INSTALLATION MANUAL

INSTALLATION MANUAL
INSTALLATION MANUAL
TRUCK STORAGE SOLUTIONS
SECURING YOUR REPUTATION ®
STEEL & ALUMINUM
SIDE ALL
BOX WITH
ALUMINUM
& STEEL
PURPOSE CHEST
®
PACK RAT DRAWER UNITS
ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS
BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT.
MODELS
644-X-01, 645-X-01, 654-X-01, 655-X-01, 664-X-01, 665-X-01, 674-X-01, 675-X-01, 684-X-01, 685-X-01
Note: X represents the color code for your model: 0 = Clear | 3 = White | 5 = Black | 52 = Matte Black
NOTICE
Use specific aluminum upfit components when installing WEATHER GUARD®
products to aluminum truck beds. Follow additional instructions if mounting
to an aluminum truck bed. There may be left over components depending on
upfit.
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.
WARNING
Prior to drilling, so as not to cut or puncture fuel tanks, fuel lines, electric
wires, etc., check under vehicle for locations. All floor 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".
©2015 KNAACK LLC
DANGER
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.
CAUTION
Before marking the leg mounting holes, check inside the box for location of
gas spring housing and components that may obstruct safe drilling. To keep
debris out of your eyes when checking the underside of the vehicle, or when
drilling, always wear protective eyewear.
WEATHERGUARD.COM
Part No. 24-0292 REV. C ECN 5583 05/15
TOOLS REQUIRED
• Electric Drill
• Bits: 3/8", 1/2"
• Open or Box End Wrench - (2) 1/2", 9/16"
• Hammer
• Pencil/Marker
• Oil/Grease
• Center Punch
• Tape Measure
PARTS LIST
(4) 5/16-18
Blind Fastener
(1)
Installation Tool
(4) Floor Mounting Spacer
(1) Tray with Dividers
(8) 5/16"
Flat Washer
(4) 5/16-18
Nylon Lock Nut
(Except Models 644 & 645)
(4) 5/16-18 x 1-1/4"
Hex Head Bolt
(1) 5/16-18 x 2-1/4"
Black Oxide Bolt
(4) Rubber Grommet
(4) 5/16"
Lock Washer
(4) 11/32" x 7/8"
Plastic Washer
(8) 5/16" x 3/4"
Plastic Washer
(2) Key
ALUMINUM BED UPFIT KIT PARTS LIST - 32-0243
(4)
Vinyl Tape
(1)
Zinc Rich Primer
(8) 1/2" x 1"
Plastic Washer
BLIND FASTENER INSTALLATION
Place a drop of oil on black oxide bolt for lubrication before assembling.
Place the Blind Fastener in the hole and use 1/2" or 7/16" wrench to
tighten black oxide bolt until fastener is fully seated (it will start out hard
and get easier as fastener “bulbs” out).
Make sure the Blind Fastener and Installation Tool do not turn during
installation.
ALUMINUM TRUCK BED INSTALLATION
Coat drilled holes with Zinc Rich Primer. Insert Blind Fastener through one
1/2" x 1" plastic washer. Insert Blind Fastener into drilled hole. Place
second 1/2" x 1" plastic washer through the bottom of the Blind Fastener.
Continue following installation instructions above to install Blind Fasteners.
Black Oxide Bolt
Flat Washer
9/16" Wrench
Installation Tool
Blind Fastener
©2015 KNAACK LLC
2
INSTALLATION INSTRUCTIONS
Note: • If your truck bed is constructed of
aluminum, use zinc rich primer to coat
drilled holes.
• If the pickup is fitted 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.
Drill 3/8"D holes
• Periodically check tightness of mounting bolts to ensure proper attachment.
• Use touch-up paint on any drilled holes
to prevent oxidation.
• Install boxes with vehicle parked on
level ground.
"X"
3"- 4"
3"- 4"
STEP 1 Locate Box in Truck Bed
Note: • Fasten truck box directly to bed floor, not bed
liners or mats. A drop of oil or grease should
be applied to both faces of grommets before
tightening the fasteners to prevent grommets
from binding on washers.
Place box in truck bed and center. Check for interference
with box cover open. Select two ribs in truck bed on which
to mount box (preferably outside of frame rails). Measure
from middle of selected rib to truck box end (dimension
“X” in figure above). Transfer dimension “X” to inside of
both sides of truck box. Mark a line 3"-4" from front and
back on inside of truck box.
FRAME RAILS
STEP 2 Drill Mounting Holes
Note: • For a one person installation, if desired, the box
may be installed using blind fasteners, eliminating the use of nuts and washers on the underside of the bed. In this case, re-drill the 3/8"
holes in the bed with a 1/2" drill bit.
For a regular installation, use a blind fastener in areas
where standard fasteners can’t be used, such as heat
shields and support channels.
Drill 3/8" holes through box and truck bed at marked locations. Install (4) rubber grommets into holes in the box.
ALUMINUM TRUCK BED INSTALLATION:
Follow additional instructions if mounting to an aluminum truck
bed as explained in the Blind Fastener Installation on page 2.
