black Oxide Bolt” will be hard until fastener “bulbs” out.

• When Blind Fastener is fully seated, continue with installation.

Figure 4

Blind Fastener

FEATURE OPERATION

LOCK SYSTEM

The WEATHER GUARD® Lock is designed to provide maximum security, while providing ease of use and years of reliable service. When in the locked mode, the button remains retracted in a tamper-resistant position. When the button is pressed in the unlock mode, the latch is activated and the cover opens.

LOCK

Turn key counterclockwise to locked position as indicated on lock bezel. When the button is now pressed, it will stay in the retracted or tamper-resistant position until unlocked.

UNLOCKED

Turn key clockwise to unlock position as indicated on the lock bezel. Button

will pop out and is now ready to release the latches when pressed.

LATCH SYSTEM

The WEATHER GUARD

Latch System utilizes an automotive grade latch in conjunction with a high strength latch striker to ensure maximum security. The WEATHER GUARD® Latch System is designed to open with a single touch of the button, and close securely. Expect years of reliable service from the WEATHER GUARD® Latch System with only minimal maintenance: Bi-annually lubricate latch pivot points with white grease. If latch striker is accidentally knocked out of alignment, simply use a mallet to realign.

MOUNTING BRACKETS

Wide ange mounting bolts provide secure mounting without crimping bed rails and allow full unobstructed use of side pockets.

12V ELECTRICAL ACCESS

WEATHER GUARD equipped with a 12 Volt Electrical Access Plug for easy electrical accessory t-ups. To use, simply cut along one or more perforations in the

Truck Boxes are

Electrical

access

Figure 5

rubber grommet and run wire through.

WARNING

To prevent electric shock, explosion, re and/or serious personal injury when using side box with:

Extension Cord -

• Follow all Extension Cord manufacturer’s warnings and instructions.

• Do NOT insert extension cord through hole without grommet in place (see Figure 5).

• Only use a three-wire extension cord with all three prongs intact. Never remove the round grounding prong.

• Extension cord must be connected to a 120 Volt GFCI protected outlet with proper ground. If GFCI outlet is not available, use an extension cord with GFCI protection built in.

• Check the insulation and plugs of extension cord before using. Do NOT use cord if it is worn or damaged.

• Do NOT overload extension cord.

Extension Cord (continued)

• Remove extension cord from the grommet hole before moving or transporting side box.

• Only use an extension cord that is rated for outdoor use.

• Do NOT connect extension cord to outlet that also supplies critical safety equipment with power.

Cordless Power Tool Battery Chargers -

• See Charger’s Owner’s Manual for proper use and care of charger and batteries. Follow all warnings and instructions provided with your battery charger.

• Place chargers and electrical connections in tray.

• Chargers are Dry location use only. Do NOT expose to liquid, vapor, or rain. Should your charger become wet, Do NOT attempt to use. Unplug extension cord from supply before handling wet charger or cords.

• Only use chargers and batteries that are intact and operating properly.

• Do NOT touch metal prongs when plugging charger into extension cord.

• Keep ammable materials like paper or rags away from charger, cords or connections.

• Do NOT place or attempt to charge lead acid, car-type batteries in side box.

FOR ADDITIONAL REPLACEMENT PARTS GO TO WWW.WEATHERGUARD.COM

SERVICE PARTS

ITEM

PART

NO.

1 Gas Spring 165-X-01

1 Gas Spring 166-X-01

1 7095 Gas Spring

1 7096 Gas Spring 176-X-01

1 Gas Spring 185-X-01

1 Gas Spring 186-X-01

2 7748-xx

3 7750-xx

4 7732

5 7106

6 7730

DESCRIPTION FITS MODEL #

164-X-01, 174-X-01, 175-X-01, 184-X-01

Lock & Key Set (xx = key code) (1 lock, 2 keys,

retainer clip)

Key Replacement (xx = key code) (2 keys)

Latch & Striker Kit (1 latch, 1 striker, & mounting

hardware)

Striker Kit (1 Striker and mounting hardware)

Weather Strip Kit (various styles for 1 box)

All Side Boxes

ITEM

NO.

10 7749 Grommet Kit All Side Boxes

11 7938-x Cover 164-X-01

11 7939-x Cover 174-X-01

11 7941-x Cover 184-X-01

11 7887-x Cover 165-X-01

11 7905-x Cover 166-X-01

11 7906-x Cover 175-X-01

11 7912-x Cover 176-X-01

11 7914-x Cover 185-X-01

11 7925-x Cover 186-X-01

PART

NO.

