model 1210 150" accessory side rail model 1211 132" accessory ...
INSTALLATION MANUAL MODEL 1210 150" ACCESSORY SIDE RAIL MODEL 1211 132" ACCESSORY SIDE RAIL - ATTENTION Read and understand all instructions and warnings before installing and using this product. Confirm contents of the shipping carton with the "Parts Identification" page before beginning installation. If a part is missing, or if you have any questions, please call WEATHER GUARD customer service at 1-800-456-7865.
WARNING This product is only intended for, and only safe for, transporting ladders, lumber, pipe and other similar materials. It is the responsibility of the user to secure these materials to the rack before transporting. Any modifications made to this product, or use of this product for any other purpose than its intended use, could create a hazardous condition that can cause serious personal injury or property damage. 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 a improperly secured ladder will cause wear and weaken the ladder. Using a damaged ladder could lead to a structural collapse and could result in a serious injury or death.
- 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. Some vehicle manufacturers require a reinforcing kit, available through the vehicle dealership, to be installed on the truck bed prior to mounting any kind of rack or tool box. Contact your dealership to see if your vehicle requires a reinforcing kit before installation.
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 of your vehicle. Consult your vehicle owners manual for specifications on load ratings and recommendations from the vehicle manufacturer regarding installation of aftermarket racks and tool boxes.
Page 1 of 6
Approximate Assembly and Installation Time: 60 min. (1 hr.) depending on truck equipment installation experience.
LIMITED WARRANTY This LIMITED WARRANTY is made by Knaack LLC, 420 E. TerraCottaAve., Crystal Lake, Illinois to the original retail purchaserof KNAACK or WEAT HER GUARD Equipmentproducts. KNAACK LLC WARRANTS TH AT KNAACK OR WEATHER GUARD EQUIPMENT WILL BE FREE FROMDEFECTS IN MATERIAL AND WORKMANSHIP FOR A PERIOD OF TWO (2) YEARS FROM DATE OFPURCHASE BY THE ORIGINAL RE TAIL PURCHASER. If, before the expiration of the Warranty period,purchaser discovers that the KNAACK or WEATHER GUARD Equipment fails to fulfill theWarranty, 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 Equipment dealer or Knaack LLC approved service company. This Warranty shall not apply if the KNAACK or WEATHER GUARD Equipment has been subjected to misuse, abnormal service or handling,improper maintenance,or alterations made by anyone other than a KNAACK or WEAT HER GUARD Equipment 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 ANDFITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. KNAACK LLC SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGESARISING OUT OF ANY BREACH OF THIS WARRANTY. NOR SHALL THE DAMAGESEXCEED 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.
WEATHER GUARD® products are protected by one or more of the following patents or trademarks: U.S. - 4509787, 842268, 1661625, 1663369, 2228051, 2434963; U.K. - 1400720; NZ - 296049; Aus. - 761964; Canada - 1218968, 282725. KNAACK LLC 420 E. TERRA COTTA AVENUE, CRYSTAL LAKE, ILLINOIS, USA 60014 815-459-6020, [email protected] © 2003 Knaack LLC
Part No. 24-0155 REV. B ECN 5315 05/13
TOOLS REQUIRED
PART IDENTIFICATION & REPLACEMENT PART NUMBERS
3/8" Drive Ratchet 3/8" Drive Socket 1/2" Deep Well 3/8" Drive Socket 7/16" 5/16" Drill Bit Electric Drill Tape Measure Hammer Center Punch 3/8" Drive Torque Wrench (foot lbs.)
NOTE: Side rails are labeled in the packaging, take note before removing them from the carton. The rear assemblies have one predrilled hole and the front assemblies have two predrilled holes. The smooth edge faces away from the truck and the grooved edge faces inward. All side rails have a replacement part number of #7619.
FIT-UP Product fit-up is based on vehicle design available at the revision date of this installation manual. The ATRTM has been fitted and is recommended for any combination of bed lengths and cab designs on most pickup trucks. IMPORTANT! Model 1205 Owners. If installing a Model 1211 on a Model 1205, compact size truck, the front accessory crossmember, Part X, will have to be cut down to 57" from 67".
