INSTALLATION & OWNER S MANUAL

Transcription

1 Rev. B, p. 1 of 25 INSTALLATION & OWNER S MANUAL POLARIS RANGER RCS (for models XP or HD) (for model years 2009-) cab without doors kit (p/n 1POLRCWD) cab with doors kit (p/n 1POLRC) doors only kit (p/n 1POLRDR) 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: 1 to 1.5 HOURS (excluding accessories) Shown with optional windshield wiper (p/n 1POLWPR). Additional options available are: a heater (p/n 9PH20S39), a snow plow (p/n 1PRGUTP), and work lights (p/n 1POLWL). (revised: 6/11/2009)

2 p. 2 of 25 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. 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 #27 Torx Bit One Phillips Head Screwdriver One 3/8 Drive Ratchet One 1/2 Deep Socket (3/8 drive) Set of standard Allen Wrenches

3 p. 3 of MOUNT KIT 1.1 Per fig. 1.1, remove and discard the two bolts and two nuts shown in the lower, front, right corner of the frame tubing. New, longer, black hardware is supplied. 1.2 Per fig. 1.2, remove and discard the two bolts and two nuts shown in the upper, middle portion of the frame tubing. New, longer, black hardware is supplied. 1.3 Skip this step and proceed to step 1.4 on the next page if not installing doors. Per fig. 1.3, install a P-clamp approximately where shown being certain to orient the flat section of the P-clamp to the outside of the vehicle as shown. The P-clamp should be ahead of and against the upper, rear cross tube welded joint. remove and discard 2 bolts and 2 nuts Fig. 1.1 (view from passenger s side) remove and discard 2 bolts and 2 nuts Fig. 1.2 (view from passenger s side) flat section to be outboard as shown Fig. 1.3 (view from passenger s side)

4 p. 4 of MOUNT KIT (cont d.) 1.4 Per figures 1.4 and 1.4.1, install the supplied Expand-a foam to the top mount. Cut the Expand-a-foam to 26-1/2 long. Note: self-adhesive backed foam is to be applied to clean, dry surfaces at room temperature for best adhesion. Peel back the protective film and attach it from end to end on the factory installed rubber trim as shown. Fig. 1.4 shows a heavy white line that represents the Expand-a-foam for clarity in the photo. Fig shows thin white lines representing the outline of the Expand-a-foam for clarity in the photo. Note: keep outside edges flush with each other as shown in the inset photo in fig Per fig. 1.5, install a P-clamp to the upper, front corner as shown. Orient it so the flat section is up. Locate it approximately where shown, in front of and as close to the welded joint as possible. Expand-a-foam shown as a heavy white line Fig. 1.4 (view of passenger s side top mount) 1.6 Per fig. 1.6, install a P-clamp to the upper, rear cross tube as shown. Orient it so the flat section is facing forward. Locate it as close to the welded joint as possible. self-adhesive side of Expand-a-foam rotated view keep the outside edges flush with each other back end of top mount Fig (enlarged view of top mount) flat section to be up as shown flat section to be forward as shown Fig. 1.6 (view from front of passenger s side) Fig. 1.5 (view from front of passenger s side)

5 p. 5 of MOUNT KIT (cont d.) 1.7 Per fig. 1.7, locate one of the four custom spacers. 1.8 Per fig. 1.8, install one of the custom spacers into the inboard, oval recess before installing the top mount on the passenger s side of the vehicle. This will provide rigid support for the mounting tab that is welded onto the top mount. 1.9 Per fig. 1.9, install the passenger s side top mount oriented as shown with the large radius cutout towards the front of the vehicle (the ball stud will be towards the front also). The Expand-a-foam should sit directly on top of the outboard frame tubing Per fig. 1.10, install new hardware in the two holes shown. Install a washer onto the 3/8-16 x 2 long button head bolt and from the inboard side, feed it through the mounting tab, then through the custom spacer, then through the frame tubing. Install a new 3/8-16 nut on the outboard side without a washer. Note: a drift pin or a screwdriver may be helpful in lining up the first hole due to the frame tubing springing when it was initially un-bolted. Do not tighten bolts. Fig. 1.7 (front and side view of custom spacers) install one custom spacer here in the inboard oval recess Fig. 1.8 (view from driver s side) large radius cutout with rubber trim bolt heads with washers here Fig. 1.9 (view from front of passenger s side) Fig (view from driver s side)

