Polaris Cab User's Manual
Contents
1. lt gt Z lt Y aa LU Z O o Z e lt l lt O lt ARIS VIII FREEDOM Gp POL POLARIS FREEDOM CAB INSTALLATION INSTRUCTIONS FOR THE POLARIS RANGER p n 2876196 067 IMPORTANT THIS ACCESSORY WEIGHS 340 POUNDS PLEASE ADJUST THE VEHICLE PAYLOAD ACCORDINGLY The contents of this manual are the property of the owner Be sure to leave with the owner when installation is complete Multiple U S and Foreign Patents Pending Rev K p 2 of 11 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 GENERAL INFORMATION Helpful Reminders Refer to parts diagram to help identify parts during assembly process Leave all bolts loose for later adjustment unless otherwise specified Read and understand all instructions before beginning Apply a clear silicone sealant to seal any minor gaps that may occur due to vehicle variations B OD Curtis Customer Service Hotline 1 800 343 7676 ext 1 ADDED i ane WEIGHT Cause illness serious injury or death Never operate vehicle if suspicious of Curtis Cabs2. 5 8 REGULAR BULB CFOR DOOR BALL STUD CONE SIDE FRAME THREAD STYLE RUBBER BLOCK 5 16 18 THREADED INSERT 2 PER SIDE FRAME T q I ARCH PSA BETWEEN J THREADED INSERTS RS o RUBBER FLAP Z NOT SHOWN RIVET SQ ED ON INSIDE OF N PLASTIC PANEL LATCHES 3 DO00R gt NOTE CENTER LATCH IS SINGLE CLICK ONLY x STRIKER BOLT ASS Y W O FINGER GUARD ONLY THE FRONT ONE ON EACH SIDE REQUIRES A FINGER GUARD C2 STRIKER BOLTS GAS g es PER SIDE SOON A x DECAL DO NOT SLAM OUTSIDE DOOR LATCH HANDLE W HEX HEAD SELF DRILLING SCREW CONE DOOR HEX HEAD SELF DRILLING SCREWS 4 PER REAR PLASTIC PANEL 3 4 SIDE BULB RUBBER 5 8 REGULAR BULB CFOR PLASTIC PANEL DECAL PUSH HERE GRIT PAPER BALL STUDS 4 SIDE FRAME RIVET STYLE RUBBER BUMPERS 2 BUMPERS STACKED PER DOOR NOTE 5 PLASTIC PANELS ARE PART UF EACH AS Y RAVEN TEXTURE BLACK PAINT DN ALL ITEMS ae EXCEPT LATCH ASS Y TYPES 1 ROUND BULB Sr pne BULE CP7N PF O4L amp RD AND FRONT MOUNT P N PF 0953 5 8 REG BULB ARCH PSA 3 4 SIDE BULB lt IN HOUSE APPLICATIONS 9PRO9
3. tom at location b use a small piece and at location c use a long piece straight up to rear window Repeat b and c for opposite side Attach the vinyl filler to the newly installed hook velcro on the vehicle 8 ROOF amp CONSOLE ASSEMBLY 8 1 Temporarily remove and save 2 fender washers and 2 locknuts where indicated in fig 8 6 1 on the next page With assistance place the roof console assembly in place oriented so the controls are towards the front of the vehicle See figure 8 1 8 2 If installing optional work lights feed the two wires through the hole in the windshield support where the Heyco plugs were located See figure 8 2 If not install ing optional work lights push the wiring back into the holes of the overhead console Rev K p 6 of 11 Y flat portion towards the ground k Ref work light wires and S bracket mounting holes a SR a ee ee RS Uu Fig 8 2 View from driver s side 8 ROOF amp CONSOLE ASS Y cont 8 3 A driver s side wiper is provided Place the driver s side wiper wire below the front tubular frame as shown in fig 8 3 If installing an optional passenger s side wiper place that wire below the front tubular frame as well If not installing a passenger s side wiper push the passenger s side wiring up into the console to hide it Caution If installing a second wiper double check that both wipers have a maximum 85 degree
4. sweep to avoid interference The motor should have a sticker on it indi cating the degree of sweep 8 4 If not installing optional work lights install four 1 4 20 x 3 4 long Truss head Phillips head bolts into factory installed threaded inserts in the front of the over head console Leave bolts loose Note two per side where the work light mounting bracket would be mounted See figure 8 2 on the previous page 8 5 OPTIONAL If installing the optional work lights kit p n 2876382 discard the two brackets with the 3 hole pattern on the light and use the supplied bracket with the 4 hole pattern See fig 8 5 Install work light brackets oriented as shown in figure 8 5 1 Use four 1 4 20 x 3 4 long Truss head Phillips head bolts into fac tory installed threaded inserts in the