Weather Guard PowerSync User manual

If you are installing Weather Guard®Remote Keyless Entry
(RKE), only one wiring harness installation is applicable
based on the vehicle you are installing (check diagrams on
page 10).
For installing the Weather Guard®Remote Keyless Entry
Upgrade Kit PS8400 or PS8401, please follow one wiring
harness installation section that is applicable for your vehicle
and the Remote Keyless Entry Upgrade Kit installation of the
instruction manual.
For installation of the truck box to the truck bed, please
reference the Weather Guard®saddle box installation
manual, included in the separate accessory/installation kit
box with your truck box.
NOTICE: Before you start the installation, please make sure to park the truck on a level surface,
turn off the truck engine, and remove the key from the ignition.
!
PS8400: To be used with Chevrolet/GMC/RAM Trucks with
the factory trailer towing packages. For Chevrolet/GMC/RAM
trucks without the factory trailer towing package, use
PS8401
WEATHERGUARD.COM
INSTALLATION GUIDE
Scan to watch installation video
FOR REMOTE KEYLESS ENTRY
ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS
BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT
MODEL: DESCRIPTION:
PS8400 HITCH WIRE HARNESS
PS8401 FUSE WIRE HARNESS
PS8402 4-WAY WIRING HARNESS
PS8403 SINGLE EXTENSION
PS8404 SINGLE EXTENSION

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Contents
INSTALLATION VIA TOW HITCH
FOR CHEVROLET, GMC OR RAM TRUCKS ONLY
SECTION 1
INSTALLATION VIA FUSEBOX
SECTION 2
INSTALLATION OF POWERSYNC RKE -
SADDLEBOX INSTALLATION
SECTION 3
KEYFOB AND CONTROLLER
SECTION 4
INSTALLATION OF POWERSYNC RKE -
SIDE BOX INSTALLATION
SECTION 5
PAGE 3
PAGE 4
PAGE 5
PAGE 7
PAGE 8
CABLE ROUTING CONFIGURATIONS
SECTION 6 PAGE 10
PARTS LIST RKE Saddle box PARTS LIST RKE Low-side
1 Keyfob
2 Velcro Strips (2)
3 Controller
4 Actuator
5 Power Cable
6 Actuator Cable
7 Actuator Linkage
8 Rod Latch Clamp
9 Bridge Bracket
10 Linkage Cover
11 Actuator Cover
Screws:
#6-32 x 1/4” Philips head (2)
#10x3/4” Philips head (3)
#8x1/2” Hex Head (6)
1 Keyfob
2 Controller
3 Velcro Strips
4 Dual Loop cable
5 Actuator
6 Power Cable
7 Actuator Cable
8 Lock Cam
9 #4-40 Shoulder bolt (1)
10 Cover Plate
11 Mounting Bracket
12 Lo Side Cover Ext
13 Linkage
14 Latch Rod Clamp
Screws:
#10x3/4” Phillips head (3)
#8x1/2” Hex head (3)
#8x16 Phillips head (1)
1 2 3 4
5
6
7
8
10 11
9
12 3 4
8 9
5
6
7
10 11 12
13 14

1
WEATHERGUARD.COM
Installation via Hitch Harness
For Chevrolet, GMC or Ram Pickup Trucks
with the factory trailer towing package only
CONNECT NEW TRUCK BOX
HARNESS TO TRUCK
Locate the factory wiring hitch harness under or behind the
rear bumper of your truck. Disconnect the existing connec-
tors as shown below. Note that there is a locking tab that
needs to be depressed to disconnect the harnesses. Connect
your Weather Guard®Hitch Harness between the factory
connectors as shown below.
Tuck in and secure the Weather Guard®Hitch Harness to the
bumper, bed, or existing factory wiring harness using zip ties.
ROUTE HARNESS TO TRUCK BED
Route the new harness between the rear bumper and the
knock out hole in the bulkhead of the truck bed. It is usually
easiest to follow the path of an existing wiring harness along
the frame of the truck (recommend driver side). Secure the
new harness to the truck in a few locations using the zip ties
supplied.
ROUTE HARNESS INTO TRUCK BOX AND
CONNECT
Remove the knock-out plug from the bulkhead of the truck
bed, feed the harness end into the truck bed and then
through the grommet in the side of the truck box.
STEP 1 STEP 2
STEP 3
NO CUTTING OR DRILLING REQUIRED TO INSTALL. USE ZIP
TIES TO SECURE CABLE TO FACTORY FITTED PARTS.
New
Connector
SECURE WITH
ZIP TIE
Existing
Connector
Existing
Connector
Bulkhead
knock-out plug
Truckbox
grommet
!
CABLE ROUTING
Best practice is to zip tie the cables to existing
wiring harnesses or fixed metalwork