6 p. 6 of MOUNT KIT (cont d.) install bolt here 1.11 Per fig. 1.11, install a 5/16-18 x 1-1/4 long button head bolt down from the top as shown. Do not use a washer under the bolt head. Pass the bolt down through the sheet metal, through the factory installed tubular spacer, and through both holes in the P-clamp. Use a washer and nut on the bottom side. Use the 1/2 deep socket in this area. Do not tighten bolt Per fig. 1.12, install a 5/16-18 x 1-1/4 long button head bolt and a one washer through both holes in the P- clamp. Thread the bolt into the factory installed clip nut. Do not tighten bolt Per fig. 1.13, install a custom spacer into the outboard recess on the lower, front, passenger s side as shown. Fig (view from front of passenger s side) 1.14 Per fig. 1.14, install a single, basic spacer in the top inboard hole and a 3/8-16 hex nut (no washer) in the lower inboard hole as shown. install one bolt and one washer here Fig (view from rear of passenger s side) single spacer up top custom spacer hex nut down bottom Fig (view from passenger s side) Fig (view from front of vehicle)

7 p. 7 of MOUNT KIT (cont d.) 1.15 Per fig. 1.15, install the driver s side front mount as shown. Install a 3/8-16 x 2-3/4 long button head bolt and a washer through the top hole starting from the outboard side. Note: a drift pin or a screwdriver may be helpful in lining up the first hole due to the frame tubing springing when it was initially un-bolted. Pass the bolt through the sheet metal, through the custom spacer, through the frame tubing, through the single spacer, then use a washer and a hex nut on the inboard side. The bottom hole requires a 3/8-16 x 2 long button head bolt and a washer under the head. This bolt passes through and engages into the previously, loosely installed hex nut without a washer on the inboard side. Do not tighten bolts Per fig. 1.16, install a P-clamp approximately where shown and oriented so the flat section is towards the center of the vehicle. Per fig , install one 5/16-18 x 1-1/4 long button head bolt, two washers, and one hex nut connecting the P-clamp to the front mount as shown. The head of the bolt and one washer are to be towards the center of the vehicle. Tighten the three newly installed bolts on this front mount. While tightening the bolts, crowd or rotate the front mount towards the center of the vehicle as shown in fig and as indicated with the direction of the arrows in the photo. This will ensure that the door seals as well as possible. install a nut and washer here Fig (view from front of vehicle) flat section of P-clamp 1.17 Tighten the bolts on the top mount starting with the middle two bolts, then the front bolt, then the rear bolt Repeat all of section 1 for the driver s side. Fig (view from front of vehicle) head of bolt and washer here Fig (view from front passenger s side) Fig (view from front of vehicle)

8 p. 8 of WINDSHIELD 2.1 Orient the windshield so the quick attach pins are up top and the latches are down bottom. See figures 2.1 through Hook the two upper pins into the receiving slots in the front of the top mounts. Snap the lower two latches onto the pins on the inside of the front mounts until they are fully engaged. Two (2) clicks means fully engaged. If adjustment is needed, use a 3/16 Allen wrench to reposition the pin in the slotted front mount assembly. Note: there is a serrated, flanged nut on the outside that can be held in place with fingers (no wrench required). Fig. 2.1 (view from front of passenger s side) slot for windshield installation slot for windshield pin ref.: slot for roof installation Fig (description of slot usage in top mount) Fig (upper passenger s side - before and after) Fig (lower passenger s side - before and after)

9 p. 9 of WINDSHIELD (cont d.) 2.2 Three areas are adjustable if a better seal is desired. First be sure that the pins are at the bottom of the receiving slots in the top mounts before beginning any adjustments. The lower latches have adjustment in and out (see fig. 2.2). The lower pins have adjustment up and down. The upper pins have adjustment in all directions due to an oversized hole. Make the necessary adjustments until you achieve double click engagement. If the issue is with the seal against the frame tubing, adjust the lower latches in or out. If the issue is with the seal against the hood, adjust the lower pins up or down. The upper pins also have up and down adjustment if more is necessary. slotted for adjustment use an Allen wrench here to adjust Fig. 2.2 (view from inside of passenger s side) Troubleshooting the windshield Condition: Latches will not double click Gap along ROPS at bottom Gap along ROPS at top Gap along hood Explanation/Solution Be sure upper pins are fully seated in slots of top mounts. Move latches backward in slots. Move latches forward. Move upper pins forward. Move latches forward. Move lower pins down. Move upper pins up.

