Weather Guard 644-X-01 User manual

1
(1) All-Purpose Chest (1) 5/16"-18 x 2-1/4" Black Oxide Hex Head
Bolt
(4) 5/16"-18 Blind Fastener
(1) Tray with Dividers
(Except Models
644 and 645)
(4) 5/16"-18 x 1-1/4" Hex Head Bolt (4) 5/16" Lock Washer
(2) Key (4) 5/16"-18 Nylon Lock Nut (4) Floor Spacer
(1) Installation
Tool
(8) 5/16" Flat Washer (4) Rubber Grommet
OPERATOR'S MANUAL
ALUMINUM & STEEL ALL-PURPOSE CHEST
Models 644-X-01 through 685-X-01
Part No. 24-0292 REV. B ECN 5315 05/13
Approximate Installation Time: 45 min. per unit (0.75 hrs.) depending on truck equipment installation experience.
SECURING YOUR REPUTATION ™ WWW.WEATHERGUARD.COM
PRODUCT REGISTRATION
For your convenience, place
product registration tear-off
sticker here.
Purchase Date: _______________
Place of purchase: _____________
Key Code: ___________________
Model # ___________Serial# _________________
INSTALLATION TIME
TOOLS REQUIRED
• Drill
• 3/8" & 1/2" Drill Bits
• 1/2" Open or Box End Wrench (qty 2)
• 9/16" Open or Box End Wrench
• Hammer
• Center Punch
• Tape Measure
• Pencil or Marker
• Oil/Grease
PARTS LIST
ATTENTION
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 damages.
Read and understand all instructions and warnings before operating or using this product.
5/16” x 2 1⁄4” Bolt.eps
NOTICE
Any modication or unintended use of this product shall immediately void all manufacturer’s warranties. Manufacturer
disclaims all liability for injuries to persons or property resulting from any modication to, or unintended use of this product.
5/16” x 1 1/4” Bolt.eps

2
INSTALLATION INSTRUCTIONS
Note:
• If your 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 insure
proper attachment.
• Use touch-up paint on any drill holes to prevent oxidation.
• Install boxes with vehicle parked on level ground.
Step 1: LOCATE BOX IN TRUCK BED
• 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 1).
• 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.
Note: Fasten truck box directly to bed oor, not bed liners or mats.
Note: 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.
Figure 1
Step 2: DRILL MOUNTING HOLES
• Drill 3/8" holes through box and truck bed at marked locations.
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. See Blind Fastener Installation on next page.
Note: For a regular installation, use a blind fastener in areas where standard fasteners can't be used, such as heat shields and support channels. See
Blind Fastener Installation on next page.
• Install (4) rubber grommets into holes in the box.
CAUTION
WARNING
Prior to drilling, so as not to cut or puncture fuel tanks, fuel lines, brake lines, electric wires, etc., check under vehicle for locations.
Before marking the leg mounting holes, check inside the box for location of gas spring housing and components that may obstruct safe
drilling.
CAUTION
To keep debris out of your eyes when checking the underside of the vehicle, or when drilling, always wear protective eye wear.
WARNING
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".
Step 3: ATTACHING ALL-PURPOSE CHEST TO TRUCK BED
Select 1 of 4 mounting styles that ts your application:
Style 1: No bedliner, using through bolts Style 2: Bedliner, using through bolts
Style 3: No bedliner, using blind fasteners Style 4: Bedliner, using blind fasteners
Frame Rails
Drill 3/8"D holes
"X"
3"- 4"
3"- 4"
All Purpose,Fig.1.eps
Mtg.Style1.eps
5/16" x 1-1/4" HH Bolt
5/16" Flat WasherBox
5/16" Flat Washer
Rubber Grommet
5/16-18
Nylon Lock Nut
Floor Rib
Mtg.Style2.eps
5/16" x 1-1/4" HH Bolt
5/16" Flat W
asher
Box
5/16" Flat Washer
Rubber Gr
ommet
Bedliner
5/16-18
Nylon Lock Nut
Floor Rib
Floor Spacer
Mtg.Style3.eps
5/16" x 1-1/4" HH Bolt
5/16" Flat Washer
Box
Installed
Blind Fastener
Rubber Grommet
5/16" Lock Washer
Floor Rib
Mtg.Style4.eps
Bedliner
Floor Spacer
5/16" x 1-1/4" HH Bolt
5/16" Flat Washer
Box
Installed
Blind Fastener
Rubber Grommet
5/16" Lock Washer
Floor Rib

