INSTALLATION & OWNER S MANUAL

Transcription

1 p. 1 of 15 INSTALLATION & OWNER S MANUAL John Deere Gator PathPro SS Cab (fits all HPX and XUV models with the O.P.S. system installed) (p/n: 1GTRXUV) (O.P.S. = Operator Protective Structure) 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 HOURS (excluding accessories) Shown with optional Windshield Wiper (p/n: 1XUVWPR) Work lights (p/n: 9LW1) Strobe Light (p/n: 9LS1) Additional options available (not shown): Interior Rear View Mirror (p/n: 9PM3) Heater (p/n: 9PH20S30) Snow Plow (p/n: 1GSP7) Rev. F 8/26/2010

2 p. 2 of 15 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 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 to the right. 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 Sockets (3/8 Drive) One 3/8 Drive Ratchet Set of Standard and Metric Open End Wrenches Two Phillips Head Screwdrivers (#2 and #3) 3/16 Allen Wrench Drill (3/8 ) Drill Bits (7/32 and 11/32 ) Scissors Vice Grips

3 p. 3 of FRONT LEGS 1.1 Per fig. 1.1, position the driver s side front leg as shown with the riveted rubber flap in it s flat natural state. 1.2 Per fig. 1.2, loosely install two U-brackets to attach the front leg to the O.P.S. tubing (Operator Protective Structure). Use the following hardware: four 5/16-18 x 1 long button head bolts, four plastic washers, eight steel washers, and four 5/16-18 locknuts. Tip: the black plastic washers can be difficult to distinguish from the black steel washers. Use a magnet or look for witness marks left on the plastic washers from the mold ejector pins. Locknuts to be on the inside as shown. Plastic washers are to be up against the painted surface of the front leg as described and illustrated in step D on the previous page. Do not tighten the bolts. 1.3 Per fig. 1.3, attach the bottom of the front leg to the outside surface of the vehicle floorboard. Utilizing the existing holes on the side of the vehicle floorboard, use the following hardware: two 5/16-18 x 1 long button head bolts, two plastic washers, four steel washers, and two 5/16-18 locknuts. Bolt heads to be on the outside as shown. Tighten all six bolts (2 here and 2 on each of the U-brackets above). 1.4 Repeat steps 1.1 through 1.3 for the passenger s side. rubber flap to be flat (not folded under) head of U-bracket bolts Fig. 1.1 (view from front of driver s side) locknut on U-bracket locknuts on U-bracket Fig. 1.2 (view from rear of driver s side) bolt heads Fig. 1.3 (view from rear of driver s side)

4 p. 4 of WINDSHIELD SUPPORT 2.1 Per figures 2.1 and 2.2, install the windshield support oriented so the rectangular notches on the outside edges (clearance for the P-clamps) are down as shown. Per fig. 2.1, attach the top corner of the windshield support as shown. The bolt head is to be inside the cab. Use the following hardware: one 5/16-18 x 2-1/2 long button head bolt, one plastic washer, two steel washers, and one 5/16-18 locknut. Note: the plastic washer goes under the outboard locknut this time (for weather sealing on top of the windshield support). Do not tighten the bolt. 2.2 Per fig. 2.2, orient the P-clamp so the flat straight portion is outboard as shown (on top of the windshield support, not underneath it). The curved portion of the P- clamp is to be inside the cab. Use the following hardware in the P-clamp: one 1/4-20 x 3/4 long hex head bolt, two steel washers, and one 1/4-20 locknut. Do not tighten the bolt. head of 2-1/2 long bolt Fig. 2.1 (view from rear of driver s side) 2.3 Repeat steps 2.1 and 2.2 for the passenger s side. 2.4 Tighten all four bolts on the windshield support (two 1/4 hex bolts and two 5/16 button head bolts).. 3. WINDSHIELD 3.1 Per fig. 3.1, with assistance, install the windshield assembly to the windshield support. Use one of the supplied 5/8 thick plastic hinge spacer blocks underneath each of the hinges as shown. Use the following hardware: four 5/16-18 x 1-1/2 long flat head bolts, four steel washers, and four 5/16-18 locknuts. Position the windshield for best fit/seal against hood (see fig ) then rotate the lower windshield latches to engage the brackets and close the windshield so it seals against the front of the O.P.S. tubing. See fig. 3.2 on the next page for full handle engagement. Tighten the four flat head bolts with a number 3 Phillips head screwdriver. head of bolt and flat, straight portion of P-clamp rectangular notch Fig. 2.2 (view from front of driver s side) flat head bolt 5/8 thick spacer seal against hood Fig. 3.1 (view from front of driver s side) Fig (view from front of driver s side)