10 p. 10 of REAR PANEL 3.1 Per fig. 3.1, use a number 27 Torx bit to temporarily remove the two original equipment bolts shown behind the seat. Repeat for driver s side. 3.2 Per fig. 3.2, install the passenger s side rear mount sandwiched between the back of the seat and the seat support oriented as shown. Re-install the two bolts that were removed in the previous step making sure that the bolts pass through the slots in the rear mount. Tighten these bolts. Repeat for driver s side. temporarily remove and save these two bolts 3.3 Lift the dump bed. 3.4 Per fig. 3.4, install the supplied 1 wide selfadhesive hook velcro to the areas shown. Note: heavy white lines on the photo represent the velcro (for contrast and clarification). Be sure the surfaces are clean, dry, and at room temperature for best adhesion. Install the first piece to the back side of the frame tubing from a (approximately the middle of the seat back support) to b (just above the bolt). The second piece goes from c (below the bolt) to d (the bottom of the vertical wall). The next piece goes from d all the way to the other side of the vehicle. Repeat a to b and b to c for the driver s side. Fig. 3.1 (view from rear passenger s side) install rear mount as shown Fig. 3.2 (view from rear passenger s side velcro a b d c Fig. 3.4 (view from rear passenger s side)

11 p. 11 of REAR PANEL (cont d.) 3.5 Per fig. 3.5, with the help of an assistant, install the rear panel assembly oriented as shown with the sliding window down bottom. Per fig , the T pull handle is to be over the top of the frame tube as shown. See the installation photos on the next page for clarification of the pin and receiver slot. rear panel assembly shown in place Fig. 3.5 (view from rear passenger s side) T pull handle to be over the top of the frame tube Fig (view from front driver s side)

12 p. 12 of REAR PANEL (cont d.) 3.6 Per fig. 3.6, hook the two upper pins into the receiving slots in the rear of the top mounts. Per fig , snap the lower two latches onto the pins on the rear mounts until they are fully engaged. Two (2) clicks means fully engaged. Be sure top pins are fully seated before making adjustments. If adjustment is needed, use a 3/16 Allen wrench to reposition the pin in the slotted rear mount or loosen the two Torx seat back bolts and adjust the entire rear mount to suit (see fig ). 3.7 Adhere the rear curtain to the newly installed velcro on the back of the frame tubing and the lower plastic shelf area. Start at the lower middle section and work the rear curtain towards the outboard edges for best fit up. slot for rear panel installation Fig. 3.6 (upper passenger s side - before and after) Fig (lower passenger s side - before and after) Troubleshooting the rear panel Condition: Latches will not double click Gap along ROPS at top Gap along ROPS at bottom Latches and pins do not line up Explanation/Solution Move latches forward. Move upper pins backward. Move upper pins up. Move latches backwards. Move lower pins left or right. Move upper pins up or down.

13 p. 13 of ROOF 4.1 Per figures 4.1, 4.1.1, and 4.1.2, install the roof assembly oriented as shown with the bolt-on-bracket towards the front of the vehicle and the T handle receiver bracket towards the rear of the vehicle. Note: the bolt-on-bracket must engage under the rubber trim as shown. This ensures that the roof is safe for forward trailering. this bolted-on bracket engages under the rubber trim 4.2 Hook the pins into the receiving slots towards the front of the top mounts and push down and forward to fully engage in the slots. See fig. 4.2 and for the correct slot to engage in. Snap the latches onto the pins located on the rear of the top mounts until they are fully engaged. Two (2) clicks means fully engaged. Fig. 4.1 (view from rear passenger s side) slot for windshield installation slot for roof pin for roof ref.: slot for roof installation Fig. 4.2 (description of slot usage in top mount) Fig (connection points for roof)

