Ventrac KW450 Operator's Manual & Parts Drawings
OperatOr’s Manual
& parts Drawings
weather Cab
MODel Kw450
Original Operator’s Manual
Revised 03/11/16
09.10083 Rev. 04
500 Venture Drive
PO Box 148
Orrville Oh 44667
www.ventrac.com
To the Owner
Contact Information and Product Identication
If you need to contact an authorized Ventrac dealer for information on servicing your product,
always provide the product model and serial numbers.
Please ll in the following information for future reference. See the picture(s) below to nd the
location of the identication numbers. Record them in the spaces provided.
Date of Purchase: __________________________________________________________________
Dealer: ___________________________________________________________________________
Dealer Address: ____________________________________________________________________
____________________________________________________________________
Dealer Phone Number: ______________________________________________________________
Dealer Fax Number: ________________________________________________________________
Model # (A): __________________________
Serial # (B): __________________________
Afx Part/Serial Number label here.
Venture Products Inc. reserves the right to make changes
in design or specications without obligation to make like
changes on previously manufactured products.
A
B
2
Blank Page
TABLE OF CONTENTS
INTRODUCTION PAGE 6
Product Description ................................................................................................................................ 6
Why Do I Need an Operator’s Manual? ................................................................................................. 6
Using Your Manual ................................................................................................................................. 7
Manual Glossary ....................................................................................................................................7
SAFETY PAGE 8
Safety Decals ......................................................................................................................................... 8
General Safety Procedures .................................................................................................................. 10
Training Required .................................................................................................................................10
Personal Protective Equipment Requirements ....................................................................................10
Operation Safety ..................................................................................................................................10
Preventing Accidents ............................................................................................................................ 11
Keep Riders Off .................................................................................................................................... 11
Operating On Slopes ............................................................................................................................12
Roadway Safety ................................................................................................................................... 12
Truck Or Trailer Transport ....................................................................................................................12
Maintenance ......................................................................................................................................... 13
Fuel Safety ........................................................................................................................................... 13
Hydraulic Safety ................................................................................................................................... 14
KW450 Safety Procedures ................................................................................................................... 15
WEATHER CAB SETUP INSTRUCTIONS PAGE 16
Identication of Parts ............................................................................................................................16
Setup Instructions for Power Unit & Weather Cab ...............................................................................18
OPERATIONAL CONTROLS PAGE 28
Operational Control Locations ..............................................................................................................28
Outer Door Handle & Lock (A) .............................................................................................................29
Inner Door Handle (B) .......................................................................................................................... 29
Emergency Exit/Window Latch Handle (C) .......................................................................................... 29
Rear Side Window Latch (D) ................................................................................................................29
Fan Speed Switch (E) ..........................................................................................................................29
Temperature Control Dial (F) ................................................................................................................29
Windshield Wiper Switch (G) ...............................................................................................................29
Front Work Light Switch (H) .................................................................................................................29
Rear Work Light Switch (I) ...................................................................................................................29
Strobe Beacon Switch (J) .....................................................................................................................29
Hazard Flasher Light Switch (K) ..........................................................................................................29
Direction Turn Signal Switch (L) ........................................................................................................... 29
Interior Light & Switch (M) .................................................................................................................... 29
Defrost Fan & Switch (N) .....................................................................................................................29
Directional Heat Vents (O) ................................................................................................................... 29
GENERAL OPERATION PAGE 30
Daily Inspection .................................................................................................................................... 30
4-Point Seatbelt ...................................................................................................................................30
Strobe Beacon .....................................................................................................................................30
4
TABLE OF CONTENTS
SERVICE PAGE 31
Cleaning & General Maintenance ........................................................................................................31
Seatbelt Upper Mount Adjustment ....................................................................................................... 31
Window Latch Adjustment .................................................................................................................... 31
Door Latch Adjustment ......................................................................................................................... 31
Lower Door Window Adjustment .......................................................................................................... 31
Wiper Blade Replacement ...................................................................................................................32
Interior Light Bulb Replacement ........................................................................................................... 32
Work Light Bulb Replacement ..............................................................................................................32
Turn Signal Bulb Replacement ............................................................................................................32
Strobe Beacon Bulb Replacement ....................................................................................................... 32
Heater Air Filter Replacement .............................................................................................................. 33
Fuse Replacement ............................................................................................................................... 33
Storage ................................................................................................................................................. 34
SPECIFICATIONS PAGE 36
Dimensions ..........................................................................................................................................36
Features ............................................................................................................................................... 36
PARTS PAGE 37
Electrical Diagram ................................................................................................................................ 37
Cab Frame & Mount ............................................................................................................................. 38
Cab Headliner & Roof Mount ...............................................................................................................40
Headliner Assembly .............................................................................................................................42
Front & Rear Work Lights .....................................................................................................................44
Canvas Bellows & Column Covers ......................................................................................................46
Front Windshield & Windshield Wiper .................................................................................................. 48
Upper Door Frame & Latch .................................................................................................................. 50
Lower Door .......................................................................................................................................... 52
Left Rear Window ................................................................................................................................. 54
Rear Window ........................................................................................................................................ 56
Right Rear Window ..............................................................................................................................58
Right Front Window/Emergency Exit ...................................................................................................60
Lower Right Window ............................................................................................................................62
Four Point Seatbelt ..............................................................................................................................64
Fuel Tank Cover, Seals, Wire Harness ................................................................................................66
70.2005-2 Directional Signal/Flasher Kit .............................................................................................. 68
70.2006-3 Strobe Beacon Kit ............................................................................................................... 70
70.2006-4 Mirror Kit .............................................................................................................................72
70.2006-6 Defrost Fan Kit .................................................................................................................... 74
70.8106 Console Fan/Heater Kit .......................................................................................................... 76
70.8136 Kubota Heater Install Kit For 4500Y & 4500Z ........................................................................78
70.8137 Kawasaki Heater Install Kit For 4500P ...................................................................................80
WARRANTY PAGE 82
5
INTRODUCTION
enture Products Inc. is pleased to provide you with your new
V
Ventrac KW450 weather cab! We hope that Ventrac equip-
ment will provide you with a ONE Tractor Solution.
