INSTALLATION & OWNER S MANUAL

Transcription

1 Rev. D, p. 1 of 14 INSTALLATION & OWNER S MANUAL Bobcat CT 230 and KIOTI CK30 cab kit with hard doors and soft rear curtain p/n 1BCT230 & 1KTCK30 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: 2 to 3 HOURS (excluding accessories) Shown with optional work lights, and turn signal lights. Additional options available are: heater, hard rear panel, interior rear view mirror and rear window wiper. Note: a front windshield wiper comes standard with this cab kit. revised: 9/28/2017 IM-1KTCK30

2 p. 2 of 14 NOTICE Cabs, blades, and general accessories add additional weight to the base vehicle. Deduct the accessory s total weight from 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 HINTS: 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. F. Use caution to avoid damaging the factory installed threaded inserts. Begin the bolt engagement by hand to guard against potential cross threading. Fastener Steel Washer Plastic Washer Cab Surface TOOLS REQUIRED: Set of standard and metric sockets Set of standard and metric open end wrenches Scissors Bar Clamp One Phillips Head Screwdriver One 3/8 Drive Ratchet One 3/16 Allen Wrench (preferably T handle type) Utility Knife 1/2 Electric Drill 17/32 Drill Bit

3 3 of 14 NOTE: The steps on this page apply to Kioti CK-30 only. If installing on Bobcat CT-230 skip to next page. 1. VEHICLE PREP 1.1 Leaving the hydraulic hose connection intact, unbolt the original equipment hydraulic hose bracket shown in figures 1.1 and Remove the two original equipment metric bolts from the factory installed weldnuts on the bottom side of the bracket. Save the two bolts for reuse in the next step. 1.2 Per figures 1.2 and 1.2.1, install the new mounting bracket oriented as shown and using two 3/8-16 x 1 long hex head bolts, four flat steel washers, and two locknuts where indicated. On the outboard end of the newly installed bracket, attach the small original bracket assembly as shown using the original equipment metric bolts into the factory installed weldnuts. Note: the hose and bracket assembly will need to be rotated 180 degrees to make room for the cab. Caution: use care to avoid cross-threading the factory installed weldnuts on the bottom side of the small bracket. Begin the threads by hand. Tighten all four bolts. original equipment hydraulic hose bracket with two metric bolts Fig. 1.1 (hydraulic hose bracket) two original equipment metric bolts original equipment hydraulic hose bracket Fig (enlarged view of fig. 1.1) new 3/8-16 bolts new mounting bracket original equipment metric bolts Fig. 1.2 (new mounting bracket) Fig (enlarged view of fig. 1.2)

4 p. 4 of VEHICLE PREP (cont d.) 1.3 Note: save any original equipment hardware that is removed unless otherwise specified to discard it. Per figure 1.3, remove the following items from the tractor: remove each front splash guard assembly and the three bolts holding it, remove each ROPS fold-down hand knob, and remove both grab handles as shown. Note: flanged hex head bolts are underneath the fenders. Discard grab handle bolts. re-use nuts 1.4 Remove both flasher lights. Save for reinstallation. Label or remember the wire configuration to make step 8 easier. 1.5 Per fig. 1.5, re-use the two nuts from the ROPS hand knobs and thread each nut onto a new 12mm bolt (supplied in the hardware bag). Install the bolt and nut where each hand knob came from. 1.6 If installing the standard soft rear curtain, skip this step and proceed to step 3 on the next page. If installing the optional hard rear panel at this time, temporarily remove the black plastic toolbox from behind the seat. Discard these two short bolts. See figure 1.6. Fig. 1.3 (vehicle prep.) 12mm hex head bolt and nut 1.7 Per fig. 1.7, remove and save the two rear deck bolts just outboard from where the toolbox is located and save for re-use in step 2 on the next page. Fig. 1.5 (fold-down ROPS) remove and save these two bolts Fig. 1.6 (plastic toolbox) Fig. 1.7 (view from inside the tractor)