14 p. 14 of ROOF (cont d.) 4.3 To achieve a better seal or to achieve a double click, the latches can be adjusted up or down. The pins can be adjusted in all directions due to an oversized hole. T pull handle shown engaged in its receiver 4.4 Per fig. 4.4, pull and stretch the rubber T handle strap to engage it in its receiver bracket. Fig. 4.4 (view from front driver s side) Troubleshooting the roof Condition: Latches will not double click Won t seal along top Too tight along top Roof hard to push forward Explanation/Solution Move latches down. Move latches up. Move front pins up. Move latches down. Move front pins down. Armor All the rubber.

15 p. 15 of DOORS 5.1 Skip this section and proceed to section 6 on page 18 if not installing doors at this time. 5.2 Per fig. 5.2, install the passenger s side hinge plate mount as shown, using a 5/16-18 x 1 long button head bolt, two washers, and a locknut. The locknut is to be towards the dump bed. Lightly snug the bolt so it stays oriented as shown. Note: for contrast and clarity, the outer edges of the hinge plate mount are highlighted in white. 5.3 Per fig. 5.3, use a straight edge against two contact points on the outside of the frame tubing as shown. Note: a wooden yardstick is shown contacting the rear frame tube. The other end must contact the upper front tube. Move the hinge plate mount in or out so that the outer face lines up flush with the outside edges of the tubing (i.e.: the inside edge of the straight edge). Leave bolt snug. Do not tighten. 5.4 Per fig. 5.4, remove and discard the original equipment bolt and nut shown at the bottom of the frame tubing behind the seat belt. New, longer hardware is provided. Note: you may have to loosen the seat belt bolt and rotate the seat belt unit down for clearance for the door frame. head of bolt and washer to be here Fig. 5.2 (view from front passenger s side) yardstick contact point 1 of 2 Fig. 5.3 (view from passenger s side) remove and discard bolt and nut ref.: seat belt bolt Fig. 5.4 (view from passenger s side)

16 p. 16 of DOORS (cont d.) 5.5 Per figures 5.5 and 5.5.1, install a 5/16-18 x 2-3/4 long hex head bolt and washer as shown. Leave the bolt head sticking out approximately 1/2. Keep the washer tight under the bolt head so the door frame unit can rotate into place under the washer. Per fig. 5.5, position the lower door frame so the closed slot at the back of the unit fits around the bolt as shown. Per fig , rotate the lower front of the door frame unit so the open ended slot engages the bolt with the washer still under the bolt head. Push the bolt all the way in and install a washer and locknut on the back side. 5.6 Per fig. 5.6, install the two adjacent bolts first, then the upper single bolt last. Use the following hardware: three 5/16-18 x 1 long button head bolts, three nylon washers, six steel washers, and three locknuts. Bolt heads to be on the outside as shown. Steel washers to be directly under the bolt head, then the nylon washer as per step D and the sketch on page 2. The two lower bolts pass through the hinge plate mount. The upper single bolt passes through the previously installed P- clamp. 5.7 Per fig. 5.7, check for gaps where indicated. If necessary, loosen and re-tighten the bolt indicated to pull the door frame tighter against the frame tubing so the factory installed 1/8 thick foam tape seals off any gaps. Repeat steps 5.2 through 5.7 for the opposite side of the vehicle. 5.8 With assistance, install the doors. Apply grease to the factory installed pin hinges and install the doors by lining up the pin hinges on the door with the hinge sleeves on the door frame. Work the doors back and forth until they are completely seated on the pin hinges. ref.: chamfered end of bolt thread Fig. 5.5 (view from rear passenger s side) ref.: open ended slot head of bolt and washer to be here (note: leave a 1/2 of bolt diameter out of tubing for open ended slot to engage with) Fig (view from front passenger s side) head of bolt and washers here seal off gaps if necessary loosen this bolt if necessary heads of bolts and washers here Fig. 5.6 (view from passenger s side) Fig. 5.7 (view from rear of vehicle)

