INSTALLATION & OWNER S MANUAL CAB INSTALLATION INSTRUCTIONS JOHN DEERE GATOR HPX and/or XUV HARD SIDED CAB ENCLOSURE (p/n: 1GTR44AS) SOFT SIDED CAB ENCLOSURE (p/n: 1GTR44SS) 111 HIGGINS STREET, WORCESTER, MA 01606 www.curtiscab.com The contents of this envelope are the property of the owner. Be sure to leave with the owner when installation is complete. 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. 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. CABS/BLADES/ SPREADERS/ACCESSORIES Rev. C, 1-5-2012 p. 1 of 10
DESIGN CONCEPT Curtis Cabs feature an assembly of parts designed for your vehicle which require adjustment and alignment of components to accommodate vehicle variations and provide proper weather protection. For accurate installation, proper operation, and years of satisfaction, please read and understand the installation instructions. From all of us at Curtis, we thank you for choosing our product. CAB INSTALLATION BEFORE YOU START HELPFUL REMINDERS: A. Leave all bolts loose for later adjustment unless otherwise specified. B. Read and understand all instructions before beginning. C. Plastic washers have been supplied to provide a weather seal around all button head exterior fasteners. 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 metal washers as required. D. Apply a clear silicone sealant to seal any minor gaps that may occur due to vehicle variances. e.g. lower rear panel to unitized frames. TOOLS REQUIRED: DRILL 3/16, 3/8, & 3/4 DRILL BITS 1-1/8 HOLE SAW 3/16 ALLEN WRENCH 1/2 & 3/4 DEEP SOCKETS 10 mm & 5/8 SOCKETS 3/4, 11/16, 1/2, 3/8 WRENCHES RATCHET NO. 1 & NO. 2 PHILLIPS HEAD SCREWDRIVER C CLAMP 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. 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. p. 2 of 10
NOTE: for 2011 and 2012 models, begin with pages 9 and 10, then resume with step 3.2B here on this page. 1. VEHICLE PREP 1.1 Reach under one of the front fenders and locate the mounting hole in the vehicle frame tube. Use dimple molded into underside of fender, above the hole in the frame, to drill a pilot hole through the fender. Drill hole out to 1-1/8 with hole saw. See Figure 1. Repeat for opposite side. 1.2 Locate dimples in plastic under seat filler and drill out to 3/4. Using 10 mm socket remove 2 bolts holding back of filler to vehicle and retain for later use. See Figure 2. Repeat for opposite side. FIG. 1 FIG. 2 2. LOWER REAR PANEL AND FILLERS 2.1 Lift the rear plastic seat filler and install the two rear panel mounts. See Figure 3. NOTE: Part descriptions can be found on pages 7 and 8. 2.2 Position the lower rear panel and install to mounts with 1/2 x 1 bolts. Re-install the bolts removed in Step 1.2. See Figure 4. FIG. 3 2.3 Position fuel fill and attach to lower rear panel with carriage bolts in holes closest to center of vehicle only. See Figure 5. 