5 p. 5 of WINDSHIELD (cont d.) 3.2 Per fig. 3.2, full windshield latch engagement is when the bracket surface closest to the seats are engaged as shown. 3.3 Per fig. 3.3, the design intent of the bracket welded on to the front leg is to have a ventilation position as shown. Note: the large rectangular opening is not functional. Rotate the handle into the narrow fitted opening when windshield ventilation is desired. 3.4 Per fig. 3.4, with assistance, install one gas shock per side of the vehicle as shown. The main body of the cylinder is to be up top and snapped on to the ball stud on the windshield assembly. The thin rod end of the gas shock is to be snapped on to the ball stud located on the front leg as shown. full engagement is on outside surface of bracket Fig. 3.2 (view from rear of driver s side) the narrow opening is used for ventilation the larger opening is not designed to be used Fig. 3.3 (view from driver s seat) main body up thin rod down Fig. 3.4 (view from rear of driver s side)

6 p. 6 of UPPER HINGE MOUNTS the bends are up in this photo 4.1 Per figures 4.1 and 4.1.1, install the driver s side upper hinge mount as shown. Orient so the hinge hole is up top and pointing forward. Use the following hardware: two 5/16-18 x 2-1/2 long button head bolts, four steel washers, and two 5/16-18 locknuts. Bolt heads to be inside the cab as shown. Tighten these two bolts. 4.2 Repeat for passenger s side. 5. LOWER REAR PANEL passenger s side driver s side 5.1 Lift the dump bed. Per fig. 5.1, install the driver s side lower rear panel as shown. Reference: the driver s side lower rear panel has been cut away for fuel overflow purposes, whereas the passenger s side is not cut away. Orient it so the two factory installed snaps are outboard as shown. Flex the large air intake hose as necessary. Use the following hardware in the two upper holes: two 5/16-18 x 1 long button head bolts, four steel washers, and two 5/16-18 locknuts. Use the existing holes in the vehicle. Bolt heads to be inside the cab as shown. Do not tighten these two bolts. 5.2 Per fig. 5.2, line up the outer two surfaces and the joint and clamp in place. Using the single lower hole in the bottom back side of the driver s side lower rear panel as a guide, drill an 11/32 diameter hole through the vehicle floorboard where shown. Use the following hardware: one 5/16-18 x 1 long button head bolt, two steel washers, and one 5/16-18 locknut. Bolt head to be outboard as shown. Fig. 4.1 (upper hinge mounts) heads of bolts hinge hole 5.3 Tighten all three bolts on the driver s side lower rear panel. Fig (view from front of driver s side) locknuts flex the air intake hose here line up this joint drill an 11/32 diameter hole here then place the head of the bolt here snaps driver s side lower rear panel Fig. 5.1 (view from rear of driver s side) Fig. 5.2 (view from rear of driver s side)

7 p. 7 of LOWER REAR PANEL (cont d.) 5.4 Per fig. 5.4, install the passenger s side lower rear panel as shown. Note: the passenger s side piece of sheet metal is larger than the driver s side. Orient the lower rear panel so the rubber seal is against the vehicle as shown. Use the following hardware in the two upper holes (not shown): two 5/16-18 x 1 long button head bolts, four steel washers, and two 5/16-18 locknuts. Use the existing holes in the vehicle. Bolt heads to be inside the cab. Do not tighten these two bolts. rubber seal heads of bolts line up the joint 5.5 Per fig. 5.4, line up the outer two surfaces and the joint and clamp in place. Using the two lower holes in the bottom back side of the passenger s side lower rear panel as a guide, drill two 11/32 diameter holes through the vehicle floorboard where shown. Use the following hardware: two 5/16-18 x 1 long button head bolts, four steel washers, and two 5/16-18 locknuts. Bolt heads to be outboard as shown. Fig. 5.4 (view from rear of passenger s side) 5.6 Tighten all four bolts on the passenger s side lower rear panel. 6. ROOF 6.1 Lower the dump bed. Per fig. 6.1, place the final two P-clamps on the top of the rear O.P.S. tubing as shown. Orient them so the flat straight portion is up top, pointing forward, and parallel to the ground. Locate them 10 (ten inches) left and right of center for a total distance of 20 (twenty inches). For now, disregard the Expand-a-foam that is shown in the photo. 6.2 Per fig. 6.2, install a 48 (forty eight inch) long piece of Expand-a-foam across the entire width of the windshield support approximately 1/2 (half an inch) above the slots. IMPORTANT: for best adhesion, you must clean the surface and be sure it is dry and at room temperature before applying the Expand-a-foam. Fig. 6.1 (view from side of driver s side) Expand-a-foam ref.: slots shown in white for clarity Fig. 6.2 (view from front of driver s side)