2
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!
Installation of fusebox wiring harness
For use with all makes and models of trucks
CHOOSE ONLY HITCH CONNECTION OR FUSEBOX CONNECTION, NOT BOTH
DETERMINE A FUSE SLOT TO USE
Identify an open fuse slot in the under-the-hood
fuse box which provides constant power. For instal-
lation, review the vehicle owners’ manual to locate
the horn fuse (or any other continuously powered
accessory) and utilize the open slot in the same row
as that fuse.
ROUTE HARNESS TO TRUCK
BED
Route the new harness inside the truck body
between the fuse box and the knock out hole in the
bulkhead of the truck bed. It is recommended to
follow the path of an existing vehicle wiring harness
along the frame of the truck (recommend driver
side). Secure the new harness to the truck in a few
locations using the zip ties supplied.
ROUTE HARNESS INTO TRUCK
BOX AND CONNECT
Remove the knock-out plug from the bulkhead of
the truck bed, feed the harness end into the truck
bed and then through the grommet in the side of
the truck box.
RECONNECT THE BATTERY
DISCONNECT BATTERY
Disconnect the negative
terminal from the truck’s
battery.
CONNECT NEW TRUCK BOX HARNESS TO TRUCK FUSE BOX AND GROUND
A. If you are utilizing a slot currently in use -
as in the case of the horn slot - remove the existing
fuse (select the fuse with 10 amp or less in rating)
and insert it into the lower fuse slot on the fuse end
of the harness. Plug in one of the 3 fuse ends
provided with your harness that fits into the fuse
slot.
B. If you are utilizing a slot currently NOT in use, plug in one of the 3
fuse ends provided with your harness that fits into the fuse slot. Please
note, if the fuse slot is not programmed to provide constant power, no
power will reach the truck box.
C. Attach the white ground wire from the harness to an existing
ground near the fuse box.
STEP 1
STEP 2
STEP 4
STEP 3
STEP 5
G
10A
Ground
!
CABLE ROUTING
Best practice is to zip tie the cables
to existing wiring harnesses or fixed
metalwork
Bulkhead
knock-out plug
Truckbox
grommet

3
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12 3
1 2
Linkage
28” Actuator
extension cable
1.1 1.4
1.3
1.2
1
2
3
12
12
PLASTIC
GUARD
LOCK
COVER
Latch Rod Clamp
Latch Rod
Actuator assembly
Actuator cable
Extension
2.2
2.3
2.1
2.4
Partition wall
!
FOR STEEL SADDLEBOXES ONLY
Install the additional bridge bracket using screws
(#8x1/2 Hex Head) provided before the actuator
assembly using screws (#8x1/2 Hex Head).
Installation of PowerSync RKE
SaddleBox Installation
BEFORE ASSEMBLING TO TRUCKBOX
STEP 1
2.1 Remove lock cover and plastic guard on the driver side only.
2.4 Feed the cable underneath the latch,
but within the latch housing. Then feed the
end of the extension cable through the
partition wall.
REMOVE COVERS, ASSEMBLE ACTUATOR
STEP 2
1.3 Secure the actuator to the actuator cover
using the three screws (#10x3/4 Phillips Head)
and attach the 28 inch extension cable to the
actuator
2.2 Line up the actuator cover to the holes in front of the saddle box next to the
driver side latch. Using screws (#8x1/2 Hex Head) provided, secure the actuator
cover to the truck box.
2.3 Lightly pull to extend actuator end. Guide the latch rod clamp over the latch
rod and tighten the screws (#6-32x1/4) to the latch rod.
1.4 Connect the actuator cable to the extension
cable provided. Ensure colors of wires are
connected together (Blue to Blue, Green to
Green)
1.1 Loosely insert the 2
screws (#6-32x1/4”) into
the latch rod clamp making
sure they don’t protrude to
the inside of the clamp.
1.2 Pass the linkage
through the end of the
actuator and through the
lower hole of the latch rod
clamp.
Bridge bracket
(STEEL SADDLE
BOX ONLY)
Linkage Cover is secured
here after linkage assembly

