Kawasaki Mule 3000 Manuals

ACCESSORIES Kawasaki Motors Corp., U.S.A. Irvine, California 92718-2016 MULE 3000 Cab (p/n KAF 30-005) INSTALLATION AND OWNER�S MANUAL The contents of this envelope are the property of the owner. Be sure to leave them with the owner when installation is complete. PAGE 1 OF 7 All Curtis cabs are designed and man- ufactured for use as reasonable weather protection. Curtis cabs are not applicable, nor should the cab be considered as protection against roll over, collision or other accidents that may result. Curtis cabs are NOT R.O.P.S. cabs. Extreme care should be taken when operating and by qualified, experienced operators only. Exposure to Carbon Monoxide can cause serious 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 system. if leaks are found, repair or replce exhaust system. Do not use vehicle until repair or replacement is complete. WARNING WARNING ACCESSORIES Kawasaki Motors Corp., U.S.A. Irvine, California 92718-2016 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 and Kawasaki, 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 exterior fas- teners. The plastic washer should be installed under each bolt head directly against the outside cab surface. Care should be taken not to overtighten the fasteners and damage 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. For example, rear mount to side frames. TOOLS REQUIRED: A. Set of std. and metric sockets and wrenches B. Utility knife or snips C. Tape measure D. Philips head screwdriver E. Drill & drill bit ( 3/8") F. Clear silicone sealant PAGE 2 OF 7 VEHICLE PREP: A: Remove bolts between front & rear cab bar. Remove nuts and bolts from top of rear screen. Save all hardware for later use. B: Loosen but do not remove bolts between front of cab bar and frame as well as rear cab bar & floor. NOTE: HEAVY DUTY FRONT SUSPENSION SPRINGS (P/N 92144-1919) ARE RECOM- MENDED WHEN INSTALLING THIS CAB. STEP 1: DOOR KITS NOTE: If installing a door kit (P/N KAF30-006, 007, 008, or 009) at this time proceed below. If not skip to Step 2. A: Loosen nuts attaching seat back to vehicle. Remove the two upper nuts but leave bottom nuts attached. Proceed to hard or soft as required. Hard sided door kit (P/N KAF30-006 or 007) only. B: Install 4 pieces of weatherseal on the inside of the two middle uprights on the rear screen. C: With the bulb rubber on the forward side install rear window panel from the door kit to the inside of the rear screen by pushing down over seat back mounts. Tighten seat back hardware once the panel is fully seated against the lower cross bar. Soft sided door kit (KAF30-008 or 009) only. Bolt on stud snaps, located in door kit hardware, to rear mount and the rear member of side frames with the snaps facing in. STEP #2 MOUNTS A: Install the rear mount by placing it between the front and rear cab bars and reinstalling the bolts removed in vehicle prep step A. NOTE: Do not tighten bolts. B: Install front mounts between front of cab bar and frame. FIG A STEP 1A STEP 2A STEP 2B ACCESSORIES Kawasaki Motors Corp., U.S.A. Irvine, California 92718-2016 PAGE 3 OF 7

INSTALLATION GUIDE FOR THE MULE™ 3000 OPERATOR ENCLOSURE 1 INSTALLATION OF THE OPERATOR ENCLOSURE FOR THE MULE™ 3000 JULY ‘07 www.essexmfg.com PO Box 92864 Southlake, TX 76092 Ph:888-643-7739 INSTALLATION GUIDE FOR THE MULE™ 3000 OPERATOR ENCLOSURE 2 PREPARATION The passenger side grab handle and mounting brackets- must be removed for the cab to install. They can be sawed or ground off. Loosen the roll cage for cab installation by loosening the three frame bolts on each side of the rear rollbar at the floor- boards and loosen the 5 bolts on each bedrail. Position the bed-sides as far back as they will adjust and retighten. This will allow you to maximize the clearance between the cab and the bed. [Fig 2] Replace the hex head bolt on the front of the bed with a pan head carriage bolt provided in the bolt kit. Note: DO NOT TIGHTEN THE ROLL CAGE UNTIL ENTIRE CAB IN- STALLATION IS COMPLETE! The enclosure is shipped with all trim and doors preassembled. All hardware is included. The fasteners for the body panel are 10mm serrated flange nuts and 6mm bolts. Use the black washers provided under the heads of the exter- nal bolts. The front Quarter panels are fastened with self-tapping Tek screws on each side. 5/16” carriage bolts se- cure the floorboards. You will need the following tools to complete the installation: • Metric Sockets, 10, 12 & 14mm, SAE 3/8, 7/16, 1/2 & 9/16 • #3 Phillips Screwdriver / 5/16” Drill Bit / Hacksaw / Angle Grinder NOTE: Use portions of these instructions for partial cab installation. 1 USE THE LONG 8MM BOLTS and NUTS PROVIDED. 