INSTALLATION & OWNER S MANUAL

Transcription

1 Rev. K, p. 1 of 19 INSTALLATION & OWNER S MANUAL V4210 CAB KIT (color: orange) and/or V4220 CAB KIT (color: camo) INSTALLATION & OWNER S MANUAL The contents of this envelope are the property of the owner. Be sure to leave with the owner when installation is complete. APPROXIMATE INSTALLATION TIME: 3-4 HOURS NOTE: cab shown with the following accessories: Standard (included with cab): overhead console with CD player and antenna. Optional (purchased separately): work lights, strobe light, and windshield wipers. (a heater is also optional) manual p/n (revised: 5/22/2008)

2 Rev. K, p. 2 of 19 DESIGN CONCEPT Curtis cabs feature an assembly of parts designed for your vehicle which require adjustment and alignment of components to accommodate vehicle variations and provide proper weather protection. For accurate installation, proper operation, and years of satisfaction, please read and understand the installation instructions. From all of us at Curtis, we thank you for choosing our product. ADDED WEIGHT Curtis Cabs, blades and general accessories add additional weight to the base vehicle. All Curtis accessory weights are listed in product brochures. Deduct the accessory's total weight from the vehicle's rated capacity and never exceed the vehicle's rated capacity including driver and passenger. Exposure to Carbon Monoxide can Cause illness, serious injury or death. Never operate vehicle if suspicious of Carbon Monoxide. Inspect exhaust system for leaks monthly. Leaks can result from loose connections, corrosion, cracks or other damage to the exhaust manifold. If leaks are found, repair or replace exhaust system. Do not use vehicle until repair or replacement is complete. CAB INSTALLATION BEFORE YOU START HELPFUL REMINDERS: A. Refer to parts diagram toward the back of this manual to help identify parts during the assembly process. B. To assist with the cab installation, leave all bolts loose for later adjustment unless otherwise specified. C. Read and understand all instructions before beginning. D. Plastic washers have been supplied to provide a weather seal under the heads of all exterior bolts. The plastic washer should be installed under each bolt head directly against the outside cab surface. Care should be taken not to over tighten the fasteners and damage the plastic washer. Also use steel washers as required. See diagram. E. Apply a clear silicone sealant to seal any minor gaps that may occur due to vehicle variations. Fastener Steel Washer Plastic Washer Cab Surface TOOLS REQUIRED: Set of standard and metric sockets Set of standard and metric open end wrenches One 3/8 Drive Ratchet One 3/16 Allen Wrench (preferably T handle type) One Phillips Head Screwdriver Two Large Screwdrivers (or small pry bars) One Rubber Mallet Snips Vice Grips Needle Nose Pliers Utility Knife

3 Rev. K, p. 3 of SOUND BARRIER Mounting surface preparation: adhesivebacked sound barrier should be applied to a clean, dry surface at room temperature. Although the mounting surface may appear clean, it is required that the surface be cleaned with isopropyl alcohol or an acetone or ammonia-based cleaner immediately prior to application of the sound barrier material. Allow cleaned surfaces to dry thoroughly. Good surface contact is required to achieve bond. Failure to follow these steps can result in the separation of the sound barrier material from the mounting surfaces. NOTE: paint thinners or products with any oil in them will not work and are detrimental to the proper cleaning of the underside of the fender. NOTE: clean rags are very important. Oily rags will leave residue. remove bolt Fig. 1.2 (view from driver s side) 1.1 Remove the seat belts from the seat belt brackets. Save all hardware for re-installation in step With assistance, remove the seat back as shown in fig Save the three (3) hex head bolts for reinstallation in step Remove the cable bracket from the seat bottom as shown in fig Save the cable, bracket, and hardware for re-installation in step With assistance, finish removing the seat bottom as shown in fig Save the cotter pins for re-installation in step Per fig. 1.5, two bolts per side can be loosened to facilitate the removal of the large molded plastic shell underneath the seat. Fig. 1.5 shows the rearmost bolt. There is also one bolt per side underneath this side piece of molded plastic that can be loosened as well. remove cable Fig. 1.3 (view from driver s side) remove cotter pin loosen bolt Fig. 1.4 (view from driver s side) molded side piece Fig. 1.5 View from driver s side