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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, he 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 tamper-resistant
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 biannually with white grease. If latch strikers are accidentally
knocked out of alignment, simply use a mallet to realign.
12V ELECTRICAL ACCESS
The 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.
Figure 3
To prevent electric shock, explosion, re and/or serious personal injury when using this box with:
Extension Cord -
• Follow all Extension Cord manufacturer’s warnings and instructions.
• Do NOT insert extension cord through hole without grommet in place (see Figure 3).
• 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 (ground fault circuit interrupter) 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 side box.
• Only use an extension cord that is rated for outdoor use.
• Do NOT connect extension cord to outlet that also supplies power for critical safety equipment.
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 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 side box.
WARNING
BlindFastInstall-1.eps
Black Oxide Bolt
Flat Washer
9/16" Wrench
Installation Tool
Blind Fastener
BLIND FASTENER INSTALLATION
Note: Make sure there is enough hole depth before installing the Blind Fastener.
Note: Black Oxide Bolt, Flat Washer, and Installtion Tool are only used to install Blind Fasteners.
• Install Blind Fastener using Figure 2 as a guide.
• Place a drop of oil on black oxide bolt for lubrication.
• Insert Blind Fastener in the hole.
• Hold the "Installation Tool" with a 9/16" wrench while turning the
"Black Oxide Bolt" with a 1/2" wrench until fully seated.
* Turning "Black Oxide Bolt" will be hard until fastener "bulbs" out.
* When Blind Fastener is fully seated, continue with installation. Figure 2
Electrical access

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SERVICE PARTS
FOR ADDITIONAL REPLACEMENT PARTS GO TO WWW.WEATHERGUARD.COM
ITEM NO. PART NO. DESCRIPTION FITS
1 7096 Gas Spring 665-X-01
1 7095 Gas Spring 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 Gas Spring 684-X-01
1 7904 Gas Spring 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, 1 striker & mounting hardware)
AllChests
5 7106 Striker Kit (1 striker and mounting hardware) All Chests
6 7730 Weather Strip Kit (various styles for 1 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, see parts
list, page 1)
All Chests
9 21-0997 Touch up Paint - Bottle All White Chests
9 21-0999 Touch up Paint - Bottle All Black Chests
10 7746 Nameplate Kit (3 stickers, 2 side bezels, 1
back bezel)
All Chests
11 7749 Grommet Kit All Chests
12 7933-X Replacement Cover 645-X-01
12 7934-X Replacement Cover 655-X-01
12 7935-X Replacement Cover 665-X-01
12 7936-X Replacement Cover 675-X-01
12 7937-X Replacement Cover 685-X-01
12 7942-X Replacement Cover 644-X-01
12 7943-X Replacement Cover 654-X-01
12 7944-X Replacement Cover 664-X-01
12 7945-X Replacement Cover 675-X-01
12 7946-X Replacement 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, 655-X-01
13 7744 Latch Rod Kit (Not Shown) 664-X-01, 665-X-01, 684-X-01,
685-X-01
13 7745 Latch Rod Kit (Not Shown) 674-X-01, 675-X-01
1
2
4
56
7
11 10
1
9
9
8
12
Mounting Kit Not Shown
13 Latch Rod Kit Not Shown
In model numbers: replace X with -0 for clear, -3 for white -5 for black
3
Bottles of Touch up Paint
Not Shown