2.4 Position right hand filler and attach to lower rear panel with carriage bolts in holes closest to center of vehicle only. Clamp bottom of filler to back of vehicle floorboard. See Figure 6. FIG. 4 3. SIDE FRAMES 3.1 With assistance, remove doors from side frames (for easier handling) by unlatching and sliding up and off the hinge pins. 3.2 See Figure 7, next page. Position left side frame on vehicle and install as follows: A) Install front mounts to vehicle with 1/2 x 2 bolts. B) Install floorboards with two carriage bolts. C) Install to fuel fill with a 5/16 x 3/4 button head socket cap screw. D) Install to bottom rear panel flange and fuel fill with a carriage bolt. E) Note: Poke holes in the lower rear panel upholstery with Philips head screwdriver before installing bolts. Remember to use nylon washers on exterior fasteners, see helpful hints. Install to lower rear panel with three 5/16 x 1 button head socket cap screws. FIG. 5 3.3 Repeat for right side frame skipping step 3.2 C. FIG. 6 CABS/BLADES/ SPREADERS/ACCESSORIES p. 3 of 10
4. WINDSHIELD SUPPORT 4.1 See Figure 8. Install the windshield support to the left and right side frames by installing 5/16 x 3/4 button head socket cap screws in the front bolt holes only. The top bolt holes will be used during roof installation. Align the edges of the windshield support with the outside edges of the side frames and tighten bolts. 5. REAR SUPPORT FIG. 7 5.1 See Figure 9. Install the rear support to the left and right side frames by installing 5/16 x 1 button head socket cap screws in the rear bolt holes only (2 per side). The top bolt holes will be used during roof installation. Align the edges of the rear support with the outside edges of the side frames and tighten bolts. 6. WINDSHIELD 6.1 See Figure 10. With assistance, install the windshield to the windshield support. Use four 5/16 x 1 3/4 long flat head screws and two 3/4 thick plastic spacer blocks placed between the plastic hinge and the windshield support. Do not tighten hardware. 6.2 See Figure 11. Lift the windshield slightly while pushing closed. Fully close latches. Align sides of windshield with side frames and check seal at bottom of frame. Check seal against hood and reposition up or down to achieve optimum seal against the hood and bottom of the side frames. Align windshield and tighten hinges. HINGES ARE PLASTIC COMPONENTS. DO NOT OVER TIGHTEN. TORQUE TO 7 FT./LBS. MAX. DO NOT ATTEMPT TO ADJUST WINDSHIELD WITH GAS SPRINGS INSTALLED. FIG. 8 FIG. 9 6.3 Install the long gas springs to the windshield and side frames with the piston end attached to the frame. See Figure 12. FIG. 10 FIG. 11 FIG. 12 CABS/BLADES/ SPREADERS/ACCESSORIES p. 4 of 10
7. HARD SIDED REAR PANEL (Optional on soft sided cabs) 7.1 See Figure 13. Have an assistant help push the panel into the formed channel of the rear support. Install the five window clips from the hardware bag with the 10-32 x 3/4 hardware provided. Note: Poke holes through the upholstery in the lower rear panel to install the 10-32 bolts. Install flat washers and nuts on inside of cab. 7.2 See Figure 13. Position one of the right angle window clips from the hardware bag in the middle of a vertical side of the window. Make sure the clip is compressing the sealing rubber enough for a good seal from top to bottom. Install the clip with a self drilling screw. Repeat for opposite side. FIG. 13 8. ROOF 8.1 Use a Phillips head screwdriver or other pointed instrument to poke holes in the roof headliner at each of the bolt holes. Puncture the headliner from the inside to the outside. 