4 Rev. K, p. 4 of SOUND BARRIER (cont d.) 1.6 Loosen or remove the differential lock pull cable (orange knob assembly) as shown in figure 1.6 and figure NOTE: on hydraulic units only, remove the hand throttle located near the differential lock. All hardware should be kept and re-installed when the differential lock is re-installed in step Per fig. 1.7, remove and save the button head bolts (qty.: 14) on the sides and the bottom of the molded plastic shell as shown. Also save the four washers that are located on the bottom four front bolts. Note: there are spring clip nuts that remain in place on the vehicle. Remove the shell from the vehicle noting the location of various levers and attachments. Note: no need to remove rubber knobs from levers. 1.8 Reminder: prepare the mounting surfaces per the cleaning instructions on the top of the previous page (page 3). Note: dry fitting the pieces to get a feel for location is suggested before peeling back the protective paper. Per figures 1.8 and 1.8.1, install the four larger pieces of aluminized mylar sound barrier to the plastic shell where shown. here Fig (differential lock pull cable) Fig. 1.6 (differential lock pull cable) 1.9 Per fig. 1.8, install the lower pan piece where shown. remove and save bolts Fig. 1.7 (viewed from driver s side) lower pan piece goes here Fig (viewed from another angle) Fig. 1.8 (viewed from a misc. angle)

5 Rev. K, p. 5 of SOUND BARRIER (cont d.) 1.10 Per figures 1.10 and , install the remaining two small pieces of sound barrier to the original equipment rubber flap that is attached to the shell via three plastic pine tree clips. Do not remove these 3 clips. With assistance, hold the rubber flap firmly in its closed position and apply the adhesive side of the two pieces to the underside of the rubber flap from the bottom side up. NOTE: some modification may be necessary to the rabbit head shape and rectangular pieces to provide a tight fit. 1. SOUND BARRIER (cont d.) 1.11 Remove 15 out of 18 pine tree plastic clips so that the original equipment floor mat can be peeled back allowing access to the triangular steel plate in the floor of the vehicle. Start from the driver s side. Do not remove the last three clips on the passenger s side vertical surface. Needle nose pliers may make removal of plastic pine tree clips easier. See fig which shows the floormat already removed. Note: pushing up from underneath helps to remove the pine tree clips Remove the three (3) M8 bolts holding the triangular steel plate in the floor. Save the hardware for reinstallation in step Clean the surface of the triangular plate. Using the 66 long piece of 1/2 wide weatherseal, cut pieces to fit along the center between the bolt holes and pieces along the left and right sides as shown in figure 1.12 for vibration deadening. Note: adhesive backed weatherseal should be applied to a clean, dry surface at room temperature. do not remove these three plastic pine tree clips Fig (view from driver s side) Note: work the floormat around and off the differential lock pedal rabbit head shape goes here rectangular piece goes here Fig (viewed from underside of shell) 1.13 Re-install the triangular plate so the weatherseal is facing down. Re-install the three (3) M8 original equipment bolts through the plate and tighten down the bolts Lay the rolled up original floor mat back down in place. Place the new sound barrier floor mat provided directly on top of the old floor mat and secure both with the new plastic pine tree clips provided. A rubber mallet may be used to assist in inserting the pine tree clips. Fig (view from driver s side) weatherseal on left, center, and right sides Fig View of triangular plate removed

