Cab Kit

Note: If you are installing the air conditioner kit, review and install the air conditioner kit with this cab kit.

1. Clear a location in your workspace under the hoist system.

   Note: Verify that your hoist system is capable of safely supporting the cab unit over the machine during the installation.

2. Move the machine underneath the hoist and engage the parking brake.

3. Shut off the engine and remove the key.

4. Chock the wheels to prevent the machine from moving during the installation.

5. Remove the battery; refer to the Operator’s Manual.

1. Unlatch and raise the operator's console panel (Figure 1).

   

   Figure 1

   1. Operator's console panel
   2. Latch

2. Remove the rubber boots from the battery terminals.

3. Remove the negative cable (black) from the negative (-) terminal and the positive cable (red) from the positive (+) terminal of the battery (Figure 2).

   

   Figure 2

   1. Positive (+) terminal
   2. Negative (-) terminal

4. Remove and retain the battery.

Important: Use an assistant to support the roll bar when you remove the bolts securing it to the machine.

1. Remove and retain the bolt securing the storage compartment located on the left side of the machine (Figure 3).

   

   Figure 3

   1. Bolt
   2. Storage compartment

2. Remove and retain the storage compartment.

3. Remove and retain the 2 bolts, reinforcement plate, and 2 flange nuts securing the roll bar to the top of the frame (Figure 4).

   

   Figure 4

   1. Bolt
   2. Roll bar
   3. Reinforcement plate
   4. Flange nut

4. Remove and retain the screw securing the reinforcement plate and the bolt securing the battery compartment (Figure 5).

   

   Figure 5

   1. Screw
   2. Bolt

5. Remove and retain the bolt and the battery-compartment clamp (Figure 6).

   

   Figure 6

   1. Battery-compartment clamp
   2. Bolt

6. Arrange the reinforcement plate and battery compartment to allow you to remove the 2 bolts, reinforcement plate, and 2 flange nuts that secure the roll bar to the top of the frame (Figure 7). Set them aside.

   

   Figure 7

   1. Bolt
   2. Roll bar
   3. Reinforcement plate
   4. Flange nut

Important: Use an assistant to support the roll bar when you remove the bolts securing it to the machine.

1. Remove the bolts securing the roll bar to the left side of the machine (Figure 8).

   

   Figure 8

   1. Bolts
   2. Roll bar

2. Use an assistant to help you remove the roll bar from the machine.

3. Store the roll bar.

Press a rubber isolator into each hole in the front mounts (Figure 9).

Figure 9

1. Rubber isolators
2. Left, front mount
3. Right, front mount

Note: Use soapy water and a mallet to assist with inserting the rubber isolators into the holes.

Follow this procedure only if necessary.

Locate and drill 2 holes (13/32 inch diameter) for the right, front mount as shown in Figure 10.

Figure 10

1. Hole (13/32 inch diameter)
2. 52 mm (2.07 inches)
3. 17 mm (0.67 inch)
4. 21 mm (0.83 inch)
5. 23 mm (0.89 inch)

1. Press a rubber isolator into the hole of the left, rear mount on the cab frame (Figure 11).

   

   Figure 11

   1. Rubber isolator
   2. Left, rear mount

2. Press a rubber isolator into the hole of the right, rear mount on the cab frame (Figure 12).

   

   Figure 12

   1. Rubber isolator
   2. Right, rear mount

Note: Use soapy water and a mallet to assist with inserting the rubber isolator into the hole.

Apply the center, front foam seal and then the left, front and right, front foam seals approximately 3 mm (1/8 inch) from the edge on the front of the cab unit (Figure 13).

Figure 13

1. Application area
2. Left, front foam seal
3. Center, front foam seal
4. Right, front foam seal

Note: Install the ends of the foam seals to interlock and create a solid seal.

1. Apply the left foam seal approximately 3 mm (1/8 inch) from the edge on the front, left section of the cab unit (Figure 14).

   Note: Install the ends of the foam seals to interlock and create a solid seal.

   

   Figure 14

   1. Application area
   2. Left foam seal

2. Apply the right foam seal approximately 3 mm (1/8 inch) from the edge on the right, front section of the cab unit.

   Note: Install the ends of the foam seals to interlock and create a solid seal.

