WEATHER GUARD 224-3-01 User Manual

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Page 1

ASSEMBLY AND INST ALLATION INSTRUCTIONS

Model 223 & 224 Quick Clamp Van Racks

(Model 223, Curbside clamping only • Model 224, Streetside and curbside clamping)

IMPORTANT

BEFORE YOU BEGIN

Read these instructions and warnings completely before assembly and installation.

223 / 224 PARTS LIST

• 4- Clamp Bar

• 4- Mounting Bracket

• 1- Front Crossmember w/ Airfoil

• 1- Rear Crossmember

• 2- Ladder Guide (223)

• 4- Ladder Guide (224)

• 2- Top Adjustable Clamp (223)

• 4- Top Adjustable Clamp (224)

• 1- Bottom Adjustable Angle (223)

• 2- Bottom Adjustable Angle (224)

• 4- Stand

• 1- Passenger Side Front Rail

• 1- Driver Side Front Rail

• 1- P.S. Rear Rail w/ handle plate

• 1- D.S. Rear Rail w/ bolt plate (223)

• 1- D.S. Rear Rail w/ handle plate (224)

• 1- P.S. Handle Assembly

• 1- D.S. Handle Assembly (224)

• 4- Mounting Pad

• 2- Roof Mounting Plate

The distinctive, trademarked RED TIPS are your assurance of WEATHER GUARD® Equipment quality.

BOLT KIT

Bolt Kit #32-0155 with Model 223 and Bolt Kit #32-0156 with Model 224. Check these bolt kits to be sure the following parts are included:

Approximate Assembly and Installation time:

223: 1 hour 48 min. per unit (1.8 hrs.) 224: 1 hour 36 min. per unit (1.6 hrs.)

Depending on van equipment installation experience

TOOLS REQUIRED

• Electric Drill

• 9/32", 13/32" drill bit

• Ratchet Wrench

• 1/2" Socket (deep well preferred)

• 3" Socket Extension

• 7/16" Socket

• 3/8" Socket

• Ruler

• 7/16" Open or Box End Wrench

• 9/16" Open or Box End Wrench

• Loctite® thread locker

Loctite® is a registered trademark of Loctite Corporation U.S.A.

WARNING

These Ladder Racks were not designed to fit 1994 and newer 113.3" wheel base Chrysler mini vans or 1994 and older Chrysler mini vans with roof gutters. If installed on these vehicles, the handle can cause serious head injuries or property damage.

32-0155 32-0156 Description

2 2 1/4-20 x 1/2" Taptite Screw SS 2 4 5/16-18 x 1-1/4" SS Carriage Bolt 28 36 5/16-16 x 7/8" SS Carriage Bolt 30 40 5/16-18 x SS Nylon Lock Nut 1 1 1/4-20 x 2-1/4" Blk. Ox. Bolt 8 8 1/4-20 x 1-1/2" SS Hex Hd. Bolt 8 8 1/4-20 SS Nylon Lock Nut 4 4 1/4" SS Lock Washer 4 4 1/4-20 Blind Fastener 1 1 Installation Tool 46 56 5/16 SS Flat Washer 8 8 Spacer - 1/8" thick 2 4 Nylon Bearing 1 1 1 oz. Tube E-6000 Sealant 2 2 Roof Mounting Pads

W ARNING

This product is only intended for, and only safe for, transporting ladders, lumber, pipe and other similar materials. It is the responsibility of the user to secure these materials to the rack before transporting. Any modifications made to this product, or use of this product for any other purpose than its intended use, could create hazardous condition that can cause serious personal injury or property damage.

Rev. A 5/05 Part No. 24-0164

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Top Adjustable Clamp

223 Driver Side Rear Rail w/ bolt plate

Driver Side Handle Assembly

Stand

224 Driver Side Rear Rail w/ handle plate

Driver Side Front Rail

Bottom Adjustable Angle

Front Crossmember (w/ Airfoil)

Mounting Bracket

Rear Crossmember 223 Rear Crossmember 224

Clamp Bar

Ladder Guide

Mounting Pad

Roof Mounting Plate

Passenger Side Handle Assembly

Passenger Side Front Rail

Passenger Side Rear Rail w/ handle plate

Figure 1. Parts Identification

Page 3

1. Crossmember / Rail Assembly

5/16-18 x 7/8" Carriage Bolt

5/16" Flat Washer and 5/16-18 Nylon Lock Nut

NOTE: Airfoil on this side of Front Crossmember when assembled.

