INSTALLATION & OWNER S MANUAL

Transcription

1 Rev. E p. of 3 INSTALLATION & OWNER S MANUAL V446 Front Cab Kit and V446 Rear Cab Kit for RTV 40 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: 3-5 HOURS NOTE: Front and rear cab shown with optional windshield wipers. manual p/n revised: 0/8/06

2 p. of 3 EXPOSURE TO CARBON MONOXIDE CAN CAUSE ILLNESS, SERIOUS INJURY, OR DEATH Inspect Exhaust system for leaks monthly Leaks can result from loose connections, corrosion, cracks, or other damage to exhaust manifold. If leaks are found repair or replace exhaust system Do not use vehicle until repair or replacement is complete 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. 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. Leave all bolts loose for later adjustment unless otherwise specified. NOTE: DO NOT DIMPLE METAL ROOF BY OVER- TIGHTENING FASTENERS. C. Read and understand all instructions before beginning. D. If installing accessories, read all accessory instructions before starting cab assembly. E. Plastic washers have been supplied to provide a weather seal around all exterior fasteners. The plastic washer should be installed directly against the outside cab surface. Care should be taken not to over tighten the fasteners and damage the plastic washer. Also use flat washers as required. F. Apply a clear silicone sealant to seal any minor gaps that may occur due to vehicle variances. 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 3/6 Allen Wrench (preferably T handle type) One 5/3 Allen Wrench One Phillips Head Screwdriver Torque wrench (0 to 40 ft.-lbs.) Rubber Mallet Utility Knife Scissors Snips

3 . INSTALL TOP MOUNTS AND SIDE FRAMES (FRONT CAB p/n V446) p. 3 of 3. Move the cargo screen to the rear of the vehicle and latch the rubber latches at the top. Disconnect the roll bar tubes it rolls on by removing the four bolts at the front. See fig.... Position the top mount in place by lifting up on the roll bar tubes and sandwiching it between the tubes and the front part of the roll bar, with the rubber seal facing the rear. Reinstall the bolts removed in the previous step. See figure.. NOTE: if installing the rear cab, tighten the bolts only one or two turns. If not installing rear cab, snug bolts but do not tighten..3 Per figure.3, remove the Christmas tree plugs from the front floor mat on both sides of the vehicle. Install the left and right floor plates with /4" button head bolts, washers ( per bolt), and nylon lock nuts as shown. If installing a rear cab, remove the Christmas tree plugs from the rear floor mat on both sides of the vehicle. Install the rear floor plates which are supplied with the rear cab. The floor plate must be oriented so that the slot that is closest to the outer edge of the part is towards the rear of the vehicle. NOTE: The rear floor plates will sit under the front side frames. If not installing a rear cab, remove the front two Christmas tree plugs so the front frame bolts can be installed in step.5 Rear cab floor plate. Do not install bolt in front hole. FIGURE.4 FIGURE. Front cab floor plate FIGURE.3.4 Per figure.4, position the left side frame and attach to the top mount with a 5/6" button head bolt, steel washers, one plastic washer, and a nylon lock nut. NOTE: The remaining bolts will be installed during installation of other parts..5 Attach left side frame to vehicle floor with two /4-0 x " button head bolts, four steel washers, and two nylon lock nuts as shown in figure.5.6 Repeat steps.4 and.5 for right side frame.. INSTALL REAR PANEL (FRONT CAB p/n V446) NOTE: Refer to figure for both steps in this section.. Move the cargo screen forward and remove all bolts attaching it to the cargo screen frame and the seat back. Retain the hardware from the seat back. FIGURE.5. Install weather seal to the back of cargo screen frame as shown, adhering to the round tubular frame on the top and along both sides and to the sheet metal behind the seat back along the bottom. Apply two strips to the front of the cargo screen between the head rest bolts as shown. With assistance, place the rear panel between the cargo screen and cargo screen frame. Attach with seven 5/6" button head bolts, 4 steel washers, and seven nylon lock nuts. Attach to seat back with three bolts removed in previous step. NOTE: If not installing a rear cab, turn to step 6 on page 5. FIGURE (Weather seal shown in white)

