WEATHER GUARD 553 User Manual [en, es, fr]

OPERATORS MANUAL

ALUMINUM LOW-PROFILE SIDE BOX

MODELS 178-X-01 through 181-X-01

TRUCK AND VAN EQUIPMENT

WWW.WEATHERGUARD.COM

PRODUCT REGISTRATION

For your convenience,

Model #_____________ Serial #: ____________________

Approximate installation time: 48 minutes (.8 hr.) depending on truck equipment installation experience.

• 1/2” deep well ratchet wrench

• 1/2” open or box end wrench

• 9/16” open or box end wrench

place product registration

tear-off sticker here.

INSTALLATION TIME

TOOLS REQUIRED

• Drill with 3/16”, 3/8” and 1/2” drill bit

• Carpenter’s square

Purchase Date :_______________ Place of Purchase: ____________ Key Code: ___________________

PARTS LIST

(1) Aluminum Low-Prole

Side Box

(2) Legs

(2) Rubber Mounting Pads

Note: The rubber mounting pad comes as a single piece and must be separated into two pieces, one for each side of the truck.

(2) Keys

(8) 5/16” Flat Washers(1) Retaining Washer

(8) 5/16” Lock Washers

(8) 5/16”-18 Blind Fastener

(1) 5/16”-18 x 2-1/4” Black Oxide Hex Head Bolt

(1) Installation Tool

(8) 5/16”-18 x 1-1/4” Hex Head Bolts

(1) 5/16”-18 Nylon Lock Nut

(2) 5/16””-18 2-1/4” Hex Head Bolt

(2) Fender Washers

(2) Mounting Clamps

(1) “J” Bolt

-ATTENTION-

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

DANGER

Danger of explosion. Do not use this product for storing or transporting ammables, explosives, hazardous materials, or hazardous waste, such as containers of gasoline, solvents, gun powder, dynamite, propane tanks, acetylene tanks and cutting torches and gas-powered equipment. This product is only intended and safe for use in storing and transporting small tools, equipment and other similar materials. Any modication made to or unintended use of this product, could create a hazardous condition that can cause death, serious personal injury or property damage.

Part No. 24-0275 REV. B ECN 5305 04/13

CAUTION

Bed Lip

Mounting Pad

End Panel Slot

Mounting Clamp

Fender Washer

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

Fender Washer

Blind Fastener

5/16" Flat Washer

5/16" Lock Washer

5/16"-18 x 1-1/4" Hex Head Bolt

Leg

Mounting Pad

Mounting Clamp

Blind Fastener

1/2" Holes

5/16"-18 x 1-1/4" Hex Head Bolt

5/16" Lock Washer

5/16" Flat Washer

Before marking the leg mounting holes, check inside the box for location of gas spring housing and components that may obstruct safe drilling.

CAUTION

To keep debris out of your eyes when checking the underside of the vehicle, or when drilling, always wear protective eye wear.

WARNING

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

WARNING

All oor mounting bolts near the gas tank area should be installed from the underside of the vehicle, to guard against the gas tank being punctured in the event of a collision. This would mean not using Blind Fastener in this area. Holes drilled in this area should be 3/8”.

INSTALLATION INSTRUCTIONS

Note:

• If your pickup is tted with a plastic drop-in bed liner, it may need to

be drilled, trimmed, or cut for proper installation of truck box.

• Truck box cover may not properly latch until box is fully bolted to

truck bed.

• Periodically check tightness of mounting bolts to insure proper

attachment.

• Use touch-up paint on any drill holes to prevent oxidation.

• Install boxes with vehicle parked on level ground.

Step 1: LOCATE BOX IN TRUCK BED

• Mount Saddle/Cross Box rst (if applicable).

• Place rubber mounting pads on bed rails.

• Place box into position on top of mounting pads. Lock should be facing the rear of the vehicle.

• Support box with blocking until mounted.

• Square box to bed and level box so top is horizontal when viewed from rear.

