WEATHER GUARD 246-3-02 User Manual [en, es, fr]
INSTALLATION MANUAL
Aluminum & Steel Hi-Side/Super Side Boxes
TRUCK STORAGE SOLUTIONS
SECURING YOUR REPUTATION
ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS
BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT.
Model# ________________ Serial#__________________
®
PRODUCT REGISTRATION
Model 246-3-02 through 396-5-02
WWW.WEATHERGUARD.COM
Purchased Date:
For your convenience,
place product
registration tear-off
sticker here.
______________________
Place of purchase:
______________________
Key Code:
______________________
DANGER
Danger of explosion. Do not use this product for storing or transporting flammables, explosives, hazardous materials, or hazardous waste,
such as containers of gasoline, solvents, gun powder, dynamite, propane tanks, acetylene tanks and cutting torches. Failure to heed this
warning will result in death or serious injury.
WARNING
This product is only intended and safe for use in storing and transporting small tools, equipment and other similar materials. This product
can reduce the driver's ability to clearly see road-ways, vehicular or pedestrian traffic 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 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. All floor mounting
bolts near the fuel tank area should be installed from the underside of the vehicle, to guard against the fuel tank being punctured in the event
of a collision. This would mean not using Blind Fasteners in this area. Holes in this area should be 5/16". Ensure ample space in roof ribs and
sidewall ribs for mounting screws so as not to puncture exterior roof or wall.
Do not install this product where it could interfere with deployment of air bags. Failure to comply could result in death or serious body injury.
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 may result in moderate injury.
– 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.
1
Part No. 24-0295 REV. B ECN 5305 04/13
INSTALLATION TIME
Approximate installation time: 42 minutes per unit (0.7 hours) depending on truck equipment installation experience.
TOOLS REQUIRED
• 1/2" Open or Box End Wrench (2)
• Electric Drill
• 1/2" & 3/8" Drill Bits
• Carpenters Square
• Utility Knife or Scissors
• Tape
• 9/16" Open or Box End Wrench
• Measuring Tape/Ruler
• Pencil/Sharpie
PARTS LIST
• 1 - Hi-Side (or Super Hi-Side) Box • 2 - Legs • 2 - Mounting Pads (20" and/or 27" and/or 45")
BOLT KIT 32-0028
NOTE: Depending on your application you may end up with extra hardware after installation is complete.
DESCRIPTION QTY.
1-3/4" Round Cap Plug 1
5/16" Lock Washer 8
5/16" Flat Washers 14
5/16-18 Blind Fastener 4
Installation Tool 1
5/16-18 x 2-1/4" Black Oxide Bolt 1
5/16-18 x 1-1/4" Hex Bolt 4
5/16-18 x 1" Hex Bolt 4
5/16-18 Nylon Lock Nut 12
"J" Bolt 4
Plastic Retaining Washer 4
Fender Washer 4
2
INSTALLATION INSTRUCTIONS
NOTE: If installing the box on top of a stake bed, disregard these instructions. Mount the box with the bottom fully
supported or structural damage will occur to the box.
NOTE: When installing in a pickup bed the box must be installed per these instructions using the mounting legs supplied.
This box must never be bolted to a ladder rack or structural damage will occur to the box.
NOTE: To prevent rust from occurring, touch-up any drilled holes.
STEP 1. Park the vehicle as level as possible.
STEP 2. Turn the box over, and at each end of the box, mark a 6" long line 7/8" in from and parallel to the end. Start the line at
the front of the bottom (see Figure 1). For Models 272-3-02/290-3-02/291-3-02/296-3-02/297-3-02/ 372-X-02/390-X-02/391-X02/396-X-02, mark a 6" long line centered side to side on the box, 12" apart (see Figure 1.).