6 Rev. K, p. 6 of SOUND BARRIER (cont d.) 1.15 With assistance, re-install the large plastic molded shell to its original position. Be sure to orient the tabs on the exterior plastic piece in front of the original equipment spring clips. See fig Note: the lower four (4) bolts on the front side use washers under the heads. Note: two large screwdriver s may be of assistance in prying and placing the shell in its proper location around the seatbelt brackets, etc.. Be certain that control levers have been installed in their proper locations and have proper range of motion. Tighten the four (4) original equipment M8 bolts loosened in step 1.6 that hold the molded side pieces in place. See fig Re-install the loose differential lock pull handle to its original condition. See fig on page 3. NOTE: on hydraulic units only, re-install the hand throttle that was removed in step Re-install the seatback and seat bench with the saved original hardware, cable, and bracket, etc Re-install the seat belts and all the saved original equipment hardware. IMPORTANT: the bolts on the seat belts must be torqued properly to meet original equipment safety standards. Torque the M10 bolts to: ft.-lbs. (48-56 N-m). Fig (view from passenger s side) tighten bolt interior piece Ref.: seam tab exterior piece 1.19 If a High Mount Air Intake is on the vehicle, remove it at this time. CAUTION: under no circumstances should the engine be run if an air cleaner is not in place Install the R.O.P.S. filler sound barrier pieces as shown in fig with the slit towards the front of the vehicle and the chamfer towards the seat. Note: a replica paper cutout is shown in the photo for visual contrast purposes only. Reminder: clean the plastic surfaces per the instructions at the beginning of step 1 before applying the self-adhesive side of the rubber filler to the vehicle. Fig View from driver s side the slit goes here Fig (view from driver s side)

7 Rev. K, p. 7 of FRONT MOUNT 2.1 With assistance, install the front mount as shown in fig ure 2.1. Use the two original equipment M10 bolts found in the front overhead ROPS tubing. Note: locknuts to be outboard as shown (bolt heads to be towards the center of the vehicle). Leave the bolts loose. M10 locknut 3. REAR MOUNT 3.1 With assistance, install the rear mount as shown in figure 3.1. Use the two original equipment M10 bolts found in the rear overhead ROPS tubing. Note: locknuts to be outboard as shown (bolt heads to be towards the center of the vehicle). Leave the bolts loose. 4. SIDE FRAME & DOOR ASSEMBLY 4.1 Remove and save for re-use two (2) floorboard bolts (one per side) as shown in fig Ref.: M8 Phillips Head Pan Head bolts. Note: there are factory installed weld nuts underneath the vehicle. 4.2 With assistance, install the side frame assembly. Orient so that the long tear-drop shaped window is towards the front of the vehicle. CAUTION: handle with care so the Expand-afoam on the lower front of the side frame does not get distorted or damaged during installation. See fig NOTE: the top rear of the side frame assembly must be underneath the stock thickness of the rear mount. front mount Fig. 2.1 View from driver s side rear mount M10 locknut Fig. 3.1 View from driver s side Expand-a-foam remove only the outboard bolt on this side and on passenger s side Fig. 4.1 View from driver s side Fig. 4.2 View from driver s side

8 Rev. K, p. 8 of SIDE FRAME & DOOR ASS Y. (cont d.) 4.3 Attach the lower corner of the front mount to the welded mounting tabs on the side frames. Use one 5/16-18 x 1 1/4 long button head bolt, one steel washer, and one plastic washer. Bolt head to be towards outside of vehicle. Use one steel washer and one locknut on the inside of the vehicle. Fig. 4.3 shows an exterior view. Fig shows an interior view. Important: be sure the gap is closed at the front vertical corners. Tighten these two bolts (one per side). 4.4 Re-install the original equipment M8 Phillips Head Pan Head bolt through the floorboard of the sideframe and through the floorboard of the vehicle and engage into the original equipment factory installed weld nuts. See fig Repeat for opposite side. Do not tighten bolts. Hint: hold floorboard in place with your foot to line up holes. close gap then tighten bolt Fig. 4.3 View from passenger s side 4.5 Install mounting brackets and hardware as follows: Attach the middle front of the side frame to the lower front vertical R.O.P.S. tubing using one U shaped clamp per side. Use two 5/16-18 x 1 long button head bolts and two steel washers to attach the clamp to the standoff on the side frame. Note: there are factory installed weld nuts on the inside of the standoffs. See fig Do not tighten bolts. washer and locknut here Fig View from driver s side re-install bolt Fig. 4.4 View from driver s side head of bolt Fig. 4.5 View from driver s side