3. Remove the paper backing from the double-faced tape on both sides of the cab unit (Figure 15).

   

   Figure 15

   1. Double-faced tape
   2. Left tank foam

4. Apply the left tank foam to the cab unit (Figure 15).

5. Apply the right tank foam to the cab unit.

1. Remove the paper backing from the double-faced tape at the back of the cab unit (Figure 16).

   

   Figure 16

   1. Left, rear foam seal
   2. Double-faced tape
   3. Right, rear foam seal

2. Apply the left, rear and right, rear foam seals to the cab unit (Figure 16).

3. Apply the rear foam seal to the back of the cab unit (Figure 17).

   

   Figure 17

   1. Rear foam seal
   2. Application area

1. Remove the existing hardware and use the 3 bolts (3/8 x 1 inch) and flange nuts to secure the mount to the machine (Figure 18).

   

   Figure 18

   1. Bolt (3/8 x 1 inch)
   2. Left mount
   3. Flange nut (3/8 inch)

2. Torque the bolts and nuts to 37 to 45 N∙m (27 to 33 ft-lb).

1. Remove the existing hardware and use the 4 bolts (3/8 x 1 inch) 2 flange nuts, and 2 locknuts to secure the mount to the machine (Figure 19).

   

   Figure 19

   1. Flange nut (3/8 inch)
   2. Locknut
   3. Left mount
   4. Bolt (3/8 x 1 inch)

2. Torque the bolts and nuts to 37 to 45 N∙m (27 to 33 ft-lb).

1. Use the new hardware to secure the left rear mount to the frame (Figure 20).

   

   Figure 20

   1. Bolt (1/2 x 6 inches)
   2. Left mount
   3. Flange nut
   4. Reinforcement plate
   5. Bolt (1/2 x 1-1/4 inches)

2. Torque the bolts (1/2 x 6 inches) and nuts to 91 to 113 N∙m (67 to 83 ft-lb).

3. Torque the bolts (1/2 x 1-1/4 inches) to 91 to 113 N∙m (67 to 83 ft-lb).

1. Use the new hardware to secure the right rear mount to the frame (Figure 21).

   

   Figure 21

   1. Bolt (1/2 x 6 inches)
   2. Right mount
   3. Bolt (1/2 x 1-1/4 inches)
   4. Flange nut
   5. Reinforcement plate

2. Torque the bolts (1/2 x 6 inches) and nuts to 91 to 113 N∙m (67 to 83 ft-lb).

3. Torque the bolts (1/2 x 1-1/4 inches) to 91 to 113 N∙m (67 to 83 ft-lb).

4. Use the bolt (5/16 x 1-1/2 inches) to secure the storage compartment to the machine (Figure 22).

   

   Figure 22

   1. Bolt (5/16 x 1-1/2 inches)
   2. Storage compartment

5. Use the screw to secure the reinforcement plate to the machine and use the bolt (1/2 x 1 inch) to secure the battery-compartment clamp and the battery compartment to the machine (Figure 23).

   

   Figure 23

   1. Screw
   2. Battery compartment
   3. Battery-compartment clamp
   4. Bolt (1/2 x 1 inch)

Route the wire harness from underneath the machine up to the battery box as shown in Figure 24.

Figure 24

Install the wire harness as shown in Figure 25.

Figure 25

Use the measurements in Figure 26 and drill holes into the cab.

Figure 26

1. 1.93 inches
2. Hole (0.31 inch diameter)
3. 3.36 inches
4. 3.87 inches
5. Hole (0.31 inch diameter)
6. 2.29 inches

1. Install the 2 clip nuts onto the cab frame (Figure 30).

   

   Figure 30

   1. Cab frame
   2. Clip nut
   3. Left, rear panel assembly
   4. Bolt (1/4 x 3/4 inch)

2. Secure the panel assembly to the cab using the 2 bolts (1/4 x 3/4 inch) as shown in Figure 30.

3. Use 1 bolt (1/4 x 3/4 inch) and 1 flange nut (1/4 inch) to complete the installation of the panel assembly (Figure 31).

   

   Figure 31

   1. Bolt (1/4 x 3/4 inch)
   2. Flange nut

4. Torque the bolts and nut to 10 to 12 N∙m (90 to 110 in-lb).

5. Repeat the previous steps to the right side of the cab.

1. Ensure the installation area is clean.

2. Align the upholstery panel with the center of the back panel inside cab to verify its fit and placement (Figure 32).

   Note: Remember or mark where the corner of the upholstery panel begins when it is centered across the back panel of the cab.