6" long line7/8" in from
end of box
3/8" Holes -
typical unless
Line marked
even with
bed lip
Front
of Box
stake beds interfere see instruction text
6" long linescentered
side to side
12" apartonly for Models
272-3-02/290-3-02
291-3-02/296-3-02
297-3-02/372-X-02
390-X-02/391-X-02/396-X-02
6" long line7/8" in from
1/2"
Mark this line
even with bed lip-
only for Models
272-3-02/290-3-02
291-3-02/296-3-02
297-3-02/372-X-02
390-X-02/391-X-02
396-X-02
Line marked
even with
bed lip
end of box
Figure 1. Box Marking
7/8"
STEP 3. Place the Mounting Pads in position on top of the truck bed (as shown in Figure 2.). Tape the Mounting Pads to the truck
bed in a few places to keep them from moving or falling off when installing the box.
3"
Max.
5/16-18 x 1-1/4"
Hex Head Bolt
5/16 Lock
Washer
Figure 2. Main Assembly View
5/16 Flat
Washer
Blind
Fastener
5/16-18 Nylon
Lock Nut
1/2" Hole
3
5/16 Flat
Washer
3/8" Holes
See
NOTE 1
Leg
5/16-18 Nylon
Lock Nut
5/16 Flat
Washer
Fender
Washer
Plastic
Retaining
Washer
5/16-18 x 1"
Hex Head Bolt
Mounting
Pad
"J" Bolt
STEP 4. Place the box in position on the bed side, support the rear of the box with scrap lumber or cribbing, and square the box to
the bed. Level the box so the top is horizontal when viewed from the rear.
NOTE: Fasten the leg mounting feet directly to the oor, not on bed liners or oor mats.
STEP 5. Place one leg close to the rear corner of the box using a square to get a proper vertical setting. The closer the legs are
mounted to the rear corner, the more stable the box will be.
NOTE: Leg can be mounted up to 3" maximum from rear corner of box (see Figure 2 inset).
NOTE 1: The foot of the Leg must be squarely mounted on or between the tops of the oor ribs.
STEP 6. Mark both leg foot holes on the oor of the truck bed, and both leg top holes in the end of the box.
STEP 7. Repeat leg placement and marking process at the other end of the box.
STEP 8. Using the bed lip as a guide, mark the underside of the box at the point where the box and bed lip meet at the ends of
the box, and in the center of the box if installing a 272-3-02/290-3-02/291-3-02/296-3-02/297-3-02/372-X-02/390-X-02/391-X02/396-X-02 (see Figure 1). If there is a stake pocket in the truck bed below the point where any of the 6" long lines intersect the
truck bed, mark the truck bed at that point.
STEP 9. Remove the box and turn it over. Mark the box in two locations for drilling (four for Models 272-3-02/290-3-02/291-302/296-3-02/297-3-02/ 372-X-02/390-X-02/391-X-02/396-X-02). Mark these holes 1/2" inward of the marked line, and on the 6"
long lines (see Figure 1).
STEP 10. If a stake pocket interfered with any "J" bolt mounting location, it will be necessary to drill the box with a 1/2" drill for
that "J" bolt, and to drill the stake pocket at the mark with a 1/2" drill bit, with the top of the hole even with the bottom edge of the
bed lip. Drill all box marks with a 3/8" drill bit. Drill the oor marks with a 1/2" drill bit. Install Blind Fasteners in the oor (See Blind
Fastener Instructions).
STEP 11. Fasten the Legs to the box.
STEP 12. Install the “J” Bolts through the holes you have drilled, and attach the Plastic Retaining Washer
Nylon Lock Nut (see Figure 3.). Tighten the nut to the top threads of the “J” Bolt 1/4 turn into the nylon.
5/16-18 Nylon
Lock Nut
Fender
Washer
, Fender Washer and
Mounting
Plastic
Retaining
Bed Lip
Pad
Washer
"J" Bolt
Figure 3. "J" Bolt Fastening
STEP 13. Stand the box upright and turn the “J” bolts to the side so they won’t interfere when placing the box on the bed of the
truck. Set the box in place on the truck bed.