17 p. 17 of DOORS (cont d.) 5.9 Door latch engagement adjustments can be made in the following order of ease and likelihood: Per figure 5.9, the latch pin can be loosened, re-positioned, and re-tighten to suit Per fig. 5.10, two of the bolts shown allow for adjustment forward and backwards. The other two bolts shown allow for adjustment in or out. Adjust as necessary to suit Per fig. 5.11, the hinges on the door itself can be adjusted. The bolt holes are intentionally oversized over the 1/4 bolts for this purpose. adjustment can be made here Fig. 5.9 (view from rear passenger s side) 5.12 Before installing the gas shocks, see the trouble shooting guide below if necessary. Continue to adjust the engagement as necessary until you get the door to close with two clicks which is confirmation that the door is fully closed and secure enough to drive Per fig. 5.13, attach the supplied gas shock to the door and top mount as shown with the quick release end connected to the factory installed ball stud on the top mount. To open the receiving socket on the quick release end, push the orange wedge towards the end of the shock. Connect the non-quick release end of the shock to the door and the quick release end to the top mount as shown. adjustments can be made here adjustments can be made here 5.14 If necessary, per fig 5.14, adjust the acorn nut and jam nut on the door handle plunger so that the plunger is as short as it can be. Use two 13mm wrenches. Further adjustment will be made in a later step. Fig (inside view of passenger s side door) adjustments can be made here jam nut acorn nut Fig (view from passenger s side) orange wedge Fig (view from below driver s side door latch) Fig (view from passenger s side)

18 p. 18 of DOORS (cont d.) 5.15 The striker bolt on the front mount can be adjusted up or down. The inside rotary latch on the door can be adjusted front to back and in and out. Continue to adjust the engagement as necessary until you get the door to fully seal and close with two audible clicks which is confirmation that the door is fully closed and secure enough to drive. The latch should engage smoothly on the pin. If contacting the top or bottom of the pin, adjust the pin in the slot to avoid excessive pin wear. If the pin is at the bottom of the slot during engagement, move it to the top of the slot, loosen the hinge bolts, and close the door so that two clicks are heard. Re-tighten the hinge bolts without opening the door. Once tight, open the door and re-adjust the pin in the slot Any or all of the following four areas can be adjusted for proper double click engagement: standard striker pin, inside rotary latch, door pin hinges, and/or the hinge sleeves Once the latch is properly adjusted for double click engagement, adjust the acorn nut so that it just misses the release on the latch with 1 mm clearance. Tighten the jam nut against the acorn nut to prevent it from loosening Repeat all of section 5 for the driver s side. Troubleshooting the door Condition: Latches will not double click Latch and pin does not line up (up and down) Latch and pin does not line up (front to back) Door does not seal Explanation/Solution Move latches in. Move pin up or down. Loosen hinges and lower or raise the front of the door. Move latch forwards or backwards. Loosen hinges and move door forwards or backwards. Move latch out. 6. FINISHING TOUCHES 6.1 Install the supplied 5/16 nut covers (qty.: 8) on the interior hex head nuts. 6.2 Peel protective film from windows. 6.3 Note: extra hardware has been provided in case they get lost. Discard extras such as black washers, etc. 6.4 Install any optional, separately purchased accessories per the installation instructions included with the specific kit (i.e.: windshield wiper, snow plow, heater, and/or work lights) 6.5 If a doors only kit (p/n 1POLRDR) is purchased after a cab without doors kit (p/n 1POLRRCWD) is already installed, follow the directions below: * Temporarily remove the roof, rear panel, and windshield. * Temporarily loosen, but do not remove, the two middle bolts and the one rear bolt on the top mounts of the cab kit in order to install the supplied P-clamp discussed in step 1.3 on page 3 of these instructions (under the Expand-a-Foam). * Follow all of Section 5 which is discussed on pages 15 thru 18 of these installation instructions. * Re-tighten the two middle bolts and the one rear bolt on the top mounts. * Re-install the rear panel, windshield, and roof. 7. CARE AND MAINTENANCE 7.1 Check and tighten hardware after 40 hours of operation. Periodically inspect and tighten hardware for the remainder of the unit s life. 7.2 Wash the painted surfaces of the unit with commercial automotive cleaning products. 7.3 Clean windows with warm soapy water. 7.4 Vinyl components should be washed with a mild solution of warm soapy water.

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