8.2 Install roof using 5/16 x 1 button head socket cap screws. FIG. 14 9. SOFT SIDED REAR CURTAIN (Skip to next step on hard sided cabs) 9.1 See Figure 14. Install rear curtain by snapping to the top of the lower rear panel. (NOTE: adhesive backed Velcro should be applied to a clean, dry surface at room temperature.) Using the curtain as a guide, apply self adhesive hook Velcro along the rear of the left and right side frames and the inside flange of the rear support. Attach rear curtain to newly applied Velcro strips. 10. FINISHING TOUCHES 10.1 Tighten all hardware. Drill holes from right hand filler into vehicle floorboard using holes in filler as a guide. Attach filler with 5/16 x 3/4 button head socket cap screws and remove clamps. Install nut covers on all interior hardware. FIG. 15 10.2 See Figure 15. Install the dump assist rod by removing the black ball knob from the assembly and putting the rod through the hole in the tab located at the bottom of the left side frame. Re-install the black ball knob to the assembly. Install the remaining part of the assembly to the two slots located next to the cutout in the rear panel using 5/16 x 1 button head socket cap screws. NOTE: SKIP THIS STEP IF VEHICLE HAS HYDRAULIC BED LIFT KIT. 10.3 See Figure 16. Install seat belt receivers to brackets in the center of the lower rear panel using 7/16 x 1 bolts. CABS/BLADES/ SPREADERS/ACCESSORIES FIG. 16 p. 5 of 10
10.4 See Figure 17. Install seat belt retractors to left and right sides of lower rear panel using 7/16 x 1 bolts. 10.5 Install doors onto hinges. Work the doors back and forth until the hinges are completely seated. (NOTE: the hinges, inside latch, and striker bolt can also be adjusted for proper engagement.) 10.6 (For hard sided cabs only) See Figure18. Install the short gas spring to the frame and door with the piston end towards the door. 10.7 On soft sided doors, install the wire cable stops as shown in Figure 19. Use 5/16 hex head bolts, washers, and locknuts. Leave locknuts loose enough that cable ends can still rotate when door is open and closed. WARNING: DO NOT ATTEMPT TO INSTALL GAS SPRINGS ON SOFT SIDE DOORS. DAMAGE TO THE DOOR WILL RESULT. 10.8 Install the windshield wiper per instructions included with the wiring and hardware kits. Care and Maintenance Instructions 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 windows. Do not roll curtains in cold weather. The windows become stiff and may crack. Keep windows clean. FIG. 17 FIG. 18 FIG. 19 CUSTOMER SERVICE HOTLINE 1-800 343-7676 CABS/BLADES/ SPREADERS/ACCESSORIES p. 6 of 10
J.D. GATOR HPX and XUV HARD SIDED CAB (1GTR44AS) PARTS LIST ROOF 1 JDH-01 REFLECTORS WINDSHIELD 1 JDH-02 HINGES SEAM REAR WINDOW 1 JDH-03 SEAM (NARROW SIDE) 1/4" HEADLINER LOGO TRIM-LOK 4 SIDES RELEASE LATCHES GAS SHOCK MOUNTS 3/4" OFFSET (3/16" ACRYLIC) SIDE 1/4" GRIP 5/8" SIDE W/ 1/4" GRIP REAR SUPPORT 1 JDH-05 LOWER REAR PANEL WINDSHIELD 1 JDH-06 SUPPORT 1 JDH-04 1/4" HEADLINER 1/4" HEADLINER 1/2" WEATHER SEAL (INSIDE) HEYCO PLUGS DECALS (INSIDE) (SERIAL # & OPTIONS) (& W/S WARNING DECAL) TRIM-LOK DUMP ASSIST ROD 1 JDG-04 RH FILLER 1 JDH-09 REGULAR REAR PANEL MOUNTS HEYCO PLUG (3 1/2") 1/2" WEATHER SEAL (OUTSIDE) 2 JDH-10 1/2" WEATHER SEAL (INSIDE) FUEL FILL COVER 1 JDH-11 LATCH FUEL FILL REGULAR REGULAR 1 JDH-08 W/ 1/4" GRIP W/ 1/4" GRIP SIDE UNITIZED SIDE FRAMES - HARD CAB QTY. RIGHT LEFT 1 1 P/N JDHAS-09L JDHAS-09R HARD DOORS QTY. LEFT 1 RIGHT 1 BALL STUD P/N JDHAS-07L JDHAS-07R BALL STUD FOAM TAPE BALL STUD RIGHT STRIKER RUBBER FILLER LEFT FOAM TAPE 5/16" - 18 INSERT GRIT THIS SIDE PAPER ONLY SIDE WINDOW W/ 5 CLIPS IN HOUSE APPLICATIONS ROPS CERT. DECAL 1" HEYCO PLUG ROTARY LATCH W/ INTEGRATED GRAB HANDLE HINGE PIN LH,RH RIGHT OUTSIDE HANDLE 5/8" SIDE HINGE SLEEVES LEFT CABS/BLADES/SPREADERS/ACCESSORIES p. 7 of 10
