Weather Guard 684-5-01, 644-5-01, 644-0-01, 654-5-01, 655-3-01 User Manual

TRUCK STORAGE SOLUTIONS

SECURING YOUR REPUTATION

ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS

BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT.

INSTALLATION MANUAL

STEEL & ALUMINUM SIDE BOX WITH

ALUMINUM & STEEL ALL PURPOSE CHEST

®

PACK RAT® DRAWER UNITS

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 specic aluminum upt 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
upt.

Any modication 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 modication 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 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".

©2015 KNAACK LLC

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. This product is only intended and safe
for use in storing and transporting small tools, equipment and other similar
materials. Any modications 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

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"

PARTS LIST

(4) 5/16-18

Blind Fastener

(1) Tray with Dividers

(Except Models 644 & 645)

(2) Key

(1)

Installation Tool (4) Floor Mounting Spacer

(8) 5/16"

Flat Washer

• Hammer

• Pencil/Marker

• Oil/Grease

(4) 5/16-18

Nylon Lock Nut (4) Rubber Grommet

• Center Punch

• Tape Measure

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

Hex Head Bolt

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

Black Oxide Bolt

(4) 5/16"

Lock Washer

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 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 ensure proper attachment.

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

• Install boxes with vehicle parked on
level ground.

STEP 1

Locate Box in Truck Bed

Note:

• Fasten truck box directly to bed oor, 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 gure 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.

3"- 4"

Drill 3/8"D holes

3"- 4"

STEP 2

Drill Mounting Holes

Note:

ALUMINUM TRUCK BED INSTALLATION:

Follow additional instructions if mounting to an aluminum truck
bed as explained in the Blind Fastener Installation on page 2.

• 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.

FRAME RAILS

"X"

©2015 KNAACK LLC

3

STEP 3

Attach Box to Truck Bed (Select 1 of 4 mounting styles that ts your application)

Style 1: No Bedliner, using through bolts

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

5/16" Flat Washer

Rubber Grommet

5/16" Flat Washer

BOX
FLOOR RIB

5/16-18
Nylon Lock Nut

ALUMINUM TRUCK BED INSTALLATION:

Place a 5/16" x 3/4" plastic washer between the oor rib and
5/16” at washer. Place another 5/16" x 3/4" plastic washer
between the rubber grommet and oor rib.

Style 3: No Bedliner, using Blind Fasteners

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

5/16" Flat Washer

BOX
FLOOR RIB

Rubber Grommet

Blind Fastener

Style 2: Bedliner, using through bolts

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

5/16" Flat Washer

BOX

FLOOR RIB

5/16-18
Nylon Lock Nut

ALUMINUM TRUCK BED INSTALLATION:

Rubber Grommet

BEDLINER

5/16" Flat Washer

Place a 5/16" x 3/4" plastic washer between the oor rib and
5/16” at washer. Place another 5/16" x 3/4" plastic washer
between the rubber grommet and oor rib.

Style 4: Bedliner, using Blind Fasteners

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

5/16" Flat Washer

BOX
FLOOR RIB

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
oor rib.

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
oor 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

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.

pressed in the unlock mode, the latches are
activated and the cover opens.

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 t-ups. To use, simply
cut along one or more perforations in the
rubber grommet and run wire through.

Electrical

Access

WARNING

Extension Cord Cordless Power Tool Battery Chargers

• 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.

©2015 KNAACK LLC

• 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 saddle/
cross box.

5

SERVICE PARTS

# PART # DESCRIPTION FITS MODEL #

1 7096 -2PK Gas Spring (2 PK) 665-X-01

1 7095 -2PK Gas Spring (2 PK)

1 7902 -2PK Gas Spring (2 PK) 684-X-01

1 7904 -2PK Gas Spring (2 PK) 685-X-01

Lock & Key Set

2 7748-XX

3 7750-XX

4 7731

5 7106

6 7730

7 615 Tray (1 tray plus dividers)

7 617 Tray (1 tray plus dividers) 684-X-01, 685-X-01

8 7733

9 21-0997 Touch up Paint (not shown) All White Chests

9 21-0999 Touch up Paint (not shown) All Black Chests

10 7746

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

(XX = key code)
(1 lock, 2 keys, retainer clip)

Key Replacement
(XX = key code ) (2 keys)

Latch & Striker Kit (1 latch,
1 striker, mounting hardware)

Striker Kit (1 striker and
mounting hardware)

Weather Strip Kit
(various styles for one box)

Mounting Kit (4 mounting
clamps, 4 bolts, 4 washers,
2 mount pads) (not shown)

Nameplate Kit (3 stickers,
2 side bezels, 1 back bezel)

644-X-01, 645-X-01, 654-X-01, 655-X-01,
664-X-01, 665-X-01, 674-X-01, 675-X-01

All Chests

All Chests

All Chests

All Chests

All Chests

654-X-01, 655-X-01, 664-X-01, 665-X-01,
674-X-01, 675-X-01

All Chests

All Saddle/Cross Boxes

12

9

1

7

2

11

5

10

6

1

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 identied 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 modication 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.

Notication 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 modications
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 notication and repair procedures. Warranty claims must
include reciprocal contact information and may be made via certied 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

WEATHERGUARD.COM

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

7