• Leave a 5-6” gap between side box and saddle/cross box (if applicable).

• Make sure cover opens fully without interference.

Note: Fasten leg mounting feet directly to bed oor not bed liners or mats.

Step 2: MARK AND DRILL MOUNTING HOLES

• Position rear leg as shown in Figure 1. Use square to ensure vertical orientation.

• Mark both holes at top of leg and both holes in truck bed oor.

Note: To maintain full oor width between wheel wells, legs should be aligned with the inside edge of wheel wells. The foot of the leg must be squarely mounted on or between the tops of oor ribs.

• Repeat leg placement and marking process for other leg. Remove box from truck.

• Drill all marks on box and truck with 3/16” drill bit. Redrill all holes with 1/2” drill bit.

• Install all Blind Fasteners (see Figure 1, 2 and 3).

Step 3: ATTACH BOX TO TRUCK BED

Note: If you encounter interference with the mounting clamp and a stake pocket in the truck bed, it may be necessary to drill a 1/2” hole in the truck box and use the “J” bolt instead of mounting clamp.

Note: It is recommended that all fasteners be tightened hand tight rst to ensure t, then go back

and fasten securely with wrench.

• Place box back in original position.

• Install all bolts in leg mounting feet as shown in Figure 1.

• Insert the two mounting clamps as shown in Figure 2.

Note: Mounting clamp bolt may be difcult to turn due to the “lock nut” feature. Apply a small amount

of grease to bolt threads prior to installation to ease assembly.

Figure 1

Figure 2

BLIND FASTENER INSTALLATION

Black Oxide Bolt

Flat Washer

9/16" Wrench

Installation Tool

Blind Fastener

Note: Make sure there is enough hole depth before installing the Blind Fastener.

Figure 3

Note: Black Oxide Bolt, Flat Washer, and Installation Tool are only used to install Blind Fasteners.

• Install Blind Fastener using Figure 3 as a guide.

• Place a drop of oil on black oxide bolt for lubrication.

• Insert Blind Fastener in the hole.

• Hold the “Installation Tool” with a 9/16” wrench while turning the ”Black Oxide Bolt” with a 1/2” wrench until fully seated.

• When Blind Fastener is fully seated, continue with installation.

FEATURE OPERATION

LOCK SYSTEM

The WEATHER GUARD® Lock is designed to provide maximum security, while providing ease of use and years of reliable service. When in the locked mode, the button remains retracted in a tamper-resistant position. When the button is pressed in the unlock mode, the latch is activated and the cover opens.

LOCK

Turn key counter-clockwise to locked position

as indicated on lock bezel. When the button

is now pressed, it will stay in the retracted or tamper-resistant position until unlocked.

UNLOCK

Turn key clockwise to unlock position as

indicated on lock bezel. Button will pop out

and is now ready to release the latches when pressed.

LATCH SYSTEM

The WEATHER GUARD Latch System utilizes an automotive-grade latch in conjunction with a high strength latch striker to ensure maximum security. The WEATHER GUARD Latch System is designed to open with a single touch of the button, and close securely. Expect years of reliable service from the WEATHER GUARD Latch System with only minimal maintenance: Bi-annually lubricate latch pivot points with white grease. If latch striker is accidentally knocked out of alignment, simply use a mallet to realign.

MOUNTING BRACKETS

Wide ange mounting bolts provide secure mounting without crimping bed rails and allow full

unobstructed use of side pockets.

12V ELECTRICAL ACCESS

WEATHER GUARD Truck Boxes are equipped with a 12 Volt Electrical Access Grommet

Figure 4

t h

for easy electrical accessory t-ups. To use, simply cut along one or more perforations in

the rubber grommet and run wire through.

WARNING

To prevent electric shock, explosion, re and/or serious personal injury when using side box with:

Extension Cord -

• Follow all Extension Cord manufacturer’s warnings and instructions.

• Do NOT insert extension cord through hole without grommet in place (see Figure 4).

