WEATHER GUARD 255 User Manual

MODEL 255 EZ-GLIDE™SYSTEM

DRIVER SIDE KIT FOR 251, 252, 253

ALUMINUM DROP DOWN LADDER RACK

ATTENTION–

–

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

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

• Phillips Screwdriver (Large)

• Needle Nose Pliers

* 3/8" Drive Torque Wrench (in. lbs.)

• Tape Measure

• Flat Screwdriver (small)

PARTS LIST

See Page 2

• Rear Rotation Assembly

• Front Rotation Assembly

• 2 - Pivot Arms

• Rear Drive Tube/Handle

• Front Drive Tube

• Center Drive Tube

• Cylinder

• 2 - Ladder Supports

• 2 - Ladder Stops

• 2 - White Plastic Bushings

• 2 - Black Plastic Bushings

• 1 - Tube E-6000 Sealant

• 15-1" Dia. Vinyl Hole Covers

• 1 - Tube Loctite290

Assembly

60 min. per unit (1 hr.) 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

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

4
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
1 Aluminum Bushing
1 Clevis Pin
1 Cotter Pin
1 Bushing Lubricant Tube

Approximate assembly and Installation time:

IMPORTANT BEFORE YOU BEGIN

HARDWARE KITS

See Page 3

1 RETRO ROTATION KIT:

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

Hd. Screw
2 5/16-18 x 4" Hex Hd. Bolt
4 5/16-18 Nylon Lock Nut
6 3/8" Flat Washer

1

Part No. 24-0103 REV. F ECN 5315 05/13

255

Rev. F

24-0103

2

Clevis Pin Cotter Pin

FASTENER CHART

5

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

5/16-18 x 2-3/4" 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

Aluminum Bushing

5/16-18 Nylon Lock Nut

3/8-16 Nylon Lock Nut

5/16" Flat Washer

3/8" Flat Washer

Flat Plastic Bushing

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

3

R

EAR ROTATION ASSEMBLY

STEP 1

Use the supplied lubricant and coat the pre-assembled Black Plastic
Bushing (A). Insert Rear Drive Tube/Handle Assembly (B) into the
Larger Black Plastic Bushing (C) in the Rear Rotation
Assembly (D) so that the Black Bushings are fully seated.

(A)

(B)

(C)

(D)

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

4

STEPS 2 & 3

Slide a White Plastic Bushing (A) onto
the Rear 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 (E) bushings
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 4

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 5

Place the Rear
Rotation Assembly on
top of the Cross-Mem­ber (A), place the
Ladder Stop (B) on top
of the Lower Rotation
Tube, and 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

N

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

STEP 6

After Rear Rotation Kit is fastened to the Rear Cross-Member, Slide Center Drive Tube (A) fully onto Rear Drive Tube (B) as
far as it will go. This will make upcoming assembly to Front Drive Tube easier.

(A)

(B)

5

FRONT ROTATION ASSEMBLY

6

STEP 7

Use 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 Rotation Assembly (D) so that the Black Bushings are fully seated.

(

A)

(B)

(C)

(D)

STEPS 8 & 9

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)

(C)

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

STEP 10

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

7

STEP 11

P

lace the Front Rotation Assembly on
top of the Cross-Member (A), place the
Ladder Stop (B) on top of the Lower
Rotation Tube, and install the
5/16-18 x (4-1/4" or 5")(Flat Hd. Screw).
I

nstall 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")
Flat Hd. Screw

(3) 3/8" Flat
Washer

(2) 5/16-18 Nylon
Lock Nut

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

STEP 12

After fastening Front Rotation Assem­bly to Front Cross-Member, slide Cen­ter Drive Tube(A) off of Rear Drive
Tube onto Front Drive Tube(B). Line up
mounting holes to match passenger
side holes.

(A)

(B)

8

FRONT TO REAR DRIVE TUBE ASSEMBLY

STEP 13

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 14

Cover any exposedholes on Front and Rear DriveTubes with

the 1" Dia. Vinyl Hole Covers

STEP 15

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.

9

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)

NOTE: Turn the Flow Control

counter clockwise to release

pressure. Adjust FlowControl

Screw Per Instruction Decal

On Handle Tube after final

assembly and installation.

STEP 17

Attach front of Cylinder as shown. Bend over

Cotter Pin after inserting it through Clevis Pin.

STEP 16

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.

10

FINAL ASSEMBLY

NOTE: Adjust Flow Control

Screw Per Instruction Decal

On Handle Tube.

11

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 All Models Except 254 1
4 7364 Ladder Support All Models Except 254 1
5 7366 Bushing Kit All Models Except 254 1
6 7582 DS Drive Shaft & Arm 255, 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 LLC, 420 E. Terra Cotta Ave., Crystal Lake, Illinois to the original retail purchaser of KNAACK® or WEATHER
GUARD® products.

KNAACK LLC WARRANTS THAT KNAACK OR WEATHER GUARD PRODUCTS WILL BE FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIP
PERIOD OF

If, before the
Knaack
replace

This Warranty
alterations

THE W
ING BUT

KNAACK LLC 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 Warranty is in lieu of all Warranties express or implied. The terms of this Warranty shall not be modified by any party, their successors or assigns. This Warranty
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

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.

TWO

YEARS FROM DATE OF PURCHASE BY THE ORIGINAL

(2)

expiration of the Warranty

to make arrangements

LLC

any defective part.

shall not apply if the KNAACK or WEATHER GUARD product has been subjected to misuse, abnormal service or handling, improper maintenance, or

made by anyone

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

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

All Warranty repairs shall be made by an authorized KNAACK Product dealer or Knaack LLC approved service company.

other than a KNAACK or

period, purchaser discovers that the KNAACK or WEATHER GUARD product fails to fulfill the Warranty, purchaser shall contact

for an inspection

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

of the product. If Knaack

WEATHER GUARD Product dealer

LIMITED WARRANTY

PURCHASER.

RETAIL

determines

LLC

or a Knaack

KNAACK LLC

©2002 Knaack LLC

a defect exists, Knaack

approved

LLC

Knaack LLC to verify fitting of product to vehicle.

LLC shall, at its

service company.

A

FOR

option and expense, repair

or

11

Part No. 24-0103 REV. F ECN 5315 05/13