Kubota F5205 Installation and Owner's Manual

Brand: Kubota

Model: F5205

Type: Installation and Owner's Manual

manual p/n 77700-01874

(revised: 4/1/2013)

INSTALLATION & OWNER’S MANUAL

The contents of this envelope are the property of the owner.

Be sure to leave with the owner when installation is complete.

Rev. C

p. 1 of 21

F5205 HARD SIDED CAB KIT

INSTALLATION & OWNER’S MANUAL

Cab is supplied with Work Lights and Windshield Wiper.

PAGE 2 OF 21

ExposuretoCarbonMonoxide

canCause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 manifold. If leaks are found,

repair or replace exhaust system. Do not use vehicle until

This cab is designed and manufac-

tured for use only as reasonable

weather protection. This cab is not applicable, nor should

the cab be considered as protection against roll over, col-

lision or other accidents that may result. This cab is NOTa

R.O.P.S.cab. Extreme care should be taken when operat-

ing and by qualified, experienced operators only.

CAB INSTALLATION

BEFORE YOU START

HELPFUL REMINDERS:

A. Refer to parts diagram toward the back of this manual to help identify parts during the assem-

bly process.

B. To assist with the cab installation, leave all bolts loose for later adjustment unless otherwise

specified.

C. Read and understand all instructions before beginning.

D. Plastic washers have been supplied to provide a weather seal under the

heads of all exterior bolts. The plastic washer should be installed under

each bolt head directly against the outside cab surface. Care should be

taken not to over tighten the fasteners and damage the plastic washer.

Also use metal washers as required.

E. Apply a clear silicone sealant to seal any minor gaps that may occur

due to vehicle variations.

F. Start all bolts by hand to avoid cross threading.

TOOLS REQUIRED:

Set of standard and metric sockets and open end wrenches

One 21mm socket with long extension

One 3/8” and one 1/2” Drive Ratchet

One 3/16” Allen Wrench

One large Phillips Head Screwdriver

Grease

Electric or cordless drill

9/32” and 3/8” drill bits

Tape measure

Scissors

Wire Crimp Tool

Electrical tape

Fastener

Cab Surface

Steel Washer

Plastic Washer

WARNING WARNING

NOTICE

Cabs and accessories add additional weight to the base

vehicle. All accessory weights are listed in product bro-

chures. Deduct the accessory’s total weight from the vehi-

cle’s rated capacity and never exceed the vehicle’s rated

capacity including driver and passenger

PAGE 3 OF 21

1. DECK SOUND BARRIER

Mounting surface preparation: adhesive-

backed sound barrier should be applied to a

clean, dry surface at room temperature. Alt-

hough the mounting surface may appear

clean, it is required that the surface be clean-

ed with isopropyl alcohol or an acetone or

ammonia-based cleaner immediately prior

to application of the sound barrier material.

Allow cleaned surfaces to dry thoroughly.

Good surface contact is required to achieve

bond. Failure to follow these steps can result

in the separation of the sound barrier mate-

rial from the mounting surfaces.

NOTE: paint thinners or products with any

oil in them will not work and are detrimental

to the proper cleaning of the underside of the

fender. NOTE: clean rags are very im-

portant. Oily rags will leave residue.

1.1 Remove the ROPS (Roll Over Protection Structure)

structure, the operator seat, the control lever handles, the

differential lock, forward - reverse and brake pedals

from the mower. Remove the operator deck by removing

the two bolts at the back of the deck and the four nuts (2

each side) from the frame supports under the left and

right foot wells. Open the hood, lift the deck up off of the

front mounting studs, tip the back of the deck up and

move to the rear lifting off of the park brake lever and

the steering column cover. Reference Kubota mower

service manual for a more detailed description.

1.2 Remove the grab handle from the left side by remov-

ing the two (2) hex nut/washer combinations (SEMS)

from underneath the fender. Discard hardware and han-

dle. See fig. 1.2.