Two Holes
Smooth Edge Up
Part O (Qty. 1) Driver Side Front Rail Assembly
One Hole
Smooth Edge Up
Part P (Qty. 1) Driver Side Rear Rail Assembly
Smooth Edge Up
Smooth Edge Up
To keep debris out of your eyes when drilling or cutting, always wear protective eye wear.
Two Holes
Part R (Qty. 1) Passenger Side Front Rail Assembly
Part Q (Qty. 1) Passenger Side Rear Rail Assembly
Part T
Part S
Side Rail Hardware Kit Part S - Side Rail Alignment Plug (Qty. 4) 1/4-20 X 5/8" Carriage Bolt (Qty. 8) 1/4-20 Stop Nut (Qty. 8) Part T - Side Rail Connecting Plate (Qty. 2) Replacement Part Number #7620
Part U (Qty. 1) Driver Side Rear Mounting Clamp Replacement Part #7617
Carefully pry off the end red cap and trim the black anti-wear strip back 10". Cut 10" off the end of the cross member. Using an industrial adhesive, reapply the red end cap.
CAUTION
One Hole
Part V (Qty. 1) Passenger Side Rear Mounting Clamp Replacement Part #7636
Cross Section
Part W (Qty. 4) Universal Driver/Passenger Front Mounting Clamp Replacement Part #7618 Page 2 of 6
Rail Mounting Hardware Kit 1/4-20 X 3/4" Carriage Bolt (Qty. 10) 1/4-20 Stop Nut (Qty. 10) 1/4" Flat Washer (Qty. 10) Replacement Part Number #7621
Part X (Qty. 1) Front / Accessory Cross Member Replacement Part #1215
STEP ONE
1/4-20 Stop Nuts
PART S
Working on level ground insert two side rail alignment plugs, Part S, into the driver side front rail assembly, Part O. Connect front driver side rail assembly, Part O, and driver side rear rail assembly, Part P, using side rail connector plate, Part T, 1/4 20 X 5/8" carriage bolts and 1/4-20 stop nuts.
PART T
PART R
1/4-20 X 5/8" Carriage Bolts
PART O
STEP TWO
PART Q
Working on level ground insert two side rail alignment plugs, Part S, into the passenger side front rail assembly, Part R. Connect front passenger side rail assembly, Part R, and passenger side rear rail assembly, Part Q, using side rail connector plate, Part T and 1/4 -20 X 5/8" carriage bolts and 1/4" stop nuts.
IMPORTANT! Do not overtighten 1/4" fasteners.
PART P
Groove edge faces in towards the truck bed. Page 3 of 6
Smooth edge faces away from the truck bed.
STEP THREE
Rear View
Front View
5/16-18 X 3" Carriage Bolt PART V- Passenger Side Not Shown
Slide the universal front mounting clamps, Part W, onto both the driver and passenger side of the installed front cross member from the Model 1200 or Model 1205. Leaving 1/4" gap (see diagram) between the clamps and legs. Tighten the 5/16" hardware to 15 foot pounds of torque.
PART W
PART U- Drivers Side
1/4" Gap
STEP FOUR
Separate the mounting clamps by removing the 5/16-18 X 3" carriage bolt from the drivers side rear mounting clamp, Part U, and the passenger side rear mounting clamp, Part V. Install the mounting clamps around the rear legs. Leaving a 1/4" gap (see diagram) between the clamps and cross member. Reinstall the 5/16-18 carriage bolts and tighten to 15 foot pounds of torque. The solid side of the clamps must face towards the rear of the vehicle.
STEP THREE
1/4" Gap
STEP FOUR Page 4 of 6
STEP FIVE 1/4-20 Stop Nuts 1/4" Flat Washers
1/4-20 X 3/4" Carriage Bolt
1/4-20 X 3/4" Carriage Bolts
Place driver side rail assembly, from Step One, into the driver side rear mounting clamp. Fasten together using the predrilled hole in the side rail and a 1/4-20 X 3/4" carriage bolt and 1/4-20 stop nut, from the rail mounting hardware kit. Repeat the process for the passenger side rail.
