WEATHER GUARD 391-0-02 User Manual

INSTALLATION INSTRUCTIONS

Hi-Side and Super Side Boxes - Models 246 through 297

IMPORTANT

BEFORE YOU BEGIN

Read these instructions and warnings completely before installation.

BOLT KIT

Bolt Kit #32-0027 is provided with Models 246 thru 265. Check this bolt kit to be sure the following parts are included:

Quan. Description

8 5/16" Lock Washer 1 4 5/16" Flat Washer 4 5/16-18 Blind Fastener 1 Installation Tool 1 5/16-18 x 2-1/4" Bolt,

black oxide 1 1-3/4" Round Cap Plug 4 5/16-18 x 1-1/4" Hex Bolt 4 5/16-18 x 1" Hex Bolt 1 0 5/16-18 Nylon Lock Nut 2 "J" Bolt 2 Plastic Retaining Washer 2 Fender Washer

Bolt Kit #32-0028 is provided with Models 272 thru 297. Check this bolt kit to be sure the following parts are included:

Quan. Description

8 5/16" Lock Washer 1 4 5/16" Flat Washer 4 5/16-18 Blind Fastener 1 Installation Tool 1 5/16-18 x 2-1/4" Bolt,

black oxide 1 1-3/4" Round Cap Plug 4 5/16-18 x 1-1/4" Hex Bolt 4 5/16-18 x 1" Hex Bolt 1 2 5/16-18 Nylon Lock Nut 4 "J" Bolt 4 Plastic Retaining Washer 4 Fender Washer

Rev. H 1/01 Part No. 24-0029

Approximate Installation Time:

42 min. per unit (0.7 hrs.) Depending on truck equipment installation experience

Figure 1. Typical Installation

D ANGER

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. This product is only intended and safe for use in storing and transporting small tools, equipment and other similar materials. Any modifications made to, or unintended use of this product, could create a hazardous condition that can cause death, serious

personal injury or property damage.

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 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.

TOOLS REQUIRED

• 1/2" Open or Box End Wrench (2)

• Ratchet Wrench w/ 1/2" deep well socket

• Electric Drill

• 1/2" & 3/8" Drill Bits

• Carpenters Square

• Utility Knife or Scissors

• Tape

• 9/16" Open or Box End Wrench

• 1 - Hi-Side (or Super Side) Box

• 2 - Legs

• 2 - Mounting Pads

PARTS LIST

(20" and/or 27" and/or 45")

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 2: 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.

14. Fasten the Leg feet to the floor.

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 tightnessof "J" bolts to insure proper attachment.

16. Snap the Cap Plug into the bottom hole. (plug may be pulled when cleaning

inside of box).

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.

INSTALLATION PROCEDURE USING BLIND FASTENERS

WARNING

Prior to drilling, so as not to cut or puncture fuel tanks, fuel lines, brake lines, electric wires, etc., check under vehicle for locations.

Place a drop of oil on the black oxide bolt before assembling as shown on right. Place the Blind Fastener in the hole and use a 1/2” or 7/16” wrench to tighten black hex bolt until the blind fastener is fully seated. 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.

Installation Tool

Black Oxide Bolt

Flat Washer

9/16” Wrench

Blind Fastener

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 manufacturer’s 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. - 842268, 1661625, 1663369, 2228051, 2362167; Canada - 282725; U.K. - 1400720; N.Z. -296049; Aus. - 761964

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

KNAACK MANUFACTURING COMPANY

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

815-459-6020