4 p. 4 of 3 3. (REAR CAB p/n V446) INSTALL REAR MOUNTS AND REAR SIDE FRAMES 3. Move the cargo screen to the front of the vehicle and latch with rubber latches at top of screen. Confirm the bolts at the front of the roll bar tubes it rolls on are loose. Remove the nuts and bolts from the back of the two roll bar tubes and push the tubes down out of the brackets on the rear roll bar. Slide the rear mount into position over the roll bar as shown in figure 3.. (It may be necessary to use a rubber mallet to remove the tubes from the brackets on the rear part of the roll bar). 3. Per figure 3., install the left and right rear tabs and roll bar tubes using the hardware removed in the previous step. Note: Align angled edge of tabs with angled edge of roll bar bracket. The bolt heads go to the outside of the vehicle, the nuts and brackets on the inside. FIGURE Per figure 3.3, position the left rear side frame and attach to the top mount with a 5/6" button head bolt, steel washers, one plastic washer and a nylon lock nut. NOTE: The side frame should sit behind and on top of rear mount. 3.4 Attach left side frame to the vehicle roll bar with a rear roll bar bracket, a 5/6" button head bolt, steel washers, and a nylon lock nut. See figure Repeat steps 3.3 and 3.4 for right side frame. 3.6 Per figure 3.6, install side bulb rubber on to rear frame mount assembly with rubber pointing forward to seal against rear panel. Rubber runs up rear frame, across rear mount and down opposite side frame. FIGURE 3. FIGURE 3.3 Start at bottom of flange FIGURE 3.4 FIGURE 3.6

5 p. 5 of 3 4. (REAR CAB p/n V446) INSTALL REAR HEADERS 4. Per figure 4., install the left header with two 5/6" button head bolts, 4 steel washers, two plastic washers, and two nylon lock nuts through the sides of the header.. NOTES: The remaining bolts will be installed during roof installation. The header goes to the outside of the side frames. Left rear header (wide flange to rear, ball stud pointing down 4. Repeat step 4. for right header. 5. (REAR CAB p/n V446) INSTALL REAR ROOF 5. Use a Phillips head screwdriver to punch a hole through the roof headliner at all of the covered bolt hole locations (0 places). Punch holes from the inside out to avoid having the headliner pull away from the inside of the roof or tear. FIGURE With assistance, install the roof oriented as shown in figure 5.. Attach to rear mount with seven 5/6" button head bolts, 4 steel washers, seven plastic washers, and seven nylon lock nuts. NOTE: The remaining bolts will be installed during front roof installation. 6. (FRONT CAB p/n V446) INSTALL WINDSHIELD AND DOOR STRIKER MOUNTS FIGURE With assistance, position the windshield on the vehicle hood and resting against the front of the roll bar. Per figure 6., sandwich left and right striker mounts between windshield and roll bar as shown and install lower mounts with 5/6" hex head bolts. NOTE: Windshield installation will be completed as the rest of the components are installed. 7. (FRONT CAB p/n V446) INSTALL FRONT HEADERS 7. Per figure 7., install the left header with two 5/6" button head bolts, 4 steel washers, two plastic washers, and two nylon lock nuts through the slots in the vertical surface. NOTES: The remaining bolts will be installed during roof installation. The header goes to the outside of the windshield, top mount and front frames. 7. Repeat step 7. for right header. FIGURE 6. Left rear header (install with wide flange to front, ball stud pointing down FIGURE 7.

6 8. (FRONT CAB p/n V446) INSTALL ROOF 8. Only if not installing a rear cab, install the roof back to the top mount with two 5/6" button head bolts ( per side), 4 steel washers, two plastic washers, and two nylon lock nuts. SEE FIGURE 8. The remaining bolts will be installed during roof installation. NOTE: This part will be discarded if installing the rear cab. 8. Use a Phillips head screwdriver to punch a hole through the roof headliner at all of the covered bolt hole locations (0 places). Punch holes from the inside out to avoid having the headliner pull away from the inside of the roof or tear. 8.3 With assistance, install the roof oriented as shown in figure 8.3. Attach rear of roof with seven 5/6" button head bolts, 4 steel washers, seven plastic washers, and seven nylon lock nuts. p. 6 of 3 FIGURE 8. (This part is not used if installing rear cab.) 8.4 Per figure 8.4, attach front of roof to windshield with front roll bar brackets, two 5/6" button head bolts, 4 steel washers, two plastic washers, and two nylon lock nuts. Install 5/6" button head bolts and hardware in remaining four holes to complete roof installation. Reminder: Plastic washers are installed against the outside of the roof. 9. FINISHING TOUCHES 9. Tighten all hardware, lining up panels as you go, following the procedure detailed below. Note: 5/6" hardware should be tightened to 9 ft.-lbs. and /4" hardware should be tightened to 0 ft.-lbs. FIGURE 8.3 Confirm the windshield is centered left to right and tighten the front roll bar clamps at the top of the windshield (step 8.4). Align front edge of header with front face of windshield and tighten the bolts that attach the header to the windshield (step 7.) Tighten the four bolts that attach the roll bar tubes to the front portion of the roll bar (step.). Tighten to 37 ft.- lbs. FIGURE 8.4 Make sure the front frames are seated tightly against the outside of the top mount and tighten bolts between front frames and top mount (step.4). Make sure the frames are vertical and that the face with the door hinges on it is parallel to the centerline of the vehicle before tightening the bolts at the base of the frame (step.5). Align rear edge of the rear cab headers with the rear face of the rear frames and tighten bolts on side of rear frames. (step 4).

