Weather Guard 236-3-03, 234-3-03 User Manual

ASSEMBLY AND INSTALLATION INSTRUCTIONS FOR

FULL SIZE SINGLE & DUAL SIDED QUICK CLAMP RACK

WWW.WEATHERGUARD.COM

MODELS 236-3-03 AND 234-3-03

VAN SOLUTIONS

FOR THE WAY YOU WORK

TM

Weather Guard / Knaack 800-456-7865 (Toll Free)
420 E. Terra Cotta Ave. 800-334-2981 (Fax)
Crystal Lake, IL 60014 USA [e-mail]

Weather Guard / Knaack 888-562-2251 (Toll Free)
9133 Leslie St. Unit 105 888-456-8460 (Fax)
Richmond Hill, ON L4B4N1 [e-mail]

WWW.WEATHERGUARD.COM

*24-0308*

1

Part No. 24-00022 REV. B ECO 102669 08/16

ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS

BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT.

BEFORE YOU BEGIN

• WEATHER GUARD ladder racks are designed to work with OEM side gutters or with WEATHER GUARD

®®

Mounting Channel kits to provide the best support for your ladders and to take advantage of OEM provided
roof mounting points. If you have not already installed the mounting channel kit to the van roof, install it now
before proceeding.

• We recommend that you use mounting channels to mount the ladder rack on to the roof due to the mounting
channels being able to distribute the load more evenly. We have provided spacers that can be used to mount
directly to the roof, but please consult the vehicle manufacturer to determine the load capacity allotted for the
roof.

• Review vehicle manufacturer’s roof mount recommendation.

• Perform the installation on a leveled surface.

• Always wear protective eyewear to keep debris out of your eyes when installing WEATHER GUARD Van

®

Products.

• All of the nylon lock nuts are torqued to 17 ft-lb when ready.

MOUNTING LONG LADDERS ON VANS

Ladders transported on a vehicle should be properly supported and the overhang of the ladders beyond
supporting points should be limited. Transporting a ladder with excessive overhang can result in reduced
ladder life. Inspect your ladder before each use. Follow ANSI 14.2-2007 for direction on securing ladders to
ladder racks.

Follow manufacturer’s guidelines for maximum allowable roof load. Do not overload the vehicle’s roof.

HARDWARE KIT

DESCRIPTION

5/16-18 x 1-3/4” SS Carriage Bolt

5/16-18 x 1-1/4” SS Carriage Bolt

5/16-18 x 7/8” SS Carriaage Bolt

5/16-18 SS Nylon Lock Nut

5/16” SS Washer

1/4-20 x 1/2” SS Taptite Screw

1/2” OD 1/8” SS Spacers

234-3-03 236-3-03

8

16

32

64

64

2

8

8

16

24

56

56

2

8

• Electric drill-driver

• 1/2” ratchet wrench

• 1/2“ and 3/8” socket

• Needle nose pliers

• Open end wrenches 7/16” and 9/16”

TOOLS REQUIRED

M8-1.25 x 40mm SS Cap Screw

4

4

2

236-3-03 FULL SIZE SINGLE QUICK CLAMP RACK PARTS LIST

Vertical

Ladder Stop

Ladder Guide

Universal

Mounting Base

Mounting Foot

Bolt Plate

J- Bracket

Plate Mount

Level

Ladder Stop

Clamp

Ladder Stop

Clamp Mount

Gutter Mount

Clamp

Stud Plate

Pivot Plate

Bracket

Nylon Bearing

DESCRIPTION

Cross Member

Ladder Guide

Ladder Stop Clamp

Ladder Stop Clamp Mount

Passenger Side

Quick Clamp

Handle

QTY.

Gas Spring

Passenger Side

Front Rail

Passenger Side

Rear Rail

Gas Spring

Guard

DESCRIPTION

2

2

2

1

Front Rails

Rear Rails

Quick Clamp Handle

QC Handle Pivot Plate

QTY.