STEP SIX
Using a center punch, mark the holes to be drilled through the square holes on the front mounting clamp. Remove the side rails from the vehicle and drill the holes using a 5/16" drill bit. Fasten the side rails to the mounting clamps using the 1/4-20 X 3/4" carriage bolts, 1/4" washers, and 1/420 stop nuts, from the rail mounting hardware kit.
1/4-20 Stop Nut 1/4" Flat Washer
IMPORTANT! Do not overtighten 1/4" fasteners.
CAUTION To keep debris out of your eyes when drilling, always wear protective eye wear. Page 5 of 6
IMPORTANT! Do not overtighten 1/4" fasteners. 1/4-20 Stop Nuts 1/4" Flat Washers
STEP SEVEN
Using the predrilled holes on the drivers side rail install the universal front side rail mounting clamp, Part W, using the 1/4-20 X 3/4" carriage bolts, 1/4" washers, and 1/4-20 stop nuts, from the rail mounting hardware kit. Repeat the process for the passenger side rail.
PART W PART X 1/4-20 X 3/4" Carriage Bolts
Installation is now complete.
IMPORTANT!
STEP EIGHT
Before operating vehicle check to ensure the 5/16" fasteners are set to a torque rating of 15 foot pounds. 1/4" fasteners should be snug. DO NOT OVERTIGHTEN 1/4" FASTENERS. At the end of the first week of use check all fasteners for proper tightness and then every three months there after. ONLY OPERATE VEHICLE WITH REAR CROSS MEMBER IN PLACE
DO NOT OPERATE VEHICLE WITH REAR CROSS MEMBER REMOVED
Insert the front cross member, Part X, into the front rail mounting clamps, Part W, installed in Step Seven. Adjust cross member to allow equal distance on both sides. Tighten the mounting clamps to the cross member using the 5/16-18 hardware preinstalled on the mounting clamp to 15 foot pounds of torque. Model 1205 owners please read note on bottom left hand corner of page 2. Page 6 of 6
Part No. 24-0155 REV. B ECN 5315 05/13
WARNING This product is only intended for, and only safe for, transporting ladders, lumber, pipe and other similar materials. It is the responsibility of the user to secure these materials to the rack before transporting. Any modifications made to this product, or use of this product for any other purpose than its intended use, could create a hazardous condition that can cause serious personal injury or property damage. 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 a improperly secured ladder will cause wear and weaken the ladder. Using a damaged ladder could lead to a structural collapse and could result in a serious injury or death.
- 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. Some vehicle manufacturers require a reinforcing kit, available through the vehicle dealership, to be installed on the truck bed prior to mounting any kind of rack or tool box. Contact your dealership to see if your vehicle requires a reinforcing kit before installation.
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 of your vehicle. Consult your vehicle owners manual for specifications on load ratings and recommendations from the vehicle manufacturer regarding installation of aftermarket racks and tool boxes.
Page 1 of 6
Approximate Assembly and Installation Time: 60 min. (1 hr.) depending on truck equipment installation experience.
LIMITED WARRANTY This LIMITED WARRANTY is made by Knaack LLC, 420 E. TerraCottaAve., Crystal Lake, Illinois to the original retail purchaserof KNAACK or WEAT HER GUARD Equipmentproducts. KNAACK LLC WARRANTS TH AT KNAACK OR WEATHER GUARD EQUIPMENT WILL BE FREE FROMDEFECTS IN MATERIAL AND WORKMANSHIP FOR A PERIOD OF TWO (2) YEARS FROM DATE OFPURCHASE BY THE ORIGINAL RE TAIL PURCHASER. If, before the expiration of the Warranty period,purchaser discovers that the KNAACK or WEATHER GUARD Equipment fails to fulfill theWarranty, 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 Equipment dealer or Knaack LLC approved service company. This Warranty shall not apply if the KNAACK or WEATHER GUARD Equipment has been subjected to misuse, abnormal service or handling,improper maintenance,or alterations made by anyone other than a KNAACK or WEAT HER GUARD Equipment 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 ANDFITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. KNAACK LLC SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGESARISING OUT OF ANY BREACH OF THIS WARRANTY. NOR SHALL THE DAMAGESEXCEED 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.