3
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Installation of PowerSync RKE
SaddleBox Installation
INSTALLING THE CONTROLLER AND
PAIRING THE KEYFOB
STEP 3
3.1 Route the actuator cable to the controller box as shown
below. Cables are shown in RED, not actual color.
3.2 Connect the power cable (with RED end) to the red Power
connector on the controller, then connect the actuator cable
to the saddlebox connector.
REPLACE COVERS
STEP 4
4.1 Install the linkage cover using screws (#8x1/2 Hex Head)
4.2 Reinstall the plastic guard and lock cover removed in
step 2.1 previously.
Controller Power Cable
to PowerSync Power Cable
Controller
Actuator
Cable to actuator
PowerSync
Power cable
enters box here
3.1
3.2
4.3
3.3
Connect
controller
power cable
to PowerSync
power cable.
Use 4-way
connector if
needed
PowerSync
Power cable
enters box
here
!TO SPLIT POWER FOR ADDITIONAL POWERSYNC ITEMS IN THE SAME BOX:
Attach the 4-way connector to the end of the PowerSync Power cable to split the power connection.
Controller
3.3 Route the Power cable on the connector down the guide
channel (where the Gas Strut is installed). Connect the
controller power cable to the Power Sync Power Harness near
the grommet where the PowerSync power cable enters the
box.
3.4 To program the keyfob and to test the controller and
actuator are working properly, see Section 4 for pairing
keyfobs.
3.5 Once programed, the actuator should pull on the latch
rod. Once verified and with the keys to your box nearby, close
the truck box lid and press the button on the key fob. The
truck box lid will open. Use the provided Velcro pads to secure
the controller to the back section of the partition.

4
Open Saddle Box
Open Drivers
side box
(if installed)
Open Passenger
side box
(if installed)
Auxiliary Button
Keyfob LED
Keyfob
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Keyfob and Controller
PAIRING THE FOB TO THE CONTROLLER
The Keyfob is equipped with a rolling encryption code.
Enter “Learning Mode” by locating and pressing the program-
ming button on the Controller 3x until red LED activates.
Ensure the PowerSync Keyless Entry system is connected to
the PowerSync Powercable. Press any Button on the Keyfob 1
time, the LED indicator on the Keyfob will flash and then
remain solid.
The Keyfob has now been paired.
System will automatically exit Learning Mode within 30
seconds
Up to 3 total Keyfobs per control box can be paired. To pair
additional Keyfobs, follow the instructions below.
On each additional Keyfob, enter “Learning Mode” by locat-
ing and pressing the programming button 3x until red LED
activates.
Press any button on each keyfob 1 time. LED indicator will
flash with each fob and then remains solid.
System will automatically exit Learning Mode within 30
seconds
If pairing and testing the keyfob(s) does not work, check the
following:
First try the pairing procedure again. If still unsuccessful,
a) check power cable and actuator cables are connected.
b) check the cables are connected in the correct positions
c) check the actuator cable colors wires are connected to the
correct colors
d) check and/or replace the batteries in the keyfob
PAIRING MULTIPLE KEYFOBS
!
TO RESET THE SYSTEM
The system can be reset by holding down the programming button for 5 seconds until the LED
flashes 3 times. All previously paired key fobs will need to be paired again.
Programming LED
Programming
Button
Controller
Passenger Side Lo-Side
Driver Side Lo-side
Saddle Box
Power

!
TO SPLIT POWER FOR ADDITIONAL POWER-
SYNC ITEMS IN THE SAME BOX
Attach the 4-way connector to the end of the
PowerSync Power cable to split the power
connection.
5
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1.1
1.2
B
A
This extension bracket
is not needed on
low-profile boxes
1.3
Installation of PowerSync RKE
BEFORE INSTALLING TO TRUCKBOX
2.1 Remove the rear and upper latch cover and set aside.
Make sure to save the 3 screws as they will be needed later
in the installation.
2.2 Remove the cam at the back of the lock assembly and
replace it with the shorter one provided in the RKE kit.
2.3 When your lock is in the “Unlock” position, the cam
should be pointing down and towards the latch and interfere
with the latch cam. When your lock is in the “Locked”
position, the cam should be pointing down and away from the
latch. Tighten the screw provided to 80 in-lb torque.
2.4 Install #4-40 Shoulder Bolt to the latch lever arm
Side Box Installation
INSTALLING NEW RKE PARTS
1.1 Install the #8-16 Philips head screw into the end of the
actuator.
1.2 Attach the actuator to the extension brackets (A) and (B)
using screws Philips head #10x3/4. Bracket (B) is not
needed on low-profile truckboxes.
1.3 Connect the Actuator cable to the new extension cable
provided.
STEP 1 STEP 2
Upper
Latch
Cover
Rear
Latch
Cover
1
2
3
2.1
#4-40
Shoulder
Bolt
Remove old
CAM and
replace with
New CAM
provided
Replace
Screw
Locked
Position
2.2
2.4
2.3