• Only use a three-wire extension cord with all three prongs intact. Never remove the round grounding prong.

• Extension cord must be connected to a 120 Volt GFCI (fround fault circuit interrupter) protected outlet with proper ground. If GFCI outlet is not

available, use an extension cord with GFCI protection built in.

• Check the insulation and plugs of extension cord before using. Do NOT use cord if it is worn or damaged.

• Do NOT overload extension cord.

• Remove extension cord from the grommet hole before moving or transporting side box.

• Only use an extension cord that is rated for outdoor use.

• Do NOT connect extension cord to outlet that also supplies power for critical safety equipment.

Cordless Power Tool Battery Chargers -

• See Charger’s Owner's Manual for proper use and care of charger and batteries. Follow all warnings and instructions provided with your battery charger.

• Place chargers and electrical connections in tray.

• Chargers are Dry location use only. Do NOT expose to liquid, vapor, or rain. Should your charger become wet, do NOT attempt to use.

Unplug extension cord from supply before handling wet charger or cords.

• Only use chargers and batteries that are intact and operating properly.

• Do NOT touch metal prongs when plugging charger into extension cord.

• Keep ammable materials like paper or rags away from charger, cords or connections.

• Do NOT place or attempt to charge lead-acid, car-type batteries in side box.

SERVICE PARTS

FOR REPLACEMENT PARTS GO TO

WWW.WEATHERGUARD.COM

ITEM NO.

1 7095-2PK Gas Spring (2 pack) 178-x-01, 179-x-01, 180-x-01, 181-x-01

2 7748-xx Lock & Key Set (xx = key code)

3 7750-xx Key Replacement (xx = key code) All Side Boxes (2 keys) 4 7731 Latch & Striker Kit (1 latch, 1 striker,

5 70107

6 7106-1PK Striker Kit (1 Striker and mounting

7 7730 Weather Strip Kit (various styles for

8 7734-x Mounting Kit (2 clamps, 2 legs,

9 70105 Nameplate Kit (3 stickers, 2 side

10 7749 Grommet Kit All Side Boxes

11 70103-x

PART

DESCRIPTION FITS MODEL NUMBER

NO.

All Side Boxes

178-x-01 179-x-01 180-x-01 181-x-01

All Side Boxes

All Low-Prole Boxes

178-x-01 & 179-x-01 180-x-01 & 181-x-01

70108 70109 70110

70104-x

(1 lock, 2 keys, retainer clip)

& mounting hardware)

Latch Rod Kit Latch Rod Kit Latch Rod Kit Latch Rod Kit

hardware)

1 box)

1 angle, 2 mount pads, related hardware)

bezels, 1 front bezel & 1 end bezel)

Cover Cover

Note: In the model numbers above, X represents the color code for your model;

0 = Clear, 3 = white, 5 = black. XX = key codes numbers.

See Description for additional included parts.

Grommet Kit

Not shown. Located mid-box under nameplate.

- 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.

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 FOR A PERIOD OF THREE (3) YEARS FROM DATE OF PURCHASE BY THE 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 LLC to make arrangements for an inspection of the product. If Knaack LLC determines a defect exists, Knaack LLC 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 LLC approved service company.

This Warranty shall not apply if the KNAACK or WEATHER GUARD product has been subjected to misuse, abnormal service or handling, improper maintenance, or alterations made by anyone other than a KNAACK or WEATHER GUARD Product dealer or a Knaack LLC approved service company.

THE WARRANTY PRINTED ABOVE IS THE ONLY WARRANTY APPLICABLE TO THIS PURCHASE. ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.

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 Knaack LLC to verify fitting of product to vehicle.

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.

LIMITED WARRANTY

Knaack LLC

TTN: Warranty Claims

A 420 E. Terra Cotta Avenue Crystal Lake, IL 60014

Knaack LLC

Part No. 24-0275 REV. B ECN 5305 04/13

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