8 p. 8 of ROOF (cont d.) 6.3 Tip: read this entire step 6.3 fully before applying the foam. Per fig. 6.3, install one long continuous piece of Expand-a-foam to the top of the O.P.S. tubing on the driver s side, transition to the back side of the rear O.P.S. tubing shown in fig , then transition back to the top of the O.P.S. tubing on the passenger s side to finish off at the end of the Expand-a-foam previously installed on the passenger s side of the windshield support. Reminder: apply self-adhesive backed foam to a clean, dry surface at room temperature for best adhesion. Note: confirm that the P-clamps have not shifted or moved off center or off the 20 (twenty inch) center to center distance. As the Expand-a-foam passes over the P-clamps, be sure the flat straight portion of the P-clamp is parallel with the ground otherwise it will be difficult to re-adjust once the adhesive makes contact (see fig. 6.1 on the previous page). The foam will provide a seal against the underside of the roof. start one long piece of Expand-a-foam here butting up against the Expand-a-foam on the windshield support ref.: slot shown in white for clarity Fig. 6.3 (view from front of driver s side) 6.4 Per fig. 6.4, place the roof on top of the Expand-afoam oriented so the snaps with nut covers are towards the rear of the vehicle as shown. Shift the roof forward so the roof contacts the rear Expand-a-foam as well. Install the following hardware through the factory installed rubber grommets in the roof: eight 1/4-20 x 1-1/2 long hex head bolts, eight standard steel washers, eight large fender washers, and eight 1/4-20 locknuts. Bolt heads and large fender washers to be outboard as shown. Note: the two center rear bolts must also pass through both legs of each P-clamp. Do not over-tighten these bolts. Snug is sufficient. Over-tightening will distort the rubber grommets. apply to top of side tubes below hole apply to back side of rear tube Expand-a-foam above bolt Fig (view from rear of driver s side) heads of hex bolts and fender washers nut covers on snaps Fig. 6.4 (view from rear of driver s side)

9 p. 9 of FUEL FILLER COVER 7.1 Per fig. 7.1, apply 5/8 wide hook velcro between the two factory installed snaps on the outboard side of the driver s side rear panel as shown (step a). Reminder: apply self-adhesive backed velcro to a clean, dry surface at room temperature for best adhesion. Install the black vinyl fuel filler cover to the two snaps and to the newly installed velcro. Fit the remaining three sides into place and use the supplied 5/8 wide hook velcro as needed. For clarity, the black vinyl cover is not shown installed in fig Where noted in fig. 7.1 (step b), mark the location of the third and final snap and drill a 7/32 diameter hole through the side of the vehicle floorboard. Using a number 2 Phillips head screwdriver and a 3/8 open end wrench, install the supplied snap so the locknut is on the inside surface of the floorboard flange. Install one more piece of velcro (step c) from the newly installed snap to the edge of the lower rear panel as shown. Locate the velcro down low along the bottom edge as shown. step a step c step b Fig. 7.1 (view from side of driver s side) 7.2 Fig. 7.2 shows the fuel filler cover completely installed. All three snaps are engaged and all sides of the cover are velcroed to the vehicle (behind the seat, under the seat, in front of the seat, and to the top of the floorboard). 7.3 Fig. 7.3 shows the access flap peeled back and rolled up for use during re-fueling. 8. DOORS 8.1 Per fig. 8.1, adjust the acorn nut and jam nut on the door handle so that the plunger is as short as it can be. Use two 13mm wrenches. Further adjustments may be necessary fuel fill access flap shown closed Fig. 7.2 (view from front of driver s side) fuel fill access flap shown rolled open jam nut acorn nut Fig. 8.1 (view of driver s side door latch) Fig. 7.3 (view from side of driver s side)