1.3 Position the operator deck upside down on a soft

table to prevent scratching. Remove all 10 plastic pine

tree clips (5/side) that hold the floor mats in place. Dis-

card these 10 small, short plastic clips. 16 larger, longer

plastic pine tree clips are provided in the hardware bag

along with 16 fender washers (1/4” I.D.).

1.4 Note: dry fitting the pieces to get a feel for location

is suggested before peeling back the protective paper.

Place the main piece of sound barrier on a flat table with

the adhesive side up. Cut the center rear section of the

adhesive backing paper 15” from the rear edge as shown

in fig. 1.4.

1.5 Position the main piece of the deck sound barrier in

place as shown in fig. 1.5. Lift up one section at a time,

peel the adhesive backing paper off and adhere the sound

barrier to the deck. DO NOT remove 15” of backing

paper of rear center section that was cut in step 1.4.

1.6 Position the left and right pieces of sound barrier as

shown in fig. 1.6, peel the adhesive backing paper off

and adhere to the deck as shown.

Fig. 1.2 (grab handle)

Fig. 1.4 (modify sound barrier)

Fig. 1.5 (main sound barrier)

Fig. 1.6 (left and right sound barrier)

rear edge

Left and right sound barrier

Main sound barrier

cut adhesive back paper 15” from

rear edge. (center section only).

PAGE 4 OF 21

Fig. 1.7.1 (loose pine tree clip and fender washer)

Fig. 1.7.2 (assembled pine tree clip and fender washer)

1. DECK SOUND BARRIER (cont’d.)

Use of the supplied plastic pine tree clips and

fender washers (qty.: 16 of ea.) is strongly

advised to help secure the sound material

around the bends in the fender and will help

prevent the sound material from premature-

ly coming loose. See figures 1.7.1, 1.7.2, and

1.7.3.

1.7 Before re-installing the floor mats, use the 5 existing

holes per fender side as guides to drill 9/32” diameter

holes through the newly installed sound material. Also

drill 3 new holes (9/32” diameter) per side as shown in

figure 1.7.3. Approximate locations are sufficient as

shown. Install 8 plastic pine tree clips per side as shown

with the thin head side up top and the fender washers

below the deck surface sandwiching the sound material

lightly (not shown). Note: no need to over-compress the

sound material with the fender washers.

1.8 Reinstall the deck, pedals, ROPS, and operator seat.

IMPORTANT: the bolts on the ROPS structure must

be torqued properly to meet original equipment safe-

ty standards. These four (4) bolts (M14 diameter) are

to be torqued to 91-108 ft.-lbs. (124-147 N-m).

DO NOT install the nuts on the front foot well mounting

studs that were removed in step 1.1, but retain them for

later use. Tuck the slit in the center rear section around

the knob and make sure to pull the seat switch wire up

through the cutout before securing the deck.

1.9 The small piece of sound barrier from the kit can be

stuffed in place under the access door for the transmis-

sion filler cap. Do not adhere it to the door. Remove this

piece when checking transmission fluid. See figure 1.9.

Fig. 1.7.3 (view from left front)

Fender would be here

Sound material would be here

Approximate locations

Fig. 1.9 (transmission filler sound barrier)

3. FRONT MOUNTS

3.1 Install two (2) small rubber mounts in the two

outboard holes in the front mount using 5/16” locknuts

and washers as shown in fig. 3.1. Threaded studs point-

ing down.

3.2 From underneath the vehicle, remove and save

the locknuts and washers from the vertical threaded

weld studs sticking down through the vehicle floor-

boards (two per side). On the left side, remove and

save the horizontal bolt, washer, and locknut (the rear-

most of the two). On the right side, remove and save

the horizontal bolt and washer (the rearmost of the

two) (note: no locknut on right side).

3.3 Position the front mounts onto the threaded studs.

Re-install the horizontal bolts. Note: left side uses a

locknut. Right side has a threaded weld plate instead.

Reinstall the original equipment locknuts and washers.

