WEATHER GUARD 253 User Manual

MODEL 253 EZ-GLIDE™SYSTEM

GM / CHEVY MINI VAN

ALUMINUM DROP DOWN LADDER RACK

–ATTENTION–

ead and understand all instructions and warnings before operating or using this product.

R

WARNING

This product is only intended and only safe for transporting ladders. It is the responsibility of the user to secure these
materials to the rack before transporting.

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 structural col­lapse resulting in serious injury or death. Place ladder in a raised position before transporting. Driving with rack in lowered
position may cause serious injury or damage to vehicle, ladder, rack or persons.

–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.

CAUTION

Never load your rack to exceed the safe capacity of your vehicle. Heavy loads when carried high can dangerously alter the
center of gravity.

Loads 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.

ASSEMBLY INSTRUCTIONS

TOOLS REQUIRED

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

• 3/8" Drive Sockets
9/16" - 1/2" - 7/16"

• 3/8" Drive Ratchet

• 5/16" Drill Bit

• Electric Drill

• Phillips Screwdriver (Large)
Needle Nose Pliers

•

• 3/8" Drive Torque Wrench (in. lbs.)

• Tape Measure

• Flat Scewdriver (small)

PARTS LIST

See Page 2

2 - Cross-Members

•

• Rear Rotation Assembly

• Front Rotation Assembly

Assemblies

2 - Pivot

•

• Rear Drive Tube/Handle Assembly
Front Drive

•

• Center Drive Tube

• Cylinder

• 4 - Mounting Brackets

• 2 - Ladder Supports

• 2 - Ladder Stops

• 2 - Drivers Side End Stops

• 2 - White Plastic Bushings

• 2 - Black Plastic Bushings

• 1 - Tube E-6000 Sealant

• 15- 1" Dia. Vinyl Hole Covers

• 1 - Tube Loctite 290

Arm

T

ube

120 min. per unit (2 hrs.) depending on van equipment and installer experience.

Read these instructions and warnings completely before installation.

Check these kits to be sure the following parts are included.

1 ROTATION KIT:

2 3/8-16 x 2-1/4" Hex Hd. Bolt
2 3/8-16 Nylon Lock Nut
11 3/8" Flat Washer
4 5/16-18 x 2" Hex Hd. Bolt
9 5/16-18 Nylon Lock Nut
12 5/16" Flat Washer
3 5/16-18 x 4-1/2" Hex Hd. Bolt
2 5/16-18 x 2-3/4" Hex Hd. Bolt
8 Flat Plastic Bushings

Aluminum Bushing

1

Clevis Pin

1
1 Cotter Pin

Bushing Lubricant

1

Approximate assembly and Installation time:

IMPORTANT BEFORE YOU BEGIN

HARDWARE KITS

See Page 3

2 GUTTERLESS KITS:

6 5/16-18 x 2-3/4" Hex Hd. Bolt
4 5/16-18 x 1" Hex Hd. Bolt
4 5/16-18 x 1-1/4" Hex Hd. Bolt
14 5/16-18 Nylon Lock Nut
24 5/16" Flat Washer
4 5/16" Rubber Washer
4 1-1/2" O.D. Fender Washer
2 Mounting Pad-Rubber See Page 2
2 Mounting Bases-See Page 2

TION KIT

A

Tube

RETRO ROT

1

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

Hd. Screw
5/16-18 x 4" Hex Hd. Bolt

2
4 5/16-18 Nylon Lock Nut
6 3/8" Flat Washer

:

Crossmembers

Qty. 2

Front Rotation Assembly

Qty. 1

Pivot Arms

Qty. 2

Rear Drive Tube/Handle Assembly

Qty. 1

Front Drive Tube

Qty. 1

Center DriveTube

Qty. 1

Cylinder

Qty. 1

Mounting Brackets

Qty. 4

Mounting Bases

Qty. 4

Ladder Supports

Qty. 2

Ladder Stops

Qty. 2

Drivers Side End Stops

Qty. 2

White Plastic Bushings

Qty. 2

Rear Rotation Assembly

Qty. 1

Mounting Pads-Rubber

Qty. 4

Black Plastic Bushings

Qty. 2

2

5/16-18 x 4-1/2" Hex Hd. Bolt

3/8-16 x 2-1/4" Hex Hd. Bolt

5/16-18 x( 4-1//4" or 5") Phillips Flat Hd. Screw

5/16-18 x 2" Hex Hd. Bolt

5/16-18 x 1" Hex Hd. Bolt

Aluminum Bushing

Clevis Pin Cotter Pin

5/16-18 Nylon Lock Nut

3/8-16 Nylon Lock Nut

5/16" Flat Washer

3/8" Flat Washer

Flat Plastic Bushing

FASTENER CHART

5/16-18 x 4" Hex Hd. Bolt

5/16-18 x 1-1/4" Hex Hd. Bolt

5/16-18 x 2-3/4" Hex Hd. Bolt

5/16" Rubber Washer

1-1/2" OD
Fender Washer

3

CROSS-MEMBER ASSEMBLY

4

STEP 1 (DRIVER SIDE Front and Rear)