front of the overhead console Leave bolts loose 8 6 Install three 1 4 20 x 3 4 long Truss head Phillips head bolts through the three rear P clamps and into the threaded inserts in the rear of the overhead console See fig 8 6 Tighten the previously installed four bolts 2 per side holding the front of the overhead console to the windshield support Per fig 8 6 1 below re install 2 fender washers and 2 locknuts temporarily removed In step 8 1 to secure the middle front of the roof overhead console assembly to the metal windshield support Do not overtighten 8 7 OPTIONAL cont d Attach the optional work lights to the mounting brackets
5. the P clamps and into the underside of the side frame tubing as shown in figure 6 2 Do not over torque these screws Reminder be sure these two clamps are spread apart approximately 13 One should be just ahead of the ball stud and the other one as far for ward as the tubular frame will allow before the welded seam 7 REAR WINDOW IMPORTANT INSTALLATION NOTICE To facilitate the rear panel installation to the cab it is recommended to lubricate the perimeter rubber seal of the rear panel with a silicone or Armor All protec tant lubricant or similar non flammable lubricant To prevent lubricant from contaminating the plastic rear panel spray lubricant onto a rag and in turn use the rag to lubricate the perimeter rubber of the rear panel This will allow the full seating of the rear panel in the opening which is necessary for proper hole alignment 7 1 Lift the bed With assistance place the rear window in position Fasten using four 1 4 20 x 1 1 4 long Truss head Phillips head bolts and four fender washers into factory installed weld nuts on the rear tabs on the side frames Snug up the bolts Do not over compress the rubber bushings 7 2 Secure the vinyl filler by applying self adhesive backed velcro to the vehicle where needed Note self adhesive backed velcro should be applied to a clean dry surface at room temperature See fig 7 2 for general lo cations At location a use a long piece along the bot
6. using the 1 7 8 long hex head bolts that came on the set of work lights Connect the four wires two per light male to female bullet con nectors qe re install fender washers and locknuts and tighten so that the plastic of the overhead console is snug against the sheetmetal windshield support Fig 8 6 1 View from front of vehicle Rev K p 7 of 11 loomed wiper wires to be under neath the front tubular frame lt discard the bracket and carriage bolt that is on the light Fig 8 5 Optional Work Light and Bracket tabs with holes I should be pointing towards the sky Sia a a T F B ar ATA AE N iag K E e ir Yu I i i factory installed threaded insert Fig 8 6 View from passenger s side I 9 GAS SHOCKS AND WIRING 91 Open the windshield and attach the two gas shocks as shown nn fig 9 1 with the rod end of the gas shock pointing down Snap the gas shock onto the ball studs Leave the windshield in the open position 92 Run the loomed battery wires over the front tubu lar frame down along the side tubular frame and into the gap behind the hood as shown in fig 9 2 Secure the loomed wire to the tubular frame using three of the sup plied cable ties Snip off excess length of cable tie if de sired Lift the hood of the vehicle Using a 10mm socket or Philips screwdriver connect the long red positive wire and the long black negative wire to th
7. CONSOLE 172 WEATHERSEAL BETWEEN CONSOLE AND ROOF ALONG FRONT EDGE 75 WINDSHIELD SUPPORT or P N CRAVEN TEXTURE BLACK 1 PF 03 DECALS INSIDE HEYCO PLUGS CONE PER SIDE LATCH ASS Y QTY PIN FLAT BLACK LEFT 1 PF 04L NO RAVEN TEXTURED RIGHT 1 PF 04R CREF FACTORY INSTALLED ON DOOR GREASE CONTACT POINTS 6 LATCH ASS Y DECAL PULL RIGHT SHOWN HERE DECAL OPEN FRONT MOUNTS QTY PN NO PAINT REQUIRED 2 PF 05 BLACK PLASTIC COATED La S IN HOUSE APPLICATIONS QTY UNIT p n 9GL 4ex6l 9PH007 9WLOeL 9WLOeR PFC HWK 9GS07 9GL 10x38L 9GL 10x38R 9WCO01 1 1 1 1 1 1 1 1 1 ANTENNA FOLDED DOWN J FORWARD REFLECTORS Je SPECIAL ANGLE CUT x 3 16 TRIM LOK 4 SIDES SEAM CENTER REAR ADDITIUNAL SERVICE PARTS REV M 7 19 07 P 10 OF 11 WINDSHIELD aw P N 1 PF 02 HEYCO PLUGS TWO ON PASSENGER S SIDE ONLY a HINGES GAS SHOCK MOUNT CBOTH POINT LEFT ADD SUPPLEMENTAL ADJUSTMENT INSTRUC TION SHEET HERE RELEASE LATCHES W 1 SPACERS MOLDED GLASS OFFSET SIDE BULB RUBBER WITH GRIP SEAM UNDER HINGE x 3 4 1 4 ARCH PSA BETWEEN A B ON BACK SIDE REAR WINDOW ry P N CLEAR PLASTIC 1 PF 06 3 4 SIDE BULB RUBBER WITH 1 4 GRIP 3 SIDES ONLY CTOP AND BOTH SIDES RAVEN TEXTURE BLACK PAINT ON ALL ITEMS EXCEPT LATCH ASS Y P N PF O4L amp RD AND FRONT MOUNT P N
