INSTALLATION INSTRUCTIONS POLARIS RANGER 400 H.O..
SAFETY INSTRUCTIONS Warning: Failure to heed all safety and operating instructions and warnings regarding use of this product can result in serious bodily injury. READ PROPERLY COMPLETE ASSEMBLY INSTRUCTIONS BEFORE STARTING OF ASSEMBLY Install all parts indicated in assembly instructions. Failure to fully assemble product before use could result in personal injury. Assembly of product requires use of hand or power tools. If you are not experienced in using these types of tools, have product dealer do the install for you. Some parts contain sharp edges, wear protective gloves if necessary. Always keep your assembly area clean, uncluttered and well lit. Keep visitors and children a safe distance away from the assembly area. Visitors should wear the same safety equipment described above. 2 Never operate your UTV with the cab doors open. Failure to properly latch the doors before moving the vehicle could result in serious injury. Dress for safety. DO NOT wear loose clothing, gloves, neckties or jewelry if using power tools to assemble this product. Tight the front glass holders screws with attention, if you tight these screws too hard the front glass may by crackle. Insert all nut covers after you finish installation.
MAINTENANCE AND CLEANING To clean polycarbonate surface use soapy water solution or other subtle means. Dirt and dust wash by gently water stream and swipe only with wet or damp means in the direction from top to bottom. The recommended frequency of cleaning of polycarbonate part is about 1 time per month or according to the actual degree of pollution. Do not use detergents that could scratch the surface plates. (abrasives, harsh fabrics, etc.) Do not use solvents or alkaline detergents or cleaners with ammonia (ammonium hydroxide). Do not remove the impurities from the surface of the razor blades or other sharp items. Do not clean cabine, when the polycarbonate plates are heated by the sun. 3 Do not use the squeegee, it could be scratched surface plates. Do not clean the water current strength greater than 50 bar (WAP) The manufacturer is not responsible for scratching the surface in case of failure to comply with the above instructions. All bolted connections of cab must be by user at regular intervals checked and tightened. ROOF PANEL 1.
Place the roof panel on to the roller cage from above and don t fix it. POLARIS RANGER 4 METAL DOOR BASES
Place the metal door bases on to the roller cage from both sides. The upper end of the door bases belongs under the roof panel. 5 Press gently the door bases onto the roller cage. Screw together the door bases with the roof panel using the prepared holes. Fix it by screw M6x20 with washer.
6 REAR PANEL Place the polycarbonate rear panel on to the metal door bases from behind. The upper end of the rear panel belongs under the roof panel.
7 Screw the bottom part of the rear panel to the roller cage in the bottom corners on both sides with bolts M8x80 and nut M8 (see the red circles).place the rear holder onto the door bases. Fix the panel with bolts M8x30 and nuts M8 and place the plastic covers on the nuts from inside.
8 Place the bottom metal rear ledge on to the body from behind.
9 Fix the ledge with bolts M6x20 and nuts M6 and two washers.
10 FRONT PANEL MOVABLE 1.
Place the bottom metal windshield ledge onto the body from the front side of the dashboard. This ledge should lay on the body on the rubber foam sealing. 11 Install the pin of door stop assembly into the door stop pin holder. Place pin holder onto ledge holder and fix these by washers, nuts and nut covers.
(Door stop pin holder left is the same with right just opposite bend.) POLARIS RANGER 12 The ledge should be fixed to the roller cage with the holders on both sides. These holders contain the door lock stoppers.
13 Fix the ledge with bolts M8x35 and nuts M8 and place the plastic covers on the nuts from inside.
14 Detail view to the right door stop.
15 Cut the tightening straps in the hinges and place the hinge washers onto the front window hinges and place the upper front ledge onto the hinge washers.
16
Fix the hinges with the front upper ledge by screws, washers, nuts and nut covers. POLARIS RANGER 17
Uninstall the screws from rear roof corner on both sides. 18
Take up the front part of the roof. 19
Place the front window with the ledge onto the roller cage and adjust to correct position. 20
Place the front ledge holders onto the roller cage to correct position. POLARIS RANGER 21
Fix the roof with the front upper ledge and with the holders to the roller cage by screws, washers, nuts and nut covers. Adjust the front panel to best position and tighten these screws gently. 22
ROOF 2. Place the rear roof holders onto the roller cage and the roof. POLARIS RANGER 23
Fix the roof with the roof holders to the roller cage by screws, washers, nuts and nut covers. Don t tighten these screws yet. 24
FRONT PANEL MOVABLE 2. Insert the front glass lock s pins (red) into the glass locks and glass lock holders on both sides. 25
Allow the glass lock screws (in red circle) on both sides and close the front glass correctly. Adjust the glass lock s metal holders on both sides to best position, tighten screws (in red circle) and take out the glass lock s pins (red). If you have any gapes between the window bottom seal and front bottom ledge, you can repair it by adjusting the holder. Tighten glass lock holder s screws and nuts hard. 26
Open the front glass and insert the gas springs to holders on both sides. 27
Insert the gas spring s bottom pins in the gas spring metal holders and fix these by nuts and nut covers. 28
ROOF Fix the door bases with the roof by screws on both sides. 29
Fix the roof with the rear window and with the door bases by screws, washers, nuts and nut covers. 30
DOOR LEFT AND DOOR RIGHT Place the right door hinges onto the right door base on correct position. POLARIS RANGER 31
Fix the door hinges by screws M8x30 and nuts M8 and place the plastic covers on the nuts from inside. Do not tighten screws hard yet. 32
DOOR ASSEMBLY Lubricate the hinge s pins and insert the door on the hinges (see the picture below) 33
Adjust the door by the door hinges to best position (no gapes between doors, roof and UTV body). Close the door slowly and insert the door stop pin into the door lock.adjust the pin holder to best position and tight the nuts. If you close the door slowly now and the door stop pin holder is adjust correctly you can hear clear metalic click. Now tighten screws and nuts hard. 34 Loosen the screws and move up or down adjustable ledge with sealing on the bottom end of
doors to close the gaps between the polycarbonate doors and the floor. The doors should seal now all-around well, there mustn t be any gap between the body and the doors. If any gap appears, repeat the positioning of the doors at hinges. 35
If you have some problems with the the door rear bottom ledge installation you can adjust that. SEE NEXT PAGES 36
Take out the nut covers and allow the nuts (in red circles). Save the cover carefolly, you need these later. 37 You may be have to take out the seal from the door ledge.