©2015 KNAACK LLC
3
STEP 3 Attach Box to Truck Bed (Select 1 of 4 mounting styles that fits your application)
Style 1: No Bedliner, using through bolts
BOX
FLOOR RIB
5/16-18
Nylon Lock Nut
Style 2: Bedliner, using through bolts
5/16-18 x 1-1/4"
Hex Head Bolt
5/16-18 x 1-1/4"
Hex Head Bolt
5/16" Flat Washer
Rubber Grommet
5/16" Flat Washer
Rubber Grommet
5/16" Flat Washer
ALUMINUM TRUCK BED INSTALLATION:
Place a 5/16" x 3/4" plastic washer between the floor rib and
5/16” flat washer. Place another 5/16" x 3/4" plastic washer
between the rubber grommet and floor rib.
Style 3: No Bedliner, using Blind Fasteners
BOX
FLOOR RIB
BOX
BEDLINER
FLOOR RIB
5/16-18
Nylon Lock Nut
5/16" Flat Washer
ALUMINUM TRUCK BED INSTALLATION:
Place a 5/16" x 3/4" plastic washer between the floor rib and
5/16” flat washer. Place another 5/16" x 3/4" plastic washer
between the rubber grommet and floor rib.
Style 4: Bedliner, using Blind Fasteners
5/16-18 x 1-1/4"
Hex Head Bolt
5/16-18 x 1-1/4"
Hex Head Bolt
5/16" Flat Washer
Rubber Grommet
5/16" Flat Washer
Rubber Grommet
Blind Fastener
BOX
FLOOR RIB
BEDLINER
Blind Fastener
ALUMINUM TRUCK BED INSTALLATION:
ALUMINUM TRUCK BED INSTALLATION:
Follow additional instructions if mounting to an aluminum truck
bed as explained in the Blind Fastener Installation on page 2.
In addition to following the blind fastener installation, place a
5/16" x 3/4" plastic washer between the rubber grommet and
floor rib.
Follow additional instructions if mounting to an aluminum truck
bed as explained in the Blind Fastener Installation on page 2.
In addition to following the blind fastener installation, place a
5/16" x 3/4" plastic washer between the rubber grommet and
floor rib.
©2015 KNAACK LLC
4
FEATURE OPERATION
Lock System
The WEATHER GUARD® Extreme Protection™
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 latches are
activated and the cover opens.
Lock
Unlock
Turn the key counterclockwise to
the locked position as indicated
on the lock bezel. When the
button is now pressed, it will
stay in the retracted or tamperresistant position until unlocked.
Turn the key clockwise to the
unlocked position as indicated
on the lock bezel. Button will
pop out and is now ready
to release the latches when
pressed.
Latch System
The WEATHER GUARD® Latch System utilizes automotive grade latches in conjunction with high strength latch strikers 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: Lubricate latch pivot points bi-annually with white grease. If
latch strikers are accidentally knocked out of alignment, simply use a mallet to re-align.
12V Electrical Access
WEATHER GUARD® Truck Boxes are equipped
with a 12 volt electrical access grommet for
easy electrical accessory fit-ups. To use, simply
cut along one or more perforations in the
rubber grommet and run wire through.
Electrical
Access
WARNING
Extension Cord
• Follow all Extension Cord manufacturer’s warnings and instructions.
• DO NOT insert extension cord through hole without grommet in place.
• 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 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
saddle/cross box.
• Only use an extension cord that is rated for outdoor use.
• DO NOT connect extension cord to outlet that also supplies critical safety
equipment with power.
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 flammable materials like paper or rags away from charger, cords or
connections.
• DO NOT place or attempt to charge lead acid, car type batteries in saddle/
cross box.
