WPS crew Doors Installation instructions

Transcription

1 WPS crew Doors Installation instructions

2 ORDER OF INSTALLATION FOR A COMPLETE ENCLOSURE OF A CREW WPS (Weather Protection System) IS AS FOLLOWS: 1. Heater 2. Rear Thresholds - Right Hand & Left Hand 3. Front Thresholds - Right Hand & Left Hand 4. Windshield - Fixed or Tip-out 5. Three Piece Top System 6. Front & Rear Doors Right Hand & Left Hand

3 Vehicle Preparation All photos are in the back of the instruction book so that they can be easily removed and laid out on your work area for easy reference. Please check Photos 1 and 2 first to get yourself familiar with the parts you will be working with. NOTE: Retain all Fasteners for Reinstallation. 1. If a windshield or Top & Back Panel has been installed, you will need to remove the windshield and loosen the bolts securing the top and back panel to the roll cage. The front edge of the door threshold fits over the roll cage and under the Windshield. 2. Remove the front side kick panels and do not replace until instructed to do so. 3. If a WPS-104 Heater System is to be installed, consult the WPS-104 installation instructions for installing the air duct vents in the side kick panels and dash. 4. Under the kick panel there are (2) 3/8 x ¾ cap bolts securing the roll cage to the frame of the vehicle on each side. Remove and replace these, (putting the bolt through from the inside out) with the stainless steel 3/8 x 1 ¼ cap bolts. Replace the nuts and tighten the cage back to the frame. These longer bolts will act as studs to secure the bottom of the hinge brackets (Shown in Photo 6). 5. The bottom outside edge of the kick panels need to be cut off just below the outside corner. Tape or mark a straight line as shown in Photo 3. Make several cuts or scores with a razor knife. 6. Remove both the front and rear lower bench seats. Remove the cross braces and the storage bin under the front seat. 7. The top lip of each rear side panel needs to be trimmed off flush with the top of the seat support. Remove the seat and tape or mark a line as shown in Photo 4 ((You may wish to remove the side panel to avoid damaging the seat support)) and make several cuts or scores with a razor knife. Make sure the side panel does NOT extend above seat support. 8. Remove the Front Side Panels and mark and trim as shown in Photo 7. Reinstall the 4.25 piece of the panel leaving out the top screw. 9. Remove the screws (4 in front, 5 in rear) securing the outside edge of the floor panel to the frame, front and rear, on both sides of the vehicle Photo Sub-assembly Front and Rear. Fasten the lower threshold brackets to the threshold using (4) 1/4 20 x ½ BHCS (Button Head Cap Screw) and Flange Nuts. Tighten securely. Fasten the filler panels to the striker bolt brackets using (2) ¼ - 20 x ½ BHCS (Button Head Cap Screw) and flange nuts. Do not tighten. Refer to Photo 2.

