Weather Guard 1906-3-02, 1904-3-02, 1904-5-02, 1915-3-01, 1915-5-01 User Manual

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Page 1

TRUCK STORAGE SOLUTIONS

SECURING YOUR REPUTATION

ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS

BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT.

INSTALLATION MANUAL

STEEL & ALUMINUM SIDE BOX WITH

PROTECT-A-RAIL® CAB PROTECTOR

PACK RAT® DRAWER UNITS

MODELS

1904-X-02, 1905-X-02, 1906-X-02, 1907-X-02

Note: X represents the color code for your model: 0 = Clear | 3 = White | 5 = Black | 52 = Matte Black

1916 Mounting Base Kit for GM 1912 Mounting Base Kit for Dodge 1913 Mounting Base Kit for 1997 or newer Ford light duty trucks 1915 Mounting Base Kit for Ford super duty and 1996 or older light duty trucks 1921 Mounting Base Kit for 5’7” Dodge Bed

NOTICE WARNING

Use specic aluminum upt components when installing WEATHER GUARD® products to aluminum truck beds. Follow additional instructions if mounting to an aluminum truck bed. There may be left over components depending on upt.

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.

DANGER

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.

Prior to drilling, so as not to cut or puncture fuel tanks, fuel 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". This product can reduce the driver’s ability to clearly see roadways, vehicular or pedestrian trafc and other objects through the rear and side windows of the vehicle, which may cause an accident. Extra precautions should be taken when driving a vehicle with this product. Make all adjustments necessary to ensure maximum visibility, including but not limited to, changing mirror or seating positions. State and local laws may prohibit obstruction or windows in a moving vehicle.

CAUTION

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

WEATHERGUARD.COM

Part No. 24-0094 REV. E ECN 5583 05/15

Page 2

TOOLS REQUIRED

• Electric Drill

• Drill Bits - 7/32", 1/4", 1/2"

PARTS LIST

(2) 5/16-18 x 1-1/4"

Hex Head Bolt

(10) 1/4"

Flat Washer

(4) 5/16-18 x 1"

Carriage Bolt

• Open or Box End Wrenches - 7/16", 1/2", 9/16"

• 3/8" Drive Ratchet

(4) 1/4-20 x 1-1/4"

Hex Head Bolt

(2) 5/16-18

Blind Fastener

(2) 1/4-20 x 1-1/2"

Carriage Bolt

(1) 5/16-18 x 2-1/4"

Black Oxide Bolt

(1)

Installation Tool

(2) Shims

• Sockets - 7/16", 1/2"

• C-clamp

• Utility Knife

(2) 5/16"

Lock Washer

(6) 1/4-20

Nylon Lock Nut

Note: The rubber mounting pad

comes as a single piece and must be separated into two pieces, one for each side of the truck.

Rubber Mounting Pad

(4) 5/16"

Flat Washer

(4) 5/16-18

Nylon Lock Nut

ALUMINUM BED UPFIT KIT PARTS LIST - 32-0243

(4)

Vinyl Tape

(1)

Zinc Rich Primer

(8) 1/2" x 1"

Plastic Washer

BLIND FASTENER INSTALLATION

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

Place the Blind Fastener in the hole and use 1/2" or 7/16" wrench to tighten black oxide bolt until fastener is fully seated (it will start out hard and get easier as fastener “bulbs” out).

Make sure the Blind Fastener and Installation Tool do not turn during

installation.

ALUMINUM TRUCK BED INSTALLATION

Coat drilled holes with Zinc Rich Primer. Insert Blind Fastener through one 1/2" x 1" plastic washer. Insert Blind Fastener into drilled hole. Place second 1/2" x 1" plastic washer through the bottom of the Blind Fastener. Continue following installation instructions above to install Blind Fasteners.