Listed below are just some of the items that can provide you
versatility as you use your KW450 weather cab. Please visit our
web site, or contact your authorized Ventrac dealer for a complete list of items available for your new KW450 weather cab.
Part Number
Accessories
Item Description
Directional Signal/Flasher Kit 70.2005-2
Strobe Beacon Kit 70.2006-3
Mirror Kit 70.2006-4
Defrost Fan Kit 70.2006-6
KW450 Console Fan/Heater Kit (Kubota engines) 70.2009-51
KW450 Console Fan/Heater Kit (Kawasaki engine) 70.2009-52
Product Description
The Ventrac KW450 weather cab is designed for the sole purpose of sheltering the operator from the
weather while providing superior visibility. Standard features include a front windshield wiper, front and rear
LED work lights, a large left-side entry door, right-side emergency exit, door and side windows that can be
quickly and easily removed, and a 4-point seatbelt.
Optional accessories include a strobe light, directional lights, defrost fan, and heater kits. Refer to your
national and/or local regulations for lighting requirements specic to your intended application.
NOTE: The KW450 weather cab cannot be used with the Ventrac KH500 versa-loader or the Ventrac
RV600 Collection Vacuum.
Why Do I Need an Operator’s Manual?
This manual has been created to help you gain the important knowledge of what is needed to safely
operate, maintain, and service your machine. It is divided into sections for convenient reference of the
appropriate section.
You must read and understand the operator’s manual for each piece of Ventrac equipment you own. Reading the operator’s manual will help you become familiar with each specic piece of equipment. Understanding the operator’s manual will help you, as well as others, avoid personal injury and/or damage to the
equipment. Keep this manual with the machine at all times. The manual should remain with the machine
even if it is sold. If this manual becomes damaged or unreadable, it should be replaced immediately. Contact your local Ventrac dealer for a replacement.
When using a Ventrac attachment, be sure to read and follow the safety and operating instructions of both
the power unit and the attachment being used to ensure the safest operation possible.
The information in this manual provides the operator with the safest procedures to operate the machine
while getting the maximum use out of the unit. Failure to follow the safety precautions listed in this manual
may result in personal injury and/or damage to the equipment.
Introduction - 6
INTRODUCTION
Using Your Manual
Throughout this manual, you will encounter special messages and symbols that identify potential safety
concerns to help you as well as others avoid personal injury or damage to the equipment.
SYMBOL DEFINITIONS
ATTENTION
This symbol identies potential health and
safety hazards. It marks safety precautions.
Your safety and the safety of others is involved.
There are three signal words that describe the level of safety concern: Danger, Warning, and Caution.
Safety should always be the #1 priority when working on or operating equipment. Accidents are more likely
to occur when proper operating procedures are not followed or inexperienced operators are involved.
Note: Right-Hand and Left-Hand orientations may be referred to at different places throughout this manual.
Right-Hand and Left-Hand is determined as if sitting on the tractor seat facing forward.
SIGNAL WORD DEFINITIONS
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury. This signal word is limited to the
most extreme cases.
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury and/or property damage. It may
also be used to alert against unsafe practices.
Manual Glossary
Power Unit A Ventrac tractor or other Ventrac engine powered device that may be operated by itself or
with an attachment or accessory.
Attachment A piece of Ventrac equipment that requires a Power Unit for operation.
Accessory A device that attaches to a Power Unit or Attachment to extend its capabilities.
Machine Describes any “Attachment” or “Accessory” that is used in conjunction with a power unit.
Introduction - 7
SAFETY
Safety Decals
The following safety decals must be maintained on your KW450 weather cab.
Keep all safety decals legible. Remove all grease, dirt, and debris from safety decals and instructional
labels. If any decals are faded, illegible, or missing, contact your dealer promptly for replacements.
When new components are installed, be sure that current safety decals are afxed to the replacement
components.
A
2
A
1
C D
Safety - 8
SAFETY
A
B
1
C
D
2
Decal Description Part Number Quantity
A Warning, Pinch Point 00.0218 2
B Warning, KW350 00.0272 1
C Danger, Gasoline Only 00.0332 1
D Danger, Diesel Only 00.0333 1
Safety - 9
SAFETY
General Safety Procedures
for Ventrac Power Units, Attachments, & Accessories
Training Required
• The owner of this machine is solely responsible for properly training the operators.