2. VEHICLE PREP.

2.2 Have one 10mm x 1.25 x 20mm long hex head

bolt ready. Remove one of the two large clamping

hand knobs from the middle of the upright of the roll

bar while holding the “U” shaped bracket in place. See

figures 2.2 and 2.2.1. Install the new hex head bolt

through the hole in the “U” shaped bracket and tighten

in place. Note: washers are not used here. Repeat for

opposite side. Discard the hand knobs.

Fig. 2.2 (clamping hand knobs)

Fig. 2.2.1 (view from front of left side)

Fig. 3.1 (view from front of left side)

Fig. 4.1 (view from rear of right side)

rubber mount

lower rear mount

remove and re-install

these two bolts

4. LOWER REAR MOUNT

4.1 Install two (2) large rubber mounts to the upper

tabs in the lower rear mount using 3/8” locknuts and

washers as shown. Remove the two, large 9/16-18 hex

head bolts and lock washers from the vehicle as shown.

Position the lower rear mount in place as shown in fig-

ure 4.1. Re-install and tighten the original equipment

hex head bolts and lock washers to secure the lower

rear mount to the vehicle. IMPORTANT: the bolts on

the ROPS structure must be torqued properly to

meet original equipment safety standards. These

two (2) bolts (9/16-18) are to be torqued to 160-192

ft.-lbs. (217-260 N-m).

PAGE 5 OF 21

Fig. 6.1 (view from rear of right side)

button head bolts,

plastic washers,

and steel washers

threaded stud

lower rear panel

Fig. 5.1 (view from rear of right side)

5. LOWER REAR PANEL

5.1 With assistance, install the lower rear panel onto

the threaded shafts of the two rubber bumpers. Use

3/8” locknuts and washers as shown in fig. 5.1. Tighten

both locknuts.

5.2 Do not peel off the backing paper on the sound

barrier material until step 7 (just prior to installing the

upper rear panel assembly).

PAGE 6 OF 21

6. RIGHT SIDE FRAME

6.1 With assistance, remove the doors from both

side frames by opening and lifting up off of the pin

hinges. Next, position the right side frame so that two

of the holes in the floorboard of the side frame line up

with the threaded inserts in the two front rubber bump-

ers. Loosely install two 5/16” x 3/4” long button head

bolts and two steel washers. Do not tighten bolts. At-

tach the rear of the side frame to the lower rear panel

using two 5/16” x 3/4” long button head bolts, two

plastic washers, and two steel washers (see fig. 6.1).

Note: the side frame tubing has factory installed

threaded inserts. CAUTION: to avoid cross thread-

ing the factory installed threaded inserts, start the

bolts by hand (no tools). Do not tighten these bolts

yet. The other side frame will be installed in step 7

(after the rear panel is positioned).

7. REAR PANEL & LEFT SIDE FRAME

7.1 NOTE:The rear panel must be positioned in

place at this time because clearances will not allow

it to be put in place after side frame installation.

7.2 At this time, peel back the narrow protective sheet

remaining on the sound barrier of the lower rear panel.

Fold it down on to the 90 degree bend of the lower rear

panel. Note: adhesive-backed sound barrier should be

applied to a clean, dry surface at room temperature.

7.3 With assistance, place the rear panel in position

and rest it against the ROPS (see fig. 7.1).

7.4 With assistance, install the left side frame so that

two of the holes in the floorboard of the side frame line

up with the threaded inserts in the two front rubber

bumpers. Loosely install two 5/16” x 3/4” long button

head bolts and two steel washers. Do not tighten bolts.

7.5 Attach the rear of the side frame to the lower rear

panel using two 5/16” x 3/4” long button head bolts,

two plastic washers, and two steel washers (as shown

in figure 6.1). Do not tighten bolts.