J.D. GATOR HPX and XUV SOFT SIDED CAB (1GTR44SS) PARTS LIST ROOF 1 JDH-01 REFLECTORS WINDSHIELD 1 JDH-02 HINGES SEAM REAR CURTAIN 1 JDH-14 1/4" HEADLINER RELEASE MOUNTS LOGO TRIM-LOK 4 SIDES LATCHES GAS SHOCK 3/4" OFFSET SIDE 1/4" GRIP REAR SUPPORT 1 JDH-05 LOWER REAR PANEL 1 JDH-06A WINDSHIELD SUPPORT 1 JDH-04 1/4" HEADLINER 1/2" WEATHER SEAL (INSIDE) 1/4" HEADLINER SNAPS (OUTSIDE) DECALS (INSIDE) (SERIAL # & OPTIONS) (& W/S WARNING DECAL) TRIM-LOK HEYCO PLUGS DUMP ASSIST ROD 1 JDG-04 RH FILLER REGULAR HEYCO PLUG (3 1/2") 1 JDH-09 REAR PANEL MOUNTS 2 JDH-10 1/2" WEATHER SEAL (INSIDE) 1/2" WEATHER SEAL (OUTSIDE) FUEL FILL COVER FUEL FILL 1 JDH-11 LATCH REGULAR REGULAR 1 JDH-08 W/ 1/4" GRIP W/ 1/4" GRIP SIDE UNITIZED SIDE FRAMES - SOFT CAB QTY. RIGHT LEFT 1 1 P/N JDHSS-09L JDHSS-09R SOFT DOORS LEFT 1 1 RIGHT JDHSS-07L JDHSS-07R BALL STUD FOAM TAPE RIGHT STRIKER RUBBER FILLER GRIT PAPER FOAM TAPE IN HOUSE APPLICATIONS SIDE WINDOW W/ 5 CLIPS ROPS CERT. DECAL LEFT 5/16" - 18 INSERT THIS SIDE ONLY 1" HEYCO PLUG ROTARY LATCH HINGE PIN LH,RH RIGHT GRAB HANDLE OUTSIDE HANDLE 5/8" SIDE W/ 1/4" GRIP LEFT CABS/BLADES/SPREADERS/ACCESSORIES HINGE SLEEVES p. 8 of 10
THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED TO INSTALL THE HARD CAB (1GTR44AS (B)) OR THE SOFT CAB (1GTR44SS (B)) ON 2011 and 2012 GATOR HPX-XUV VEHICLES IMPORTANT NOTE: The cab will not fit with the following options: Bench Seat (2011) Heavy Duty Front fender guards (BM22987) (these can be removed) p. 9 of 10
PARTS INCLUDED IN THIS KIT: (2) 1/2-13 x 2-1/4 Grade 8 Hex Head Bolts (1) Butt Splice connector (22-18 ga.) 1. VEHICLE PREP (Replaces Vehicle prep from page 3 of 10. 1.1 Per fig. 1.1, disconnect the wire to the driver s side seat belt receiver. Cut the connector off of the vehicle side of the harness and attach wires together with butt splice connector provided. 1.2 Remove Operator Protective Structure (OPS) from vehicle as an assembly. Retain hardware (one nut and one bolt per side) from rear mounting points. Ref. fig. 1.2. Cut wires and splice together. FIG. 1.1 1.3 Remove and discard four large washers (two per side) from on top of and inside of the front shock towers where the OPS was bolted to. Ref. figure 1.2. 1.4 Per figure 1.4, cut out the raised portion of the plastic underseat filler with a utility knife or cut-off wheel to allow the rear panel to fit properly. 2. LOWER REAR PANEL MOUNTING (Replaces Steps 2.1 and 2.2 on page 3 of 10) 2.1 Install the lower rear panel with the rear OPS hardware retained in Step 1.2 above. NOTE; Do not use the rear panel mounts or bolts for pre 2011 model vehicles. 3. SIDE FRAMES (ALL MODEL YEARS) 3.1 Use the enclosed 2-1/4 long hex head bolts in place of the 2 long bolts to install the front mounts. Reference step 3.2A on page 3 of 10. Note: These longer bolts can be used on all model years. Cut raised portion off along white lines Keep this hardware FIG. 1.2 Continue with step 3.2B on page 3 of 10. FIG. 1.4 p. 10 of 10