9 Rev. K, p. 9 of SIDE FRAME & DOOR ASS Y. (cont d.) 4.6 Install the hip restraint mounting bracket with two 5/16-18 x 1 long hex head bolts, two internal tooth lock washers, and two steel washers into factory installed threaded inserts in the side frame tubing as shown in fig Note: lock washer to be closest to the bolt head, then the flat washer. Install the lower bolt first, then the upper bolt. Do not tighten bolts. 4.7 Install mounting brackets and hardware as follows: Attach the rear of each side frame to the bottom of the vertical ROPS tubing using one U shaped clamp per side. See fig Use two 5/16-18 x 1 1/4 long button head bolts and two steel washers to attach the clamp to the mounting holes in the side frame. Heads of bolts to be inside the cab. Use two steel washers and two locknuts on the outside of the vehicle. install lower bolt first Fig. 4.6 View from driver s side 4.8 Tighten all cab bolts at this time. IMPOR- TANT: the bolts on the ROPS structure must be torqued properly to meet original equipment safety standards. Torque the M10 bolts to ft.-lbs. (48-56 N-m). See fig Note: no washers on these bolts. 4.9 IMPORTANT: when latching door open or closed, be sure latch system is fully seated on latch pins. Please note there are double latch devices for both open or closed door positions. Be sure latches are fully seated on latch pins at all times. head of bolt here Fig. 4.7 View from driver s side IMPORTANT: torque to ft.-lbs. (48-56 N-m) Fig. 4.8 View from driver s side

10 Rev. K, p. 10 of GLASS WINDSHIELD 5.1 Have the following items ready to use: two plastic spacer blocks, four flat head bolts (1 3/4 long), four flat steel washers, and four 5/16-18 locknuts. With assistance, place the windshield in place on the windshield support (i.e.: front mount) with the 3/4 thick plastic spacer blocks underneath the plastic hinges for mounting up against the outer surface of the windshield support. See fig The windshield can be loosened and adjusted up or down to ensure that the lower bulb rubber seals against the top surface of the vehicle s hood. Adjust windshield alignment with latches engaged and tighten bolts. Note: hinges are plastic components. Do not overtighten. Torque to 7 ft.-lbs. maximum. 5.2 Once the windshield is aligned and tightened, install the two (2) supplied gas shocks between the ball studs on the side frame and the windshield with the piston side down as shown in fig ROOF, OVERHEAD CONSOLE, & ACRYLIC REAR WINDOW Fig. 5.1 View from driver s side connect here spacer block Note: work lights or strobe light must be installed before installing roof to vehicle. See fig. 6. The strobe light is to be mounted to the large embossed area on the top of the roof. If lights are not being installed, proceed directly to step 6.1 below. Prep. for lights: drill holes for work lights or strobe light if necessary. Work light hole sizes: 11/32 diameter for the threaded shaft and 7/16 diameter for the rubber grommets for the wires to go through. Fig. 5.2 View from driver s side Strobe light hole size: two 7/32 diameter holes 4 apart. One 7/16 diameter hole exactly between the two 7/32 holes (for rubber grommet for wiring). Wiring: plug in to the appropriately labeled female bullet connectors inside the overhead console. 6.1 With assistance, install the roof and overhead console assembly on top of the R.O.P.S. tubing. Orient the roof so the reflectors are facing the rear of the vehicle. 6.2 Remove the four (4) 5/16-18 x 1 long temporary bolts, washers, and whiz nuts used to ship the overhead console pre-wired and assembled. Discard this hardware. 6.3 Route the loomed battery wires over the top of the rear mount and down the back side of the driver s side rear vertical R.O.P.S. tubing as shown in fig. 6.3 on the next page. Secure with 3 of the 4 supplied cable ties equally spaced as necessary. The wiper wires from the overhead console should go over the front ROPS tubing and underneath the windshield support (i.e.: front mount). drill a mounting hole in the semi-vertical surface shown Fig. 6. View from driver s side