Fig. 7.1 (view from front of left side)

8. COWL

8.1 With assistance, install the cowl to the lower front

of the side frames. Use two 5/16” x 3/4” long button

head bolts, two steel washers, and two plastic washers

per side to connect to the factory installed threaded

inserts in the side frame tubing. See fig. 8.1. Install one

5/16” x 3/4” long button head bolt, two steel washers,

and one locknut through the floorboard with the head

of the bolt up top as shown in fig. 8.1.1. Repeat for

opposite side. Leave bolts loose.

Fig. 8.1 (view from front of right side)

button head bolts,

plastic washers,

and steel washers

Fig. 8.1.1 (view from front of right side)

bolt through cowl

(bolt head up top)

PAGE 7 OF 21

9. WINDSHIELD SUPPORT

9.1 With assistance, install the windshield support to

the upper front of the side frames. Use one 5/16” x

3/4” long button head bolt, one steel washer, and one

plastic washer in the lower hole on each side of the

windshield support (into the factory installed threaded

insert in the side frame tubing). See fig. 9.1. Install two

5/16” x 3/4” long button head bolts, four steel washers,

two plastic washers, and two locknuts to the middle

and upper holes in the windshield support. Locknuts to

be towards the inside of the cab. Repeat for opposite

side. Leave bolts loose.

10. WORK LIGHTS

10.1 Install the two supplied grommets in the lower of

the two holes in the front face of the windshield sup-

port. Install the work light bolts into the upper of the 2

holes in the windshield top. Run the wires through the

holes with grommets below as shown in Figure 10.1.

(Note: The work lights are mounted upside down)

plastic washer

Fig. 9.1 (view from front of right side)

Fig. 10.1 (view from front of right side)

11. REAR PANEL

11.1 Attach rear panel to the left and right side frames

with eight 5/16-18 x 3/4” long button head bolts and

steel washers (four per side) into factory installed

threaded inserts. See figure 11.1.

12. ROOF

12.1 Remove the tethered pins and tip the folding

ROPS to the rear being careful not to scratch the rear

panel. Install the roof so that the visor portion is facing

forwards (see fig. 12.1).

(Note: For easier installation, use a screwdriver to

puncture through the foam headliner on the roof

through each of the bolt holes before installing. Do

this from the inside to prevent any unwanted tearing.)

12.2 Install one 5/16” x 3/4” long button head bolt,

with one steel washer, and one plastic washer each on

the left and right side of the roof into factory installed

inserts, in the top, front section of the side frames.

12.3 Use two 5/16” x 1” long button head bolts, four

steel washers, two plastic washers, and two locknuts

for the two holes directly in front of the two bolts in-

stalled previously. The locknuts should be underneath

the roof.

12.4 Use two 5/16” x 3/4” long button head bolts,

four steel washers, two plastic washers, and two lock-

nuts for the two front holes, locknuts to be underneath

the roof.

12.5 Use six 5/16” x 3/4” long button head bolts,

twelve steel washers, six plastic washers, and six lock-

nuts for the four rear holes, locknuts to be inside the

cab.

12.6 Lift folding portion of ROPS back into position

and re-install the tethered pins, including the cotter

pins.

13. ROLL BAR BRACKETS

13.1 Attach the larger half of the two piece roll bar

bracket assembly to the rear of the side frame using

two 5/16” x 3/4” long button head bolts and two steel

washers. Orient as shown in fig. 13.1. Do not tighten

bolts. Assemble the other half by inserting the tab into

the slot. Install one 5/16” x 3/4” long carriage bolt, one

steel washer, and one locknut so that the locknut and

washer are on the outside as shown.

Fig. 11.1 (viewed from front of left side)

button head bolt

and steel washer

PAGE 8 OF 21

Fig. 12.1 (viewed from front of left side)

1” button

head bolts

larger half of

roll bar brackets

washer and locknut

Fig. 13.1 (view from rear of right side)

outside surface

of side frame

14. WINDSHIELD

14.1 Install the 3/4” thick plastic spacers onto the wind-

shield hinges and insert four 5/16” x 1 3/4” long flat

head bolts. See figure 14.1.