Figure 2. Front Crossmember /

Front Rail Assembly

2. Rack Assembly

NOTE: If installing a Model 225, assemble it at this time.

Insert the Rear Rail into the Front Rail and align the holes, then fasten. Use a drop of Loctite ® on the 1/4-20 x 1/2" taptite screws (repeat on opposite side).

5/16-18 x 7/8" Carriage Bolt

NOTE: For an extended Chevy Astro, insert the Rear Rail tube into the Front Rail tube until the first Rear Rail tube hole is aligned with the front rail hole. All other vans will use the second Rear Rail tube hole.

5/16-18 x 7/8" Carriage Bolt

Nylon Bearing

Figure 3. Rear Crossmember / Rear Rail / Handle Assembly

Loosely fasten the Stands to the Crossmembers.

5/16" Flat Washer and 5/16-18 Nylon Lock Nut

5/16-18 x 7/8" Carriage Bolt

5/16-18 x 1-1/4" Carriage Bolt

NOTE: See Figure 11. Before Assembling

5/16" Flat Washer and 5/16-18 Nylon Lock Nut

Loosely fasten the Mounting Brackets to the Stands to allow them to pivot on the bolts.

5/16" Flat Washer and 5/16-18 Nylon Lock Nut

5/16-18 x 7/8" Carriage Bolt

Figure 4. Side Rail / Stand Assembly

5/16-18 x 7/8" Carriage Bolt

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3. Adjust then tighten the Stand As-

semblies to the following dimensions: Chevy Astro/GMC Safari:

Front Crossmember "A" - 1-1/16"

"B" - 56-7/8"

Rear Crossmember "A" - 5-7/8"

"B" - 47-1/4"

Ford Windstar:

Front & Rear Crossmember:

"A" - 7-5/8" "B" - 43-3/4"

4. With the help of others, lift the rack and position it on the vehicle. Locate the rear of the rack on the roof centered side to side at the dimension shown at right. Mark through the obrounds in the Mounting Brackets at the point where the Mounting Bracket radius meets the roof.

"A"

"B"

Dimension "A" should center the Stands side to side. Adjust both Stands accordingly if they are not even.

Figure 5. Stand Adjustment

Gap between Door and Roof

"A"

Dimension "A" - Stand

placement ahead of rear

edge of roof

Astro/Safari - 3" Windstar - 1-1/4"

Figure 6. Stand Placement

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Step 5 for Astro / Safari

5. Drill the marks at the rear of the

roof with a 9/32" drill bit, then apply a small bead of E-6000 around the holes. Drill the marks at the front of the roof with a 13/32" bit. Apply E-6000 Sealant to the roof around each hole. Install Blind Fasteners following the installation instructions on the back page. Once installed, fill the top of the Blind Fastener holes with E6000 Sealant. Fasten the rack (

ures 7. & 8.)

Mounting Bracket w/ Stand

Roof Mounting Plate

E-6000 Sealant

Mounting Pad

Fig-

CAUTION

Do not apply too much pressure when drilling. Too much pressure may cause dimples in the roof around the holes. Also, there may be a danger of penetrating the interior head liner.

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

1/4” Lock Washer

Clamp Bar

Spacer

Roof Mounting Pad

Roof

E-6000 Sealant

CAUTION

To keep debris out of your eyes when drilling, always wear protective eyewear.

Roof

13/32" hole with Blind Fastener installed

9/32" hole

5/16” Flat Washer

Figure 7. Astro Rear Stand Mounting

Step 5 for

Ford Windstar

5. Drill the marks with a 9/32” drill bit.

Apply E-6000 Sealant to the roof around each hole. Fasten the Rack to the roof (

Figure 9.)