10 p. 10 of DOORS (cont d.) 8.2 Per fig. 8.2, install the driver s side door by guiding the welded hinge pins into the receiving holes in the upper and lower hinge mounts. Note: grease or a suitable lubricant can be used underneath the washers that are welded on to the pins. Fig. 8.1 shows the top of the door. Per figures 8.2.1, adjust the striker pin on the front leg to suit. Per fig , adjust the door latch to suit. This has not been factory pre-set. Continue to adjust until two clicks of the door latch are achieved. See the trouble shooting guide at the bottom of this page for common situations that may be encountered. 8.3 Per fig. 8.2, apply 1 wide loop velcro to the exact middle of the outside surface of the O.P.S. tubing (step d). The length of velcro is determined by where it appears to be needed by the flap on the door (from top to bottom). Note: avoid covering any pertinent information on the decals if possible. Reminder: apply self-adhesive backed velcro to a clean, dry surface at room temperature for best adhesion. Install 1 wide loop velcro to the exact middle of the rear surface of the O.P.S. tubing (step e). Step e is in preparation for the rear curtain installation which is next (step 9). Start from the Expand-a-foam under the roof and end at the top of the welded cross plate near the bottom of the O.P.S. tubing. Per fig. 8.3, install a 5 long piece of loop velcro to suit the bottom flap on the rear of the door. Note: white lines represent the outline of the black velcro in the photo for clarity. 8.4 Do not velcro the door flap to the O.P.S. tubing. 8.5 Repeat steps 8.1 through 8.4 for the passenger s side. Fig. 8.2 (view from side of driver s side) striker pin step d upper door pin fits into upper hinge mount hole Fig (view from rear of driver s side) step e 5 long piece of velcro front to back adjustment nuts Fig. 8.3 (view of driver s side) Troubleshooting the door Condition: Door latch will not double click Door latch and striker pin does not line up (up and down) Door latch and striker pin does not line up (front to back) Door does not seal in and out adjustment nuts (remove plastic cover for access to the bolt heads) Fig (view of driver s side door latch) Explanation/Solution Move latch on door in towards center of vehicle. Move striker pin on front leg up or down. Move latch on door forwards or backwards. Move latch on door out away from center of vehicle. Flex the frame of the door until the desired seal is achieved.

11 p. 11 of REAR VINYL CURTAIN 9.1 Lift the dump bed. Per fig. 9.1, install the rear curtain by engaging all five (5) snaps on the inside back surface of the roof. Work the side flaps over to the O.P.S. tubing on each side and tuck the vinyl underneath the roof as shown. Wrap the cuff portion of the rear panel around the tubing and velcro it to itself. See fig for more detail. The door flap can now be velcroed to the mating velcro that is sewn on to the exterior of the cuff portion of the rear curtain. The velcro previously installed on the O.P.S. tubing for the door flap can be utilized if the rear curtain is removed (not being used). 9.2 Per fig. 9.2, apply 1 wide loop velcro to the upper rear surface of the lower cross member of the vehicle as shown. Note: in the very small area directly above the bolts, the overlapping extra width of the velcro can be folded over onto the opposite side of the cross member plate so it stays well adhered to the vehicle. Reminder: apply self-adhesive backed velcro to a clean, dry surface at room temperature for best adhesion. 9.3 Adhere all the edges of the rear curtain to the newly applied velcro on the vehicle. See fig. 9.3 for finished installation. tuck under the roof vinyl door flap peeled back snap together (5 places) cuff portion in the closed position Fig. 9.1 (view from rear of driver s side) cuff portion of the rear curtain Fig (view from front of driver s side) velcro shown in white for contrast rear curtain installed Fig. 9.2 (view from rear of driver s side) Fig. 9.3 (view from rear of driver s side)

12 p. 12 of FINISHING TOUCHES 10.1 Make sure all bolts have been tightened. Install the supplied black, plastic, nut covers to the interior locknuts for a finished appearance 1/4 (quantity: 8) and 5/16 (quantity: 12). Push them on all the way Per fig. 10.2, the zippered window in the rear curtain can be rolled up as shown using the three mated velcro straps shown. Note: it is suggested to roll the window up from and towards the inside to avoid rain and/or debris accumulation on top of the rolled up window Per fig. 10.3, the door window can be unzipped and left to hang down on the inner surface of the door as shown. 1/4 nut cover 5/16 nut covers 10.4 Available optional accessories are as follows: windshield wiper, work lights, strobe light, interior rear view mirror, heater, and snow plow. Install these accessories per the installation instructions included in each kit. Fig (view from driver s seat) 10.5 Note: extra hardware has been provided in case they get lost. Discard extras such as black washers, etc. 11. CARE AND MAINTENANCE 11.1 Check and tighten hardware after 40 hours of operation. Periodically inspect and tighten hardware for the remainder of the unit s life For the cleaning of all cab components: NEVER USE AN ALCOHOL-BASED PRODUCT FOR CLEANING. Do not use WINDEX, GLASS PLUS, FANTASTIC, etc.. Do not use any CITRUS BASED CLEANERS such as orange or lemon. Use of these products will result in deterioration of the windows. window in rear curtain rolled up Fig (view from front of driver s side) Wash with a mild soap or detergent using your bare hands to free or dislodge any caked-on dirt or other foreign particles. A soft, grit-free cloth, sponge, or chamois may be used but only as a means of carrying water to the windows. The interior should be lightly dusted (NOT WIPED) with a clean soft cloth or chamois. The cloth or chamois should be kept free of grit by frequent rinsing in clean water. Grease and oil may be removed with kerosene. upper window open and hanging down on the inside of the door Novus I and Novus II are recommended plastic cleaners and can be used to remove light scratches. Fig (view from front of driver s side)

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