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Model #:_____________ Serial #:_______________
OPERATORS MANUAL
STEEL & ALUMINUM PORK CHOP BOX
MODELS 160-X-01 THRU 173-X-01
WWW.WEATHERGUARD.COM
PRODUCT REGISTRATION
For your convenience,
place product registration
tear-off sticker here
Purchase Date: __________________
Place of Purchase: _______________
Key Code: ______________________
INSTALLATION TIME
Approximate installation time: 45 minutes (depending on truck equipment installation experience)
TOOLS REQUIRED
• Drill with 3/16”, 3/8”, and 1/2” drill bits
• 1/2” open or box end wrench (qty. 2)
• 9/16” open or box end wrench
• Hammer
(1) Pork Chop Box
(2) Mounting Angle
(1) Floor Mounting Angle
(14) 5/16” Flat Washer
PARTS LIST
(3) 5/16” - 18 Blind Fastener
(1) Blind Fastener Installation Tool
(1) 5/16” - 18 x 2 1/4” Black Oxide
Hex Head Bolt
(3) 5/16” - 18 x 1 1/4” Hex Head Bolt
• Center Punch
• Carpenter’s square
• Pencil or marker
• Oil/Grease
(6) 5/16 - 18 Nylon Lock Nut
(3) 5/16” Lock Washer
(6) 5/16” - 18 x 1” Hex Head Bolt
(2) Floor Mounting Spacer
–
ATTENTION
Read and understand all instructions and warnings before operating or using this product.
DANGER
Danger of explosion. Do not use this product for storing or transporting
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 mod cations made to, or unintended use of this product, could create a hazardous condition that can cause death, serious personal
injury or property damage.
–
explosives, hazardous materials, or hazardous
Part No. 24-0176 REV. D ECN 5403 01/14
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CAUTION
Before marking the leg mounting holes, check inside the box for location of gas spring housing and components that may obstruct
safe drilling.
CAUTION
To keep debris out of your eyes when checking the underside of the vehicle, or when drilling, always wear eyewear.
WARNING
Prior to drilling, so as not to cut or puncture fuel tanks, fuel lines, brake lines, electric wires, etc., check under vehicle for locations.
WARNING
All
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”.
INSTALLATION INSTRUCTIONS
Note:
• If your pickup is 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
• 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.
bolted to truck bed.
Step 1: LOCATE BOX IN TRUCK BED
• Place box into position with cover open.
• Support box as required during installation.
• Verify tailgate closes with
• Bottom of box should be
•
Side of box (not cover) should be approximately 1” from bed rail.
mounting angle in position.
on the r.
Note: Fasten box and leg mounting feet directly to bed r, not bed
liners or mats.
Step 2: ATTACH END MOUNTING ANGLE (see Fig. 2)
Note: This step may be omitted if you are able to use the alternate
method in Fig. 4.
• Place Mounting Angle against end of box with foot touching
stake pocket (or inner wall of truck bed).
Mark one hole on the box and one hole on the truck.
•
• Center punch the holes to be drilled.
• Drill truck box and stake pocket (or inner wall) with 3/16” drill bit.
-drill hole in truck box with 3/8” drill bit.
• Re
• Re-drill hole in stak
e pocket (or inner wall) with 1/2” drill bit.
• Install Blind Fastener (per Fig. 6) in stake pocket (or inner wall).
• Install mounting bracket per Fig. 2.
Note: Make sure there is enough hole depth before installing the
Blind Fastener.
Figure 1
Figure 2
Lock Washer
Hex Head Bolt
Nylon Lock Nut
Bed Lip
Support Here
Blind Fastener
Angle
Hex Head Bolt
(3 places)
Step 3: ATTACH LOWER MOUNTING ANGLE (see Fig. 3)
Note: This step may be omitted if you are able to use the alternate
method in Fig. 4.
• Place Mounting Angle under box and against wheel well (see Fig. 3)
•
Mark one hole on bottom of box and both holes on wheel well.
• Center punch the holes to be drilled.
• Drill truck box and wheel well with 3/16” drill bit.
• Install mounting bracket per Fig. 3.
Note: Install bolts from underside when fastening Mounting Angle to
wheel well.
Figure 3
5/16”-18 x 1-1/4”
Hex Head Bolt
(3 places)
5/16”
Flat Washer
(6 places)
5/16”-18 x 3/4”
Nylon Lock Nut
(3 places)
Angle
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Alternate Mounting Method Figure 4
Use if truck
allows box to rest directly on wheel well.
• Mark, center punch and drill 3/16” hole in bottom of box and top
of wheel well as shown in Fig. 4.
•
Re-drill holes with 3/8” drill bit.
• Install bolt per Fig. 4.
Figure 4
5/16” Flat Washer
5/16”-18
Nylon Lock Nut
Note: Install bolts from underside when fastening Mounting Angle to
wheel well.
Step 4: ATTACH FLOOR MOUNTING ANGLE (see Figure 5)
• Place Floor Mounting Angle on or, centered behind the box.
• Mark, center punch and drill all four holes with 3/16” drill bit.
Note: If holes in Floor Mounting Angle are not positioned above rib,
use Floor Mounting Spacers provided.
• Re-drill holes in box with a 3/8” drill bit.
• Re-drill holes
in truck bed with 1/2” drill bit.
