INSTALLATION MANUAL

TRUCK STORAGE SOLUTIONS

SECURING YOUR REPUTATION ®

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".

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.

©2015 KNAACK LLC

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"

PARTS LIST

• Hammer

• Pencil/Marker

• Oil/Grease

• Center Punch

• Tape Measure

(4) 5/16-18

Blind Fastener

(1) Tray with Dividers

(Except Models 644 & 645)

(1)

Installation Tool (4) Floor Mounting Spacer

(4) 5/16-18 x 1-1/4"

Hex Head Bolt

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

Black Oxide Bolt

(8) 5/16"

Flat Washer

(4) 5/16-18

Nylon Lock Nut (4) Rubber Grommet

(4) 5/16"

Lock 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.

(4) 11/32" x 7/8"

Plastic Washer

(8) 5/16" x 3/4"

Plastic Washer

Black Oxide Bolt

Flat Washer

9/16" Wrench

Installation Tool

Blind Fastener

©2015 KNAACK LLC

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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.

• 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.

3"- 4"

Drill 3/8"D holes

"X"

3"- 4"

FRAME RAILS

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.

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

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STEP 3

Attach Box to Truck Bed

(Select 1 of 4 mounting styles that fits your application)

Style 1:

No Bedliner, using through bolts

Style 2:

Bedliner, using through bolts

BOX

FLOOR RIB

5/16-18

Nylon Lock Nut

5/16-18 x 1-1/4"

Hex Head Bolt

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.

BOX

FLOOR RIB

5/16-18 x 1-1/4"

Hex Head Bolt

5/16" Flat Washer

Rubber Grommet

BEDLINER

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 3:

No Bedliner, using Blind Fasteners

5/16-18 x 1-1/4"

Hex Head Bolt

5/16" Flat Washer

Rubber Grommet

BOX

FLOOR RIB

Blind Fastener

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.

Style 4:

Bedliner, using Blind Fasteners

BOX

FLOOR RIB

5/16-18 x 1-1/4"

Hex Head Bolt

5/16" Flat Washer

Rubber Grommet

BEDLINER

Blind Fastener

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.

©2015 KNAACK LLC

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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

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.

Unlock

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

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SERVICE PARTS

# PART # DESCRIPTION

1 7096 -2PK Gas Spring (2 PK)

FITS MODEL #

665-X-01

1 7095 -2PK Gas Spring (2 PK)

1 7902 -2PK Gas Spring (2 PK)

1 7904 -2PK Gas Spring (2 PK)

2

3

7748-XX

7750-XX

Lock & Key Set

(XX = key code)

(1 lock, 2 keys, retainer clip)

Key Replacement

(XX = key code ) (2 keys)

4

5

6

7731

7106

7730

Latch & Striker Kit (1 latch,

1 striker, mounting hardware)

Striker Kit (1 striker and mounting hardware)

Weather Strip Kit

(various styles for one box)

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

All Chests

All Chests

All Chests

All Chests

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

684-X-01, 685-X-01 7

8

617

7733

Tray (1 tray plus dividers)

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

12 7933-X

12 7934-X

12 7935-X

12 7936-X

12 7937-X

12 7942-X

12 7943-X

Grommet Kit

Cover

Cover

Cover

Cover

Cover

Cover

Cover

All Saddle/Cross Boxes

645-X-01

655-X-01

665-X-01

675-X-01

685-X-01

644-X-01

654-X-01

12 7944-X

12 7945-X

12 7946-X

13 7742

13 7743

13 7744

13 7744

Cover

Cover

Cover

Latch Rod Kit (not shown)

664-X-01

675-X-01

684-X-01

644-X-01, 645-X-01

Latch Rod Kit (not shown) 654-X-01, 655-X-01

Latch Rod Kit (not shown) 664-X-01, 665-X-01, 684-X-01, 685-X-01

Latch Rod Kit (not shown) 674-X-01, 675-X-01

2

Note: X represents the color code for your model:

0 = Clear | 3 = White | 5 = Black | 52 = Matte Black

7

1

3

9

11

12

5

6

10

4

1

©2015 KNAACK LLC

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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

Part No. 24-0292 REV. C ECN 5583 05/15

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