5 p. 5 of OPTIONAL HARD REAR PANEL 2.1 If installing the standard soft rear curtain, skip this step and proceed to step 3 below. If installing the optional hard rear panel at this time, tip the seat forward and with assistance, rest the hard rear panel assembly in place behind the seat, up on the fenders, and up against the forward face of the ROPS tubing on the tractor. Note: orient the window so it pivots and opens to the outside rear of the tractor. Per fig. 2.1, the bulb rubber is to be oriented inboard as shown. Re-use the two original equipment rear deck bolts where shown. Keep bolts loose. 3. SIDE FRAME bulb rubber to be inboard re-use the two long original equipment rear deck bolts 3.1 With assistance, temporarily remove the doors from the side frames for ease of handling. Open the door and lift up and off the pin hinges on the side frames. Fig. 2.1 (view from front left side of tractor) 3.2 Per fig. 3.2, unsnap the outer edges of the floor mats from their engagement holes by using pliers to pull up on the plugs and pushing up from the bottom on the male plugs in the sheet metal holes. 3.3 See fig With assistance, install the side frame so that the side frame floorboard is underneath the floor mat and on top of the tractor floorboard. The bulb rubber is to be oriented outboard on the fender as shown in fig ure Thrust the side frame back so the bulb rubber is tight against the fender. Re-use 2 of the 3 original equipment splash guard bolts under the mat as shown in fig Note: use caution to avoid cross-threading the factory installed weldnut underneath the tractor floorboard. Repeat for the opposite side frame. male plug male plugs Fig. 3.2 (view from left side of tractor) side frame rubber to be outboard two original equipment bolts Fig. 3.3 (view from left side of tractor) Fig (view from left side of tractor)

6 p. 6 of SIDE FRAME (cont d.) 3.4 Attach the lower rear mounting bracket to the back side of the side frame oriented as shown in fig Note: if installing a hard rear panel, the bolts will pass through that so it is sandwiched. Use the following hardware into the factory installed threaded inserts: two 5/16-18 x 1 long button head bolts, two plastic washers, and two steel washers. Connect to the bracket welded on to the ROPS structure using the following hardware: one 5/16-18 x 3/4 long button head bolt, two steel washers, and one locknut. Locknut to be inboard. Leave bolts loose. 3.5 Attach the roll bar bracket to the back side of the side frame oriented as shown in fig. 3.5 and 3.6. Note: if installing a hard rear panel, the bolts will pass through that so it is sandwiched. Use the following hardware into the factory installed threaded inserts: two 5/16-18 x 1 long button head bolts, two plastic washers, and two steel washers. 3.6 Attach the mating half of the roll bar bracket as shown in figures 3.5 and 3.6. Note: the use of a bar clamp will assist in compressing the bulb rubber (see figure 3.6.1). Use the following hardware: two 5/16-18 x 1 long carriage bolts, 2 steel washers, and 2 locknuts. Locknuts to be inboard. 1 long carriage bolts bolt into back of side frame bolt thru bracket on ROPS tubing Fig. 3.4 (view from left side of tractor) bolt into back of side frame Fig. 3.5 (view from right rear side of tractor) bar clamp Fig. 3.6 (view from right rear side of tractor) Fig (view from right rear side of tractor)

7 p. 7 of SIDE FRAME (cont d.) 3.7 For standard soft rear curtain only: install the top rear cross brace with the snaps facing outboard per fig Use the following hardware per side into factory installed threaded inserts in the top rear corners of the side frame: one 5/16-18 x 1 long button head bolt, one plastic washer, and one steel washer. Tighten bolt. Repeat for opposite side. 3.8 For the optional hard rear panel: install the following hardware into the top corner slots: one 5/16-18 x 1 long button head bolt, one plastic washer, and one locknut. Tighten bolt. Repeat for opposite side. See figure COWL head of bolt snap 4.1 Per fig. 4.1, install the cowl with the top bends oriented as shown and the bulb rubber inboard. Note: the bulb rubber on the bottom of the cowl is to sit on top of the floor mat. Fig. 3.7 (view from right rear side of tractor) corner slot Fig. 3.8 (view of optional hard rear panel) bends to be inboard Fig. 4.1 (view from left rear side of tractor)