5
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Installation of PowerSync RKE
Side Box Installation
3.1 Secure the dual loop cable provided to the end of the
actuator and the #4-40 Shoulder Bolt making sure the cable
is looped around the guide bar. Push the free end of the
cable over the head of the screw that was installed earlier to
the latch lever arm in Step 1.3
3.3 Using the 2 screws that secured the rear latch cover that
was removed, secure the actuator assembly.
INSTALLING INTO SIDE BOX
STEP 3
4.1 Connect the extension power cable (with RED end) to the
red connector on the controller box, then connect the actua-
tor cable to the connector. If you have a controller box in
another truckbox, for example in a saddlebox, then the cable
will need to be routed through to the controller in the other
box.
4.2 Connect the controller power cable to the Power Sync
Power Harness
4.3 Program keyfob to test the controller and actuator are
working properly. See Section 4 for pairing keyfobs.
INSTALLING THE CONTROLLER AND
PAIRING THE KEYFOB
STEP 4
PowerSync
Power Cable
Connects to Connector
Power Extension
Controller
Actuator
Cable
Extension
Controller
Power Cable
Actuator
Cable Connector
4.4 Once programed the actuator should pull on the latch rod.
Once verified and with the keys to your box nearby, close the
truck box lid and press the button on the key fob. The truck
box lid will open. Use the provided Velcro pads to secure the
controller to the back section of the partition
Rear Latch
Cover
Actuator
Guide Bar
Dual Loop Cable
Center Power
Pass
3.1
3.2
REPLACE COVERS
STEP 5
5.1 Install the RKE upper latch cover using 3 screws (#8x1/2
Hex Head), this includes the one removed earlier.
5.2 Using an #8x1/2 hex head screw provided, secure upper
latch cover to the extension bracket (not for Low Profile
Truckboxes). For low profile side boxes, secure the upper
latch cover to the return of the front panel
RKE Rear Latch
Cover
RKE UPPER
LATCHCOVER
EXTENSION
BRACKET
2
1
3
4
5.2 Tuck
extension
bracket under
here (not for
low-profile
boxes)
!
IF THERE IS ALREADY A CONTROLLER IN
ANOTHER TRUCKBOX
The Actuator extension cable will need to be
routed through to the controller in the other
box.
4.1
4.2

124256-01 Rev A 6/21
WEATHERGUARD.COM
Cable Routing Configurations
CABLE ROUTING CONFIGURATIONS
Saddle box with Low-Sides
Saddle box only Low-Sides
Control Box Actuator cable Actuator
Hitch or fusebox
power connection
Hitch or fusebox
power connection
Hitch or fusebox
power connection
6
Fuse connection wiring harness 7ft Extension cable 15ft Extension cable
Hitch Connection wiring harness 4-way splitter
LIMITED LIFETIME WARRANTY
WERNER CO. (the Manufacturer) warrants to the original purchaser, only, that
WEATHER GUARD®truck products (the "WEATHER GUARD®Product") will be free from
defects material and workmanship from the date of purchase and continuing for the
expected lifetime of the WEATHER GUARD®Product. This warranty applies to all
WEATHER GUARD®product except E-LINE Products, which have a 10-year warranty.
PowerSync, which has a 3-year warranty. Please call our customer service department
toll free at 1.800.456.7865 with any questions or comments.
DO NOT use these products for storing or transporting flammables, explosives,
hazardous materials or waste, such as gasoline, solvents, gun powder, dynamite,
gases or any tanks, torches or gas powered equipment. These products are intended
and safe for storing and transporting small tools and other non-combustible,
non-flammable materials. Any modification made to, or unintended use of, these
products may create a dangerous condition causing death, serious bodily jury or
property damage.
NOTICE
Any modification or unintended use of these products 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
these products.
For U.S. Terms and Conditions of Sale please reference form number 78-1117.
For Canada Terms and Conditions of Sale please reference form number
78-1145.