1 (PS)

1 (PS)

1 (PS)

1

Universal Mounting Base

Mounting Level Plate

Mounting Foot Bolt Plate

Curved Mounting foot Bracket

Stud Plate

4

4

4

4

4

QC Nylon Bearing

Vertical Ladder Stop

Gas Spring

Gas Spring Guard

Gutter Mount Clamp

3

2

2

1

1

4

234-3-03 FULL SIZE DUAL QUICK CLAMP RACK PARTS LIST

Ladder Stop

Driver Side

Front Rail

Clamp

Driver Side

Rear Rail

Driver Side

Quick Clamp

Handle

Nylon Bearing

Universal

Mounting Base

Stud Plate

Gas Spring

Pivot Plate

Bracket

Mounting Foot

Bolt Plate

Plate Mount

Level

Gas Spring

Guard

Ladder Guide

J-Bracket

Ladder Stop

Clamp Mount

Gutter Mount

Clamp

Passenger Side

Front Rail

Passenger Side

Rear Rail

DESCRIPTION

Cross Member

Ladder Guide

Ladder Stop Clamp

Ladder Stop Clamp Mount

Universal Mounting Base

Mounting Level Plate

Mounting Foot Bolt Plate

Curved Mounting foot Bracket

Stud Plate

Passenger Side

Quick Clamp

Handle

QTY.

2

2

2

2

4

4

4

4

4

DESCRIPTION

Front Rails

Rear Rails

Quick Clamp Handle

QC Handle Pivot Plate

QC Nylon Bearing

Vertical Ladder Stop

Gas Spring

Gas Spring Guard

Gutter Mount Clamp

QTY.

DS/PS

DS/PS

DS/PS

2

4

0

2

2

4

4

INSTALLATION INSTRUCTIONS

STEP 1A. LOOSELY INSTALL J-BRACKET TO UNIVERSAL MOUNTING BASE
(Ford Transit, RAM Promaster, Nissan NV, and MB Sprinter)
Using (2) 7/8” tall carriage bolts, (2) washers, and (2) nylon lock nuts.

NOTE: J-bracket can be installed in multiple configurations to result in the best fitment to your vehicle.
Bolts can be installed from both direction. Most vehicle installations will benefit from having the lowest
installed height with the mounting bracket lining up with the start of the curve on the J-bracket. Due to
vehicle roof curvatures, some adjustment for final assembly height may be required after the cross
members are installed on the roof.

VEHICLE

OR

STEP 1B. LOOSELY ASSEMBLE GUTTER MOUNT CLAMP AND J-BRACKET TO UNIVERSAL MOUNTING BASE
(GMC Savana / Chevy Express, and Ford E-Series)

Using (2) 1-1/4” tall carriage bolts, (1) 1-3/4” tall carriage bolt, (3) washers, and (3) nylon lock nuts.

NOTE: J-bracket must be installed as shown but it can be mounted on either top or bottom set of square
holes on the universal mounting base (bottom mounting position shown below).

5

INSTALLATION INSTRUCTIONS

STEP 2. MOUNT MOUNTING FEET TO CROSS MEMBERS

Use one 7/8” carriage bolt, washer and nylon lock nut per mounting foot, Install feet to cross member,
Refer to table and diagram below for mounting foot location and orientation.

NOTE: Mounting feet can be installed in the other direction if need be (Toes in vs. Toes out).

MOUNTING FOOT DISTANCE

Ford Transit

RAM Promaster

Nissan NV

MB Sprinter

GMC Savana / Chevy Express *

Ford E-Series *

F: 58-7/8”

F: 62-7/8”

A

55-1/2”

59-5/8”

59-3/8”

53-1/4”

F: 57-7/8”

F: 60-3/4”

F: 5-1/16”

F: 3-1/16”

B

6-3/8”

5-7/8”

8-1/2”

8-13/16”

F: 5-5/8”

F: 4-1/8”

MOUNTING METHOD

WG Mounting Channel

WG Mounting Channel

WG Mounting Channel

WG/OEM Mounting Channel

Gutter Mount

Gutter Mount

* Due to the curvature of the gutter on each van, the dimensions given are a reference point.
Please make appropriate adjustments to ensure a tight and secure t, with the cross member
centered on the width of the van.