   

   Figure 32

   1. Cab
   2. Upholstery panel

3. Remove 1 section of the backing to expose the adhesive.

4. Start with the upper corner of the upholstery panel and adhere it to the back of the cab so that it is centered once it is completely installed.

5. Adhere the panel, 1 section at a time, from one end to the other, until the upholstery panel is completely applied.

1. Remove the insulation blanket from the shipping tube.

   Note: Do not unroll the insulation blanket until it is in position.

2. Position the blanket across the storage compartments behind the operator’s seat.

3. Tuck in the edges of the blanket around the operator’s seat as you unroll it toward the front of the machine.

4. Remove the backing from the adhesive on the hook and loop strips at the end of the blanket and adhere the strips where they lie.

   Note: Ensure the surface where the adhesive backed hook and loop strip adheres to the platform is clean.

5. Adhere the hook and loop strips firmly to the platform.

1. Ensure that the installation area is clean.

2. Install the floor tread onto the platform inside the cab.

   

   Figure 33

   1. Floor tread

3. Ensure that the bolt heads on the platform are aligned with the cutouts in the floor tread.

1. Apply sealant to the fitting (3/8 NPT x 0.625 barb); skipping the first thread.

2. Remove the heater supply and return hose plugs from the engine and install the fittings (3/8 NPT x 0.625 barb) as shown in Figure 34.

   

   Figure 34

   1. Fitting (3/8 NPT x 0.625 barb)
   2. Return hose plug
   3. Fitting (3/8 NPT x 0.625 barb)
   4. Supply hose plug

3. Tighten the fittings (3/8 NPT x 0.625 barb) 2 to 3 turns past finger-tight.

4. Route the hoses for the heater and the drain hose through the hose ring on the rear cab mount (Figure 35).

   

   Figure 35

   1. Hose ring
   2. Drain hose
   3. Heater hose
   4. Drain hose

5. Slide the hose clamp over the supply hose and then insert the hose over the fitting (3/8 NPT x 0.625 barb) as shown in Figure 36.

   Note: The supply hose is designated by a red plug at 1 end of the assembly. Remove the plug before installing the hose.

   

   Figure 36

   1. Heater-supply hose
   2. Hose-clamp
   3. Barb fitting

6. Slide the hose-clamp over the return hose and then insert the hose over the fitting (3/8 NPT x 0.625 barb) as shown in Figure 37.

   Note: The return hose is designated by a green plug at 1 end of the assembly. Remove the plug before installing the hose.

   

   Figure 37

   1. Heater-return hose
   2. R-clamp
   3. Barb fitting
   4. Hose clamp

Note: Thoroughly lubricate the O-ring before installing the fittings with PAG Oil 46 or an equivalent lubricant.

1. Remove the exhaust pipe, muffler bracket, and engine fan (Figure 38).

   

   Figure 38

   1. Engine fan
   2. Fan bolts
   3. Muffler bracket

2. Install the right-angle fitting (7/8 inch) and O-ring (size 8) to the low-pressure or suction port on the air-conditioning pump (Figure 39).

   Note: Ensure the fittings are installed at the angles shown in Figure 40 and Figure 41.

   

   Figure 39

   1. Right-angle fitting (3/4 inch)
   2. O-ring (size 8)
   3. Right-angle fitting (7/8 inch)
   4. O-ring (size 10)
   5. Air-conditioning pump

3. Torque the fitting to 34 to 47 N∙m (25 to 35 ft-lb)

4. Install the right-angle fitting (3/4 inch) and O-ring (size 10) to the high-pressure or discharge port on the air-conditioning pump (Figure 39).

5. Torque the fitting to 34 to 47 N∙m (25 to 35 ft-lb)

6. Position the compressor into the machine and secure it as shown in the Air Conditioner Kit (Model No. 30877) instructions.

7. Install the engine fan, muffler bracket, and exhaust pipe (Figure 38).

1. Connect the air-conditioning low-pressure hose (7/8 inch) from the cab unit to the right-angle fitting (7/8 inch) as shown in Figure 40.

   

   Figure 40

   1. Right-angle fitting (3/4 inch)
   2. Right-angle fitting (7/8 inch)

2. Torque the fitting to 34 to 47 N∙m (25 to 35 ft-lb)

3. Connect the air-conditioning high-pressure hose (3/4 inch) from the cab to the right-angle fitting (3/4 inch) as shown in Figure 41.