• Install Blind Hole Fasteners in truck bed per Fig. 6
• Install Floor Mounting Angle per Fig. 5.
BLIND FASTENER INSALLATION
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 Fig. 6 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.
5/16”
Lock Washer
(2 places)
5/16”
Flat Washer
(6 places)
5/16”-18 x 3/4”
Hex Head Bolt
(2 places)
Floor Mounting
Angle
Floor Mounting Spacer
(When Needed)
5/16”-18 x 1” Hex Head Bolt
Tailgate End
5/16”-18 x 1-1/4”
Hex Head Bolt
(2 places)
Installed
Blind Fastener
(2 places)
5/16”-18
Nylon Lock Nut
(2 places)
Figure 5
Figure 6
LOCK SYSTEM
The WEATHER GUARD® Extreme Protection™ 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.
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 re-align.
Blind Fastener
FEATURE OPERATION
UN-LOCKED
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.
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SERVICE PARTS
FOR REPLAC EMENT PARTS GO TO WWW.WEAT HERGUARD.COM
ITEM PART DESCRIPTION FITS
NO. NO. MODEL #
1 7095 Gas Spring 170-X-01, 171-X-01, 172-X-01, 173-X-01
1 7096 Gas Spring 162-X-01, 163-X-01
2 7748-xx Lock & Key Set (xx = key code) All Pork Chop
(1 lock, 2 keys, retainer clip)
3
7750-xx Key Replacement (xx = key code) All Pork Chop
(2 keys)
4
7731 Latch & Striker Kit (1 latch, All Pork Chop
1 striker, & mounting hardware)
5 7106 Striker Kit All Pork Chop
(1 Striker & mounting hardware)
6
7730 Weather Strip Kit All Pork Chop
(various styles for 1 box)
7
7735-x Mounting Kit All Pork Chop
8 7746 Nameplate Kit (3 stickers,
2 side bezels, 1 back bezel)
9
7788-x Cover 170-X-01
9 7789-x Cover 171-X-01
9 7790-x Cover 172-X-01
9 7795-x Cover 173-X-01
9 7926-x Cover 160-X-01
9 7927-x Cover 161-X-01
9
7928-x Cover 162-X-01
9 7932-x Cover 163-X-01
10 70740 Latch Rod Kit (Not shown)
10
7741 Latch Rod Kit (Not shown) 161-X-01, 163-X-01, 171-X-01, 173-X-01
Note: In the model numbers above, X represents the color code for your model;
0 = Clear, 3= White, 5 = Black
All Pork Chop
160-X-01, 16
2-X-01, 170-X-01, 172-X-01
6
5
9
2
8
4
1
7
3
–NOTICE–
Any 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
This LIMITED WARRANTY is made by Knaack LLC, 420 E. Terra Cotta Ave., Crystal Lake, Illinois to the original retail purchaser of KNAACK
GUARD
® products .
KNAACK LLC WARRANTS THAT KNAACK
PERIOD OF THREE (3) YEARS FROM DATE OF PURCHASE BY THE ORIGINAL RETAIL PURCHASER.
If, before the expiration of the Warranty period, purchaser discovers that the KNAACK
contact Knaack LLC to make arrangements for an inspection o
repair or replace any defective part. All Warranty repairs shall be made by an authorized KNAACK
This Warranty shall not apply if the KNAACK
alter-ations made by anyone other than a KNAACK
THE WARRANTY PRINTED ABOVE IS THE ONLY WARRANTY APPLICABLE TO THIS PURCHASE. ALL OTHER WARRANTIES, EXP
BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.
KNAACK LLC SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF ANY BREACH OF THIS WARRANTY. NOR SHALL
THE DAMAGES EXCEED THE RETURN AMOUNT OF THE PURCHASE PRICE PAID BY THE ORIGINAL PURCHASER.
This Warranty is in lieu of all Warranties express or implied. The terms of this Warranty shall not be modified by any party, their successors or assigns. This Warranty gives
you specific legal rights, and you may also have other rights which vary from state to state.
Product fits based on vehicle design available at the revision date. Vehicle manufacturers may change specs after the
revision date, so if you have a vehicle produced with a model year date after the revision date, please contact your
distributor or Knaack LLC to verify fitting of product to vehicle.
WEATHER GUARD® Products are protected by one or more of the following patents: U.S. 5145087, 5308126,
4509787, 4573731, 4618083, D-346355, D-346994, D-353574; Canada 1218968, 1224230, 1235100 and; U.K.
2233036. Other patents pending.
® OR WEATHER GUARD® PRODUCTS WILL BE FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIP FOR A
f the product. If Knaack LLC determines a defect exists, Knaack LLC shall, at its option and expense,
® or WEATHER GUARD® product has been subjected to misuse, abnormal service or handling, improper maintenance, or
® or WEATHER GUARD® Product dealer or a Knaack LLC approved service company.
LIMITED WARRANTY
to, or unintended use of this product.
® or WEATHER
® or WEATHER GUARD® product fails to fulf ill the Warranty, purchaser shall
® Product dealer or Knaack LLC approved service company.
RESS OR IMPLIED, INCLUDING
KNAACK LLC
420 E. Terra Cotta Ave, Crystal Lake, IL 60014, 815-459-6020, info@knaack.com
©2014 Knaack LLC
Part No. 24-0176 REV. D ECN 5403 01/14
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