• The owner/operator is solely responsible for the operation of this
machine and prevention of accidents or injuries occurring to him/herself, other people, or property.
• Do not allow operation or service by children or untrained personnel.
Local regulations may restrict the age of the operator.
• Before operating this machine, read the operator’s manual and understand its contents.
• If the operator of the machine cannot understand this manual, then it
is the responsibility of this machine’s owner to fully explain the material
within this manual to the operator.
• Learn and understand the use of all controls.
• Know how to stop the power unit and all attachments quickly in the event of an emergency.
Personal Protective Equipment Requirements
It is the responsibility of the owner to be sure that the operators use the proper personal protective equipment while operating the machine. Required personal protective equipment includes, but is not limited to,
the following list.
• Wear a certied ear protection device to prevent loss of hearing.
• Prevent eye injury by wearing safety glasses while operating the machine.
• Closed toe shoes must be worn at all times.
• Long pants must be worn at all times.
• When operating in dusty conditions, it is recommended that a dust mask be worn.
Operation Safety
• Inspect machine before operation. Repair or replace any damaged, worn, or missing parts. Be sure
guards and shields are in proper working condition and are secured in place. Make all necessary
adjustments before operating machine.
• Some pictures in this manual may show shields or covers opened or removed in order to clearly illustrate
any instructions. Under no circumstance should the machine be operated without these devices in place.
• Alterations or modications to this machine can reduce safety and could cause damage to the machine.
Do not alter safety devices or operate with shields or covers removed.
• Before each use, verify that all controls function properly and inspect all safety devices. Do not operate
if controls or safety devices are not in proper working condition.
• Check parking brake function before operating. Repair or adjust parking brake if necessary.
• Observe and follow all safety decals.
• All controls are to be operated from the operator’s seat only.
• Always wear a seat belt if the machine has a roll cage/bar installed and in upright position.
• Ensure the attachment or accessory is locked or fastened securely to the power unit before operating.
• Ensure that all bystanders are clear of the power unit and attachment before operating. Stop machine if
someone enters your work area.
• Always be alert to what is happening around you, but do not lose focus on the task you are performing.
Always look in the direction the machine is moving.
• Look behind and down before backing up to be sure of a clear path.
• If you hit an object, stop and inspect the machine. Make all necessary repairs before operating machine again.
• Stop operation immediately at any sign of equipment failure. An unusual noise can be a warning of equipment
failure or a sign that maintenance is required. Make all necessary repairs before operating machine again.
Safety - 10
SAFETY
General Safety Procedures
for Ventrac Power Units, Attachments, & Accessories
Operation Safety (continued)
• If equipped with a high/low range feature, never shift between high and low range while on a slope.
Always move the machine to level ground and engage the parking brake before shifting range.
• Do not leave machine unattended while it is running.
• Always park the machine on level ground.
• Always shut off engine when connecting attachment drive belt to the power unit.
• Never leave the operator’s seat without lowering the attachment to the ground, setting the parking
brake, shutting off the engine, and removing the ignition key. Make sure all moving parts have come to
a complete stop before dismounting.
• Never leave equipment unattended without lowering the attachment to the ground, setting the parking
brake, shutting off the engine, and removing the ignition key.
• Only operate in well-lit conditions.
• Do not operate when there is a risk of lightning.
• Never direct the discharge of any attachment in the direction of people, buildings, animals, vehicles, or
other objects of value.
• Never discharge material against a wall or obstruction. Material may ricochet back towards the operator.
• Use extra caution when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
• Do not run the engine in a building without adequate ventilation.
• Do not touch the engine or the mufer while the engine is running or immediately after stopping the engine.
These areas may be hot enough to cause a burn.
• Do not change the engine governor settings or over-speed the engine. Operating engine at excessive speed
may increase the hazard of personal injury.
• To reduce the hazard of re, keep the battery compartment, engine, and mufer areas free of grass, leaves,
and excessive grease.
Preventing Accidents
• Clear working area of objects that might be hit or thrown from machine.
• Keep people and pets out of mowing area.
• Know the work area well before operation. Do not operate where traction or
stability is questionable.
• Reduce speed when you are operating over rough ground.
• Equipment can cause serious injury and/or death when improperly used.
Before operating, know and understand
the operation and safety of the power
unit and the attachment being used.
• Do not operate machine if you are not in good physical and
mental health, if you will be distracted by personal devices, or are
under the inuence of any substance which might impair decision, dexterity, or judgment.
• Children are attracted to machine activity. Be aware of children
and do not allow them in the working area. Turn off the machine if
a child enters the work area.
Keep Riders Off
• Only allow the operator on the power unit. Keep riders off.
• Never allow riders on any attachment or accessory.
Safety - 11
SAFETY
General Safety Procedures
for Ventrac Power Units, Attachments, & Accessories
Operating On Slopes
• Slopes can cause loss-of-control and
tip-over accidents, which can result in
severe injury or death. Be familiar with the
emergency parking brake, along with the
power unit controls and their functions.
• If power unit is equipped with a fold down
roll bar, it must be locked in the upright
position when operating on any slope.
• Use low range (if equipped) when operating
on slopes greater than 15 degrees.
• Do not stop or start suddenly when operating on slopes.
• Never shift between high and low range while on a slope. Always move the power unit to level ground
and engage the parking brake before shifting range or placing the power unit in neutral.