4 Threshold Installation Repeat all steps until both sides are complete. 1. Position the roll cage clamps (5 per side) so the flat side is on the outside of the tube and the bolt holes are located inside the door opening. The bottom clamps are located in the space immediately above the arm loop. Check the instructions and position the clamps for the Back Panel and Windshield. The Back Panel clamps will be difficult to position once the thresholds are installed Photo Position the rear threshold. First slide the rear corner inside the roll cage support, then slide the bottom flange between the floor panel and the frame. Loosely fasten the clamps using ¼ x 1 button head bolts, bonded washers (outside), 5/16 flat washers (inside), and flange nuts (inside). Replace the 4 (omit the front screw) floor screws, but do not tighten. Photos 8 and 9. Note: The bottom of the rear thresholds are notched to provide access to the flange nuts which secure the lower bracket to the threshold. (Flange nuts can usually be kept from turning with finger pressure.) Loosening the (4) ¼ button head bolts on the bottom outside of the threshold will allow the threshold to move front to back to align with mounting clamps and the front threshold. Tighten after adjusting. Photo 2 3. Loosely fasten the center roll bar mount bracket to the rear threshold as shown in Photos 10 and 11. Use a 5/16 x ¾ BHCS (Button Head Cap Screw), and flange nut (inside) on the lower hole. Use a 5/16 x ¾ BHCS (Button Head Cap Screw), limiter bracket (outside), and flange nut (inside), on the top hole. The forward mounting holes will be used later to attach the front threshold and hinges. 4. Position the Front Threshold. First slide the rear corner inside the roll cage support and over the rear threshold, then slide the bottom flange between the floor panel and the frame. Align the overlapping holes and loosely fasten the clamps and flanges using ¼ x 1 button head bolts, bonded washers (outside), 5/16 flat washers (inside), and flange nuts (inside). Replace the 4 floor screws but do not tighten. 5. Align the center mount brackets and thresholds, and using 5/16 x 3/4 button head bolts and flange nuts (inside), loosely fasten the upper and lower hinge pin receivers to the outside of the thresholds Photos 10 and Loosely fasten the front mount bracket to the threshold using (2) 5/16 x 5/8 button head bolts and flange nuts. Install a door limiter bracket on the outside of the middle hole using a ¼ x ¾ button head bolt and flange nut Photo Set the windshield in position and loosely hold in place with the top clamps. 8. Position the hinge bracket bottom over the extended bolts in the wheel well and fasten with flange nuts, finger tight Photo 6. Align the hinge bracket top with the holes in the wind shield ((SEE NOTE BELOW)), threshold, and front mounting bracket; fasten loosely using 3/8 x 1 ¾ button head bolts with flange nuts on the inside. Position the outer edge of the hinge bracket at 1 from the threshold and tighten securely Photo 6A. For proper fit you must make sure the lower part of the windshield frame is tight against the roll cage. Use a clamp if necessary. Tighten the 5/16 nuts to secure the threshold to the bracket. Align the limiter bracket vertically and tighten Photo 12.

5 NOTE: Hinge brackets are slotted and may need to be adjusted in or out after the door is installed. If your windshield only has 1 mounting hole, you will need to drill a 3/8 hole after securing the existing hole. Drill the hole at the same location with in the hinge slot to allow for adjustment. 9. Align the lower flush fit seams (beside the front seat) and loosely fasten the inside horizontal flanges (below the seat belt) and vertical flanges (top and bottom) using ¼ x 1 button head bolts, 5/16 flat washers (inside and outside) and nylock nuts. 10. Align the front and rear thresholds to provide an even overlapping seam. Secure by tightening the overlap fasteners, hinge pin receivers, and center mount bracket Photo 11. NOTE: Align the hinge pin receivers and the limiter bracket vertically before tightening. Align and secure the lower seams. 11. FRONT AND REAR. Loosely fasten the filler panel to the bottom of the striker support bracket using the ¼ x ½ button head bolts and flange nuts Photo 1. With the seat removed, align the striker support bracket with the threshold and install the striker bolt (washer outside), and (3) 5/16 x 5/8 button head bolts and flange nuts. Tighten the striker first. Align the slots in the bracket over the seat support and drill 3/8 holes thru the CENTER of the seat support (you should use an angle head drill). Fasten loosely using 3/8 x 1 ¾ button head bolts, washers (top), and flange nuts Photo FRONT AND REAR. Adjust the threshold to provide as flat of a surface as possible for the door to close against. First push the bottom of the threshold tight against the frame and tighten the 4 floor screws. Next hold the clamps and threshold parallel to the door opening and tighten. Push the door threshold and strike support bracket in or out to align and tighten in place. Position the filler panel tight against the plastic side panel and tighten. 13. Install the kick panels omitting the outside screws. Retain the screws for future use should the door threshold ever be removed. 14. Use the OEM screws and clips and fasten the rear seat kick panel to the rear threshold. (Clips shown in Photo 5)