A

ttach Driver Side End Stop (A) to
Cross-Member (B) with 5/16-18 x 2-3/4"
Fasteners.

(B)

(A)

(2) 5/16-18 x 2-3/4"
H

ex Hd. Bolt

(4) 5/16-18 Flat
Washer

(2) 5/16-18 Nylon
L

ock Nut

STEP 2 (4 Places)

Attach Mounting Brackets (A) to
Mounting Bases (B) with 5/16-18 x 1"
Fasteners

(A)

(B)

(2) 5/16-18 Nylon
Lock Nut

(4) 5/16-18 Flat
Washer

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

NOTE: To allow for final
fit-up, do not tighten
these fasteners at this
time.

STEP 3 (4Places)

Attach Mounting Brackets (A) to
Cross-Members (B) with 5/16-18 x 2-3/4"
Fasteners

NOTE: To allow for final
fit-up, do not tighten
these fasteners at this
time.

(A)

(B)

(2) 5/16-18 Nylon
Lock Nut

(4) 5/16-18 Nylon
Lock Nut

(2) 5/16-18 x 2-3/4"
Hex Hd. Bolt

5

REAR ROTATION ASSEMBLY

6

S

TEP 4

Use the supplied lubricant and coat the pre-assembled Black Plastic
B

ushing (A). Insert Rear Drive Tube/Handle Assembly (B) into the
larger Black Plastic Bushing (C) in the Rear Cross-Member
Assembly (D) so that the black bushings are fully seated.

(A)

(B)

(C)

(D)

STEPS 5 & 6

Slide a White Plastic Bushing (A) onto the Rear Drive Tube (B) until
it is butted up to the Cross-Member (C). Align holes in the tube and
bushing. Slide the Pivot Arm (D) over the tube and bushing, align
holes, and install the 3/8-16 x 2-1/4" Fastener. Next install the
5/16-18 x 4-1/2" Fastener with four Flat Plastic bushings (E) as
shown.

(A)

(B)

(D)

* 3/8-16 x 2-1/4"
Hex Hd. Bolt

(2) 3/8" Flat
Washer

3/8-16 Nylon
Lock Nut

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

Hex Hd. Bolt

(2) 3/8" Flat
Washer

5/16-18 Nylon
Lock Nut

(E)

STEP 7

Place the Ladder
Support (A) on top of
the Connecting Tube
(B) and install the
5/16-18 x 2-3/4"
Fastener.

(A)

(B)

5/16-18 x 2-3/4"
Hex Hd. Bolt

(2) 5/16" Flat
Washer

5/16-18 Nylon
Lock Nut

STEP 8

Place the Rear
Rotation Assembly on top
of the Cross-Member (A)
and place the Ladder Stop
(B) on top of the Lower
Rotation Tube, install the
5/16-18 x (4-1/4" or 5")
Fastener (Flat Hd. Screw).
Install 5/16-18 x 4" Hex
Hd. Bolt through Lower
Rotation Tube and
through the Cross-Mem­ber.

(B)

(A)

5/16-18 x 4"
Hex Hd. Bolt

(3) 3/8" Flat Washer

(C)

5/16-18 Nylon Lock Nut

5/16-18 x (4-1/4" or 5")
Flat Hd. Screw

NOTE: Large Black Plastic Bushings
are keyed to fit the Cross-Members

NOTE: Tighten all Marked (*)
fasteners to 200 in. lbs.

7

FRONT ROTATION ASSEMBLY

8

STEP 9

U

se the supplied lubricant and coat the pre-assembled Black Plastic Bushing (A). Insert Front Drive Tube (B) into the larger

Black Plastic Bushing (C) in the Front Crossmember Assembly (D) so that the black bushings are fully seated.