• Variables such as wet surface and loose ground will reduce the degree of safety. Do not drive where
machine could lose traction or tip over.
• Keep alert for hidden hazards in the terrain.
• Stay away from drop-offs, ditches, and embankments.
• Sharp turns should be avoided when operating on slopes.
• Pulling loads on hills decreases safety. It is the responsibility of the owner/operator to determine loads
that can safely be controlled on slopes.
• Transport machine with attachment lowered or close to the ground to improve stability.
• While operating on slopes, drive in an up and down direction when possible. If turning is necessary
while driving across slopes, reduce speed and turn slowly in the downhill direction.
• Assure a sufcient supply of fuel for continuous operation. A minimum of one-half tank of fuel is recommended.
Roadway Safety
• Operate with safety lights when operating on or near roadways.
• Obey all state and local laws concerning operation on roadways.
• Slow down and be careful of trafc when operating near or crossing roadways. Stop before crossing
roads or sidewalks. Use care when approaching areas or objects that may obscure vision.
• If there is doubt of safety conditions, discontinue machine operation until a time when
operation can be performed safely.
• When operating near or on roadways, have a Slow Moving Vehicle Emblem clearly
displayed.
Truck Or Trailer Transport
• Use care when loading or unloading machine into a truck or trailer.
• Use full width ramps for loading machine into a truck or trailer.
• The parking brake is not sufcient to lock the machine during transport. Always secure the power unit
and/or attachment to the transporting vehicle securely using straps, chains, cable, or ropes. Both front
and rear straps should be directed down and outward from the machine.
• Shut off fuel supply to power unit during transport on truck or trailer.
• If equipped, turn the battery disconnect switch to the Off position to shut off electrical power.
Safety - 12
SAFETY
General Safety Procedures
for Ventrac Power Units, Attachments, & Accessories
Maintenance
• Keep all safety decals legible. Remove all grease dirt, and debris from safety decals and instructional labels.
• If any decals are faded, illegible, or missing, contact your dealer promptly for replacements.
• When new components are installed, be sure that current safety decals are afxed to the replacement
components.
• If any component requires replacement, use only original Ventrac replacement parts.
• Always turn the battery disconnect to the Off position or disconnect the battery before performing any
repairs. Disconnect the negative terminal rst and the positive terminal last. Reconnect the positive
terminal rst and the negative terminal last.
• Keep all bolts, nuts, screws, and other fasteners properly tightened.
• Always lower the attachment to the ground, engage parking brake, shut off engine, and remove the
ignition key. Make sure all moving parts have come to a complete stop before cleaning, inspection,
adjusting or repairing.
• If the power unit, attachment, or accessory requires repairs or adjustments not instructed in the operator’s
manual, the power unit, attachment, or accessory must be taken to an authorized Ventrac dealer for service.
• Never perform maintenance on the power unit and/or attachment if someone is sitting in the operator’s seat.
• Always use protective glasses when handling the battery.
• Check all fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed.
• To reduce the hazard of re, keep the battery compartment, engine, and mufer areas free of grass,
leaves, and excessive grease.
• Do not touch the engine, the mufer, or other exhaust components while the engine is running or imme-
diately after stopping the engine. These areas may be hot enough to cause a burn.
• Allow the engine to cool before storing and do not store near an open ame.
• Do not change the engine governor settings or over-speed the engine. Operating engine at excessive
speed may increase the hazard of personal injury.
• Springs may contain stored energy. Use caution when disengaging or removing springs and/or spring
loaded components.
• An obstruction or blockage in a drive system or moving/rotating parts may cause a buildup of stored
energy. When the obstruction or blockage is removed, the drive system or moving/rotating parts may
move suddenly. Do not attempt to remove an obstruction or blockage with your hands. Keep hands,
feet, and clothing away from all power-driven parts.
• Dispose of all uids in accordance with local laws.
Fuel Safety
• To avoid personal injury or property damage, use extreme care in handling gasoline. Gaso-
line is extremely ammable and the vapors are explosive.
• Do not refuel machine while smoking or at a location near ames or sparks.
• Always refuel the machine outdoors.
• Do not store machine or fuel container indoors where fumes or fuel can reach an open
ame, spark, or pilot light.
• Only store fuel in an approved container. Keep out of reach of children.
• Never ll containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers
on the ground away from your vehicle before lling.
• Remove machine from the truck or trailer and refuel it on the ground. If this is not possible, refuel the
machine using a portable container, rather than from a fuel dispenser nozzle.
• Never remove fuel cap or add fuel with the engine running. Allow engine to cool before refueling.
• Never remove fuel cap while on a slope. Only remove when parked on a level surface.
• Replace all fuel tank and container caps securely.
Safety - 13
SAFETY
General Safety Procedures
for Ventrac Power Units, Attachments, & Accessories
Fuel Safety (continued)
• Do not overll fuel tank. Only ll to bottom of fuel neck, do not ll fuel neck full. Overlling of fuel tank could
result in engine ooding, fuel leakage from the tank, and/or damage to the emissions control system.
• If fuel is spilled, do not attempt to start the engine. Move the power unit away from the fuel spill and
avoid creating any source of ignition until fuel vapors have dissipated.
• If the fuel tank must be drained, it should be drained outdoors into an approved container.
