WEATHER GUARD 236-3-01 User Manual

ASSEMBLY AND INSTALLATION INSTRUCTIONS

Models 234 / 236

(Model 236, Curbside clamping only  Model 234, Streetside and Curbside clamping)

IMPORTANT

BEFORE YOU BEGIN

Read these instructions and
warnings completely before
assembly and installation.

234 / 236 PARTS LIST

 2- Crossmembers
 4- Ladder Guides (234)
 2- Ladder Guides (236)
 4- Top Adj. Clamp (234)
 2- Top Adj. Clamp (236)
 2- Bottom Adj. Angle (234)
 1- Bottom Adj. Angle (236)
 1- P.S. Rear Ass'y.
 1- D.S. Rear Ass'y. (236)
 1- D.S. Rear Ass'y. (234)
 1- P.S. Front Ass'y.
 1- D.S. Front Ass'y.
 1- Airfoil
 4- 8" Mtg. Clamps
 2- 4" Mtg. Clamps
 1- Bulk Cushion Strip
 2- Center Support

 2- Center Rails

Approximate Assembly and Installation time:

234: 1 hour 20 min. per unit (1.3 hrs.)
236: 1 hour 12 min. per unit (1.2 hrs.)

Depending on van equipment installation experience

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

TOOLS REQUIRED

 Ruler
 3/8" Socket
 Ratchet Wrench
 3" Socket Extension

 Loctite® thread locker

 Electric Drill w/ 5/16" & 3/8" drill bits
 7/16" Open or Box End Wrench (2)
 1/2" Socket (deep well preferred)

WARNING

These Ladder Racks were
not designed to fit Chrysler
minivans. If installed on
these vehicles, the handle
can cause serious head
injuries or property damage.

BOLT KIT

Bolt Kit #32-0159 with Model 236 and Bolt Kit
#32-0157 with Model 234. Check these bolt
kits to be sure the following parts are included:

32-0159 32-0157 Description

4 4 1/4-20 x 1/2" Taptite Screw
3 3 1/4-20 x 3/4" Hex Hd. Bolt
33 42 5/16" Flat Washer
4 6 5/16-18 x 1-1/4" Carriage Bolt
25 32 5/16-18 x 7/8" Carriage Bolt
33 42 5/16-18 x Nylon Lock Nut
3 3 1/4-20 Nylon Lock Nut
6 6 5/16-18 x 2" Carriage Bolt

WARNING

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 a hazardous
condition that can cause serious personal injury
or property damage.

Rev.A 4/04 Part No. 24-0181

2

DS Handle

DS Handle

Ladder Guide

PS Rear

Crossmember

Center Rail

234
DS Rear

Center Support

Bottom Adj Angle

236
DS Rear

DS Front

Top Adj Clamp

4" Mtg Clamp

Figure 1. Parts Identification

PS Front

Airfoil

8" Mtg Clamp

1. Airfoil to Front Crossmember Assembly

CAUTION

Cut off Dodge Airfoil
straight through notch
and remove burrs

Dodge mounting holes

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

If mounting a Conduit Carrier
remove appropriate knockouts for "U"
Clamp mounting clearance.

Center the Airfoil side to side on the
Crossmember. Mark the center
mounting hole and drill a 5/16" hole.

Ford / GM mounting

this hole only

Figure 2. Airfoil

1/4-20 Nylon
Lock Nut

Use this portion for Dodge vans only.

All other vans use entire Airfoil.

1/4-20 x 3/4"
Hex Hd. Bolt

Airfoil is to face forward.

Figure 3. Ford / GM Front Crossmember to Airfoil marking/fastening

Center the Airfoil side to side on the
Crossmember. Mark the mounting
holes on the top and drill the 5/16"
holes.

1/4-20 x 3/4"
Hex Hd. Bolt

1/4-20 Nylon
Lock Nut

Airfoil is to face forward.

Figure 4. Dodge Ram Front Crossmember Airfoil marking/fastening

3

4

2. Rack Assembly

1996 and newer Chevy GMT 600/GMC
Savana use these two holes
(Ford/Dodge mounting holes
shown in use).