6 Installing and Adjusting Doors Front and Rear Refer to Photos 14 and 15 NOTE: Before making any adjustments regarding the seal or operation of the latch, the door must be hung and adjusted on the hinges with the proper alignment of the latch and striker, along with the proper clearance (1/8 ) between the plastic latch covers and the threshold. 1. Loosely install the hinges (pin down) to the outside of the lower half of the door using the ¼ x ¾ button head bolts, stainless steel washers (outside) backing plates then flange nuts on the inside. Install the door limiter bracket under the nut on the top hinge, center bolt on front doors, bottom bolt on rear doors. The doors and hinges are slotted for adjustment and must not be tightened at this time. 2. Set the Brass Washers on the hinge pins (Works well to super glue them on to prevent future loss.) and hang the door on the hinge bracket. Slowly attempt to close the door and adjust on the loose hinges to align the latch with the striker bolt. The latch should be centered or slightly high (to compensate for the weight of the upper half of the door) on the striker bolt. Allow 3/16 clearance between the plastic latch cover and the threshold. Using a 3/16 shim taped to the threshold on both sides of the striker bolt may help to maintain this clearance. Make sure the hinges are bottomed out against the hinge bracket and tighten securely. Slowly close the door several times to check for proper latch alignment and clearance. Adjust if necessary. Minor adjustments may be made to the latch after the top half of the door is installed. 3. Attach the top half of the door to the bottom using ¼ x ¾ hex head bolts with a lock then a flat washer on each bolt. The 2 inside bolts require flange nuts inside the armrest, the other have threaded weld nuts in place. Start all bolts first, and then tighten securely. ((Make sure outside of the door halves are lined up before tightening.))

7 Final Adjustment Note: When properly fit and adjusted, the door should close smoothly by use of the inside grab handle or a firm pressure in the latch area (just below the handle) from the outside. The bulb seal should contact the threshold with only a slight compression. The latch is a double latch and must be in the second catch position for proper seal. Closing the door slowly you should be able to hear and feel the second catch in the latch. Front and Rear Refer to Photos 16 and Slowly try the door several times to check the alignment of the latch and the striker along with clearance of the plastic latch cover. If needed, loosen the hinges bolts and adjust. 2. The hinge bracket on the Front door only may be moved in or out to adjust the seal on the front edge of the door. Loosen the 4 nuts securing the bracket and adjust the top or bottom as needed. Too much compression of the bulb seal on the front portion of the door will cause a binding effect. 3. The striker support bracket may be moved in or out to adjust the seal at the rear of the door. Loosen the 2 bolts securing the bracket to the seat support and adjust as needed. Moving the striker may effect the operation of the latch and the pressure needed to close the door. The latch may need to be adjusted to compensate for the seal adjustments ((see next step)). 4. The latch has 2 adjustments. It may be moved in or out to adjust the compression of the bulb seal and the amount of force necessary to close the door. It can also be moved from front to back to adjust the latch clearance. To adjust the latch, remove the retaining screw and the plastic latch cover. On the end of the latch are 2 screws which hold the latch to the bracket. Loosening these screws will allow you to move the latch in or out from the striker. To move the latch front to back, you will need to remove the plastic cover on the front of the inside handle with a screwdriver and loosen the nut. Loosen the nuts under the latch which secure the bracket to the door. Make sure the retaining screw for the latch cover is in place and move the handle and latch as needed 5. Install the limiter strap using the quick release pin on the threshold and the ¼ x 1 ½ button head bolt and nylock nut on the door mounted bracket.

8 At this point your door installation should be complete. Double check all fasteners, reinstall your seat and take it for a test ride. You earned it! Note: After several hours of use with the new doors installed, it is recommended to go through the steps of the installation and tighten and or readjust and align as needed. Please make your customer aware that future adjustment may be needed as all these components are breaking in. We recommend that all installation manuals are packaged with any other owner s manuals that are shared with the customer upon purchasing any of our products.

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18 Your RangerWare product can be registered at: If you have questions during your install our technical department can be contacted at or River Road Grand Rapids, MN 55744