8 p. 8 of COWL (cont d.) 4.2 Per fig. 4.2, use the following hardware through the mounting tab on the inside of the side frame: two 5/16-18 x 3/4 long button head bolts, 4 steel washers, plastic washer, and 2 locknuts. Repeat for opposite side. Per fig ure 4.2.1, use the following hardware to attach to the front of the side frames and into the factory installed threaded inserts: three 5/16-18 x 3/4 long button head bolts, three plastic washers, and three steel washers. Repeat for opposite side. 4.3 Per figures 4.3 and 4.3.1, install the front mount as shown using the following hardware: re-use the original equipment bolt from the splash guard for the tractor side. To connect the front mount to the cowl itself, use one 5/16-18 x 3/4 long button head bolt, one plastic washer, 2 steel washers, and one locknut. Locknut to be on the inside of the cab. no plastic washer required here use plastic washers here Fig. 4.2 (view from left front side of tractor) use plastic washers here Fig (view from left front side of tractor) new 5/16 button head bolt front mount original metric bolt Fig. 4.3 (view from left front side of tractor) Fig (enlarged view of fig. 4.3)

9 p. 9 of WINDSHIELD SUPPORT 5.1 Per fig. 5.1, install the windshield support oriented so the long bent flanges are down and in as shown. Install just one bolt in the lower corner of each side. The remaining holes will get bolts once the roof is installed. Use the following hardware: one 5/16-18 x 1 long button head bolt, one plastic washer, two steel washers, and one locknut. Repeat for opposite side of tractor. one bolt here 6. WINDSHIELD 6.1 See fig Have the following items ready: four 5/16-18 x 1 3/4 long flat head bolts, 4 steel washers, 4 locknuts, and 2 plastic spacer blocks. With assistance, install the windshield hinges to the windshield support with the two spacer blocks between the hinge and the windshield support. Attach windshield latches to windshield latch receivers on the cowl by squeezing tabs to retract spring loaded pins. See fig Lift up on bottom of windshield and close latches. Check alignment of windshield with side frames and tighten hinge hardware. CAUTION: hinges are plastic components. Do not overtighten hardware. Torque to 7 foot-pounds max.. Fig. 5.1 (view from right front side of tractor) 3/4 thick spacer block Fig. 6.1 (view from right front side of tractor) Fig (view from left rear side of tractor)

10 10 of ROOF 7.1 Use a Phillips head screwdriver to punch a hole through the headliner at all of the covered bolt hole locations (10 places). Punch holes from the inside out to avoid having the headliner pull away from its glued surface. 7.2 With assistance, install the roof oriented so the reflectors are towards the rear of the tractor. See fig Per fig , use the following hardware in the front corners: one 5/16-18 x 1 long button head bolt, two steel washers, one plastic washer, and one locknut (locknuts on the inside surface). Install the bolt through the roof, windshield support, and mounting tab. 7.3 Per fig , the middle side bolt location uses the following hardware per side: one 5/16-18 x 3/4 long button head bolts, one steel washer, and one plastic washer. These bolts are installed into factory installed threaded inserts in the top of each side frame. NOTE: use caution to avoid damaging the internal threads on the factory installed threaded inserts. Repeat for opposite side. 7.4 Per fig. 7.4, the four rear holes and the two front middle holes use the following hardware: six 5/16-18 x 3/4 long button head bolts, 12 steel washers, 6 plastic washers, and 6 locknuts. Locknuts to be on the inside surface. 7.5 Tighten all roof and all cab bolts at this time. Fig. 7.2 (view from left front side of tractor) 1 long bolts here into factory installed threaded inserts Fig (view from left front side of tractor) 3/4 long with locknuts Fig. 7.4 (view from left front side of tractor)