6

INSTALLATION INSTRUCTIONS

STEP 3. INSTALL FRONT RAIL ASSEMBLY

Using (2) 1-1/4” tall carriage bolts, (2) washers, and (2) nylon lock nuts.

STEP 4. INSTALL PIVOT PLATE BRACKET ON REAR CROSS MEMBER

Using (2) 7/8” tall carriage bolts, (2) washers, and (2) nylon lock nuts.

NOTE: Mount using 2 and 4 on the passenger side. Use 1 and 3 when mounting to driver side (234-3-03).

7

INSTALLATION INSTRUCTIONS

STEP 5. INSTALL REAR RAIL ASSEMBLY

A. Loosen the adjustable end fitting of the gas spring such that the mounting socket on either end are
facing opposite directions. Slide the gas spring guard over the gas spring as shown below.

B. Insert nylon bearings into pivot plate bracket as well as on the rear rail assembly.

C. Install handle by sliding it into the nylon bearing on the pivot plate bracket. Install gas spring onto ball
stud on the handle.

D. Slide the nylon bearing installed on the rear rail assembly onto the handle. Install gas spring onto ball
stud on the rear rail assembly.

E. Tighten rear rail assembly to rear cross member by using (2) 1-1/4” tall carriage bolts, (2) washers, and
(2) nylon lock nuts.

NOTE: For 234-3-03, install driver side front and rear assembly by following the same sequence above.

8

INSTALLATION INSTRUCTIONS

STEP 6. INSTALL DRIVER SIDE VERTICAL LADDER STOP (236-3-03 ONLY)

Using (2) 1-1/4” tall carriage bolts, (2) washers, and (2) nylon lock nuts, fasten the vertical ladder stop.

STEP 7. RACK ASSEMBLY

With the front and the rear cross member assembly on the roof, insert the rear rail into the front rail.
Use the 1/4-20 x 1/2” taptite screws through the obround near the tip of the front rail to fasten the
rails together. Use a drop of thread locking adhesive.

NOTE: If installing a 233-3-03 Accessory Quick Clamp cross member, do not use the thread locking
adhesive yet. Refer to the 233-3-03 instruction manual.

9

INSTALLATION INSTRUCTIONS

STEP 8. INSTALL LADDER CLAMPS

Rear Assembly
Place the ladder on the rack to adjust the clamp position fit fit your ladder.
Using (2) 7/8” tall carriage bolts, (2) washers, and (2) nylon lock nuts, fasten the rear clamp as shown.

Front Assembly
Place the ladder on the rack to adjust the clamp position fit your ladder.
Using (2) 7/8” tall carriage bolts, (2) washers, and (2) nylon lock nuts, fasten the rear clamp as shown.

Front Assembly Option 1 Front Assembly Option 2

NOTE: Use option 1 for most standard extension ladder applications and option 2 for some step ladder

applications.

10

INSTALLATION INSTRUCTIONS

STEP 9. INSTALL LADDER GUIDES

Place the ladder on the rack to adjust the ladder guide position fit fit your ladder.
Using (2) 1-1/4” tall carriage bolts, (2) washers, and (2) nylon lock nuts, fasten the ladder guide.

STEP 10A. MOUNT CROSS MEMBERS TO VEHICLE - (Ford Transit, Nissan NV, and MB Sprinter)

Slide two stud plates per mounting channel if not already done. Lift the assembled ladder rack and
place it on the stud plates on all four corners . Use (2) washers, (2) nylon lock nuts, and a bolt plate
to fasten each mounting foot.

11

INSTALLATION INSTRUCTIONS

STEP 10B. MOUNT CROSS MEMBERS TO VEHICLE - (GMC Savana / Chevy Express, and Ford E-Series)

Make sure that the gutter is clamped between the gutter clamp and the inverted J-bracket.

Gutter Position

Position the cross member to desired position and tighten the two nuts to 17 ft-lb. Vertically constrain
the inverted J-bracket and the gutter clamp using one 1-3/4” carriage bolt, washer, and a nut.