8. PF 053 ADD SUPPLEMENTAL ADJUSTMENT INSTRUC TION SHEET HERE USE NEW RUBBER P N 9PR36 VINYL FILLER BLACK REAR P N PF 06A ATTACH TO INSIDE MOUNTS oan SURFACE OF WINDOW USING 65 OF PSA HOOK amp 3 BOLTS amp NUTS 2 PF 11 BOLT HEADS ON THE OUTSIDE CRAVEN TEXTURE BLACK BUSHINGS 4 REF WITH WELD NUT ON THIS SIDE B A RUBBER TYPES ARCH PSA 9PRO9 1 2 WEATHER SEAL 3 4 OFFSET SIDE BULB W 1 4 GRIP 9PR36 REAR SLIDER GO 9PR26 RUBBER DESCRIPTION MOLDED WINDSHIELD ASSEMBLY POP OUT WINDSHIELD HINGE KIT SINGLE POP OUT WINDSHIELD RELEASE LATCH KIT LH POP OUT WINDSHIELD RELEASE LATCH KIT RH HARDWARE FASTENER KIT WINDSHIELD GAS SHOCK 200N LEFT FRONT SIDE WINDOW W RUBBER RIGHT FRONT SIDE WINDOW W RUBBER WINDOW MOUNTING CLIP 3 4 SIDE BULB 3 16 TRIM LOK W 1 4 GRIP p IPROLB POLARIS FREEDOM CAB p n 2876196 067 REV M 7 19 07 P 11 OF 11 SIDE FRAME ASS Y QTY PIN DOOR ASS Y QTY PIN RAVEN TEXTURE BLACK LEFT 1 PF 09L RAVEN TEXTURE BLACK gt EFT 1 PF O7L RIGHT 1 PF 09R BLACK PLASTIC RIGHT 1 PF 0 R 1 4 20 WELD NUT 3 4 SIDE BULB RUBBER 2 PER SIDE FRAME WITH 1 4 GRIP FOR WINDOW CON THE INSIDE AS SHOWN 1 ROUND BULB 3 16 18 WELD NUT 2 PER SIDE FRAME W ON THE INSIDE lt A lt U LATCH ASSEMBLY lt M FACTORY INSTALLED ON DOOR A ROD WITH RUBBER BUMPER P WINDOW J CLIPS 3 PER SIDE FRAMED
9. blades and general accessories DO NOT TRAVEL WITH WIND add additional weight to the base vehicle All Carbon Monoxide Inspect exhaust system for leaks monthly A WARNING SHIELD IN FULL OPEN POSITION 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 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 Serious Injury or Death This cab enclosure does not provide protection from rollover or other accidents s cot This cab enclosure does not provide protection 5 i from flying objects including golf balls This cab enclosure does not provide protection from lightning When lightning threatens take cover and do not operate vehicle TOOLS REQUIRED 1 4 amp 3 8 DRIVE RATCHETS HAND DRILL 3 8 DEEP SOCKET 3 8 DRIVE 2 PHILLIPS HEAD BIT TO USE IN DRILL 1 2 SOCKET 3 8 DRIVE 2 and 3 PHILLIPS HEAD SCREWDRIVERS 10mm SOCKET 3 8 DRIVE T27 TORX BIT 5 32 AND 3 16 ALLEN WRENCHES BAR CLAMP Rev K p 3 of 11 WARNING Gasoline Flammable Explosive Do not operate gasoline vehicle in an enclosed area with out proper ventilation The engine produces carbo
10. e battery Wires are labeled Connect the key controlled wire as follows using a 3 8 deep socket temporarily remove the nut on the top threaded stud as shown in fig 9 2 1 Place the supplied ring terminal onto the stud and re install the original nut and tighten Ref the top stud should already have an orange wire with a white stripe This is the vehicle s key controlled wire 93 Note there are two 2 extra wires with female bullet connectors that are only used if a heater 1s being installed The blue wire is for the low speed and the gray wire 1s for the high speed When finished with the wire connections coil up the extra length of loomed wire and use a cable tie to secure the wires in place as desired 10 FINISHING TOUCHES 10 1 Make sure the rubber flaps are appropriately seal ing against the sides of the plastic hood of the vehicle See figure 10 1 10 2 Using a 5 32 Allen wrench set the antenna at a desired angle and re tighten the set screw 10 3 Install wiper per instructions included in the wiper kit One wiper is included with the cab A second wiper is available as an additional option Caution If install ing a second wiper double check that both wipers have a maximum 85 degree sweep to avoid interference The motor should have a sticker on it indicating the degree of sweep 10 4 Note extra hardware has been provided in case they get lost Discard extras such as washers locknuts P clamps cable tie
