DFK Hard Cabs CAN-AM DEFENDER, Installation Instructions Manual

Page 1: ...INSTALLATION INSTRUCTIONS CAM AM DEFENDER MAX ...

Page 2: ...rp 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 under 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...

Page 3: ...ee 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 Do not use the squeegee it could be scratched surf...

Page 4: ...PARATION FOR INSTALLATION Uninstall all additional systems from the roller cages work lights rear mirrors drink holders etc It is necessary to uninstall rear side tubes red lines from the UTV s from both sides Save the tubes with the original screws for later usage Losen the fixing screws red circles and uninstall the tubes ...

Page 5: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 5 CAB PREVIEW ...

Page 6: ...MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 6 FRONT PANEL Place the front console assembly onto UTV roll cage and fix by included fixing assembly on both sides ...

Page 7: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 7 Place the front panel onto UTV roll cage and adjust to the best position ...

Page 8: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 8 Fix the front panel with included fixing assemblies ...

Page 9: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 9 Install gas spring onto gas spring holders on both sides ...

Page 10: ...FENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 10 Adjust the front glass stop assembly into the best position and tighten screws hard on both sides ...

Page 11: ...AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 11 ROOF Uninstall the rear roof panel holders screw before the rear roof panel installation ...

Page 12: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 12 Place and adjust the rear roof panel onto the UTV roll cage ...

Page 13: ...DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 13 Close the rear roof panel holders and fix with included washers screws and covers Tighten hard ...

Page 14: ...464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 14 If you install the cab without the doors fix the rear roof panel with the fixing assemblies If you have the complete cab with the doors fix the rear roof panel with the rear doors frame hinges page 23 ...

Page 15: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 15 Uninstall the front roof panel holders red circles ...

Page 16: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 16 Place and adjust the front roof panel onto UVT roll cage ...

Page 17: ... AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 17 Connect the front and rear roof panel together and fix with included fixing assemblies ...

Page 18: ...DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 18 Install the front roof panel holders to the correct position and tighten the screws correctly ...

Page 19: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 19 Fix the front roof panel onto UTV roll cage with included fixing assemblies ...

Page 20: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 20 REAR PANEL Losen the rear panel holders screws and turn the rear panel holders ...

Page 21: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 21 Place and adjust the rear panel to the best position onto UTV roll cage ...

Page 22: ...N AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 22 Turn the rear panel holders to the correct position and tighten the screws correctly ...

Page 23: ...rdCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 23 LEFT REAR DOOR RIGHT REAR DOOR Install the left rear door hinges and fix onto UTV roll cage with included fixing assemblies ...

Page 24: ...ENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 24 Install the door stop assembly into the rear left door stop holder Fix by included fixing assemblies ...

Page 25: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 25 Place the left rear door stop assembly onto the UTV roll cage ...

Page 26: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 26 Fix the rear left door stop assembly with included screws washers and covers ...

Page 27: ...FENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 27 Place the left rear door onto the hinges If necessary install the washers 10 onto the hinges pins ...

Page 28: ...N AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 28 If necessary losen the hinge srews red circles and set the door to the best position ...

Page 29: ... DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 29 Adjust the rear left door stop assembly into the best position and tigheten the screws hard ...

Page 30: ... AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 30 Install the gas spring holder onto UTV roll cage and fix with included fixing assembly ...

Page 31: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 31 Install the gas spring pins and fix with included washers screws and covers ...

Page 32: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 32 Install the gas spring onto the gas spring pins ...

Page 33: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 33 Repeat previous steps with right rear door ...

Page 34: ... 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 34 LEFT FRONT DOOR RIGHT FRONT DOOR Unscrew the cover fixing screws red cricles and uninstall the plactic cover Save the fixing assemblies for later usage ...

Page 35: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 35 Remove the plastic cover ...

Page 36: ...ENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 36 Install the bottom left front door hinge and fix onto UTV roll cage with included fixing assemblies ...

Page 37: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 37 Remove the hinge cover red rectangle ...

Page 38: ... DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 38 Place the plastic cover back to the correct position and fix with original fixing assemblies ...

Page 39: ...FENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 39 Install the upper left front door hinge and fix onto UTV roll cage with included fixing assemblies ...

Page 40: ...DER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 40 Install the door stop assembly into the front left door stop holder Fix with included fixing assemblies ...

Page 41: ...R MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 41 Place the left front door stop assembly onto the left front console and fix with included fixing assemblies ...

Page 42: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 42 Place the left front door onto the hinges ...

Page 43: ...N AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 43 If necessary losen the hinge srews red circles and set the door to the best position ...

Page 44: ... DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 44 Adjust the left front door stop assembly into the best position and tigheten the screws hard ...

Page 45: ... AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 45 Install the gas spring holder onto UTV roll cage and fix with included fixing assembly ...

Page 46: ...EFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 46 Install the gas spring pins onto gas spring holders a fix with included washers nuts and covers ...