2 Remove the rear screen and seat back. Install the 8mm long bolts provided and reattach the seat back. 3 Fit the lower closeout panel into position over the four 8mm lower screen bolt. Adjust the positition for best fit and cut out the marked sections at the bottom to fit the gas or diesel oil details at the frame rail. Use zipties to secure the panel to the lower and upper cross tubes of the Mule as shown. There are pairs of holes in the panel; start the ziptie through the top hole from inside the cab and feed it back thru the lower hole. Do not tighten the ties until all of them are started and the panel has been adjusted for best fit. REAR FABRIC PANEL FLOORBOARDS & MOUNTING BRACKETS Position the left and right treadplate floorboards. The notch should be located around the front wheel well member. Re- move the bolt from the rubber boot and use it to secure the floorboard. Drill two 5/16” holes thru the square holes in the boards into the floor for the left & right sides. Install carriage bolts and tighten. If planned, install the heavy duty battery at this time before the rear quarter panels are installed. [Fig 2] Loosen the 19mm rollbar bolts to provide a gap for the front quarter panel brace and the lower windshield brace to fit alongside the frame. [Fig 3] Remove the two screws on each front wheel well and install the left & right side mounting brackets. Fig. 1. Fig. 2. Fig. 3. INSTALLATION GUIDE FOR THE MULE™ 3000 OPERATOR ENCLOSURE 3 REAR QUARTER PANELS 1 Install the 1x2" angle brackets on the floorboard us- ing 6mm bolts. Don’t tighten until later. Repeat for the other side 2 [Fig 2] Set the rear qtr panel on the floorboard and against the rear cage. Use an 8mm bolt from the rear screen to fasten the door post tab to the floor- board on each side. Fasten the panel to the angle bracket with a 6mm bolt. 3 [Fig 3] Line up the holes in the rear quarter panels and roof and loosely install 6mm bolts. 4 Leave the nuts loose until adjustments are made for the door opening STEEL HARDTOP 1 [Fig 1] Attach the visor to the roof using six 6mm bolts. Install the top bolts on each side first, then ro- tate to a 45 degree position for the others. Use the black washers under the outside bolt heads. 2 Place the rectangular black gasket over the air intake before you install the roof. Set the roof in place in- side the rear window panel Locate the roof as far for- ward as it will fit. Tighten the rear screen first and then the seat back. REAR WINDOW 1 The rear window fits on the outside of the roof and on the outside of the rear quarter panels. Foam gasket is preinstalled on the top and sides of the window. 2 Install the window panel against the bolt tabs and secure each 8mm bolt with a washer and two 8mm nuts provided. Adjust the first nut so that the sliding window operates smoothly and ’lock it with the 2nd nut. 3 [Fig 4] Install the rear screen guard and secure it with the original 8mm nuts. Fig. 1. Fig. 3. Fig. 2. Fig. 4. INSTALLATION GUIDE FOR THE MULE™ 3000 OPERATOR ENCLOSURE 4 WINDSHIELD AND FRONT PANELS Inside Latch Handle Swell Latch Parts Outside Latch view Install the "swell" latches into the aligned holes of the windshield and lower closeout panel. [Fig 4] The pivot handle is on the inside; washer, rubber sleeve and nut to the outside. [Fig 3] Position the lower windshield assembly on the hood so that it fits on the rubber sleeves of the upper corner latches and lies flush against the hood as shown. ADJUST IT AND CENTER THE LOWER WINDSHIELD PANEL BE- FORE DRILLING THE MOUNTING HOLES. Drill 1/4" holes for the mounting bolts on the front side of the lower win- dow assembly. [Fig 5] Raise the hood and fasten it with M6 bolts and the inside squeeze plate as shown. Drill the two rear 1/4" holes from the inside and install M6 bolts. [Fig 6] Pull the gasket tight and fold it around the lower edge of the hood. [Fig 7] Install the plastic clip to secure it as shown. Adjust the swell latches for smooth closure by tightening, or loosening the nut on the front side. Once adjusted for proper closure, we suggest that you secure the nut with LocTite or teflon tape to keep it from coming loose. Slide the upper windshield assembly with flip-up glass across the front of the Mule behind the roll cage. [Fig 1] Once it is in position, push the top forward against the top roll bar frame and start the 6mm bolts in the top of the windshield to attach it to the nuts welded in the roof. Leave them loose until the quarter panels and doors are adjusted [Fig 2] Assemble the quarter panels to the frame by aligning the side holes with the mounting bracket and with the hole in the side of the roof. Install the lower closeout bracket in the rollbar bolt slot and the flange into the seam of the corner beam. Slide the upper windshield panel into position aligning it with the nuts in the roof beam. Start M6 bolts to hold it in place. Seat the tongue of the windshield panel fully into the side seams in the corner beams. Install the M6 bolts to secure the windshield to the corner beams. Install the T handles for the upper window and adjust the nylock nuts for smooth operation. The inside tongue fits in the track of frame. LOWERWINDSHIELD PANEL Fig. 1 Fig. 7 Fig. 3 Fig. 2 Fig. 6 Fig. 5 Fig. 4