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Curtis 1JDZ994RPR, Installation & Owner'S Manual

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Curtis 1JDZ994RPR Installation & Owner'S Manual Download Page 6

CAB INSTALLATION

 

 6 of 34

 

Fig. 1.13 (Remove Footrests & Brake Pedal Bolt)

 

STEP 1: (VEHICLE PREP CONT

’

D.)

 

 

1.11

 

Install Bracket and Spacer assembly from Step 

1.10, on the outside of the right R.O.P.S. as well 

as the sleeve and retainer with new M8X1.25 Nut 

per fig 1.11. Leave hardware loose.

 

 

 

Hardware Used

   

 

Qty

 

 

M8X1.25 Lock Nut

 

1

 

 

 

Tools required

 

 

13mm socket and wrench

 

 

1.12

 

Re

-

install right fender removed from step 1.4.  At 

this time, leave hardware installed on step 1.11 

loose.  See Figure 1.12.

 

 

 

Tools required

 

 

T25 Torx Bit

 

 

10mm socket or wrench

 

 

13mm socket and wrench

 

 

1.13

 

Remove and set aside footrests (this includes 

bolts, fender washers, and nuts).  Next, remove 

M10 Carriage bolt and nut found below brake 

pedal.  See Fig. 1.13.

 

 

 

 

Tools required

 

 

13mm socket and wrench

 

 

15mm socket 

 

 

1.14

 

Remove (2) M10 lock nuts and washers from the 

left side of the vehicle

’

s caster arm per Fig. 1.14a.  

Install front mount using the recently removed 

M10 lock nut. Leave mounts loose per Fig. 1.14b. 

Repeat on right side of vehicle.

 

 

 

 

Tools required

 

 

18mm wrench

 

 

19mm socket 

 

 

Fig. 1.11 (Install Bracket & Spacer)

 

Curtis Bracket and 

Spacer

 

Retainer

 

& Sleeve

 

Right Fender

 

 Set Aside 

Footrests

 

Remove Bolt 

and Nut

 

Fig. 1.14a (Remove M12 Washers and Nuts)

 

Remove Washers 

and Nuts

 

Fig. 1.14b (Install Front Mount, Left Side)

 

Front Mount

 

Fig. 1.12 (Re

-

Install Right Fender)

 

Summary of Contents for 1JDZ994RPR

Page 1: ... Curtis products However failure to do so will not diminish right to warranty Curtis Industries does not sell or share your information with anyone else Curtis strives to continuously improve our products technical documentation etc Therefore the installation manual for this product may have been updated after your product was packaged The latest revision of the installation manual can always be f...

Page 2: ...ABLE OF CONTENTS WARNINGS TIPS REQUIRED TOOLS 3 VEHICLE PREP 4 12 CAB INSTALLATION 13 24 CAB FEATURES OPERATION 24 CARE AND MAINTENANCE 25 TROUBLESHOOTING 25 SERVICE PARTS 26 32 BOLT TORQUE SPECIFICATIONS 33 34 ...

Page 3: ... are listed in product add additional weight to the base vehicle All Curtis Cabs blades and general accessories ADDED WEIGHT brochures Deduct the accessory s total weight from the vehicle s rated capacity and never exceed the vehicle s rated capacity including Exposure to Carbon Monoxide can Cause illness serious injury or death Never operate vehicle if suspicious of Carbon Monox ide Inspect exhau...

Page 4: ...at marked edge Apply touch up paint to the cut edges Tools required Cut Off Wheel or Jigsaw 1 6 Remove right fender Remove sleeve and retainer and set aside for later re installation Remove bracket and M8X1 25 Lock Nut See Figures 1 4 1 6 Remove Torx fasteners around instrument panel Remove two fasteners securing the bottom of the fender Tools required T25 Torx Bit 10mm socket or wrench 13mm socke...

Page 5: ... of air cleaner and later install remove Cover found over the radiator CAUTION DO NOT RUN THE VEHICLE UNTILL STEP 2 38 Tools required 13mm socket or wrench 5 16 socket or wrench 1 9 Remove cover from 2 pin connector found on right side of vehicle Next cut wire tie and ensure connector is accessible See Figure 1 9 Tools required Angle Wire Cutters 1 10 Install spacer on outside of compressor mounti...

Page 6: ...1 13 Remove and set aside footrests this includes bolts fender washers and nuts Next remove M10 Carriage bolt and nut found below brake pedal See Fig 1 13 Tools required 13mm socket and wrench 15mm socket 1 14 Remove 2 M10 lock nuts and washers from the left side of the vehicle s caster arm per Fig 1 14a Install front mount using the recently removed M10 lock nut Leave mounts loose per Fig 1 14b R...