STEP 10C. MOUNT CROSS MEMBERS TO VEHICLE - (RAM Promaster)

The 2113-0-01 or 2115-0-01 mounting channel kits are used on RAM Promaster vans. For 159”
wheel-base and the 159” wheel-base extended versions as well as 136” wheel-base with the
2113-0-01 mounting channel kit, the rear cross member is mounted directly to the rear-most
mounting point on the roof. The front cross member and the center cross member (if used), mount
to the channels as shown in step 10A.

2

6

1

3

1. Rotate roof cleat 90°

2. Place stud plate over cleat.

3. Rotate roof cleat back to the original position.

4. Place channel over studs.

5. Place brackets over the channel.

6. Retain with 5/16-18 nut and washer.

4

5

STEP 11. TIGHTEN DOWN ALL HARDWARE

Make sure everything is aligned and installed properly and torqued to 17 ft-lb.

12

SERVICE PARTS

PART NO.

7870

7707

2070-3-01

7830-3-01

7577-3-01

7831-3-01

7578-3-01

70514

72213

72214

DESCRIPTION

Ladder Guide

Ladder Stop Clamp

70” Cross Member & Mounting Feet

Passenger Side Front & Rear Rail

Passenger Side Handle

Driver Side Front & Rear Rail

Driver Side Handle

Vertical Post

Rear Handle Pivot Plate Bracket

Bolt Kit AP

72215

72216

72217

Bolt Kit QC

Bolt Kit 125

Gutter Clamp Kit

13

WARNING

This product can reduce the driver’s ability to clearly see roadways, vehicular or pedestrian traffic and other objects through the rear and
side windows of the vehicle, which can 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 and seating positions. State and local
laws may prohibit obstruction of windows in a moving vehicle.

These instructions are to be followed using the parts and fasteners supplied for proper installation. Any modifications or improper installation
of this product will create a hazardous condition that could result in death, serious personal injury and/or property damage.

CAUTION

Prior to drilling, so as not to cut electric wires, fuel lines, brake lines, etc., check behind and underneath drilling and mounting locations. To keep
debris out of your eyes when checking the underside of the vehicle, or when drilling, always wear protective eye wear. Failure to heed this warning
will result in death or serious injury.

– NOTICE –

Any modification or unintended use of this product shall imediately 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.

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
(the “WEATHER GUARD
the WEATHER GUARD
terminates if the original purchaser transfers the WEATHER GUARD

What is Covered
All WEATHER GUARD

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

®

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
be used toward the purchase of new WEATHER GUARD

What is Not Covered
This limite

No
This Limited Lifetime Warranty is the sole and exclusive warranty for WEATHER GUARD

alter this warranty or make any other warranty on behalf of Knaack LLC.

Noti

If the WEATHER GUARD
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 modificatio ns made to the WEATHER GUARD
Product by ot
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:

d 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

• 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
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

Other Express Warranty Applies

cation Pro cedures

her than the Manufacturer or its authorized agent will nullify this limited warranty. Coverage under this limited warranty is conditioned at all times upon

®

Product”) will be free from defects in material and workmanship from the date of purchase and continuing for the expected life time of

®

Product. A copy of the original sales receipt must be supplied to the Manufacturer at the time a warranty claim is made. This warranty

®

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

without charge to the original purchaser for parts or labor: (a) repairing the defective portion of the WEATHER

®

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

®

Product other than those authorized or provided by the Manufacturer.

®

Product in accordance with the Manufacturer’s written instructions or guidelines included with the WEATHER GUARD® Product or

®

Product does not conform with the terms of this limited warranty, the original owner must promptly notify the Manufacturer in writing upon

®

Product.

®

PRODUCT OR THE MANUFACTURER’S NEGLIGENCE.

®

Product to any other person.

Knaack LLC

ATTN: Warranty Claims

420 E. Terra Cotta Avenue Crystal Lake, IL 60014

Truck and Van Products

®

products. No employee, agent, dealer, or other person is authorized to

®

*24-0308*

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

©2016 Knaack LLC

14

Part No. 24-00022 REV. B ECO 102669 08/16