NOTE: When placing the box back in position, if it was necessary to drill a stake pocket, that "J" bolt will have to be held
on an angle from the underside of the box and guided into the hole in the stake pocket.
STEP 14. Fasten the Leg feet to the oor.
STEP 15. Turn the “J” bolts so they are under the lip of the bed. Pull the “J” Bolt up until it contacts the lip of the bed. Push the
Plastic Retaining Washer down, using the Fender Washer, so the “J” Bolt is held in position. Tighten the Nylon Lock Nut, making
sure the “J” Bolt hook remains under the lip of the truck bed.
NOTE: Periodically check the tightness of "J" bolts to insure proper attachment.
STEP 16. Snap the Cap Plug into the bottom hole (plug may be pulled when cleaning inside the box).
4
INSTALLATION INSTRUCTIONS USING BLIND FASTENERS
STEP 1. Place a drop of oil on the black oxide bolt before
assembling.
STEP 2. Place the Blind Fastener in the hole and use a 1/2"
wrench to tighten black hex bolt until the blind fastener is fully
seated.
1/2” Wrench
(Or 1/2” Socket)
Black Oxide Bolt
NOTE: 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.
FOR ADDITIONAL REPLACEMENT PARTS GO TO WWW.WEATHERGUARD.COM
PART NO. DESCRIPTION
70136 ARMOR TUF® Brite White Touchup Paint 1/2 oz.
32-0028 Bolt Kit
7749 Grommet Kit
7101-3 Replacement Hi-Side Leg-White
886-1CN WEATHER GUARD® White Touch up Paint 12 oz.
7101-5 Replacement Hi-Sides Leg-Black
Flat Washer
9/16” Wrench
Installation Tool
Blind Fastener
SERVICE PARTS
PART NO. DESCRIPTION
70159-5 Replacement Door 347/391-5-02
70160-0 Replacement Door 364-0-02
70160-5 Replacement Door 364-5-02
70161-0 Replacement Door 365-0-02
70161-5 Replacement Door 365-5-02
70168-XXX D-Handle Lock Cylinder (XXX = Key Code)
70167-XXX D-Handle Lock Kit (XXX = Key Code)
70151-3 Replacement Door 246/290-3-02
70152-3 Replacement Door 247/291-3-02
70153-3 Replacement Door 264-3-02
70154-3 Replacement Door 265-3-02
70155-3 Replacement Door 272-3-02
70156-3 Replacement Door 296-3-02
70157-3 Replacement Door 297-3-02
70158-0 Replacement Door 346/390-0-02
70158-5 Replacement Door 346/390-5-02
70159-0 Replacement Door 347/391-0-02
70162-0 Replacement Door 372-0-02
70162-5 Replacement Door 372-5-02
70163-0 Replacement Door 396-0-02
70163-5 Replacement Door 396-5-02
70164 Door Cables (13") and Caribiners
70165 Door Cables (16") and Caribiners
70166 Door Cables (24") and Caribiners
70169 Latch Rods for 246/247/346/347/290/291/390/391-X-02
70170 Latch Rods for 264/265/364/365-X-02
70171 Latch Rods for 272/372-X-02
70172 Latch Rods for 296/297/346-X-02
70173 Weather Strip Kit for "-02" Hi-Sides/Super Sides
5
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 wor
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.
kmanship from the date of purchase and
What is Covered
All WEATHER GUARD
®
Products identified 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. In addition, the manufacturer may elect at its option, not to repair or replace the WEATHER GUARD
®
Product or (b) replacing the entire 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 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
modification 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.
Notification 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 modifications 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 notification and repair procedures. Warranty claims
must include reciprocal contact information and may be made via certified mail to:
Knaack LLC
A WTTN: arranty Claims
420 TE. erra ACotta
Crystal Lake,
venue
IL 60014
If you have any questions, please call toll free at 1-800-456-7865.
©2013 Knaack LLC
6
Part No. 24-0295 REV. B ECN 5305 0
4/13
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