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

NOTE: If installing a Model 233, as­semble it at this time, and use it in
place of the Center Supports.

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

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

Not used on Chevy
GMT600/GMC
Savana vans, use
only two bolts
through the Bottom
Adj. Angle.

NOTE:
See Figure 11.
before assembly

Align Center Rail holes, with holes
in both front and rear rails, then
fasten (repeat on opposite side).

Use a drop of Loctite
1/4-20 x 1/2" Taptite screws.

NOTE:
Holes have been predrilled in the rails to allow for
the adjustment of the rack to the length that best fits
what is needed. (80-1/16", 93-5/16", 105-9/16")
These dimensions are center to center on the stands.

Figure 5. Side Rail / Crossmember / Center Rail / Center Support Assembly

Center Rail

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

® on the

Loosely tighten fully
seated Crossmembers.
Repeat the procedure
on the opposite side.

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

3. Mounting Cushion Installation

Mounting Cushion (cut from bulk)
cut to length and wrapped around
each Stand and Center Support.

Figure 6. Mounting Cushion Installation

4. Adjust the stands to the approxi­mate gutter width dimensions below.
With the help of others, lift the rack
and position it on the vehicle. For
proper clamping on all vans except
the 1996 and newer Chevy GMT600/
GMC Savana, locate the stands as
close as possible to the roof. Make
sure the Crossmembers are centered
between the stands before tightening
the Crossmember/Socket bolt.

Figure 7. Breaking spot weld

8"
MAX

NOTE: If van has a sliding door
with a guard, it may be necessary
to remove and notch the guard to
accept the mounting clamp. If the
guard is spot welded, simply place
the blade of a common screwdriver
at the weld and strike with a ham­mer. This will give the guard flex­ibility to insert the Clamp
under the rain gutter.

8" Max dimension is from the rear
edge of the rear Stand to the rear
of the gutter.

Approximate Gutter Widths

Front Center Rear

Ford 64-1/4" 64-1/4" 62-3/4"

Dodge 65-1/4" 64-7/8" 64-1/2"

GM* 66-1/8" 66-3/4" 64-3/4"

GM** 58-3/4" 58-3/4" 57-3/8"

* - 1996 and older GM vans
** - 1996 and newer Chevy GMT600/

GMC Savana vans

Figure 8. Rear Stand Location

5/16-18 Carriage Bolt
GM van use 1-1/4" long bolt
Ford or Dodge van use 2" long bolt.

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

5/16-18 x 2"
Carriage Bolt

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

Figure 9. Clamp Installation

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

5

5. Airfoil to Socket Drilling and Fastening

Drill 5/16" holes in Airfoil using
holes in socket flange as a
guide.

NOTE: Be careful not to thrust the
drill into the vehicle roof. A block of
wood held under the Crossmember
will help avoid this.

1/4 -20 Nylon Lock Nut

6. Loosely fasten the Top Adj. Clamp
to the Front and Rear Assemblies. To
adjust Clamps, place the ladder on
the rack (Figure 13.), and adjust the
clamps forward or back / up or down
to capture the nearest ladder rung.
Tighten the bolts.

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

1/4-20 x 3/4"
Hex Hd. Bolt

Figure 10. Airfoil/Socket

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

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

Figure 11. Rear DS Clamp

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

6

Figure 12. Front DS Clamp

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.

9. Assemble the Ladder Guides

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

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

Figure 13. Clamp Adjustment

CAUTION

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

WARNING

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 an 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

Figure 14. Ladder Sway Brace

7

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, 2362167; Canada - 1235100, 282725; U.K. - 1400720;

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

N.Z. - 296049; Aus. - 761964; other patents and trademarks pending.

KNAACK MANUFACTURING COMPANY

420 E. TERRA COTTA AVENUE - CRYSTAL LAKE, ILLINOIS, USA 60014 - 815-459-6020

©2004 Knaack Manufacturing Company