7 9. FINISHING TOUCHES (continued) Per figure 9., lift up or push down on the rear frames so that the flange which the roll bar bracket bolts to is centered between the seat latch striker and the rear screen rocker rod bracket. Make sure the flange that the hinges are bolted to remain parallel with the sides of the cargo bed while tightening rear roll bar bracket bolts (Step 3.4). p. 7 of 3 Rocker rod bracket Push the rear mount forward or back in the roof slots until the rear frames are vertical (parallel to the rear of the roll bar and tighten the rear roof bolts) (step 5.). Tighten all remaining roof bolts. Tighten bolts attaching roll bar tubes to rear of roll bar (step 3.) Tighten to 37 ft.-lbs. Rear frame flange 9. Install supplied nut covers. 0. (FRONT CAB p/n V446) INSTALL FRONT FILLERS NOTES: Cut supplied adhesive backed velcro to match velcro on fillers. Velcro should be applied to a clean, dry surface at room temperature. Seat latch striker 0. Per figure 0. place left and right front fillers in position as shown and Velcro in place. FIGURE 9.. (REAR CAB p/n V446) INSTALL REAR FILL- ERS AND SEALS SEE NOTES IN STEP 0.. Place left and right rear fillers over cargo screen latch bracket and latch cargo screen in place. (Figure ). Velcro to back of cargo screen. (Figure ).3 Velcro to rear side frames and under seat as shown. (Figure ).4 Per figure.4, install a " piece of expand-a-foam seal under the rear seat on left and right sides. Runs from end of seat foam to existing rubber seal on seat base. FIGURE 0. Expand-a-Foam FIGURE.4 FIGURE

8 . DOORS. 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. p. 8 of 3 NOTES: Specific adjustments can be made per steps. and.3. The top of the doors should end up visually parallel with side of roof. 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 without forcing the top or bottom of the door out.. Per fig.., 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 9mm open end wrenches. Note: finger guard to end up being centered and facing inward. The front striker mounts can also be adjusted in and out by loosening the lower mounts on the windshield..3 Per fig..3, the /4-0 hex head bolts on the door hinges can be loosened on the side frames, 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 and be sure the hinges are in line with each other before tightening. CAUTION: Over tightening door hinge bolts can crush door tubing. Torque hinge bolts to 0 ft.-lbs. FIGURE. FIGURE.3.4 The inside latches can also be adjusted for proper engagement. See figure.4.5 Once the door and latch is properly adjusted for double click engagement, use two 3mm wrenches to adjust the acorn nut on the outside handle so that it just misses the release lever on the latch with mm clearance (ref.: /3 ). Tighten the jam nut against the acorn nut to prevent it from loosening..6 Install the gas shock to the frame and door with the small piston end towards the door. If equipped, press the button on the compression fastener to lock the gas shock to the ball stud. CAUTION: FOR SAFE OPERATION, DO NOT DRIVE WITH DOORS OPEN. MAKE SURE DOORS ARE CLOSED AND PROPERLY LATCHED WHEN DRIVING. WHEN TRANSPORTING THE VEHICLE IN AN OPEN TRAILER, ENSURE THAT DOORS ARE "DOUBLE CLICK" LATCHED AND LOCKED. MAKE SURE ALL WINDOWS ARE CLOSED FIGURE.4 Jam Nut Acorn Nut FIGURE.5

9 KUBOTA RTV 40 HARD SIDED FRONT CAB KIT SERVICE PARTS LIST (PAGE OF 3) p. 9 of 3 QTY. DESCRIPTION FRONT ROOF (COMES WITH FOAM HEADLINER AND EDGE TRIM) TRIM-LOK (0") /" WEATHER SEAL RUBBER (84") FRONT HEADER LEFT (COMES WITH WEATHERSEAL AND BALLSTUD) FRONT HEADER RIGHT (COMES WITH WEATHERSEAL AND BALLSTUD) BALL STUD 4 /" WEATHER SEAL RUBBER (3") TOP MOUNT 5/8" BULB RUBBER (70") FRONT FRAME LEFT (COMES WITH HINGE SLEEVES, RUBBER, AND PINS) FRONT FRAME RIGHT (COMES WITH HINGE SLEEVES, RUBBER, AND PINS) LOW PROFILE HINGE SET (4 HINGES) 5/8" SIDE BULB RUBBER (80") FRONT RUBBER FILLER LEFT (COMES WITH VELCRO) FRONT RUBBER FILLER RIGHT (COMES WITH VELCRO) GAS SPRINGS FRONT ROOF BACK ACRYLIC REAR PANEL HARDWARE KIT (RTV 40 FRONT CAB) INSTRUCTIONS (RTV 40 CAB) STRIKER PIN ASSEMBLY LEFT FRONT FLOOR PLATE RIGHT FRONT FLOOR PLATE /" WEATHER SEAL RUBBER (84") (FOR REAR PANEL)