   

   Figure 41

4. Torque the fitting to 34 to 47 N∙m (25 to 35 ft-lb)

5. Install 1 R-clamp around each air-conditioning hose and use the 2 existing bolts to secure them to the machine frame (Figure 42).

   

   Figure 42

   1. High-pressure hose
   2. Low-pressure hose
   3. Bolt (5/16 x 1 inch)
   4. R-clamp

1. Use 2 carriage bolts (5/16 x 3/4 inch) and 2 flange nuts (5/16 inch) to secure the tank plate to the coolant-bottle support (Figure 43)

   

   Figure 43

   1. Coolant-bottle support
   2. Carriage bolt (5/16 x 3/4 inch)
   3. Tank plate
   4. Flange nut (5/16 inch)

2. Torque the bolt and nut to 1,978 to 2,542 N∙cm (175 to 225 in-lb).

3. Use 2 carriage bolts (5/16 x 3/4 inch) and 2 flange nuts (5/16 inch) to secure the washer bottle and R-clamp to the tank mount (Figure 44).

   

   Figure 44

   1. Tank mount
   2. Flange nut (5/16 inch)
   3. Washer bottle
   4. R-clamp
   5. Carriage bolt (5/16 x 3/4 inch)

4. Install the swell-latch assembly to the tank mount (Figure 45).

   

   Figure 45

   1. Swell latch
   2. Swell-latch bushing
   3. Swell-latch nut

5. Insert the tab into the slot and the swell-latch bushing into the hole in the tank plate (Figure 46).

   

   Figure 46

   1. Swell latch
   2. Tank mount

6. Flip the swell-latch lever down (Figure 46).

   Note: The swell latch should hold the tank mount firmly to the tank plate. Adjust the nut to change the pressure applied by the swell latch.

1. Route the washer hose through the hose ring on the rear cab mount (Figure 47).

   

   Figure 47

   1. Hose ring
   2. Washer hose

2. Route the washer hose through the R-clamp and connect it to the washer bottle (Figure 48).

   

   Figure 48

   1. Washer hose
   2. Bottle connection
   3. R-clamp

Important: Use care around the cab seals and lights (Figure 58). If you are using a pressure washer, keep the washer wand at least 0.6 m (2 ft) away from the machine. Do not use the pressure washer directly on the cab seals and lights or under the rear overhang.

Figure 58

1. Seal
2. Light
3. Keep wand 0.6 m (2 ft) away.
4. Do not pressure-wash under the rear overhang.

1. Remove the screws and grates from both the in-cab and rear cab air filters (Figure 59 and Figure 60).

   

   Figure 59

   In-Cab Air Filter

   1. Filter
   2. Grate
   3. Screw
   

   Figure 60

   Rear Cab Air Filter

   1. Filter
   2. Grate
   3. Screw

2. Clean the filters by blowing clean, oil-free, compressed air through them.

   Important: If either filter has a hole, tear, or other damage, replace the filter.

3. Install the filters and the grate with the thumbscrews.

The purpose of the cab pre-filter is to prevent large debris, such as grass and leaves from entering the cab filters.

1. Rotate the screen cover down.

2. Clean the filter with water.

   Note: Do not use a pressure washer.

   Important: If the filter has a hole, tear, or other damage, replace the filter.

3. Allow the pre-filter to dry before installing it into the machine.

4. Rotate the filter screen around the tabs until the latch locks into the latch-mount assembly (Figure 61).

   

   Figure 61

   1. Latch-mount assembly
   2. Latch
   3. Screen cover

1. Shut off the engine and remove the key.

2. Disconnect the wire for each fan (Figure 62).

   

   Figure 62

   Right fan shown

   1. Fan
   2. Wire
   3. Knob

3. Remove the 2 knobs and remove the fan assembly (Figure 62).

4. Open the 4 latches on the air-conditioning assembly and remove the screen (Figure 63).

   

   Figure 63

   1. Air-conditioning coil
   2. Latch
   3. Air-conditioning screen

5. Remove the air filters (Figure 60).

6. Clean the air-conditioning assembly.

7. Install the air filters, screen, and fan assembly (Figure 60, Figure 63, and Figure 62).

8. Connect the wire for each fan (Figure 62).