14.2 With assistance, lift the windshield in place and

engage the bolts into the slots. Attach 5/16” steel wash-

ers and 5/16” locknuts to the inside. Align the sides of

the windshield with the side frames, engage both wind-

shield latches in the closed position, then tighten the four

flat head bolts in the upper hinges. Note: hinges are

plastic components. Do not overtighten. Torque to 7

ft./lbs. max..

14.3 The left and right windshield latches can engage in

three positions: closed, open 1”, or open 2” at the bot-

tom.

15. TIGHTEN ALL BOLTS

15.1 Tighten all bolts at this time. First tighten the roll

bar brackets and the lower rear panel bolts that go into

the back of the sideframes. Then work from the front to

the rear. (lower front of side frames, cowl, windshield

support, roof, then rear panel.)

16. DOORS

16.1 Apply grease to the pins mounted on the doors.

With assistance, install the doors pins into the sleeves on

the sideframes. Work the doors back and forth until the

hinges are completely seated. Note: the hinges, and

striker pin can be adjusted for proper engagement. The

rotary latch should be adjusted to get two (2) “clicks”

when latching.

16.2 Install the gas shock to the side frame and door

with the small piston end towards the door. Press the

button on the compression fastener to lock the gas shock

to the ball stud. See figure 16.2.

CAUTION: for safe operation, do not drive with

doors open. Make sure doors are closed and properly

latched when driving.

17. FINAL WIRING

17.1 Connect the ring terminals on the wire harness

containing the relay and fuse to the respective colored

battery posts. (Red to positive; black to negative) The

red terminal can be re-tightened, but leave the black ter-

minal loose because more wires will be attached in later

steps. Stretch the harness forward and connect the male

bullet terminal on the end of the purple wire to the fe-

male bullet terminal on the vehicle wire harness. This is

located on a pigtail under the deck near the HST dipstick

and filler cap. See fig. 17.1.

compression

fasteners

this end on door

Fig. 16.2 (gas shock for hard sided doors)

PAGE 9 OF 21

Fig. 17.1 (view from left side of vehicle)

female bullet terminal

3/4” thick

plastic spacer

Fig. 14.1 (view from front of left side)

17. FINAL WIRING (cont’d.)

17.2 Route the wiper wire harness (black plug on one

end) down the steering column and back to the battery.

Drill a 3/8” hole in the vehicle steering column cover

(Note: Be sure to check for clearance inside the col-

umn, do not drill too deep) and feed the harness

through the hole, and down the inside of the steering

column. (Note: A wire hook or snake can be used to

pull the wire down through the column easily) Leave

8” out of the hole so there is enough wire to open the

windshield. Route the wires back to the battery. Be

careful to avoid any moving parts which may pinch or

sever the wires. Crimp the supplied ring terminal to

the end of the black wire. See fig. 17.2.

17.3 Attach the toggle switch bracket to the passenger

side of the windshield support using two 1/4-20 x 3/4”

hex head bolts, four 1/4” steel washers, and two 1/4-20

locknuts. See Fig. 17.3.

17.4 Locate the wire harness with the toggle switch.

Remove the nut on the toggle switch and put the toggle

switch through the hole in the mount. Make sure that

the groove on the toggle switch is at the bottom of the

hole so that the point that is laser cut in the hole keeps

the switch from spinning. Reinstall the nut and tighten.

17.5 Connect the two sets of female bullet connectors

to the male bullet connectors on the work lights.

17.6 Attach the adhesive cable tie mounts to the cab

as shown in Fig. 17.6. (3 on the windshield support, 3

on the side frame, and 4 down the side of the rear pan-

el). Starting at the driver’s side work light, neatly ca-

ble tie the wires to the vehicle.

17.7 Route the wires out the hole in the bottom corner

of the cab between the fender and sideframe. Connect

the three ring terminals on the black wires from the

three harnesses to the negative battery post and tighten.