• Dispose of all uids in accordance with local laws.
• Check all fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed.
• The fuel system is equipped with a shut-off valve. Shut off the fuel when transporting the machine to
and from the job, when parking the machine indoors, or when servicing the fuel system.
Hydraulic Safety
• Make sure all hydraulic connections are tight and all hydraulic hoses and tubes are in good condition.
Repair any leaks and replace any damaged or deteriorated hoses or tubes before starting the machine.
• Hydraulic leaks can occur under high pressure. Hydraulic leaks require special care and attention.
• Use a piece of cardboard and a magnifying glass to locate suspected hydraulic leaks.
• Keep body and hands away from pinhole leaks
or nozzles that eject high pressure hydraulic uid.
Hydraulic uid escaping under high pressure can
penetrate the skin causing serious injury, leading to
severe complications and/or secondary infections
if left untreated. If hydraulic uid is injected into the
skin, seek immediate medical attention no matter
how minor the injury appears.
• Hydraulic system may contain stored energy. Before performing maintenance or repairs on the hydraulic
system, remove attachments, engage parking brake, disengage weight transfer system (if equipped), shut
off engine, and remove ignition key. To relieve pressure on the auxiliary hydraulic system, shut off the power
unit engine and move the secondary S.D.L.A. lever left and right before disconnecting the auxiliary hydraulic
quick couplers.
• Dispose of all uids in accordance with local laws.
Safety - 14
SAFETY
KW450 Safety Procedures
WARNING
10 degree maximum angle of operation of power
unit with weather cab installed.
•
The cab door must be closed and latched during operation of power unit and KW450 weather cab.
• Window latches must be locked in either the closed or open position during operation of power unit and
KW450 weather cab.
• Do not place any part of your body outside of the cab (through windows, door, or any other opening) during
operation of power unit and KW450 weather cab.
• Do not place hands or ngers between power unit dash and cab front frame cross member. Pinch points
may be created by the oscillation of the power unit front frame.
• Always wear the 4-point seatbelt when operating a power unit and KW450 weather cab. The seatbelt must
be adjusted to t individual operators.
• Do not operate power unit and KW450 weather cab without the headrest cushion in place.
• The KW450 weather cab is equipped with an emergency exit (the right side front window). Learn to use the
emergency exit prior to operating the power unit and KW450 weather cab. Refer to General Operation section of this manual for instructions on using the emergency exit.
• The power unit’s steering cylinder must be installed in the outer position when equipped with a KW450
weather cab. Damage to the power unit and/or the weather cab will occur if the steering cylinder is installed
in the center or inner positions. Refer to Setup section for steering cylinder mounting instructions.
Do not exceed 30 amp draw to weather cab and
additional accessories.
CAUTION
Safety - 15
WEATHER CAB SETUP INSTRUCTIONS
Identication of Parts
5
3
1
2
4
6
7
9
8
18
16
19
10
20
12
13
11
14
21
22
15
17
24
23
Setup - 16
WEATHER CAB SETUP INSTRUCTIONS
26
25
28
32
Ref. Name Qty.
1 Sling, 4 Point Assy 1
2 Cushion, Headrest 1
3 Mount, Seatbelt Upper (w/seatbelt) 1
4 Cover, Pump W/Flanges 1
5 Window, Lower Rear Canvas 1
6 Cover, Fuel Tank Kw450 1
7 Canvas, Rear Frame 1
8 Support, Cab Front Rh 1
9 Canvas, Pleated Right 1
10 Canvas, Pleated Left 1
11 Support, Cab Front Lh 1
12 Bracket, Mount Support 1
13 Mount, Cab Rear Right 1
14 Mount, Cab Rear Left 1
15 Bracket, Window Right Lower 1
16 Mount, Canvas Column Right 1
17 Mount, Canvas Column Left 1
18 Bracket, Window Rear Right 1
19 Support, Door Window Lower 1
20 Bracket, Window Door Lower 1
21 Mount, Window Rear Lower 1
22 Bracket, Window Rear Top 1
23 Strap, Bellows Support 4
24 Bracket, Window Rear Left 1
25 Canvas, Column Right 1
26 Canvas, Column Left 1
27 Mount, Cab Front Right 1
28 Cover, Opt. Light Kit Access 1
29 Mount, Cab Front Left 1
30
27
31
29
Ref. Name Qty.
30 Harness, Wire Tractor To KW450 1
31 Clamp, Wire Mt Adh. 1/2 Gray 2
32 Washer, .531 X 1.75 3/16 Thick 4
33 Plate, Drill Template KW450 1
33
Setup - 17
WEATHER CAB SETUP INSTRUCTIONS
Setup Instructions for Power Unit & Weather Cab
Installation Time (estimated) 3.0 hours
Before making repairs or adjustment, set the parking brake, turn off engine, and remove ignition key.
Always disconnect the negative battery cable
from the battery when working with electrical
components. Always work in a manner that does
not put safety at risk!
Safety glasses must be worn during installation.
Ear (hearing) protection must be worn when using
air or power tools.
Use only the KW450 lift sling attached at all four
lift points to lift the cab.
Never walk or stand beneath cab when it is raised
off the ground.
Place wheel chocks in front and back of wheels
to prevent power unit from rolling during setup of
power unit and weather cab.