11 11 of REAR FLASHER LIGHTS 8.1 Per figures 8.1 and 8.1.1, re-locate each of the two rear lights from original location a to new location b. Re-connect the wires back to the original configuration. 9. SOFT REAR CURTAIN 9.1 If not installing a soft rear curtain, skip to step 10 on the next page. 9.2 Snap the rear curtain to the factory installed snaps on the outside surface of the top rear cross brace (ref.: 7 snaps). 9.3 Per figures 9.3 and 9.3.1, apply PSA (pressure sensitive adhesive) hook velcro to the back inside surface of the vertical rear tube of the side frames. Continue the hook velcro down along the fender of the tractor and on to the top flat surface of the rear deck. Note: surfaces must be clean, dry, and at room temperature for best adhesion new location b original location a Fig. 8.1 (view from left side of tractor) Fig (view from right rear side of tractor) apply velcro apply velcro apply velcro apply velcro Fig. 9.3 (view from right front side of tractor) Fig (view from right rear side of tractor)

12 12 of DOORS 10.1 Apply grease to the pin hinges. With assistance, reinstall the doors onto the pin hinges. Work the doors back and forth until the hinges are completely seated. Specific adjustments can be made per steps 10.2 and Note: top of door should end up visually parallel with side of roof. Note: the door latch is a rotary type with two positions to close. Adjust door so that when fully closed door latch clicks twice for total engagement Per fig. 10.2, the large striker bolt and nut can be loosened and reset higher or lower or in or out for better engagement in the door latch assembly if necessary. Use two 19mm open end wrenches. Note: finger guard to end up being centered and facing inward Per fig. 10.3, the 1/4-20 hex head bolts on the door hinges can be loosened on the rear tube, or on the door itself, or in both places, in order to slightly rotate the door up or down as necessary for proper latch assembly and striker bolt engagement. Note: an assistant will be needed for this step. Keep the hinge sleeves fully seated on the pin hinges. Tighten all hinge bolts using caution to not over tighten. Over tightening will crush (damage) the structural tubing. Torque to 40 inch/pounds. Fig (striker bolt) EXTERIOR VIEW OF RIGHT SIDE DOOR 10.4 The inside latches can also be adjusted for proper engagement. CAUTION: FOR SAFE OPERATION, DO NOT DRIVE WITH DOORS OPEN. MAKE SURE DOORS ARE CLOSED AND PROPERLY LATCHED WHEN DRIV- ING. 11. LUBRICATION 11.1 Once the doors are properly adjusted, lubrication (preferably grease) can be applied to the striker bolts and door latch assemblies. Re-apply periodically as needed (same goes for the door pin hinges as necessary). Fig (right side door) 13. FRONT WINDSHIELD WIPER 13.1 Install the front windshield wiper per the installation instructions included with the wiper kit.

13 13 of FINISHING TOUCHES 14.1 If an optional hard rear panel was installed, the plastic tool box can be re-installed to the lower vertical inside wall of the hard rear panel as shown in fig Use the following hardware: two 5/16-18 x 3/4 long button head bolts, 4 steel washers, 2 plastic washers, and 2 locknuts. Locknuts to be towards the rear of the tractor Using a utility knife, cut the mat (2 long) where shown in figure 14.2 so the mat will sit flat. Repeat for opposite side of tractor Install the gas shock to the frame and door with the small piston end towards the door. Press the button on the compression fastener to lock the gas shock to the ball stud Install the supplied 5/16 nut covers (qty.: 22) on the interior hex locknuts by snapping over nut. heads of bolts Fig (view from right front side of tractor) 14.5 Per fig. 14.5, install the four small, black plugs into the open fender holes where the grab handles were located. Two per fender Peel protective film from windows. cut mat here 14.7 Note: extra hardware has been provided in case they get lost. Discard extras such as washers, etc. Discard any original equipment hardware not re-used Install the front windshield wiper per the installation instructions included with the wiper kit Additional optional equipment available: Work Lights, Heater, Hard Rear Panel, and Rear Window Wiper. 15. CARE AND MAINTENANCE 15.1 Check and tighten hardware after 40 hours of operation. Periodically inspect and tighten hardware for the remainder of the unit s life Wash the painted surfaces of the unit with commercial automotive cleaning products Clean windows with glass cleaner Vinyl components should be washed with a mild solution of warm soapy water Clear vinyl can be easily scratched. Be careful cleaning frost or snow from rear curtain. Do not roll curtain in cold weather. The curtain becomes stiff and may crack. Keep curtain clean. Fig (view from left front side of tractor) plug both holes Fig (view from left front side of tractor)