5
Product fits based on vehicle design available at the revision date. Vehicle manufacturers may change specs after the revision date, so if
you have a vehicle produced with a model year date after the revision date, please contact your distributor or Knaack LLC to verify fitting
of product to vehicle.
If you have any questions regarding this manual, call customer service at 800-456-7865, Monday-Friday 8:00 a.m. - 4:30 p.m. CST.
420 E. Terra Cotta Ave, Crystal Lake, IL 60014, 1-800-456-7865
WWW.WEATHERGUARD.COM
©2010 Knaack LLC
Part No. 24-0292 REV. B ECN 5315 05/13
The following limited lifetime warranty applies to those WEATHER GUARD® Products indicated below which are purchased on or after January
1, 2009. If you have any questions or need assistance regarding the warranty of your product, please call our customer service department:
[phone] 8:00 am - 4:30 pm CST.
WEATHER GUARD® — Limited Lifetime Warranty - KNAACK LLC, located at 420 E. Terra Cotta Avenue, Crystal Lake, IL 60014 (the “Manufacturer”)
warrants to the original purchaser only, subject to the exclusions described below, and expressly, that all other WEATHER GUARD® Truck and Van
Products (each a “WEATHER GUARD® Product”) purchased on or after January 1, 2009 will be free from defects in material and workmanship for the
expected lifetime of the WEATHER GUARD® Product. This limited warranty terminates if the original purchaser transfers the WEATHER GUARD®
Product to any other person.
What is Not Covered - This limited warranty does not extend to and expressly excludes:
•Losses or damages to the WEATHER GUARD® Product which are expected to occur during the normal course of its use, including with
limitation, cosmetic rust, scratches, dents or comparable and reasonably expected losses or damages.
•Losses or damages to the WEATHER GUARD® Product resulting from conditions beyond the Manufacturer’s control including without limita-
tion, misuse, accident, abuse, neglect, negligence (other than Manufacturer’s), overloading, unauthorized modification or alteration, use beyond
rated capacity, or failure to install, maintain, assemble, mount or apply the WEATHER GUARD® Product in accordance with the Manufacturer’s
written instructions or guidelines as provided by Manufacturer to the original purchaser.
•Damage to the contents of the WEATHER GUARD® Product.
•Normal wear and tear for the following parts which are covered under this limited warranty for up to 3 years from the date of purchase: gas
shocks, locks, latches, striker, weather seal, cables, rollers, bearings, fill cap, straps, hydraulic cylinder, and elastic cords.
What We Will Do to Correct Problems - If a claim is covered under this limited warranty, the Manufacturer or its authorized representative or local
authorized dealer will, at the Manufacturer’s sole option, (a) repair the defective portion of the WEATHER GUARD® Product or (b) replace the entire
WEATHER GUARD® Product, or (c) a refund equal to the purchase price paid for the WEATHER GUARD® Product or a credit to be used toward
the purchase of new WEATHER GUARD® Product. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF THIS LIMITED WARRANTY SHALL
BE LIMITED TO REPAIR, CORRECTION OR REPLACEMENT OF THE WEATHER GUARD® PRODUCT, OR REFUND OR CREDIT OF THE
PURCHASE PRICE.
No Other Express Warranty Applies - This limited warranty is the sole and exclusive warranty provided to original purchasers of any
WEATHER GUARD® Product identified above which is purchased on or after January 1, 2009. No employee, agent, dealer, or other person is autho-
rized to alter this limited warranty or make any other warranty on behalf of the Manufacturer. The terms of this limited warranty shall not be modified by
the Manufacturer, the original owner, or their respective successors or assigns.
How to Notify Us - The original purchaser must promptly notify the Manufacturer upon its discovery that the WEATHER GUARD® Product
contains a defect in materials or workmanship by calling the following number: [phone]. In order for a warranty claim to be processed, a
copy of the original sales receipt must be provided to the Manufacturer or at Manufacturer’s instruction, to its authorized representative or local
authorized dealer. The Manufacturer will determine, in its sole and absolute discretion whether the claim is covered or subject to the limitations or
exclusions described in this limited warranty. The original purchaser may be asked to contact Manufacturer’s authorized representative or local
authorized dealer for further instructions on how to obtain the remedies available to it under this limited warranty. Repairs or modifications made to the
WEATHER GUARD® Product by other than the Manufacturer, its authorized representative or local authorized dealer will nullify this limited warranty.
Coverage under this limited warranty is conditioned at all times upon the original purchaser’s compliance with these required notification and repair
procedures.
Limitation of Liability - 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.
SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE AND IN NO EVENT, REGARDLESS OF THE FORM
OF THE CLAIM OR CAUSE OF ACTION (WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT
OR OTHERWISE), SHALL MANUFACTURER’S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXCEED THE PRICE PAID BY THE ORIGINAL
OWNER FOR THE WEATHER GUARD® PRODUCT. The term “consequential damages” shall include, but not be limited to, loss of anticipated profits,
business interruption, loss of use or revenue, cost of capital or loss or damage to property or equipment.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.
This limited warranty gives you specific legal rights, and you may also have other rights which vary from State to State.
LIMITED LIFETIME WARRANTY