INSTALLATION & OWNER S MANUAL

Transcription

1 Rev. O p. 1 of 16 INSTALLATION & OWNER S MANUAL V4213 BALL CAGE KIT 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. APPROXIMATE INSTALLATION TIME: 3-5 HOURS manual p/n (revised: 1/4/2008)

2 Rev. O p. 2 of 16 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 repair or replacement is complete. This cab is designed and manufactured for use only as reasonable weather protection. This cab is not applicable, nor should the cab be considered as protection against roll over, collision or other accidents that may result. This cab is NOT a R.O.P.S. cab. Extreme care should be taken when operating and by qualified, experienced operators only. ADDED WEIGHT Cabs, blades and general accessories add additional weight to the base vehicle. All accessory weights are listed in product brochures. Deduct the accessory's total weight from the vehicle's rated capacity and never exceed the vehicle's rated capacity including driver and passenger.

3 CAB INSTALLATION BEFORE YOU START HELPFUL REMINDERS: A. Refer to parts diagram toward the back of this manual to help identify parts during the assembly process. B. Leave all bolts loose for later adjustment unless otherwise specified. NOTE: DO NOT DIMPLE METAL ROOF BY OVERTIGHTENING FASTENERS. C. Read and understand all instructions before beginning. D. If installing accessories, read all accessory instructions before starting cab assembly. E. If installing overhead console, bench install the radio antenna onto the roof before putting the roof in place. Finish wiring accessories to overhead console before bolting roof in place. F. Plastic washers have been supplied to provide a weather seal around all exterior fasteners. 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 flat washers as required. G. Apply a clear silicone sealant to seal any minor gaps that may occur due to vehicle variances. TOOLS REQUIRED: Rev. O p. 3 of 16 7/16 SOCKET (1/4 DRIVE) 1/4 DRIVE RATCHET 3/8 DRIVE RATCHET 1/2 SOCKET (3/8 DRIVE) 19MM OPEN END WRENCH 1/2 OPEN END WRENCH 7/16 OPEN END WRENCH

4 Rev. O p. 4 of INSTALL WINDSHIELD ASSEMBLY 1.1 With assistance, place the windshield assembly on the front of the vehicle and attach with the following: 2 lower mounting brackets, four 5/16 x 3/4 long hex head bolts, and 4 flat washers. (see Fig. 1.1) NOTE: do not fully tighten these four (4) hex head bolts until step Place a molded rubber spacer between windshield top and front horizontal tube at four double hole locations. (see Fig. 4.1) Fig. 1.1 Inside view of Windshield Assembly

5 Rev. O p. 5 of INSTALL REAR PANEL ASSEMBLY NOTE: remove protective film from rear panel. 2.1 With assistance, place the rear panel assembly on the back of the vehicle and attach with the following: 2 lower mounting brackets, four 5/16 x 3/4 long hex head bolts, and 4 flat washers. (See Fig. 2.1) NOTE: do not fully tighten these four (4) hex head bolts until the roof is installed in step Place a molded rubber spacer between the rear panel top and the horizontal tube at each set of holes. (see Fig. 2.1 and 4.1) Fig. 2.1 Inside view of Rear Panel Assembly 3. INSTALL DOOR RECEIVERS 3.1 Install each door receiver so that the bent, rectangular tubing is on the outer side of the cab (see photo at right), and the end with the single mounting slot is towards the front of the vehicle. Attach to the windshield assembly using one 5/16-18 x 3/4 long hex head bolt and flat washer, and to the rear panel assembly using two 5/16-18 x 3/4 long hex head bolts and flat washers. (NOTE: front and rear assemblies have factory installed threaded inserts in the tubing). Repeat procedure for opposite side. Do not tighten bolts at this time. tubing to be flush

6 Rev. O p. 6 of INSTALL ROOF MOUNT & ROOF NOTE: If installing an overhead console, place the unit in position on the vehicle s two frame tubes that run front to back. Final position the back edge of the overhead console even with the front of the roof cross stiffener. Bench install the radio antenna onto the roof before putting the roof in place. Read all additional accessory instructions and finish wiring all accessories to overhead console before bolting roof in place. 4.1 With assistance, attach the windshield assembly and the roof mount to the vehicle s tubular frame with the following: 4 U bolts, 4 molded rubber spacers, 8 flat washers, and 8 locknuts. (see Fig. 4.1) NOTE: orient the roof mount as shown with the Z bend towards the front, and centered so that the U bolts are equally spaced outside the two overhead frame tubes. Align the roof mount so that it is parallel with the top of the windshield. Tighten locknuts snugly being careful not to overcompress the molded rubber spacers. 4.2 With assistance, place the roof in position with the long angled visor portion to the front as shown in Fig Attach the rear of the roof with the following: 2 U bolts, 2 molded rubber spacers, 4 nylon washers, 4 flat washers, and 4 locknuts. (see Fig. 4.1) Do not tighten these four locknuts. 4.4 The front of the roof attaches to the roof mount with the following: four 5/16-18 x 3/4 long hex head bolts, 4 nylon washers, 8 flat washers, and 4 locknuts NOTE: flat washers and locknuts go underneath the flange of the roof mount as shown in Fig Do not tighten these four locknuts. 4.5 Secure the middle of the roof with two U bolts, 4 nylon washers, 4 steel washers, and 4 locknuts. NOTE: DO NOT DIMPLE METAL ROOF BY OVERTIGHTENING. Fig. 4.1 Side view of Roof

