INSTALLATION & OWNER S MANUAL INSTALLATION INSTRUCTIONS KAWASAKI MULE 4000 TRANS 4 FRONT CAB KIT (p/n: KAF40T-001WA and p/n: KAF40T-001BA) NOTE: Hard sided doors, soft sided doors, and rear cab are sold separately. This manual is the property of the owner. Be sure to leave with the owner when installation is complete. Front and rear cab shown. Rev. C p. 1 of 7 p/n: IM-KAF40T-001
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 vehicles 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. TOOLS REQUIRED: Set of standard and metric sockets Set of standard and metric open end wrenches Drill 3/8" drill bit. Bar Clamp One Phillips Head Screwdriver One 3/8 Drive Ratchet One 3/16 Allen Wrench Utility Knife Tape Measure p. 2 of 7
VEHICLE PREP: NOTE: HEAVY DUTY FRONT SUSPENSION SPRINGS (P/N 92144-1919) ARE REQUIRED WHEN IN- STALLING THIS CAB. INFLATE FRONT TIRES TO 1.0 kg/cm2 or 14.2 PSI AND MAINTAIN AT THIS PRES- SURE. A. (Figure 1) Remove two bars from front cab bar to rear cab bar. STEP 1 REAR MOUNT A. (Figure 1) Install the rear mount by placing it between the front and rear cab bars and reinstalling the bars removed in vehicle prep step A. NOTE: Do not tighten bolts. STEP 2 SIDE FRAME INSTALLATION A. Remove the protective film from the side frame windows before installing to the vehicle. B. (Figure 2) Install supplied pieces of expand a foam to front cowl as shown. NOTE: Adhesive seal should be applied to a clean, dry surface at room temperature. VP Step A Remove both bars Figure 1 Step 1A Install rear mount & reinstall both bars. C. (Figure 3, 4, & 5) With assistance, install the left and right side frames by resting the frame floorboard on the vehicle floor. Align the frame front to back with the Phillips head screw shown in fig 4. Rotate the top of the frame up, while lifting up on the front so as not to drag the rubber seal against the black plastic front fenders. Place the top rear corner under and behind the rear mount installed in step 1. Temporarily install bolts or screwdrivers through the top of the rear mount into the left and right side frame tabs to help hold the side frame in place. D. (Figure 6 next page) Install the front mounts to the left and right side frames with 5/16" x 3/4" bolts, and washers, provided. Figure 2 Figure 3 Figure 4 Figure 5 p. 3 of 7
STEP 3 FUEL FILLER INSTALLATION A. (Figure 7) Tip the front seat bottom forward, remove the cap from the fuel tank, and install the fuel filler to the right side frame with four 10-32 machine screws provided. Install fuel filler gasket by pressing over neck of fuel tank. Re-install fuel tank cap. STEP 4: WINDSHIELD & WINDSHIELD SUPPORT A. (Figure 8) Bolt the windshield support to the left and right side frames with 5/16 x 3/4 carriage bolts in the lower holes only (1 per side). Install with six slots at top of support. Align outer edges of windshield support with edges of side frames and tighten carriage bolts. B. (Figure 9). With assistance, lift the windshield onto the front of the side frames and bolt hinges to windshield support with hinge spacers, 5/16 X 1-3/4 flat head bolts, washers, and locknuts. Align sides of windshield with side frames and while holding in position close latches against the back side of the windshield strikers. NOTE: If the windshield does not seal to the side frames near the bottom, it is hitting the hood too hard, undo the latches and adjust the windshield up. If it does not seal against the hood, adjust the windshield down. Tighten bolts to 7 ft-lbs. CAUTION: Do not over torque fasteners through plastic hinges. Figure 6 Gasket Figure 7 C. Install the supplied gas springs to the windshield and side frames with the piston pointing down. Push gas spring ends over ball studs and snap covers into place to secure. STEP 5 SEAT FILLER A. Install seat filler to rear of side frames with four 5-16-18 X 3/4 button head bolts, washers, small nylon washers, washers and nylon lock nuts as shown. Note: The seat filler goes in front of flanges on the side frames. (Figure 10) IMPORTANT NOTE: IF INSTALLING THE REAR CAB, PROCEED TO REAR CAB INSTRUCTIONS. IF INSTALLING ONLY THE FRONT CAB, PRO- CEED TO NEXT STEP. Figure 8 Figure 9 Figure 10 p. 4 of 7