(4) 11/32" x 7/8"

Plastic Washer

(8) 5/16" x 3/4"

Plastic Washer

Black Oxide Bolt

Flat Washer

9/16" Wrench

Installation Tool

Blind Fastener

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INSTALLATION INSTRUCTIONS

Note: If your truck bed is constructed of aluminum, use zinc rich primer to coat drilled holes.

1904

1905 1906 1907

Protect-A-Rail

Mounting Pad

Driver’s Side

Mounting Base

Passenger’s Side

Mounting Base

PERFORM THE FOLLOWING STEPS TO THE DRIVER SIDE & PASSENGER SIDE

STEP 1

Protect-A-Rail to Mounting Base Procedure

Place frame of unit between the bases and install fasteners (snug but do not tighten at this time).

(2) 5/16"

Flat Washer

STEP 2

(2) 5/16-18 Lock Nut

Mounting Pad

Cut off 2" of the mounting pad and save for tool box installation.

(2) 5/16-18 x 1"

Carriage Bolt

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STEP 3

Protect-A-Rail Location

Note:

• Remove any plastic tabs from the under side of the truck top tail that are in the way.

STEP 4

Re-drill Procedure

Unclamp, move Protect-A-Rail, remove at washer, redrill front hole, and install Blind Fastener.

Tape washer, clamp, and drill top, side, and front (with mounting pads In places).

Drill (4) 1/4" diameter holes

Mounting Pad under Base

STEP 5

Protect-A-Rail Installation

Centered in a 3/8" diameter hole

Tape a 5/16" Flat Washer between

front of Mounting

Base and bed

ALUMINUM TRUCK BED INSTALLATION:

Follow additional instructions if mounting to an aluminum truck bed as explained in the Blind Fastener Installation on page 2.

(1) 5/16-18 Blind Fastener

Drill 1/2" diameter hole

Replace rack and install top, side, and front fasteners (tighten all fasteners).

ALUMINUM TRUCK BED INSTALLATION:

Use one 5/16" x 3/4" plastic washer as a barrier between the 1/4" at washer and the aluminum truck bed.

(1) 1/4-20 x 1-1/2"

Carriage Bolt

(1) 5/16"

Lock Washer

(1) 5/16-18 x 1-1/2" Hex Head Bolt

(2) 1/4-20 x 1-1/4" Hex Head Bolt

(3) 1/4-20

Nylon Lock Nut

(5) 1/4"

Flat Washer

Page 5

STEP 6

(Optional) Cross, Saddle and Side Box Mounting Procedure

If a truck mounted box is to be used with the Protect-A-Rail, use the 3/16" thick shims that are provided along with the 2" mounting pads that were cut off in Step 1. This will ensure a level mounting of the box. Make sure the box cover(s) can be fully opened without hitting the louvered Protect-A-Rail. Check to make sure all fasteners are tight.

ALUMINUM TRUCK BED INSTALLATION:

Use vinyl tape as a barrier between the “J” Bolt and truck bed.

FASTENERS SUPPLIED WITH BOX

CAB PROTECTOR

to the bed lip

MOUNTING PAD SUPPLIED WITH BOX

SHIM

SHIM PAD

BED LIP

“J” BOLTHook “J” Bolt

Page 6

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

What is Covered

All WEATHER GUARD® Products identied 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 or (b) replacing the entire WEATHER GUARD® Product. In addition, the Manufacturer may elect at its option, not to repair or replace the 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 a 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 modication 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® Product in accordance with the Manufacturer’s written instructions or guidelines included with the WEATHER GUARD®

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.

Notication 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 modications 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 notication and repair procedures. Warranty claims must include reciprocal contact information and may be made via certied 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

WEATHER GUARD® Products are protected by one or more of the following trademarks: U.S. - 842268, 1661625, 1663369, 1750034, 2228051, 2291111, 2362167; Canada - 282725; U.K. - 1400720; N.Z. - 296049; AUS - 761964. Other trademarks pending.

WEATHERGUARD.COM

Part No. 24-0094 REV. E ECN 5583 05/15