7 911 Tray All Side Boxes

8 7734-x

9 7746

DESCRIPTION FITS MODEL #

Mounting Kit (2 clamps, 2 legs, 1 angle, 2 mount pads,

related hardware)

Nameplate Kit (3 stickers, 2 side bezels, 1 back bezel)

All Side Boxes

Note: In the model numbers above, X represents the color code for your model; 0 = Clear, 3 = White, 5 = Black

KNAACK LLC LIMITED LIFETIME WARRANTY FOR WEATHER GUARD® PRODUCTS

WEATHER GUARD® Products — Limited Lifetime Warranty (Purchased on or after 1/1/2009)

Knaack LLC (the “Manufacturer”) warrants to the original purchaser only that WEATHER GUARD® Truck and Van Products (the “WEATHER GUARD® Product”) continuing for the expected lifetime of the WEATHER GUARD® Product. A copy of the original sales receipt must be supplied to the Manufacturer at the time a warranty claim is made. This warranty terminates if the original purchaser transfers the WEATHER GUARD® Product to any other person.

will be free from defects in material and workmanship from the date of purchase and

What is Covered

All WEATHER GUARD

Products identified above that are purchased on or after January 1, 2009.

What We Will Do to Correct Problems

Subject to the limitations and exclusions described in this limited warranty, the Manufacturer will remedy defects in materials or workmanship by providing one of the following remedies at its option and without charge to the original purchaser for parts or labor: (a) repairing the defective portion of the WEATHER GUARD Product. In addition, the manufacturer may elect at its option, not to repair or replace the WEATHER GUARD

Product or (b) replacing the entire WEATHER GUARD®

Product, but rather issue to the original purchaser a refund equal to the purchase price paid for the WEATHER GUARD® Product or a credit to be used toward the purchase of new WEATHER GUARD® Product.

What is Not Covered

This limited warranty expressly excludes:

• Defects caused by normal wear and tear, cosmetic rust, scratches, accidents, unlawful vehicle operation, or modification to the product, or any types or repair of a WEATHER GUARD

Product other than those authorized or

provided by the Manufacturer.

• Defects resulting from conditions beyond the Manufacturer’s control including, but not limited to misuse, overloading, or failure to assemble, mount or use the WEATHER GUARD instructions or guidelines included with the WEATHER GUARD

Product in accordance with the Manufacturer’s written

Product or made available to the original purchaser.

• Damage to the contents of the box or vehicle.

• TO THE EXTENT PERMITTED BY LAW, IN NO EVENT SHALL THE MANUFACTURER BE LIABLE FOR ANY INCIDENTAL, SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, INCLUDING ANY ECONOMIC LOSS, WHETHER RESULTING FROM NONPERFORMANCE, USE, MISUSE OR INABILITY TO USE THE WEATHER GUARD

PRODUCT OR THE MANUFACTURER’S NEGLIGENCE.

No Other Express Warranty Applies

This Limited Lifetime Warranty is the sole and exclusive warranty for WEATHER GUARD

products. No employee, agent,

dealer, or other person is authorized to alter this warranty or make any other warranty on behalf of Knaack LLC.

Notification Procedures

If the WEATHER GUARD

Product does not conform with the terms of this limited warranty, the original owner must promptly notify the Manufacturer in writing upon discovery of the nonconformity. In order to receive the remedies under this limited warranty, the warranty claim must describe the nature of the nonconformity, and a copy of the original sales receipt, invoice, bill or other proof of purchase must accompany the claim. Repairs or modifications made to the WEATHER GUARD® Product by other than the Manufacturer or its authorized agent will nullify this limited warranty. Coverage under this limited warranty is conditioned at all times upon the owner’s compliance with these required notification and repair procedures. Warranty claims must include reciprocal contact information and may be made via certified mail to:

Knaack LLC

ATTN: Warranty Claims

420 E. Terra Cotta Avenue Crystal Lake, IL 60014

If you have any questions, please call toll free at 1-800-456-7865.

Part No. 24-0199 REV. C ECN 5305 04/13

*24-0199*

+ 12 hidden pages

WEATHER GUARD 110-SM User Manual [en, es, fr]

Specifications and Main Features

Frequently Asked Questions

User Manual