Page 7: ...side of the ballast box Fully tighten the front bolts and then the top bolts See Figures 1 15a and 1 15b Hardware Used Qty 1 2 13X1 1 4 Carriage Bolt 4 1 2 13 Flange Lock Nut 4 Tools required 3 4 Ratchet Wrench 3 4 Socket or Wrench 1 16 Place the footrest lip floormat on the vehicle Place floormat material found on the lower right and left into the sides of the vehicle frame Install 5 16 hardware ...

Page 8: ... remove the prop rod from the seat frame and set the seat back down See Figure 1 19 Tools required Needle Nose Pliers 1 20 Remove and save seat frame hinge bolts and nuts per Fig 1 20 Remove seat from vehicle Tools required 13mm socket and wrench Fig 1 19 Disconnect Seat Connector Prop Rod Disconnect Seat Harness Fig 1 18 Tilt Seat Forward Seat Latch Bar Remove and Set Aside Fig 1 20 Remove Front ...

Page 9: ...e the locating pin is on the front hole as shown in Figure 1 22 Hardware Used Qty 1 4 20X3 4 Flange Hex Screw 2 1 4 20 Flange Lock Nut 2 Tools required 3 8 socket 7 16 wrench 1 23 Install 13 pieces of Velcro as shown in Figure 1 23 Tools required Scissors Fig 1 21 Install Velcro to Arm Restrictors Apply Velcro Fig 1 22 Install Arm Restrictors Right 1 4 20 Hardware Here Fig 1 23 Install Velcro Plac...

Page 10: ...ts back on Fully tighten left side hardware first followed by the right side See Figures 1 24 and 1 26 Tools required 13mm deep socket 1 27 Install supplied release lever by pushing through the underside of seat pans rubber filler Placing the hole of the lever onto the seat frame s latch bar mounting bolt and the fork of the lever onto the latch bar Install lock nut onto the mounting bolt See Figu...

Page 11: ...of the seat and re install the harness clip to the seat frame Lower the seat back down See Figure 1 29 Tools required Needle Nose Pliers 1 30 Install left and right R O P S brackets onto the vehicle s R O P S See Figures 1 30a and 1 30b Hardware Used Qty 5 8 11X1 1 4 Hex Flange Bolt 4 5 8 11 Flange Hex Lock Nut 4 Tools required 15 16 wrench and socket Fig 1 30b Install R O P S bracket right Fig 1 ...

Page 12: ... to 19 ft lbs 26 N M See Figure 1 32 Note washers are required on the top holes so bolt do not bottom out in the engine Tip Start bottom back side screw before placing the compressor mount on the engine Hardware Used Qty M8X1 25X25 flange hex screw 2 M8X1 25X40 hex screw 2 M8 washer 2 Tools required 13mm wrench and socket 1 33 Clean the vehicle frame rails on either side of the floorboard Apply P ...

Page 13: ...shipping bracket located inside the cab as well as the 4 bolts holding the floorboards to the front shipping brackets See Figures 2 4a b and c Tools required 1 2 wrench or socket 2 5 With assistance lift the cabin and position over the vehicle Be sure to support the A C compressor so that it never hangs from the hoses 2 6 Lower the cab slowly onto the vehicle being careful to not scratch the fende...

Page 14: ...Torque to 110 ft lbs 150 Nm See Figure 2 9 Tools required 18mm wrench 18mm socket Torque Wrench 2 10 Install one of the supplied brushes to the underside of the right cab floorboard Next install a second brush along with the supplied floorboard insert on the inboard side of the deck lift lever See Figure 2 10 Hardware Used Qty 8 32 X5 8 Pan Head Screw 6 8 32 Flange Lock Nut 6 Tools required 11 32 ...

Page 15: ...tension tester in the center and perpendicular to the belt between the 2 pulleys and next to the straight edge Push the tensioner towards the theoretical center making sure that a deflection force of 3 1 lbs gets 2 inches of belt deflection at the center of the belt See Figures 2 12 and 2 13 Tools required 9 16 wrench or socket 5 16 allen wrench Belt tensioner tester Straight edge Fig 2 11a Instal...

Page 16: ... Install left filler onto the cab from the inside using provided hardware per Figures 2 16a and b Hardware Used Qty 5 16 18X3 4 Flange Hex Screw 5 Tools required 1 2 wrench and socket 2 17 Apply P S A Velcro on the left fender up the left filler per Figure 2 17 Continue the Velcro on the lower edge of the window Tools required Scissors Fig 2 15 Install Right Filler Into Inserts Into Lock Nuts Fig ...