11. ew from driver s side Rev K p 4 of 11 w lt ee pam z S at portion towards the sky Fig 2 1 View from passenger s side _ om 7 portion towards the i welded joint w WW Fig 2 1 1 View from passenger s side _ 3 SIDE FRAME amp DOOR ASS Y cont d A l 3 2 Carefully open the door to the midway or slightly beyond position to gain access for installing the hip re straint bracket Insert the tongue of the bracket as shown in fig 3 2 and rotate the bracket up and install one 5 16 18 x 1 long hex head bolt one internal tooth locking washer and one flat steel washer into the factory in stalled weld nut Leave bolt loose 333 Re install the three original equipment floorboard screws through the bolt holes in the floorboard of the side frame See fig 3 3 Reminder these are self tapping screws that were factory installed Use care to avoid cross threading or damaging the original female threads underneath the vehicle floorboard Leave bolts loose 3 4 Repeat steps 3 1 through 3 3 for opposite side frame assembly i re install 3 bolts per side 4 WINDSHIELD SUPPORT TI Using care to avoid damag ee ing female threads under 4 1 If installing optional work lights pop the two neath vehicle floorboard Heyco plugs out and discard them If not installing op tional work lights leave the plugs in place With assis tance install the windshield sup
12. n monoxide which is an odorless deadly poison This vehicle and enclosure will not provide protection from rollover flying objects lightening or other hazards If caught in a storm exit the vehicle and seek shelter in accordance with ap plicable safety guidelines for your location Only trained technicians should service or repair the enclosure Anyone doing repairs or ser vice should have knowledge and experience in electrical and mechanical repair The appropri ate instructions must be used when performing maintenance service or installation Follow the procedures exactly as stated in these instructions and heed all DANGER WARN ING and CAUTION statements both in this instruction manual as well as those posted on the vehicle Prior to servicing the vehicle turn the key switch to OFF and set the parking brake Always wear safety glasses or approved eye protection when servicing the vehicle Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service while engine exhaust system or motor are hot Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Avoid shorting com ponents or wiring If wires are removed or installed make sure wiring and wire harness are properly routed and secured Failure to properly route and secure wiring could result in vehicle malfunction prop erty damage personal injury o
13. or chamois should be kept free of grit by frequent rinsing In clean water Grease and oil may be removed with kerosene Novus I and Novus II are recommended plastic cleaners for acrylic units and can be used to remove light scratches GLASS WINDOWS 1 Windex and other glass cleaners can be used on glass windows DOORS AND BODY PANELS 1 2 3 4 NEVER USE AN ABRASIVE DETERGENT VEHICLE CLEANER OR A WIRE BRISTLED BRUSH Do not use any CITRUS BASED CLEANERS such as orange or lemon Use of these products will cause the plastic to become permanently damaged Clean the plastic enclosure surfaces thoroughly with warm soapy water and a COTTON cloth or chamois Be sure to use mild soap specifically a dish liquid or equivalent Clean in a light circular motion for best results Use EXTRA CAUTION when cleaning the interior of the enclosure The interior is more sensitive than the exterior because the exterior has an extra coating for U V stability Remove grease and oil with mineral spirits and a COTTON cloth or chamois WARNING do not travel with windshield in full open position It is recommended that with a cab installed the vehicle should be trailered facing backwards Curtis Customer Service Hotline 1 800 343 7676 ext 1 POLARIS FREEDOM CAB p n 2876196 067 ROOF ASS Y BLACK PLASTIC ADD SUPPLEMENTAL INSTRUCTION SHEET 5 P QTY P N 1 PF 01 REAR CARGO LIGHT OVERHEAD