1/4-20 Nylon Lock Nut

E-6000 Sealant

1/4-20 Nylon Lock Nut

Figure 8. Astro Front Stand Mounting

Roof

5/16” Flat Washer

Figure 9. Windstar Mounting

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6. Adjust the Airfoil to eliminate wind noise by bending it downward to the following dimensions:

Astro/Safari:

15/16" above roof at center 1-11/16" above roof at each end

Windstar:

11/16" above roof at center 1-5/8" above roof at each end

NOTE: These dimensions are guidelines, it may be necessary to adjust the Airfoil further.

7. Loosely fasten the Top Adj. Clamp

to the Front and Rear Assemblies. To adjust Clamps, place the ladder on the rack (Figure 12.) and adjust the clamps forward or back / up or down to capture the nearest ladder rung. Tighten the bolts.

5/16-18 x 7/8 Carriage Bolt

5/16 Flat Washer and 5/16-18 Nylon Lock Nut

This application is used for standard Extension Ladders.

5/16-18 x 7/8 Carriage Bolt

Figure 10. Rear DS Clamp

5/16 Flat Washer and 5/16-18 Nylon Lock Nut

This application will be needed for Dead-head ladders and some Step ladders.

Figure 11. Front DS Clamp

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8. Assemble the Ladder Guides

through the slots of the Crossmembers and slide up to the ladder. Tighten Fasteners.

CAUTION

To keep debris out of your eyes when drilling, always wear protective eyewear.

CAUTION

Load should be approximately centered front to rear. Failure to do this will cause damage to the vehicle roof. Long loads that extend out the rear of the vehicle will prevent the rear hatch from fully opening and cause damage if attempted.

W ARNING

Ladders must be secured per ANSI standard A142.2-1990 paragraph 8.4.4. Ladder damage will occur from road shock and vehicle vibration if the ladder is not properly secured to the ladder rack. Bouncing and side to side motion of a improperly secured ladder will cause wear and weaken the ladder. Using a damaged ladder could lead to a structural collapse and could result in a serious injury or death.

5/16" Flat Washer and 5/16"-18 Nylon Lock Nut

5/16-18 x 7/8" Carriage Bolt

Figure 12. Clamp Adjustment and Ladder Guide Installation

Page 8

INSTALLATION PROCEDURE

USING BLIND FASTENERS

CAUTION

Do not apply too much pressure when drilling. Too much pressure may cause dimples in the roof around the holes. Also, there may be a danger of penetrating the interior head liner.

Place a drop of oil on the black oxide bolt before assembling as shown on right. Place the Blind Fastener in the hole and use a 1/2” or 7/16” wrench to tighten black hex bolt until the blind fastener is fully seated. When setting black hex bolt, it will start out hard. As the Blind Fastener “bulbs” out it will get easier, until it bottoms out or sets. Make sure the Blind Fastener and Installation Tool do not turn during installation.

Black Oxide Bolt

Flat Washer

9/16” Wrench

Installation Tool

Blind Fastener

WEATHER GUARD® PRODUCT REFINISHING PROCEDURES

All WEATHER GUARD® products are finished with a polyester powder coating, and it is important to follow these procedures to get proper adhesion. As Knaack Manufacturing Co. cannot control the finishing of the products, the warranty for WEATHER GUARD® products on paint is not applicable on refinished products.

1. Sand the surface to be painted with 180-200 grit sand paper to rough up the surface. This should be followed by wet sanding with a 400 grit wet or dry paper.

2. Wipe down the sanded surface with ketone based thinner. This removes the dust and softens the powder coating for better paint adhesion.

3. Wipe sanded area with a tack rag to remove loose dust and particles before painting.

NOTE: Do not use a lacquer over the powdered coating.

- NOTICE -

Any modification 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 modification to, or unintended use of this product.

If you have any questions, please give us a call. Call Toll Free 1-800-456-7865

U.S. - 4618083, 5829654, 842268, 1661625, 1663369, 1750034, 2228051; Canada - 1235100, 282725; U.K. - 1400720; N.Z. - 296049

WEATHER GUARD® products are protected by one or more of the following patents or trademarks:

Aus. - 761964

KNAACK MANUFACTURING COMPANY

420 E. TERRA COTTA AVENUE - CRYSTAL LAKE, ILLINOIS, USA 60014

815-459-6020