Page 17: ...ower corner of rear panel vinyl onto installed Velcro Tools required Scissors 2 20 Once the rear panel s vinyl filler is fully installed onto the mating Velcro install hardware through the Vinyl into the 2 fillers See Figures 2 20a and b Do not over tighten or vinyl will be damaged Hardware Used Qty 1 4 20X3 4 PH Truss Head Screw 2 1 4 20 Flange Lock Nut 2 Tools required 3 Phillips Head Screwdrive...

Page 18: ...nto drive handles that will secure the top edge of the boot and mark the top edge at the appropriate location See Figure 2 21 Slide the boot down the handle and apply Velcro around the handle below the mark Secure the top of the boot to the Velcro Tools required Scissors Marker 2 22 Repeat installation for the left boot Slide the hole in the left boot over the head of the adjustment bolt as shown ...

Page 19: ...et 2 25 Re install reconfigured air intake per Figure 2 25 Make sure air intake is pointed vertically At that point re install clips into the air cleaner s mount removed on step 2 23 Fully tighten down hose clamps found on the engine and air cleaner Make sure the extra part of the hose clamp located on engine is pointing down away from the fuel lines If radiator cover was removed on step 1 8 re in...

Page 20: ...or socket Angle Wire Cutters 2 27 Run drain hose for AC Unit down in front of the alternator and out the bottom of the vehicle Keep hose away from moving components and hot engine parts See Figures 2 27a b and c for routing recommendations Use provided Wire Ties as needed Hardware Used Qty 11 Heavy Duty Wire Ties As Needed Tools required Angle Wire Cutters Fig 2 26 Install Hose Clamps on R O P S B...

Page 21: ...ness per Figure 2 29 Use supplied Wire Ties as needed Hardware Used Qty 11 Heavy Duty Wire Ties As Needed Tools required Angle Wire Cutters 2 30 Run the harness fuse holder side to the Positive Terminal on the Vehicle s battery per Figure 2 30a Next run the black wire ring terminal to the disconnected battery wire and install onto the ground lug Reconnect lug onto the battery per Figure 2 30b Hard...

Page 22: ...wn on Figure 2 32a Apply touch up paint to drilled holes Hardware Used Qty 5 16 18X3 4 Flange Hex Screw 1 Use hardware set aside on step 1 4 Tools required T25 Torx Bit 1 2 wrench or socket Center Drill 9 32 Drill Bit Drill 2 33 Per Figure 2 33 install hardware through shroud into grille Hardware Used Qty 1 4 20X5 8 Flange Hex Screw 3 1 4 20 Flange Lock Nut 3 Tools required 3 8 wrench or socket 7 ...

Page 23: ...between the left side of the cab and fender On the right side at the corner of the side frame and rear filler as well as near the floorboard Make sure to apply adhesive side onto the fenders of the vehicle Per Figures 2 35a and b Tools required Scissors Narrow Plastic Putty Knife 2 36 Per Figure 2 36a re install the left and right doors Next install gas shocks onto the doors and side frames as sho...

Page 24: ...URES OPERATION AIR CONDITIONING OPERATION See Figure 2 38 above Turn the 4 position ventilation switch to activate the blower This can be used as just a blower with the A C compressor turned off Rotate the A C switch to the desired temperature setting to turn the compressor on off In order for the A C compressor to function the vehicle throttle must be set at full speed The blower must be turned o...

Page 25: ...ris daily This product is designed with the use of R134a as a refrigerant Never substitute other refrigerants use of any other refrigerant will void warranty Charge unit with 2 3 lbs of R134a refrigerant Apply vacuum for a minimum of 30 minutes prior to charging the air conditioner with R134a Do not vent refrigerant to the atmosphere If the unit has to be discharged for any reason recover the refr...

Page 26: ...T FB RIGHT P N 8SV SM 02455 R BACKING PLATE BALLAST BOX P N 8SV SM 02478 FLOOR MAT FOOTREST LIP P N 8SV 9FR 00090 BALLAST BOX W WEIGHTS P N 8SV 113 00326 ARM RESTRICTOR BRKT ASS Y L P N 8SV 113 00320 L ARM RESTRICTOR BRKT ASS Y R P N 8SV 113 00320 R FLOOR MAT FOOTREST P N 8SV 9FR 00089 CLIPPED WASHER 3 8 X 1 1 4 P N 8SV SM 02548 MNT BRACKET ASS Y COMPRESSOR P N 8SV 113 00316 ...

Page 27: ...N 8SV 110 00118 R WELDMENT COMP MOUNT P N 8SV WA 00554 WELDMENT COMP TENSIONER P N 8SV WA 00555 GUARD BELT P N 8SV SM 02435 COMPRESSOR SECT A BELT DRIVEN P N 9SV 9AC 00048 V BELT P N 9SV 9BLT 16 REAR FILLER LEFT P N 8SV 111 00046 L FLEX BRUSH 1 6 X 012 X 9 PAIR P N 8SV 9SL 00021 FLOORBOARD FILLER P N 8SV SM 02458 SEAT PAN ASSEMBLY P N 8SV 113 00314 ...