Unless specied otherwise, use the bolt torque
specications listed below for all bolts used during
setup and installation of the weather cab.
Bolt Torque Specications
Bolt Size Torque (English) Torque (Metric)
1/4-20 100 in-lbs. 11.5 Nm
5/16-18 210 in-lbs. 24 Nm
3/8-16 31 ft-lbs. 42 Nm
7/16-14 50 ft.lbs 68 Nm
1/2-13 75 ft.lbs 102 Nm
1. Place wheel chocks in front and back of wheels
to prevent power unit from rolling.
2. If power unit is equipped with a rear work light
kit, the lights must be removed from the roll bar.
If the cab will be removed in warm weather and
the work light kit will be reinstalled, the wire harness can be left in place. If the kit is to be permanently removed, the wire harness will need to
be disconnected in the power unit’s tool box area
and the connector will need to be removed from
the harness with a metri-pack terminal removal
tool. After pulling the wire harness, remove the
fuse from slot 6 in the front fuse panel. Remove
the light switch from the dash and install a blank
plug into the cutout.
3. If power unit is equipped with a directional signal light kit, the light kit must be removed from
the roll bar. If the cab will be removed in warm
weather and the directional signal light kit will be
reinstalled, the roll bar mount brackets and the
wire harness can be left in place. If the kit is to
be permanently removed, disconnect the wire
harness splitter from the power unit’s connector.
Disconnect the left and right wire harnesses from
the harness splitter. Remove the connectors from
the left and right harness ends with a weather
pack terminal removal tool. After pulling the wire
harness, remove the 10 amp fuse from slot 7 in
the front fuse panel. If a back up alarm kit or a
horn kit are installed, replace the 10 amp fuse
with a 5 amp fuse. Remove the directional signal
light switch and the hazard asher switch from the
dash and install blank plugs into the cutouts.
4. If power unit is equipped with a strobe light kit, the
light must be removed from the roll bar. Disconnect
the wire harness in the power unit’s tool box area
and remove the connector from the harness with a
metri-pack terminal removal tool. If the kit is to be
permanently removed, pull the fuse from slot 6 in
the front fuse panel. Remove the light switch from
the dash and install a blank plug into the cutout.
5. If power unit is equipped with a propane kit, the
propane hose and wire harness must be disconnected from the lock off valve, and the propane
posts must be removed from the mount brackets.
This will be reinstalled after the cab is in place.
6. Check the left
and right outside
anges of the lower
rear frame. If your
power unit already
has lower mounting
holes (A), skip to
step 13.
A
Setup - 18
WEATHER CAB SETUP INSTRUCTIONS
7. If your power unit does not have lower mounting
holes, install the included template onto the right
side of the lower rear frame. Fasten to the existing holes using included 5/16 bolts and nuts,
making sure to keep the template parallel with
the top surface of the foot platform. Drill 1/8” pilot
holes (B) into the ange.
8. BMove the template to the ange on the left side
of the lower rear frame and drill 1/8” pilot holes.
9. Drill out the 4) pilot holes to 11/32”, remove any
metal shavings, and use red touch up paint on
the drilled holes.
10. Position the template on top of the right foot platform aligning it with the frame and the break on
the foot platform. Clamp the template in place.
13. Install the mount support bracket (D) under the
right foot platform. Fasten loosely with 2) 1/4” x
3/4” button head bolts (E) and ange nuts.
E
F
D
F
14.
Install the right and left front cab mounts (F) on
the lower mounting holes in the lower rear frame.
Fasten using 3) 5/16 x 3/4” bolts and 5/16” at
washers inserted through the front cab mounts
and the lower rear frame and fasten with 5/16”
ange nuts. Use 1) 5/16 x 1” bolt and at washer
at the front hole of the right cab mount where
the bolt also goes through the mount support
bracket. Tighten the 5/16” bolts and then tighten
the 1/4” bolts for the mount support plate.
15. Install the power unit’s steering cylinder in the
outer position.
Torque to 170 ft lbs (230 Nm).
11. CDrill 1/8” pilot holes (C) in the foot platform.
NOTE: some units may already have the outside
hole in the foot plate, covered by the ex tread.
12. Drill out the pilot holes to 9/32”, remove any
metal shavings, and use red touch up paint on
the drilled holes.
Inner Position
Center Position
Outer Position
Failure to install the power unit’s steering cylinder
in the outer position will result in damage to the
power unit and/or weather cab.
Setup - 19
WEATHER CAB SETUP INSTRUCTIONS
16. Remove the right and left foot pegs from the
power unit front frame. Reinstall bolts and tighten.
17. Remove the right dash access panel.
18. Install the right canvas column mount and the
dash access panel onto the dash using 2) 1/4” x
3/4” button head bolts and ange nuts with 1) 1/4”
at washer on the top bolt between the canvas
column mount and the dash panel and 2) 1/4” at
washers on the bottom bolt between the canvas
column mount and the dash access panel.
21. Install a 5” piece of 1/2” wide velcro loop (H) to
the left dash panel above the front fuse panel.
H
I
22.
Install a 2.5” piece of 1” wide velcro loop (I) to
the front frame between the high/low shift lever
and the high/low shift select bracket.