Page 47: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 47 Install the the gas spring onto the gas spring pins ...

Page 48: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 48 Repeat previous steps with right front door ...

Page 49: ...324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 49 ELECTROINSTALLATION WIPER WASHER Install the washer tank holder to the rear part of vehicle red circle Carefully unistall the central tunel cover ...

Page 50: ...CAN AM DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 50 Lead the washer harness through the central tunel and under the dashboard ...

Page 51: ...X HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 51 Install the washer tank onto the washer tank holder and connect the washer motor to the washer harness DETAILED VIEW ...

Page 52: ... Ave Downers Grove IL 60515 info hardcabs com 52 Carefully cut of the dashboard switch blank Lead the wiper washer switch harness branch through the dashboard Connect the wiper washer switch with the wiper washer switch harness branch and press the switch into the dashboard ...

Page 53: ... DEFENDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 53 Drill the hole Ø16 mm into the upper part of the dashboard Install the grommet into the hole ...

Page 54: ...NDER MAX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 54 Lead the wiper motor harness branch with the washer tube around the UTV roller cage to the wiper motor ...

Page 55: ...owners Grove IL 60515 info hardcabs com 55 Install the harness cover ledge into the position and fix by included fixing assemblies Lead the washer tube through the front glass and connect the tube to the washer jet Connect the wiper harness branch to the wiper motor DETAILED VIEW ...

Page 56: ...bs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 56 Connect the wiper washer harness to the UTV original electroinstalation FILL THE WASHER TANK WITH THE WASHER LIQUID BEFORE FIRST USE ...

Page 57: ...AX HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 57 ELECTROINSTALLATION HEATER IMPORTANT IT IS ABSOLUTELY NECESSARY TO TAKE OUT THE RUBBER PLUGS FROM THE HEATER TUBES ...

Page 58: ...s 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 58 Uninstall front floor cover from the UTV Cut the hole 12cmx12cm to the bottom part DETAILED VIEW Install the cover back SEE NEXT PAGES ...

Page 59: ... Ave Downers Grove IL 60515 info hardcabs com 59 Before drilling holes check the space under the dashboard and if necessary take the harness out of the way to prevent damage Cut two holes Ø55mm into the dasboard for the air vents lead the hot air hoses through DETAILED VIEWS ...

Page 60: ... hardcabs com 60 Lead the hot water tube with the el valve to the front radiator red arrow DETAILED VIEW Cut the hot water hose and install the hot watter pump fix the hot water pump by tightening straps and tighten hard Connect the hot water pump to the pump harness and lead the harness back to the heater ...

Page 61: ...0515 info hardcabs com 61 Secure the original cooling system hot water hose by clamps not included cut the hose and install included Y coupling into the hose Connect the heater hose to the coupling and fix all ends by inlcuded tightening straps Cut the hose with the air vent to the correct length ...

Page 62: ...s turn of engine 2 To achieve engine operating temperature depress the accelerator to increase The engine RPM This will increase the preasure and flow of the water pump forcing more coolant through the heater After operating temperature ceache turn of engine and open it Trapped air should come out from heater system throughout bleeding valve Repeat this procedure until heater cooling system is com...

Page 63: ...fo hardcabs com 63 Secure the original cooling system cold water hose by clamps not included cut the hose and install included Y coupling into the hose Connect the heater hose to the coupling and fix all ends by inlcuded tightening straps Connect the el valve to the el valve harness branch DETAILED VIEW ...

Page 64: ...0 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 64 Connect the heater to the heater harness branch DETAILED VIEW Install the heater holder onto the heater and fix by included screws and washers ...

Page 65: ...rdcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 65 Place the heater assembly onto the UTV floor and fix by icluded fixing assemblies It is necessary to drill holes for the rubber nuts in accordance with the heater holder holes ...

Page 66: ...sconsin Ave Downers Grove IL 60515 info hardcabs com 66 Connect the prepared hot air hoses PVC to the heater vens and fix by included Al tape DETAILED VIEW Prepare two shorter pieces of the hot air hose PVC to the rest of heater vents and fix by al tape DETAILED VIEW ...

Page 67: ...dCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 67 Connect the valve harness and the pump to the pre installed valve switch Connect the heater harness to the heater switch base ...

Page 68: ...consin Ave Downers Grove IL 60515 info hardcabs com 68 Cut the hot air hoses PVC to the correct length connect the hoses to the air vent and fix by tightening straps DETAILED VIEW Repeat previous step with the dashboard air vents and press the vents into the dashboard ...

Page 69: ... HardCabs 630 324 8585 www hardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 69 Lead the harness under the dashboard and connect the heater harness to the original electroinstalation SEE NEXT PAGES ...

Page 70: ...ardcabs com 2464 Wisconsin Ave Downers Grove IL 60515 info hardcabs com 70 Place the heater cover with all tubes and harnesses connected into the best position and fix it by included rubber rivets If necessary drill holes Ø8mm for the rubber rivets ...

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