Page 28: ...RELOCATION BRACKET P N 8SV SM 02318 COVER ASSEMBLY A C BLACK P N 8SV 303 00013 BP CONDENSER PLENUM FAN BLACK P N 8SV 304 00027 BP CONDENSER SUPPORT ASSEMBLY BLACK P N 8SV 304 00029 BP COVER ASSY SIDE COMPRESSOR P N 8SV 113 00315 WIRE HARNESS A C P N 9SV WH 00147 REAR FILLER RIGHT P N 8SV 111 00046 R A C UNIT REAR MOUNTED BLACK P N 8SV 301 00006 BP ...

Page 29: ... HOSE 6 DRIER TO EVAP P N 8SV 305 00023 HOSE 8 COMP TO COND P N 8SV 305 00022 HOSE 10 EVAP TO COMP P N 8SV 305 00024 HOSE 6 COND TO DRYER P N 8SV 305 00025 KNOB P N 9SV OHC 27 LOUVERED PLUG WITH FILTER P N 9SV 9DP25 EVAPORATOR P N 9SV 9AC 00046 AIR FILTER P N 9SV 9HR 00032 DIVERTER FLAP ASSEMBLY A C P N 8SV 113 00258 BP REAR MOUNT FRAME ASSEMBLY P N 8SV 113 00323 ...

Page 30: ...LEG RIGHT W HARDWARE P N 8SV 108 00030 R REAR LEFT FILLER WINDOW W HARWARE RUBBER P N 8SV P 00168 ROOF ASSEMBLY P N 8SV 101 00067 WINDSHIELD ASSEMBLY P N 8SV 102 00041 SIDE FRAME ASSEMBLY RIGHT P N 8SV 109 00028 R SIDE FRAME ASSEMBLY LEFT P N 8SV 109 00028 L DOOR ASSEMBLY RIGHT P N 8SV 107 00060 R DOOR ASSEMBLY LEFT P N 8SV 107 00060 L ...

Page 31: ...INDOW W HARWARE RUBBER P N 8SV P 00169 WINDSHIELD SUPPORT LOWER P N 8SV SM 02454 WELDMENT LOWER BRACE RIGHT P N 8SV WA 00574 R DOOR SKIN LEFT W HARDWARE P N 9SV P 00167 L DOOR SKIN RIGHT W HARDWARE P N 9SV P 00167 R A PILLAR CLAMP UPPER RIGHT P N 8SV SM 02361 R A PILLAR CLAMP UPPER LEFT P N 8SV SM 02361 L ...

Page 32: ...EVES 2L 2R 9SV DP10 DOME PLUG 375 HOLE BAG OF 10 9SV DP16 DOME PLUG 750 HOLE BAG OF 4 9SV DP04 DOME PLUG 1 125 HOLE BAG OF 15 9SV 9OR 01 O RINGS INCL 1 OF EA 301 ID 426 ID 551 ID 9SV GS02A BALL STUD 10MM BAG OF 10 9SV DL06S INTERIOR DOOR LATCH W COVER 1L 1R 9SV 9AC 00001 CONDENSER 9SV 85 01 0022 RELAY 12V 20 40A SPDT MINI ISO 9SV 9AC 00003 DRIER RECEIVER 9SV 9AC 00005 PRESSURE SWITCH 2 28KG CM2 9S...

Page 33: ...9 56 66 4 75 9 1 5 52 64 70 5 86 7 8 8 81 93 109 8 126 90 106 122 143 6 10 9 96 109 130 1 147 7 107 124 145 168 M16 5 6 2 0 67 77 90 8 104 3 1 5 69 83 93 6 112 5 8 8 116 130 157 2 176 2 120 138 162 6 187 10 9 129 145 174 8 196 5 140 158 189 7 214 1 M18 5 6 2 0 88 100 119 2 136 1 5 100 117 136 158 5 8 8 150 168 203 3 227 6 177 199 239 8 269 6 10 9 175 194 237 1 262 9 202 231 273 7 313 M20 5 6 2 5 1...

Page 34: ...ic nylon or rubber washers threaded inserts etc If more than one application below applies use the lower torque value FASTENER SIZE FASTENER TYPE WASHER MATERIAL APPLICATION TORQUE INCH POUNDS 5 10 Machine Screws in Nylon P Clamps 20 10 Machine Screws Strobe Light plastic base 35 M5 Set Screws Wiper Arm 20 1 4 Cap Nut Windshield Wiper 20 1 4 Bolts Tubing 5 8 to 3 4 wide 132 1 4 Bolts Rubber 60 1 4...

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