Adjust the ledge to best position and tighten nuts gently. Place the seal onto the ledges and close the door few times. If the ledge is adjusted correctly, tighten the nuts and place the nut covers 38 INSTALLATION OF THE LEFT DOOR IS IDENTICAL WITH THE INSTALLATION OF THE RIGHT DOOR
39
ELECTROINSTALLATION WASHER SYSTEM: Overall wiring diagram (wiper, washer, heating). 40 Accessories for mounting the bottle washer.
Bottle washers placed in front of the cart through the bracket bolt to the truck frame. 41
DIP SWITCH no. 510: Connection on pins: 2, 4, 5 2 yellow+black wire, minus pole 4 yellow+green, washer motor 5 green, wiper motor 42
CONNECTION: WIPER MOTOR 12V, 175 POLARIS RANGER Connect the wiring harness for motor and washer to the UTV. 43
Position of switches for controlling the wiper motor (first position) and washer (second position). 44
Continue with the wiring inside the dashboard and lead it up on the left side of the roller cage to the wiper motor Runs along the original wiring harness in the dashboard. There is a washer hose inside the wiring harness. 45
Detailed schematic diagram of the motor wiring harness: 46 Hose connection to washer jet in the roof. Fill the water to the washer tank before starting usage.
ELECTROINSTALLATION HEATER SYSTEM: Accessories for mounting the heater system harness heater cover Y coupling heater tightening strap screw rivets 47 Air vent valve electromagnetic vent Heater flange
Heater is designed to be inside the glove box at the dashboard. Uninstall door of the glove box from the hinge. POLARIS RANGER 48 Drill 2 holes ø25mm on the left side of the glove box at the dashboard.
Outside view from the front side. (Holes are in red circles) Drill hole ø20mm to the upper side of glove box. 49 Insert hot water hoses and harness into the holes.
Connect the hoses with the pipes of the heater. Connect the harness branch no.: 3 with heater (detail of connection). 50 Connect the harness of heater with switcher in heater cover.
Pull out the plastic button from switch. Uninstall the nut from switch and pull the switch out from the cover. View on to the switch assembly. Connect the heater harness with switch. 51 View on to connected harness. Install switcher back into the heater cover.
Connect the harness branch no.: 4 to the electric vent switch on the heater cover. When the swith is backlit, electric vent is turn off and hot water from engine cooling don t run in heater. Press the heater holder onto the dashboard, drill 3 holes φ8mm, insert screw rivet and tighten. Fix the heater cover with middle holder with the heater holder by 4x screw M5x20. 52
For placing of the electric vent cut the water tube connected to the upper pipe of the heater and insert the electric vent. Fix the water tube with vent by tightening strap. The vent must by in same orientation like in picture. 53 Connect the harness branch no.: 2 with the vent. Detail of connection.
Cut the hose without the electromagnetic vent and insert tightening straps onto the hose. Insert the air vent valve into the both end of the hose and tight the straps hard. Detail view. Principle involved: Hot water heating system connected to the primary (short) circuit of the engine cooling. Cut the cooling system hose lead the cooling liquide back to the engine and install the Y coupling to the heater hose and connect with the hot water hose (red arrow) from heater with the air vent valve. Lead the hose (violet arrow)containing the vent from the floor tunnel to the UTV s engine. 54
Unistall the thermostat flange and thermostat (violet arrow) from the engine body and place the heater flange (red arrow) onto correct position. The heater flange seal must lie on the engine body. Place the thermostat in original orientation onto the heater flange and install the thermostat flange. Fix the flanges with the engine body by included screws and washers. Connect the hot water hose with the heater flange tube and tight very hard by tightening strap. 55 Principle an electric connection to the network of UTV s body: - Heating is connected through a fuse box and then through the ignition box of the truck. SEE NEXT PAGE
Important notice: 1. Before the first turning on the hot water heater it is necessary to check the tightness of the cooling circuit of the hot water heater. 2. If necessary add more cooling liquid to the cooling circuit. 3. Turn UTV s engine on and open the air vent valve. 4. Turn heater on and wait for the maximum temperature. When the cooling liquid starts to leak from the air vent valve close the valve. Turn off heater and add more cooling liquid to the cooling circuit if need it. In cab units where you are installing the glove compartment heater provided in the standard DFK Cab Kit, it is important to check the coolant level regularly at least 4-5 times during the first several days of operation and fill as necessary until the coolant level has stabilized. The heater will draw and retain coolant, sometimes at the expense of coolant to the engine. This can cause engine overheating if not managed properly. 56