10 KUBOTA RTV 40 HARD SIDED FRONT CAB KIT SERVICE PARTS LIST (PAGE OF 3) p. 0 of 3 QTY. DESCRIPTION WINDSHIELD FRAME (W/ RUBBER) WINDSHIELD (GLASS, HINGES, LATCHES, PLUGS, RUBBER EDGE TRIM) 3 POP OUT WINDSHIELD HINGE KIT POP OUT WINDSHIELD LATCH 3 SPACER BLOCK FOR WINDSHIELD HINGE 5/8" SIDE BULB RUBBER WITH /4" GRIP (64") " BULB RUBBER (70") 4 /" WEATHERSEAL RUBBER (3") WIPER PLUG LARGE WIPER PLUG SMALL 7/6" HEYCO PLUG LOWER U-CLAMP MOUNTS FRONT ROLL BAR BRACKETS FRONT STRIKER PIN MOUNT LEFT FRONT STRIKER PIN MOUNT RIGHT STRIKER PIN ASSEMBLY

11 KUBOTA RTV 40 HARD SIDED FRONT CAB KIT SERVICE PARTS LIST (PAGE 3 OF 3) p. of 3 QTY. DESCRIPTION LEFT STEEL DOOR FRAME (NO GLASS OR HARDWARE) RIGHT STEEL DOOR FRAME (NO GLASS OR HARDWARE) INSIDE ROTARY LATCH LEFT (FOR RIGHT DOOR) INSIDE ROTARY LATCH RIGHT (FOR LEFT DOOR) BALL STUD 4 WINDOW MOUNTING RUBBER (0") UPPER GLASS SLIDER LEFT UPPER GLASS SLIDER RIGHT LOWER ACRYLIC WINDOW LOW PROFILE HINGE SET (4 HINGES) OUTSIDE ROTARY DOOR LATCH HANDLE WITH KEY INSIDE GRAB HANDLE 5/8" SIDE BULB RUBBER (80") 5/8" BULB RUBBER (70") KEYS FOR OUTSIDE DOOR HANDLES

12 KUBOTA RTV 40 HARD SIDED REAR CAB KIT SERVICE PARTS LIST (PAGE OF ) p. of 3 QTY. DESCRIPTION REAR ROOF (COMES WITH FOAM HEADLINER AND EDGE TRIM) TRIM-LOK (0") REAR HEADER LEFT (COMES WITH WEATHERSEAL AND BALLSTUD) REAR HEADER RIGHT (COMES WITH WEATHERSEAL AND BALLSTUD) BALL STUD ARCH PSA RUBBER ( FEET) REAR MOUNT REAR FRAME LEFT (COMES WITH HINGE SLEEVES AND WEATHERSEAL) REAR FRAME RIGHT (COMES WITH HINGE SLEEVES AND WEATHERSEAL) LOW PROFILE HINGE SET (4 HINGES) REAR MOUNTING TAB LEFT REAR MOUNTING TAB RIGHT REAR ROLL BAR BRACKETS REAR RUBBER FILLER LEFT (COMES WITH VELCRO) REAR RUBBER FILLER RIGHT (COMES WITH VELCRO) GAS SPRINGS HARDWARE KIT (RTV 40 REAR CAB) INSTRUCTIONS (RTV 40 CAB) 5/8" SIDE BULB RUBBER (80") LEFT REAR FLOOR PLATE RIGHT REAR FLOOR PLATE EXPAND-A-FOAM (/4" X 3/4"-9" LONG)

13 KUBOTA RTV 40 HARD SIDED REAR CAB KIT SERVICE PARTS LIST (PAGE OF ) p. 3 of 3 QTY. DESCRIPTION LEFT STEEL DOOR FRAME (NO GLASS OR HARDWARE) RIGHT STEEL DOOR FRAME (NO GLASS OR HARDWARE) INSIDE ROTARY LATCH LEFT (FOR RIGHT DOOR) INSIDE ROTARY LATCH RIGHT (FOR LEFT DOOR) BALL STUD 4 WINDOW MOUNTING RUBBER (0") UPPER GLASS WINDOW LOWER ACRYLIC WINDOW LOW PROFILE HINGE SET (4 HINGES) OUTSIDE ROTARY DOOR LATCH HANDLE WITH KEY INSIDE GRAB HANDLE 5/8" SIDE BULB RUBBER (80") 5/8" BULB RUBBER (70") KEYS FOR OUTSIDE DOOR HANDLES