23. Install a 2” piece of 1/2” wide velcro loop (J) to the
parking brake cover in front of the parking brake.
1) Washer
2) Washers
19.
Repeat for left canvas column mount.
20. Replace the pump cover on the power unit with
the included pump cover with anges (G).
G
J
K
24.
Install a 1” piece of 1” wide velcro loop (K) to the
parking brake cover between the parking brake
and the center dash panel.
25. Disconnect the negative battery cable from the
power unit’s battery.
26. Open the toolbox lid and remove the left (L) and
right (M) toolbox liner panels.
M
Setup - 20
L
WEATHER CAB SETUP INSTRUCTIONS
27. Place the wire harness in the power unit’s seat
box area. Connect the ring terminal to the ground
stud (N). Route the wire with the terminal along
the main harness into the tool box area. Use zip
ties to fasten the wires to the main harness.
28. NUse a needle nose pliers to remove the green
plug (O) from position A2 (P - red highlighted
position) on the rear fuse panel.
C
B
D
C
EX
30
86
P
NC
NO
EX
87a
87
85
C
EX
30
86
NC
NO
EX
87a
87
85
C
EX
30
86
NC
NO
EX
87a
87
85
C
EX
30
86
NC
NO
EX
87a
87
85
C
EX
30
86
NC
NO
EX
87a
87
85
O
NOTE: Both the picture
and the sketch are shown
1
2
3
4
5
6
7
8
9
10
AA
A
from the rear of the fuse
panel inside the toolbox.
29.
Install the terminal into position A2 in the fuse
panel. NOTE: the terminal can only be installed
one way. Orient the terminal with the hole pointing up and insert into the fuse panel. The terminal needs to snap into place. If necessary, use a
needle nose pliers to push the terminal in, being
careful not to damage the wire insulation. Double
check the connection by tugging gently on the
wire with your hand.
31. Tilt the seat forward as far as possible and
secure in place.
32. Install a 16” piece of 1/2” wide velcro loop (Q) to
the top ange on the front of the seat box frame.
Q
R
33.
Install 2) 8” pieces of 1” wide velcro loop (R) to
the top ange on the rear of the seat box frame.
34. Remove the seat pin bolt and seat pin from the
seat box rear ange.
35. Install the lower rear window mount on the under-
side of the seat box rear ange using 2) 1/4 x 1/2”
button head bolts (S) down through the outside
set of holes in the seat box ange and lower rear
window mount and fasten with 1/4” ange nuts.
36. Fasten the center hole using the seat pin and bolt.
S
37.
Install the rear frame canvas onto the velcro at
S
the front of the seat box frame, stretch the canvas
across the frame, and fasten onto the velcro at
the rear of the seat box frame. Make sure the seat
springs stick up through the cutouts in the canvas.
30. Reinstall the toolbox liner panels.
Setup - 21
WEATHER CAB SETUP INSTRUCTIONS
38. Remove the existing seat belt from the power unit.
Install the seatbelt upper mount to the back edge
of the roll bar as shown below.
Install 2) U-bolts from the front of the roll bar
through the holes in the seatbelt upper mount.
Center the seatbelt upper mount on the top of the
roll bar and fasten with 4) 3/8” locking ange nuts.
Make sure there are no twists in the seatbelt and
fasten the lower seat belt anchors to the power
unit’s seat box rear panels.
Install a 7/16 x 1-1/4”
bolt and 7/16” at
washer through each
seat belt anchor. Add
2) 7/16” at washers
between each seat
belt anchor and the
seat box rear panels.
Fasten to the seat
box rear panels with a
7/16” at washer and a 7/16 lock nut.
39. Remove the 2) 1/4 x 3/4” button head bolts from
the inside of the right fender. Place the rear
window right bracket (T) on the back side of the
fender ange and fasten with 2) 1/4” button head
bolts and 1/4” locking ange nuts.
40. Remove
the 2) 1/4
x 3/4” button head
bolts from
the right
seat box
rear panel
above the
cooling fan
and install
the rear
window
top bracket (U).
T
U
41. Remove the 2) 1/4 x 3/4” button head bolts from
the inside of the left fender and discard the ange
nuts. Place the rear window left bracket (V) on the
back side of the fender ange and fasten with the
1/4” button head bolts through the fender and into
the u-nuts on the bracket.
42. VInstall a 4” piece of 1” wide velcro loop (W) onto
the underside of the fuel tank cover, between the
manual holder and the roll bar.
43. WIdentify the left and right rear cab mounts. The
cab mounting surface will be angled toward the
front and the upper hole on the roll bar mount will
also be toward the front.
Upper mounting hole
Setup - 22
WEATHER CAB SETUP INSTRUCTIONS
44. Install the rear cab
mounts
onto the
roll bar
using 2)
U-bolts
and 4) 3/8” locking ange
nuts. The bottom face of
the mounting ange
should be parallel to the
top face of the seat box
panel and approximately
13-5/8” up from the
bottom of the roll bar.
45. Install a two piece isolator
in the mounting hole of
both rear cab mounts.
Insert the stepped piece
of the isolator down
through the cab
mount and install the
bottom piece.
Parallel with
top face of the
seat box panel.
dow open slightly and lower the handle so the
latch pin exits through the release slot.
13-5/8”
Remove the window from the cab by lifting the
window off the hinge pins.