(A)

(B)

(C)

(D)

STEPS 10 & 11

Slide a White Plastic Bushing (A) onto the Front Drive Tube (B) until
it is butted up to the Lower Rotation Tube (C). Align holes in the tube
and bushing. Slide the Pivot Arm (D) over the tube and bushing,
align holes, and install the 3/8-16 x 2-1/4" Fastener. Next install the
5/16-18 x 4-1/2" Fastener with four Flat Plastic bushings (E) as
shown.

(A)

(B)

(D)

* 3/8-16 x 2-1/4"
Hex Hd. Bolt

(2) 3/8" Flat
Washer

3/8-16 Nylon
Lock Nut

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

Hex Hd. Bolt

(2) 3/8" Flat
Washer

5/16-18 Nylon
Lock Nut

(E)

STEP 12

Place the Ladder Support (A) on top of
the Connecting Tube (B) and install the
5/16-18 x 2-3/4" Fastener.

(A)

(B)

5/16-18 x 2-3/4"
Hex Hd. Bolt

(2) 5/16" Flat
Washer

5/16-18 Nylon
Lock Nut

(C)

NOTE: Tighten all Marked (*)
fasteners to 200 in. lbs.

9

S

TEP 13

Place the Front Rotation
Assembly on top of the
Cross-Member (A) and
place the Ladder Stop (B)
o

n top of the Lower
Rotation Tube, install the
5/16-18 x (4-1/4" or 5")
(Flat Hd. Screw).
Install 5/16-18 x 4" Hex
Hd. Bolt through Lower
Rotation Tube and through
the Cross-Member.

(B)

(A)

5/16-18 x (4-1/4" or 5")
F

lat Hd. Screw

(3) 3/8" Flat
Washer

(2) 5/16-18
Nylon Lock Nut

5/16-18 x 4"
H

ex Hd. Bolt

10

CYLINDER INSTALLATION

Cotter Pin

Clevis Pin

5/16-18 Nylon

Lock Nut

(3) 3/8" Flat

Washer

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

Hex Hd. Bolt

(A)

(C)

(B)

STEP 15

Attach front of Cylinder as shown. Bend over

Cotter Pin after inserting it through Clevis Pin.

NOTE: Turn the Flow Control

counter clockwise to release

pressure. Adjust Flow Control

Screw Per Instruction Decal

On Handle Tube after final

assembly and installation.

STEP 14

Insert Aluminum Bushing (A) into Rear

Cross-Member (B). Attach back of Cylinder (C)

to crossmember by installing 5/16-18 x 4-1/2"

Fastener. NOTE: After installing Bolt, apply

Loctite 290 to threads, then install the nut.

11

HOW TO DETERMINE RACK LENGTH FOR YOUR VAN

5' or 6' or 7' or 8'

APPROX.

12"

Center a Mounting Base over the "B" pillar behind the front door. Next set a Mounting Base approx. 12" from the rear of the vanroof to the rear of the base. Measure

the distance between the bases (center to center) round to the nearest foot dimension. The rack is predrilled at 12" spacing for 5', 6', 7', and 8' lengths.

USE THESE HOLES FOR DESIRED LENGTH

8'

5'

6'

7'

Rear Pivot Arm

Front Pivot Arm

"B"Pillar

12

FRONT TO REAR DRIVE TUBE ASSEMBLY

STEP 16

Locate desired front to rear length

(5' or 6' or 7' or 8') and install

5/16-18 x 2" Fasteners

(Tighten fasteners to 200 in. lbs.)

(4) 5/16-18

Nylon Lock

Nut

(8) 5/16" Flat

Washer

(4) 5/16-18 x 2"

Hex Hd. Bolt

STEP 17

Cover any exposedholes on Front and Rear Drive Tubes with

the 1" Dia. Vinyl Hole Covers

STEP 18

Seal the ends of the Center Drive Tube, the four 5/16-18 Fasteners,

and the two 3/8-16 Fasteners with the tube of sealant supplied.

13

VEHICLE MOUNTING PROCEDURE

14

S

TEP 19

WITH HELP! Place entire unit on vehicle in desired position. Check to verify that the Handle clears the rear of the van.

It may be neccessary to move the rack to the rear.

(A)

(2) 5/16
Rubber Washer

(2) 5/16"
Flat Washer

Mounting
Pad-Rubber

(2) 5/16-18 x 1-1/4"
Hex Hd. Bolt

S

TEP 20 (4 Places)

With unit centered side to side, mark the holes in the

Mounting base (A). Move the unit out of the way

enough to drill the holes. Reposition unit and secure to

the van roof with the 5/16-18 x 1-1/4" Fasteners.