14 14 of 14 SOFT REAR CURTAIN BOBCAT CT230 & KIOTI CK30 CAB PARTS LIST (p/n 1BCT230 & 1KTCK30) 1 8SV-BC23003-VC SS TOP REAR PANEL 1 8SV-KI2805-G3 ROOF * (2) REFLECTORS 1 8SV-KL2801-G3 * SNAPS (7) (LOCKNUTS TO BE ON THIS SIDE) * TRIM-LOK (ALL 4 SIDES) ROLL BAR BRACKET 2 8SV-KU312-G3 SIDE FRAMES LEFT 1 RIGHT 1 * SIDE WINDOW W/ 7/16" SIDE BULB 1/4" GRIP & 2 WIPERS 8SV-BC23009L-G3 8SV-BC23009R-G3 * HEADLINER (INSIDE) * 5/16-18 THREADED INSERTS, 9/FRAME * BALL STUD WINDSHIELD SUPPORT * 1/2" WEATHER SEAL (L&R INSIDE) 1 8SV-KU304-G3 * HEYCO PLUG ROLL BAR MOUNTS * ARCH PSA 2 PCS. (JUST THIS SURFACE) * ARCH PSA * (4) WINDOW 2 PCS. (ALL 3 INSIDE SURFACES) CLIPS 2 8SV-KL2811-G3 * HINGE PIN LH,RH & HINGE PLATES RIGHT LEFT * LATCH PIN * HEATER LABEL (INSIDE) * HEYCO PLUG WINDSHIELD * DECALS (INSIDE) (SERIAL NO., R.O.P.S., & OPTIONS) 1 * HINGES SEAM 8SV-CI02 REAR MOUNTING BRACKETS 2 8SV-BC23014-G3 * 1" FLAT BULB COWL 1 8SV-BC23008-G3 * 3/4" SIDE BULB W/ 1/4" GRIP & 2 WIPERS * LATCHES HARD DOORS * BALL STUD LEFT 1 RIGHT 1 8SV-BC23007L-G3 8SV-BC23007R-G3 * WINDSHIELD LATCH MOUNTS * 1" FLAT BULB * X-SERIES SLIDER * HINGE SLEEVES LEFT * 1" HEYCO PLUG * 1/2" WEATHER SEAL (INSIDE) * OUTSIDE HANDLE * HINGE SLEEVES RIGHT * GRAB HANDLE * DOOR LATCH HYDRAULIC MOUNTING BRACKET 1 8SV-CK3010-G3 * 5/8" REGULAR BULB FRONT MOUNTS 2 8SV-BC23013-B3 * 3/4" SIDE BULB * IN HOUSE APPLICATIONS ADDITIONAL SERVICE PARTS /UNIT DESCRIPTION 1 CK30-HWK HARDWARE KIT 1 9SV-HSLP DOOR HINGE KIT - LEFT AND RIGHT 1 9SV-IHRL DOOR LATCH KIT - LEFT AND RIGHT 1 9SV-GH GRAB HANDLES (2) 1 9SV-OHRL OUTSIDE R-LATCH HANDLE W/ KEY (2) 1 8SV-SWC2L LEFT DOOR SLIDER ASSEMBLY 1 8SV-SWC2R RIGHT DOOR SLIDER ASSEMBLY 1 9SV-GS02 GAS SPRING, DOOR (2) 1 9SV-HWS WINDSHIELD HINGE KIT (2) 1 9SV-WL1 WINDSHIELD LATCH KIT (2) 1 8SV-PG230LD LOWER DOOR WINDOW