50. Remove the right and left rear windows. Lift up
on the handle to unlatch and push to open window. Pull the handle toward the rear of the cab
until it can be removed from the latch pin.
46. XPlace a 3/16” thick,
notched washer
onto a 1/2 x 3” bolt.
Insert the bolt
through the isolator
on the right cab front
support. Install the
right cab front
support (X) on the
right front cab
mount. Fasten with a
1/2” locking ange
nut. Do not tighten.
47. Repeat for left cab
front support.
48. Remove the
gas door
shock where
it attaches to
the cab frame.
Insert a at
screwdriver
under the
spring clip (Y)
and pry down
to release. Remove the shock end from the
mounting stud. Remove the door from the cab by
lifting the door off the hinge pins.
49. Remove the right front window (emergency exit).
Lift up on the handle to unlatch. Push the win-
Y
Remove the rear windows from the cab by lifting
the windows off the hinge pins.
51. Remove the fuel tank cover from the cab.
52. Attach lift sling to a hoist and position above the
weather cab.
Clip the 4) lift sling hooks to the lift points at each
corner of the cab.
Lift point decal
Lift point decals are located under each lift point
for easy identication.
Setup - 23
WEATHER CAB SETUP INSTRUCTIONS
53. Lift the weather cab and position it over the
power unit.
Use only the KW450 lift sling attached at all four
lift points to lift the cab.
Never walk or stand beneath cab when it is raised
off the ground.
54.
Lower the cab onto the
power unit. Insert a 1/2
x 3” bolt into the cab
mount brackets and
guide into the rear cab
mount isolators.
55. Raise or lower the
weather cab until the
front cab supports align
with the cab mounting
holes (cab supports
mount on the inside).
Install 4) 1/4 x 1-1/4” step bolts (Z) and fasten
with 1/4” ange nuts. Do not tighten.
56. Lower the weather cab until the rear cab mount
brackets are resting on the rear cab mount isolators. Install a 3/16” thick, notched washer onto the
1/2” bolt on the bottom side of each cab mount
isolator and fasten with a 1/2” locking ange nut.
57. Tighten the hardware for the front cab supports
to the cab, the front cab supports to the cab front
mounts, and the cab to the cab rear mounts.
58. Install the fuel tank
cover by sliding
the anges down
inside the mount-
ing anges on the
cab. Press the fuel
tank cover down
far enough to seal
against the top of
the fuel tank.
Install 2) 1/4 x 1/2”
button head bolts
through the front
mounting ange
and the front of the fuel tank cover. Fasten with
1/4” ange nuts. Install 2) 1/4 x 1/2” button head
bolts through the rear holes on the fuel tank
cover and through the rear mounting ange.
Fasten with 1/4” ange nuts.
59. Install the door onto the cab by placing the hinge
pivots over the hinge pins on the cab.
Z
Setup - 24
WEATHER CAB SETUP INSTRUCTIONS
60. Align the gas
door shock end
with the mounting stud on the
cab frame and
press until
shock end
snaps over the
head of the
mounting stud.
The gas door shock must be installed to prevent
the door from opening too far or swinging open or
shut too fast.
Damage to the door glass and/or weather cab
glass may occur if gas door shock is not installed.
61.
Install the right lower window and right lower
window bracket. Remove the nuts from the 4)
step bolts installed
in the window. Do
not remove the
spacers. Insert the
bolts into the 3)
mounting tabs (1,
2, & 3) on the cab
frame. Install the
right lower window
bracket (AA) on
the 3) rear step
bolts (2, 3, & 4)
and fasten all four
places with 1/4”
ange nuts.
Tighten only until
rubber washer
under the step bolt head begins to bulge slightly.
62. Install the lower
door window
support to the
door frame with
2) 5/16 x 3/4”
bolts (BB) and
5/16” at washers. Fasten
with 2) 5/16”
locking ange
nuts. Tighten
until snug but
support can still
be moved.
1
2
4
3
BB
63. Install the lower door
window and the
lower door window
bracket (DD).
Remove the nuts
from the 4) step
bolts installed in the
window. Do not
remove the spacers.
Insert the bolts into
the two mounting
tabs (1 & 2) on the
door frame and the
mounting hole (3) on
the lower door
window support (CC).
Install a 1/4” ange
nut on the top front
bolt (1) to hold the
window in place.
Install the lower door
window bracket (DD) on the 3) rear step bolts and
fasten with 1/4” ange nuts. Tighten all four ange
nuts only until rubber washer under the step bolt
head begins to bulge slightly.
64. Shut the cab door and check the seal of the lower
window to the power unit and weather cab. Move
the bottom of the lower door window support in or
out until window seals properly.
3/4” bolts at the top of the lower door window
support. Note: If door latch adjustment is required,
refer to the service
AA
section of this manual.
65. Install the left column
canvas (EE) onto the
left side of the front
frame column. Fasten
the Velcro to the dash
panel (1), the frame
plate (2), and the
ange on the pump
cover (3).
66. Install the right column canvas (FF) onto
the right side of the
front frame column.
Fasten the Velcro
to the parking brake
cover (1 & 2), and the
ange on the pump
cover (3).
2
4
DD
Tighten the 5/16 x
1
EE
1
2
3
1
CC
3
2
3
FF
Setup - 25
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