STEP 6 ROOF A. Use a Phillips head screw driver to punch a hole through the headliner at nine bolt hole locations. Punch holes from the inside out to avoid having the headliner pull away from its glued surface. B. (FIGURE 11) Remove bolts or screwdrivers temporarily installed in rear mount in Step 2 C.With assistance, position the roof so that the row of six holes lines up with the row of six holes in the windshield support. Install 3/4 long carriage bolts, with large nylon washers under the bolt heads, in all roof holes except the four corners. The corner holes will require 1 long carriage bolts and large nylon washers. Install steel washers and locknuts on the inside of the cab. Figure 11 STEP 7 POSITION AND TIGHTEN CAB A. Check that the rear mount is centered left to right and tighten the bolts on the R.O.P.S. installed in step 1. B. (Figure 12) Check that the tab at the top rear of the left side frame is centered (front to back) on the slot in the rear mount. Push the top rear corner in until the side frame contacts the left edge of the rear mount and tighten the bolt. Repeat for right side. C. (Figure 13) Double check that the notch in the rear vertical piece is centered, front to back, over the Phillips head screw in the floorboard and tighten the front mount. D. Tighten all remaining cab hardware. Install the supplied nut covers. E. (Figure 14) Align edge of side frame floorboard with edge of plastic trim on vehicle floor. Drill 3/8" holes through vehicle floor using the slotted holes in the side frame as a guide. Attach w/ 3/4" long carriage bolts with washers and locknuts under the vehicle. F. (Figure 15) If a rear cab was not installed, then install a 5/16 X 3/4 button head bolt with flat washers, nylon washers and locknut in each of the rear corners of the rear mount. Figure 12 Figure 13 Align Figure 14 Figure 15 p. 5 of 7
STEP 8 REAR CURTAIN A. (Figure 16) Install rear curtain by snapping into place and applying Velcro along seat. NOTE: Adhesive backed Velcro should be applied to a clean, dry surface at room temperature. The rear curtain can be used for the front and the rear cab. If using for the rear cab the 2 rectangular flaps should be folded down to make room for the air intakes on the back of the vehicle cab bar. STEP 9 FINISHING TOUCHES A. (Figure 17) Install left and right fillers by snapping into place and applying adhesive backed Velcro (see note in Step 8) to seat filler, seat base, and floor Figure 16 B. (Figure 18) Install left and right seat back bar fillers. C. (Figure 19) Install rubber seals to edges of hood as shown. CARE AND MAINTENANCE A. Check and tighten hardware after 40 hours of operations. Periodically inspect and tighten hardware for the remainder of the unit s life. B. Wash the painted surfaces of the unit with commercial automotive cleaning products. Figure 17 C. Clean windows with glass cleaner. D. Vinyl components should be washed with a mild solution of warm soapy water. E. Clear vinyl can be easily scratched. Be careful cleaning frost or snow from windows. Do not roll curtains in cold weather. The windows become stiff and may crack. Keep windows clean. Figure 18 Figure 19 p. 6 of 7
KAWASAKI MULE 4000 TRANS 4 FRONT CAB PARTS LIST p/n KAF40T-001BA (BLACK), KAF40T-001WA (WHITE) HEADLINER OFF WHITE OR ROOF 1 KAT4-01 TRIM-LOK ( 9PR01, 3 SIDES) REFLECTORS RELEASE LATCHES & SPACERS WINDSHIELD HINGES w/ NYLON SPACERS 1 KAM4T4-02 (2) HEYCO PLUGS SEAM BULB GAS SHOCK MOUNTS 3/4" SIDE BULB W/ 1/4" GRIP (9PR38) TRIM LOCK 9PRO1 5/8" OFFSET SIDE BULB 3/4" SIDE BULB W/ 1/4" GRIP 9PR38 SEAL 9PR27 9PR20 1" ROUND BULB 1" SIDE BULB WINDSHIELD SUPPORT SERIAL # DECAL, OPTIONS DECAL, AND W/S WARNING DECAL (INSIDE) UPPER MOUNTS RUBBER COATED 1 KAM4T4-03 HEYCO PLUGS 2 KAFT4-04 REAR MOUNT SEAT FILLER SNAPS (INSIDE) 1 KAM4T4-04 TRIM-LOK 1 KAM4T4-06 1/4" X 3/4" EXPAND A FOAM (9PR30, INSIDE) SEAL (OUTSIDE) 1" ROUND BULB (9PR19) 9PR30 9PR19 1/4" x 3/4" EXPAND-A-FOAM 9PR16 7/16" SIDE BULB W/ 1/4" GRIP 9PR29 UNITIZED SIDE FRAMES RIGHT BALL STUD LATCH PIN LEFT RIGHT 1 KAM4T4-09L 1 KAM4T4-09R TRIM-LOK SNAPS 7 PER LATCH SIDE PIN (OUTSIDE) 1" ROUND BULB LEFT HINGE SLEEVES (HS-P1) 1" ROUND SIDE BULB (9PR16) REAR CURTAIN SEAL (OUTSIDE) 1 KAT4-07 5/8" OFFSET SIDE BULB 3/8" HEYCO PLUGS 2 THIS SIDE ONLY CAB FILLERS FUEL FILLER LEFT RIGHT LEFT RIGHT 1 KAT4-08L 1 KAT4-08R (RUBBER) 1 KAM4T4-13 4 SIDES ADDITIONAL SERVICE PARTS QTY/CAB p/n DESCRIPTION 1 9GL-34x56 2 9PH007 & 9BLK01 1 9WL02L 1 9WL02R 2 9WL02E 4 HS-P1 1 KAT4-10 1 KAT4-11R MOLDED WINDSHIELD ASSEMBLY POP OUT WINDSHIELD HINGE KIT-SINGLE POP OUT WINDSHIELD RELEASE LATCH KIT-LH POP OUT WINDSHIELD RELEASE LATCH KIT-RH POP OUT WINDSHIELD LATCH EXTENSIONS UNITIZED FRAME HINGE SLEEVES FUEL FILLER GASKET SEAT BAR FILLER (RH) ADDITIONAL SERVICE PARTS QTY/CAB p/n DESCRIPTION 1 KAM4T4HWK-01 HARDWARE FASTENER KIT 2 9GS09 WINDSHIELD GAS SHOCKS 2 PG-4000SF FRONT SIDE WINDOWS 1 KAT4-11L SEAT BAR FILLER (LH) p. 7 of 7