7 Rev. O p. 7 of INSTALL ROOF MOUNT & ROOF ((cont d.) 4.6 Tighten all nuts and bolts, including the 6 upper bolts for the door receivers, and the 8 lower bolts for the mounting brackets. NOTE: where there is a molded rubber spacer, tighten the locknuts snugly, being careful not to overcompress the rubber. DO NOT DIMPLE METAL ROOF BY OVER- TIGHTENING. 4.7 Install 12 nut covers on the 8 locknuts and 4 bolt heads on the top, exterior side of the roof. 5. INSTALL STRIKER MOUNTS 5.1 Install striker mounts as shown in Fig Use 5/16 x 3/4 long hex. head bolts and flat washers to attach the striker mount to the inside of the lower, front tubing of the windshield assembly where there are factory installed threaded inserts. Install striker bolt in striker mount as shown below. (NOTE: finger guard to end up being centered and facing inwards.) Repeat procedure for opposite side. Fig. 5.1 Inside view of driver s side

8 Rev. O, p. 8 of 16 IMPORTANT NOTICE! The enclosed door hinges must be installed and adjusted accurately for proper door performance including the prevention of hinge fatigue and/or premature wear of the striker bolt. 6. INSTALL DOOR HINGES Install right side door hinges per figures 1 and 2, use 1 1/2 long bolts to install the pin hinges to the outside surface of the curved rear tube as shown, paying careful attention to the pin orientation in fig. 1. The head of each rear tube bolt, the washer, and the tube spacer should all be towards the inside of the cab as shown in fig. 2. Locknuts to be towards the outside of the cab. Leave bolts loose for now. On a flat, padded working surface, install the hinge sleeves to the exterior of the door as shown in fig. 2. Use 7/8" long bolts. Discard all hinge plates and any extra bolts. The head of each bolt is to be on the inside surface of the door with the locknuts towards the outside surface of the door as shown in fig. 2. Leave bolts loose for now. Apply lubricant (preferably grease) to the pins. With assistance, install the door onto the pin hinges by guiding both hinge sleeves onto their respective pin hinges as shown. NOTE: with the door in hand, approach the pin hinges from approximately a 45 degree angle from the rear of the vehicle as shown in fig. 4 on the next page (so the roof will not interfere with door installation). Work the doors back and forth until the hinges are completely seated. CAUTION: be extremely aware of pinch points between upper door section and roof, as well as between the pin hinge and the hinge sleeves themselves. Repeat for left side of vehicle per figures 2 and 3 (again paying special attention to the pin hinge orientation shown in fig. 3). Fig. 1 Right side rear panel tube and door Fig. 2 Hardware Detail Fig. 3 Left side rear panel tube and door Per this straight line drawn up through fig. 1, use a straight edge to be sure the hinges are in line with each other when tightening bolts.

9 Rev. O, p. 9 of 16 Fig. 4 Door and roof clearance diagram 7. FINAL DOOR ADJUSTMENTS With the door loose, close and latch the door. Per fig. 1 on the previous page, use a straight edge to be sure the hinges are in line with each other. Tighten all hinge bolts. NOTE: Top of door should end up visually parallel with side of roof. Specific adjustments can be made as follows: (NOTE: an assistant will be needed to accomplish this step.) Per fig. 5, the 1/4-20 hex head bolts on the door hinges can be loosened on the rear tube, or on the door itself, or in both places, in order to slightly rotate the door or adjust up and down, front to back as necessary for proper alignment with the cab and front to back engagement of the latch with the striker pin. Keep the hinge sleeves fully seated on the pin hinges. Per fig. 6, the large striker bolt and nut can be loosened and reset for better engagement in the latch assembly if necessary. Use two 3/4 open end wrenches. (NOTE: finger guard to end up being centered and facing inwards.) On soft sided and driving range enclosures, the inside door latch can also be adjusted front to back for better engagement with the striker bolt. NOTE: the latch is a rotary type with two positions to close. Adjust door so that when fully closing door latch clicks twice for total engagement. CAUTION: FOR SAFE OPERATION, DO NOT DRIVE WITH DOORS OPEN. MAKE SURE DOORS ARE CLOSED AND PROPERLY LATCHED WHEN DRIVING. EXTERIOR VIEW OF RIGHT SIDE DOOR Fig LUBRICATION Once the doors are properly adjusted, lubrication (preferably grease) can be applied to the striker bolts and latch assemblies. Reapply periodically as needed (same goes for the door hinges as necessary). Fig. 6

10 KUBOTA RTV 900 V4211, V4212A, V4213, V4262, V4275 Door Hinge Kit Kubota p/n (ref.: code no.: 9PH008X) Rev. O, p. 10 of 16 PIN HINGES HINGE PLATES TUBE SPACERS 1/4-20 x 7/8 LONG HEX HEAD BOLTS HINGE SLEEVES 1/4 USS FLAT WASHERS 1/4-20 x 1 1/2 LONG HEX HEAD BOLTS 1/4-20 LOCK NUTS CONTENTS OF ONE HINGE KIT: (2 hinge kits required per cab) 8-1/4-20 x 1 1/2 long hex head bolts (for Hard Sided doors and Rear Panel hinges) 4-1/4-20 x 7/8 long hex head bolts (for all doors except Hard Sided doors) 8-1/4-20 locknuts 4-1/4 USS flat washers (for rear panel tube only) 2 - hinge sleeves (for doors) 1 - pin hinge (left hand) (for rear tubing) 1 - pin hinge (right hand) (for rear tubing) 2 - hinge plates (for hard sided door tube only) 4 - tube spacers One kit equals one door. Two kits required per cab.

11 Rev. O p. 11 of 16 CARE AND MAINTENANCE Check and tighten hardware after 40 hours of operation. Periodically inspect and tighten hardware for the remainder of the unit s life. Wash the painted surfaces of the unit with commercial automotive cleaning products. Clean windows with glass cleaner.

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