©2015 KNAACK LLC
5
SERVICE PARTS
# PART #
DESCRIPTION
FITS MODEL #
1
Gas Spring (2 PK)
665-X-01
7096 -2PK
1
7095 -2PK
Gas Spring (2 PK)
644-X-01, 645-X-01, 654-X-01, 655-X-01,
664-X-01, 665-X-01, 674-X-01, 675-X-01
1
7902 -2PK
Gas Spring (2 PK)
684-X-01
1
7904 -2PK
Gas Spring (2 PK)
685-X-01
2
7748-XX
Lock & Key Set
(XX = key code)
(1 lock, 2 keys, retainer clip)
All Chests
3
7750-XX
Key Replacement
(XX = key code ) (2 keys)
All Chests
4
7731
Latch & Striker Kit (1 latch,
All Chests
1 striker, mounting hardware)
5
7106
Striker Kit (1 striker and
mounting hardware)
All Chests
6
7730
Weather Strip Kit
(various styles for one box)
All Chests
7
615
Tray (1 tray plus dividers)
654-X-01, 655-X-01, 664-X-01, 665-X-01,
674-X-01, 675-X-01
7
617
Tray (1 tray plus dividers)
684-X-01, 685-X-01
8
7733
Mounting Kit (4 mounting
clamps, 4 bolts, 4 washers,
2 mount pads) (not shown)
All Chests
9
21-0997
Touch up Paint (not shown)
All White Chests
9
21-0999
Touch up Paint (not shown)
All Black Chests
10 7746
Nameplate Kit (3 stickers,
2 side bezels, 1 back bezel)
All Saddle/Cross Boxes
11 7749
Grommet Kit
All Saddle/Cross Boxes
12 7933-X
Cover
645-X-01
12 7934-X
Cover
655-X-01
12 7935-X
Cover
665-X-01
12 7936-X
Cover
675-X-01
12 7937-X
Cover
685-X-01
12 7942-X
Cover
644-X-01
12 7943-X
Cover
654-X-01
12 7944-X
Cover
664-X-01
12 7945-X
Cover
675-X-01
12 7946-X
Cover
684-X-01
13 7742
Latch Rod Kit (not shown)
644-X-01, 645-X-01
13 7743
Latch Rod Kit (not shown)
654-X-01, 655-X-01
13 7744
Latch Rod Kit (not shown)
664-X-01, 665-X-01, 684-X-01, 685-X-01
13 7744
Latch Rod Kit (not shown)
674-X-01, 675-X-01
12
5
6
9
1
1
7
2
11
10
4
3
Note: X represents the color code for your model:
0 = Clear | 3 = White | 5 = Black | 52 = Matte Black
©2015 KNAACK LLC
6
KNAACK LLC LIMITED LIFETIME WARRANTY FOR WEATHER GUARD® PRODUCTS
WEATHER GUARD® Products — Limited Lifetime Warranty
(Purchased on or after 1/1/2009)
KNAACK LLC (the “Manufacturer”) warrants to the original purchaser only that WEATHER GUARD® Truck and Van Products (the “WEATHER GUARD®
Product”) will be free from defects in material and workmanship from the date of purchase and continuing for the expected lifetime of the WEATHER
GUARD® Product. A copy of the original sales receipt must be supplied to the Manufacturer at the time a warranty claim is made. This warranty terminates
if the original purchaser transfers the WEATHER GUARD® Product to any other person.
What is Covered
All WEATHER GUARD® Products identified above that are purchased on or after January 1, 2009.
What We Will Do To Correct Problems
Subject to the limitations and exclusions described in this limited warranty, the Manufacturer will remedy defects in materials or workmanship by
providing one of the following remedies at its option and without charge to the original purchaser for parts or labor: (a) repairing the defective portion of
the WEATHER GUARD® Product or (b) replacing the entire WEATHER GUARD® Product. In addition, the Manufacturer may elect at its option, not to repair
or replace the WEATHER GUARD® Product, but rather issue to the original purchaser a refund equal to the purchase price paid for the WEATHER GUARD®
Product or a credit to be used toward the purchase of a new WEATHER GUARD® Product.
What is Not Covered
This limited warranty expressly excludes:
•
Defects caused by normal wear and tear, cosmetic rust, scratches, accidents, unlawful vehicle operation, or modification to the product, or any
types or repair of a WEATHER GUARD® Product other than those authorized or provided by the Manufacturer.
•
Defects resulting from conditions beyond the Manufacturer’s control including, but not limited to misuse, overloading, or failure to assemble, mount
or use the WEATHER GUARD® Product in accordance with the Manufacturer’s written instructions or guidelines included with the WEATHER GUARD®
Product or made available to the original purchaser.
•
Damage to the contents of the box or vehicle.
•
TO THE EXTENT PERMITTED BY LAW, IN NO EVENT SHALL THE MANUFACTURER BE LIABLE FOR ANY INCIDENTAL, SPECIAL, INDIRECT, OR CONSEQUENTIAL
DAMAGES, INCLUDING ANY ECONOMIC LOSS, WHETHER RESULTING FROM NONPERFORMANCE, USE, MISUSE OR INABILITY TO USE THE WEATHER
GUARD® PRODUCT OR THE MANUFACTURER’S NEGLIGENCE.
No Other Express Warranty Applies
This Limited Lifetime Warranty is the sole and exclusive warranty for WEATHER GUARD® Products. No employee, agent, dealer, or other person is
authorized to alter this warranty or make any other warranty on behalf of KNAACK LLC.
Notification Procedures
If the WEATHER GUARD® Product does not conform with the terms of this limited warranty, the original owner must promptly notify the Manufacturer in
writing upon discovery of the nonconformity. In order to receive the remedies under this limited warranty, the warranty claim must describe the nature of
the nonconformity, and a copy of the original sales receipt, invoice, bill or other proof of purchase must accompany the claim. Repairs or modifications
made to the WEATHER GUARD® Product by other than the Manufacturer or its authorized agent will nullify this limited warranty. Coverage under this
limited warranty is conditioned at all times upon the owner’s compliance with these required notification and repair procedures. Warranty claims must
include reciprocal contact information and may be made via certified mail to:
KNAACK LLC
ATTN: Warranty Claims
420 E. Terra Cotta Avenue
Crystal Lake, IL 60014
If you have any questions,
please call toll free 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.
©2015 KNAACK LLC
WEATHERGUARD.COM
Part No. 24-0292 REV. C ECN 5583 05/15 7
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