14. port as shown in fig 4 1 Install four 5 16 18 x 3 4 long hex head bolts four in ternal tooth locking washers and four flat steel washers Factory installed weld nuts are provided on the tabs of the side frame See right side of figure 4 1 Leave bolts loose 5 WINDSHIELD 5 1 Have the following items ready four 5 16 18 x 1 3 4 long flat head bolts four steel washers four 5 16 18 locknuts and two plastic spacer blocks With assis tance place the windshield in place on the windshield support with the 3 4 thick plastic spacer blocks under neath the plastic hinges for mounting up against the outer surface of the windshield support per fig 5 1 Adjust windshield seal to the vehicle hood with side latches en gaged and tighten NOTE hinges are plastic compo nents Do not overtighten Torque to 7 ft lbs max WARNING do not travel with windshield in full open position 5 2 Install the supplied nut covers qty 4 on the lock nuts inside the cab front windshield hinge bolts Rev K p 5 of 11 Ref hip restraint tube 3 4 thick of plastic spacer Fig 5 1 View from driver s side 6 TIGHTEN ALL BOLTS 61 Tighten all cab bolts at this time Reminder do not over tighten the six 6 self tapping floorboard screws 6 2 Use a small bar clamp to hold the side frame against the top side tubular frame Using a drill and a Phillips head bit install two self drilling and self tapping screws through
15. r death 1 VEHICLE PREP 1 1 Using a T27 Torx bit remove three 3 original equipment screws on each side of the vehicle floorboard as shown nn fig 1 1 Save these six 6 bolts for re installation in step 3 3 Note these are self tapping screws that were factory installed Use care when remov ing and re installing to avoid cross threading or damag ing the female threads underneath the vehicle floorboard dis P CLAMPS 2 1 Install a total of seven 7 P clamps as follows per fig 2 1 place three 3 clamps on the rear tubular frame oriented as shown One in the center of the tubular frame and one per side on the outer edges Per fig 2 1 1 install two 2 clamps on each side tubular frame oriented as shown The front most clamp can be close to the front welded joint and the rear most clamp can be 13 behind the front one Hardware will be installed in step 6 2 3 SIDE FRAME amp DOOR ASS Y 31 With assistance place the side frame assembly in place on top of the vehicle floorboard per fig 3 1 Attach the middle front using the bracket shown two 5 16 18 x 1 long hex head bolts two internal tooth locking wash ers and two flat steel washers into the factory installed threaded inserts See fig 3 1 1 Hand tighten only place floorboard of side frame onto floorboard of vehicle lining up 3 holes Fig 3 1 View from passenger s side Ref front clamp Fig 3 1 1 Vi
16. s etc It is recommended that with a cab installed the vehicle should be trail ered facing backwards Rev K p 8 of 11 x this end towards the ground x Fig 9 1 Gas shock for windshield into this gap run loomed wire as n ey attach to the top threaded stud that has the orange wire with white stripe lt Fig 10 1 View from driver s side Rev K p 9 of 11 CARE AND MAINTENANCE IMPORTANT be sure to leave this page with the owner once installation is complete Check and tighten hardware after 40 hours of operation Periodically inspect and tighten hardware for the remainder of the unit s service life IMPORTANT CLEANING INFORMATION Keep the enclosure components clean in order to prevent dust and dirt from forming an unattractive film The life of your acrylic windows doors and body panels depends upon following these care procedures REAR ACRYLIC WINDOW 1 2 3 4 5 6 NEVER USE AN ALCOHOL BASED PRODUCT FOR CLEANING Do not use WINDEX GLASS PLUS FANTASTIC etc Use of these products will result in deterioration of the acrylic item Wash with a mild soap or detergent using your bare hands to free or dislodge any caked on dirt or other for eign particles A soft grit free cloth sponge or chamois may be used but only as a means of carrying water to the windows The interior should be lightly dusted NOT WIPED with a clean soft cloth or chamois The cloth
Download Pdf Manuals
Related Search