WEATHER GUARD® products are protected by one or more of the following patents or trademarks: U.S. - 4509787, 842268, 1661625, 1663369, 2228051, 2434963; U.K. - 1400720; NZ - 296049; Aus. - 761964; Canada - 1218968, 282725. KNAACK LLC 420 E. TERRA COTTA AVENUE, CRYSTAL LAKE, ILLINOIS, USA 60014 815-459-6020, [email protected] © 2003 Knaack LLC
Part No. 24-0155 REV. B ECN 5315 05/13
TOOLS REQUIRED
PART IDENTIFICATION & REPLACEMENT PART NUMBERS
3/8" Drive Ratchet 3/8" Drive Socket 1/2" Deep Well 3/8" Drive Socket 7/16" 5/16" Drill Bit Electric Drill Tape Measure Hammer Center Punch 3/8" Drive Torque Wrench (foot lbs.)
NOTE: Side rails are labeled in the packaging, take note before removing them from the carton. The rear assemblies have one predrilled hole and the front assemblies have two predrilled holes. The smooth edge faces away from the truck and the grooved edge faces inward. All side rails have a replacement part number of #7619.
FIT-UP Product fit-up is based on vehicle design available at the revision date of this installation manual. The ATRTM has been fitted and is recommended for any combination of bed lengths and cab designs on most pickup trucks. IMPORTANT! Model 1205 Owners. If installing a Model 1211 on a Model 1205, compact size truck, the front accessory crossmember, Part X, will have to be cut down to 57" from 67".
Two Holes
Smooth Edge Up
Part O (Qty. 1) Driver Side Front Rail Assembly
One Hole
Smooth Edge Up
Part P (Qty. 1) Driver Side Rear Rail Assembly
Smooth Edge Up
Smooth Edge Up
To keep debris out of your eyes when drilling or cutting, always wear protective eye wear.
Two Holes
Part R (Qty. 1) Passenger Side Front Rail Assembly
Part Q (Qty. 1) Passenger Side Rear Rail Assembly
Part T
Part S
Side Rail Hardware Kit Part S - Side Rail Alignment Plug (Qty. 4) 1/4-20 X 5/8" Carriage Bolt (Qty. 8) 1/4-20 Stop Nut (Qty. 8) Part T - Side Rail Connecting Plate (Qty. 2) Replacement Part Number #7620
Part U (Qty. 1) Driver Side Rear Mounting Clamp Replacement Part #7617
Carefully pry off the end red cap and trim the black anti-wear strip back 10". Cut 10" off the end of the cross member. Using an industrial adhesive, reapply the red end cap.
CAUTION
One Hole
Part V (Qty. 1) Passenger Side Rear Mounting Clamp Replacement Part #7636
Cross Section
Part W (Qty. 4) Universal Driver/Passenger Front Mounting Clamp Replacement Part #7618 Page 2 of 6
Rail Mounting Hardware Kit 1/4-20 X 3/4" Carriage Bolt (Qty. 10) 1/4-20 Stop Nut (Qty. 10) 1/4" Flat Washer (Qty. 10) Replacement Part Number #7621
Part X (Qty. 1) Front / Accessory Cross Member Replacement Part #1215
STEP ONE
1/4-20 Stop Nuts
PART S
Working on level ground insert two side rail alignment plugs, Part S, into the driver side front rail assembly, Part O. Connect front driver side rail assembly, Part O, and driver side rear rail assembly, Part P, using side rail connector plate, Part T, 1/4 20 X 5/8" carriage bolts and 1/4-20 stop nuts.