(2) 5/16-18
Nylon Lock Nut

(2) 1-1/4" OD
Fender Washer

NOTE: Tighten all loose
fasteners at this time.

CAUTION

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

NOTE: Seal the top of the bolts that go
through the roof with the sealant that is
supplied.

15

FINAL ASSEMBLY

NOTE: Adjust Flow Control

Screw Per Instruction Decal

On Handle Tube.

16

REPLACEMENT PARTS

ID# PART NUMBER DESCRIPTION USE WITH QUANTITY

1 7360 Hydraulic Cylinder All Models Except 254 1
2 7361 Handle Clamp All Models Except 254 1
3 7363 Ladder Stop 251, 252, 253, 255, 256, 257 1
4 7364 Ladder Support 251, 252, 253, 255, 256, 257 1
5 7365 PS Drive Shaft & Arm 251, 252, 253, 256, 1
6 7366 Bushing Kit 251, 252, 253, 255, 256, 257 1

1

2

3 4

5

ACCESSORIES

PART NUMBER DESCRIPTION USE WITH QUANTITY

254 Driver Side Clamp Kit 251, 252, 253 1

255 Driver Side Drop Down Kit 251, 252, 253 1
2501 Warning Light Holder 251, 252, 253 1
2502 Mirror Holder 251, 252, 253 1
2503 Two Velcro Straps 251, 252, 253 2
2504 Mirror 2502 1
2511 Accessory Cross Member 251 1
2521 Accessory Cross Member 252 1
2531 Accessory Cross Member 253 1

6

This LIMITED WARRANTY is made by Knaack Manufacturing Company, 420 E. Terra Cotta Ave., Crystal Lake, Illinois to the original retail purchaser of KNAACK® or
WEATHER GUARD® products.

KNAACK MANUFACTURING COMPANY WARRANTS THATKNAACK OR WEATHER GUARD PRODUCTS WILLBE FREE FROM DEFECTS IN MATERIALAND
WORKMANSHIP FOR APERIOD OF TWO (2) YEARS FROM DATE OF PURCHASE BYTHE ORIGINAL RETAIL PURCHASER.

If, before the expiration of the Warranty period, purchaser discovers that the KNAACK or WEATHER GUARD product fails to fulfill the Warranty, purchaser shall contact
Knaack Manufacturing Company to make arrangements for an inspection of the product. If Knaack Mfg. Co. determines a defect exists, Knaack Mfg. Co. shall, at its
option and expense, repair or replace any defective part. All Warranty repairs shall be made by an authorized KNAACK Product dealer or Knaack Mfg. Co. approved
service company.

arranty shall not apply if the KNAACK or WEA

This W
alterations made by anyone other than a KNAACK or WEATHER GUARD Product dealer or a Knaack Mfg. Co. approved service company.

ARRANTY PRINTED ABOVE IS THE ONLY WARRANTY APPLICABLE TO THIS PURCHASE. ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUD-

THE W
ING BUT

KNAACK MANUFACTURING COMPANY SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF ANY BREACH OF
THIS WARRANTY. NOR SHALL THE DAMAGES EXCEED THE RETURN AMOUNT OF THE PURCHASE PRICE PAID BY THE ORIGINAL PURCHASER.

This W
gives you specific legal rights, and you may also have other rights which vary from state to state.

Product fits based on vehicle design available at the revision date. Vehicle manufacturers may change specs after
the revision date, so if you have a vehicle produced with a model year date after the revision date, please contact
your distributor or Knaack Mfg. Co. to verify fitting of product to vehicle.

If you have any questions, please call our customer service department at 1-800-456-7865. WEATHER GUARD
Products are protected by one or more of the following patents: U.S. 5145087, 5308126, 4509787, 4573731,
4618083, D-346355, D-346994, D-353574; Canada 1218968, 1224230, 1235100 and; U.K. 2233036. Other patents
pending

NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR APARTICULAR PURPOSE ARE HEREBY DISCLAIMED.

arranty is in lieu of all W

arranties express or implied.

.

420 E. Terra Cotta Ave, Crystal Lake, IL 60014, 815-459-6020, [e-mail]

KNAACK MANUFACTURING COMPANY

2002 Knaack Manufacturing Company

©

THER GUARD product has been subjected to misuse, abnormal service or handling, improper maintenance, or

The terms of this W

LIMITED W

ARRANTY

arranty shall not be modified by any party

, their successors or assigns. This Warranty

KNAACK

MANUF

ACTURING

COMPANY

Rev

. D 10/04 Part No. 24-0099