11 Rev. K, p. 11 of REAR WINDOW (cont d) 6.4 Place the rear window in place as shown in figure 6.3 and Install the 1/4-20 x 1 1/4 long Truss head, Phillips head bolt and 1/4 fender washer (1 O.D.) in the top driver s side corner. Snug up the bolt without over compressing the rubber bushing. Install a bolt and washer in the lower driver s side. See fig Lastly, install the hardware in the passenger s side. 6.5 Install eight (8) roof bolts. Use 5/16-18 button head bolts, steel washers, and plastic washers on the outside surface of the roof. The four front bolts are to be 1 1/4 long and the four rear bolts are to be 1 1/2 long. With an assistant pushing down on the roof and bolt head to help compress the foam headliner, install the steel washers and locknuts on the inside of the cab. See fig. 6.5 for inside rear corner. 6.6 At this time install Kubota kit numbers V4272 and V4274 (or V4273 and V4274) per the installation instructions included with the kits. See ref.: info. below: V4272 is a kit that converts any standard RTV 900 air cleaner kit to a CAB-style high mount air cleaner. V4273 is a kit that converts a ROPS-style high mount air cleaner to a CAB-style high mount air cleaner. V4274 is a supplementary kit that is necessary to mount High Mount Air Cleaner kits (i.e.: V4272 or V4273) to these new RTV 900 cabs (V4210 and V4220). 7. WIRING FOR CONSOLE 7.1 Note: wires are labeled. Connect to the battery as follows: wire with ring terminal to positive, wire with ring terminal to negative, and wire with male bullet connector to key controlled signal wire on vehicle. Ref.: the vehicle has a factory installed female bullet connector for this purpose. It can be found behind the driver s side molded plastic siding (near the battery). Use the last of the four cable ties to gather these wires together neatly near the battery. * CAUTION: Be sure wires cannot catch on any moving parts. 7.2 Note: the wiring harness has two (2) additional wires with female bullet connectors. These are for an optional heater. The blue wire is for low and the white wire is for high. If connecting a heater, run one wire to ground and two wires under the seat and to these two female bullet connectors so the heater can be controlled by the overhead console panel. 8. FINISHING TOUCHES 8.1 The antenna is shipped in the down position. Use a Phillips head screwdriver to loosen the bolt on the side. Position the antenna as desired and re-tighten the bolt. 8.2 Install the supplied nut covers (qty.: 14) on the locknuts on the inside of the cab. 8 on the roof locknuts, 4 on the windshield locknuts, and 2 on the windshield support locknuts (i.e.: front mount). 8.3 NOTE: there is extra hardware provided. Discard if not needed. Ref.: two of each of the following: two 5/16-18 locknuts, two 5/16 flat steel washers, and two 3/8 plastic washers. loomed battery wires Fig. 6.3 View from driver s side loomed battery wires Fig View from driver s side fender washer and head of Truss head bolt here Fig. 6.4 View from driver s side washer and locknut go here rear window rear window Fig. 6.5 View from driver s side

12 Rev. K, p. 12 of 19 CARE AND MAINTENANCE (IMPORTANT: be sure to leave this page with the owner once installation is complete. Check and tighten hardware after 40 hours of operation. Periodically inspect and tighten hardware for the remainder of the unit s service life. IMPORTANT CLEANING INFORMATION Keep the enclosure components clean in order to prevent dust and dirt from forming an unattractive film. The life of your roof, glass windshield, acrylic rear window, and doors depends upon following these care procedures: GLASS WINDSHIELD: 1) Clean with any conventional glass cleaner. Do not use on rear window. See below. ACRYLIC REAR WINDOW: 1) NEVER USE AN ALCOHOL-BASED PRODUCT FOR CLEANING. Do not use WINDEX, GLASS PLUS, FANTASTIC, etc. Use of these products will result in deterioration of the acrylic item. 2) To clean the inside of the rear window, remove the four Truss head bolts and fender washers. Wash with a mild soap or detergent using your bare hands to free or dislodge any caked-on dirt or other foreign particles. 3) Grease and oil may be removed with kerosene. 4) Novus I and Novus II are recommended plastic cleaners for acrylic units and can be used to remove light scratches. PLASTIC ROOF AND DOOR PANELS: 1) NEVER USE AN ABRASIVE DETERGENT/VEHICLE CLEANER OR A WIRE BRISTLED BRUSH. Do not use any CITRUS BASED CLEANERS such as orange or lemon. Use of these products will cause the plastic to become permanently damaged. 2) Clean the plastic surfaces thoroughly with warm soapy water and a COTTON cloth or chamois. Be sure to use mild soap, specifically a dish liquid or equivalent. Clean in a light circular motion for best results. 3) Remove grease and oil with mineral spirits and a COTTON cloth or chamois.

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