Connect the two piggy back terminals together from

the work light and wiper harnesses and wrap electrical

tape around them leaving the end open. Attach them to

the outermost open post on the relay. Secure all wires,

the relay, and the fuse to the vehicle with cable ties so

that they cannot catch on any moving parts.

17.8 See Fig. 17.8 for a full wiring schematic.

PAGE 10 OF 21

Fig. 17.2 (viewed from front right side)

3/8” drilled hole

Fig. 17.3 (viewed from rear right side)

Fig. 17.6 (viewed from rear right side)

Fig. 17.8 (wiring schematic)

Battery Positive (Red)

Battery Negative (Black) To Worklights

25A

Relay

Signal Wire (purple)

Wiper Plug

Piggybacks (Red)

Toggle Switch

1” button

head bolts

Toggle

Switch

Cable Tie

Holders

2 Not

Shown

wiper wire connector

18. WINDSHIELD WIPER

CAUTION: Make sure that the metal parts of the wiper motor do not contact the glass during installation. Damage

could occur. WARNING: Over tightening wiper mounting hardware can damage windshield and components.

18.1 Install the pantograph wiper motor as shown below in figure 18.1. Install blade to arm and arm to wiper motor.

A factory installed set screw has been provided to ensure that the arm does not work its way off the splined shaft of

the motor. Tighten that one set screw to 2 foot-pounds max. (or 24 inch-pounds max.).

PAGE 11 OF 21

19. FINISHING TOUCHES

19.1 Install nut covers on all exposed nuts inside the cab. Also install on the nut protruding from the roll bar brackets.

19.2 Cut the supplied grit paper to fit on each of the side frame floorboards to prevent slipping when entering or exiting

the cab. Adhere the grit paper to a clean dry surface at room temperature.

20. CARE AND MAINTENANCE

20.1 Check and tighten hardware after 40 hours of operation. Periodically inspect and tighten hardware for the remainder

of the unit’s life.

20.2 Wash the painted surfaces of the unit with commercial automotive cleaning products.

20.3 Clean windows with glass cleaner.

Fig. 18.1 (wiper motor installation)

1/4-20 Cap Nut

Plastic Cup Washer

Large Rubber Washer

Hex Nut

Plastic Cup Washer

Large

Rubber

Washer

10-32 x 3/4”

Bolt

Pantograph

Wiper Mount

Small White

Nylon Bushing

Large White

Nylon Bushing

Medium White

Nylon Bushing

Windshield

Steel Washer

10-32 Locknut

Small Rubber

Washer

Black Plastic

Standoff

1/4-20 x 5/8” Bolt

Internal tooth

lock washer

DESCRIPTIONQTY.

F5205 HARD SIDED CAB KIT

PARTS LIST FOR ROOF

P. 12 OF 21

F5205 HARD SIDED CAB KIT

PARTS LIST FOR WINDSHIELD

P. 13 OF 21

F5205 HARD SIDED CAB KIT

PARTS LIST FOR REAR PANEL ASSEMBLY

P. 14 OF 21

P. 15 OF 21

PARTS LIST FOR WINDSHIELD SUPPORT AND COWL

F5205 HARD SIDED CAB KIT

PARTS LIST FOR LOWER REAR PANEL AND LOWER REAR MOUNT

F5205 HARD SIDED CAB KIT

P. 16 OF 21

PARTS LIST FOR FRONT MOUNTS AND ROLL BAR BRACKETS

P. 17 OF 21

F5205 HARD SIDED CAB KIT

PARTS LIST FOR SIDE FRAMES

P. 18 OF 21

PARTS LIST FOR HARD SIDED DOORS

P. 19 OF 21

F5205 HARD SIDED CAB KIT

PARTS LIST FOR WIPER

F5205 HARD SIDED CAB KIT

P. 20 OF 21

O.L. = obtain locally

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Kubota F5205 Installation and Owner's Manual

Kubota F5205 Installation and Owner's Manual

Kubota F5205 Installation and Owner's Manual

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