PART T
PART R
1/4-20 X 5/8" Carriage Bolts
PART O
STEP TWO
PART Q
Working on level ground insert two side rail alignment plugs, Part S, into the passenger side front rail assembly, Part R. Connect front passenger side rail assembly, Part R, and passenger side rear rail assembly, Part Q, using side rail connector plate, Part T and 1/4 -20 X 5/8" carriage bolts and 1/4" stop nuts.
IMPORTANT! Do not overtighten 1/4" fasteners.
PART P
Groove edge faces in towards the truck bed. Page 3 of 6
Smooth edge faces away from the truck bed.
STEP THREE
Rear View
Front View
5/16-18 X 3" Carriage Bolt PART V- Passenger Side Not Shown
Slide the universal front mounting clamps, Part W, onto both the driver and passenger side of the installed front cross member from the Model 1200 or Model 1205. Leaving 1/4" gap (see diagram) between the clamps and legs. Tighten the 5/16" hardware to 15 foot pounds of torque.
PART W
PART U- Drivers Side
1/4" Gap
STEP FOUR
Separate the mounting clamps by removing the 5/16-18 X 3" carriage bolt from the drivers side rear mounting clamp, Part U, and the passenger side rear mounting clamp, Part V. Install the mounting clamps around the rear legs. Leaving a 1/4" gap (see diagram) between the clamps and cross member. Reinstall the 5/16-18 carriage bolts and tighten to 15 foot pounds of torque. The solid side of the clamps must face towards the rear of the vehicle.
STEP THREE
1/4" Gap
STEP FOUR Page 4 of 6
STEP FIVE 1/4-20 Stop Nuts 1/4" Flat Washers
1/4-20 X 3/4" Carriage Bolt
1/4-20 X 3/4" Carriage Bolts
Place driver side rail assembly, from Step One, into the driver side rear mounting clamp. Fasten together using the predrilled hole in the side rail and a 1/4-20 X 3/4" carriage bolt and 1/4-20 stop nut, from the rail mounting hardware kit. Repeat the process for the passenger side rail.
STEP SIX
Using a center punch, mark the holes to be drilled through the square holes on the front mounting clamp. Remove the side rails from the vehicle and drill the holes using a 5/16" drill bit. Fasten the side rails to the mounting clamps using the 1/4-20 X 3/4" carriage bolts, 1/4" washers, and 1/420 stop nuts, from the rail mounting hardware kit.
1/4-20 Stop Nut 1/4" Flat Washer
IMPORTANT! Do not overtighten 1/4" fasteners.
CAUTION To keep debris out of your eyes when drilling, always wear protective eye wear. Page 5 of 6
IMPORTANT! Do not overtighten 1/4" fasteners. 1/4-20 Stop Nuts 1/4" Flat Washers
STEP SEVEN
Using the predrilled holes on the drivers side rail install the universal front side rail mounting clamp, Part W, using the 1/4-20 X 3/4" carriage bolts, 1/4" washers, and 1/4-20 stop nuts, from the rail mounting hardware kit. Repeat the process for the passenger side rail.
PART W PART X 1/4-20 X 3/4" Carriage Bolts
Installation is now complete.
IMPORTANT!
STEP EIGHT
Before operating vehicle check to ensure the 5/16" fasteners are set to a torque rating of 15 foot pounds. 1/4" fasteners should be snug. DO NOT OVERTIGHTEN 1/4" FASTENERS. At the end of the first week of use check all fasteners for proper tightness and then every three months there after. ONLY OPERATE VEHICLE WITH REAR CROSS MEMBER IN PLACE
DO NOT OPERATE VEHICLE WITH REAR CROSS MEMBER REMOVED
Insert the front cross member, Part X, into the front rail mounting clamps, Part W, installed in Step Seven. Adjust cross member to allow equal distance on both sides. Tighten the mounting clamps to the cross member using the 5/16-18 hardware preinstalled on the mounting clamp to 15 foot pounds of torque. Model 1205 owners please read note on bottom left hand corner of page 2. Page 6 of 6
Part No. 24-0155 REV. B ECN 5315 05/13
