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DFK INTIMIDATOR XD 4 Installation Instructions Manual

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INSTALLATION INSTRUCTIONS
INTIMIDATOR
XD 4
.

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Summary of Contents for DFK INTIMIDATOR XD 4

  • Page 1 INSTALLATION INSTRUCTIONS INTIMIDATOR XD 4...

  • Page 2: Safety Instructions

    Failure to properly latch/lock front window before driving the vehicle could result in serious injury. Please be careful not to break the plastic washers, if you’re tightening screws with plastic washers use max torque of 3.7 foot-pound force (5 Nm)!!! FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...

  • Page 3: Maintenance And Cleaning

    INTIMIDATOR XD 4 WARNING: For safety purposes, if the DFK Cab doors are removed, it is mandatory that the OEM manufactured Half Doors or Nets are REINSTALLED before operating the vehicle. MAINTENANCE AND CLEANING To clean polycarbonate surface use soapy water solution or other subtle means.

  • Page 4: Tools Needed

    Metric wrench 13mm, Socket beg 8 mm Utility knife 17mm (0,31 in) Hex key 5mm, 6 mm and Hole saw 76 mm Drill ø 2,5-4mm (3 in) ( 0,1- 0,16 in) FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 5 INTIMIDATOR XD 4 Drill ø 8mm Drill ø 12 mm Drill ø 21mm (0,31-0,33 in) (0,5 in) (0,83 in) FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...

  • Page 6: Preparation For Installation

    Uninstall all additional systems from the roller cages (work lights, rear mirrors, drink holders etc.) Uninstall the safety nets from the UTV’s body and roller cage. Don’t cut nets, you can use these in future. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 7 INTIMIDATOR XD 4 CAB PREVIEW FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 8 INTIMIDATOR XD 4 LEFT DOOR BASE + RIGHT DOOR BASE Uninstall the originall screw (in red circle) from the UTV’s body and save these carefully. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 9 INTIMIDATOR XD 4 Place the right door base onto the roller cage to correct position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 10 INTIMIDATOR XD 4 Fix the door base with the UTV’s body by original screw and incuded washers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 11 INTIMIDATOR XD 4 Adjust the door base to best position gently. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 12 INTIMIDATOR XD 4 Place the right door base upper holder onto the door base and onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 13 INTIMIDATOR XD 4 Fix the holder with the base to the roller cage by screws, washers, nuts and covers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 14 INTIMIDATOR XD 4 Place the door base holder “Ω” onto the door base and onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 15 INTIMIDATOR XD 4 Fix the door base with the holder to the roller cage by screws, washers, nuts and covers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 16 INTIMIDATOR XD 4 Place the door base middle right holder onto the door base and onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 17 INTIMIDATOR XD 4 Fix the door base with the holder to the roller cage by screws, washers, nut and covers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 18 INTIMIDATOR XD 4 Place the base upper holder onto the door base and onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 19 INTIMIDATOR XD 4 Fix the holder with the base to the roller cage by screw, washer, nut and cover. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 20 The left door base installation is similar with the right door base, just repeat previous steps with left parts. Tighten all nuts and screws on door base assemblies hard. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...

  • Page 21: Rear Panel

    INTIMIDATOR XD 4 REAR PANEL Place the rear window holders onto the door base holder’s welded screws. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 22 INTIMIDATOR XD 4 Fix the window holders with the base holders by nuts, washers and covers on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 23 INTIMIDATOR XD 4 Uninstall the originall screws (in red circles) from the UTV’s body. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 24 INTIMIDATOR XD 4 Place the rear bottom ledge onto the forklift frame and adjust to best position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 25 INTIMIDATOR XD 4 Place the rear ledge holder onto the rear ledge and onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 26 INTIMIDATOR XD 4 Fix the rear bottom ledge with the holders to the roller cage by nuts, washers and covers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 27 INTIMIDATOR XD 4 Fix the bottom rear ledge with the UTV’s body by washer 10 and original screws. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 28 INTIMIDATOR XD 4 Take out the protective films from the rear window. Place the rear window with sealing onto the roller cage and move that to the bottom ledge. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 29 INTIMIDATOR XD 4 Adjust the rear window holders to best position and fix the holders with the window by screws, washers, nuts and covers on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 30 INTIMIDATOR XD 4 Adjust the rear assembly to best position and tighten all screws and nuts hard. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 31 Use the right door stop holder and right front ledge holder(on picture) on right side of the roller cage. YOU CAN’T MAKE MISTAKE BETWEEN LEFT AND RIGHT PARTS, IF YOU MAKE MISTAKE, YOU ARE GOING TO HAVE BIG PROBLEM WITH DOOR STOP ADJUSTING! FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 32 INTIMIDATOR XD 4 Uninstall the originall screws (in red circles) from the roller cage and save these. (See next page) FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 33 INTIMIDATOR XD 4 Detail view… FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 34 INTIMIDATOR XD 4 Place the front bottom ledge onto the dashboard and onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 35 INTIMIDATOR XD 4 Fix the front bottom ledge with the roller cage by original screws on right side and repeat previous steps on left side of the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 36 INTIMIDATOR XD 4 Place the front ledge holder assemblies onto the front ledge and onto the roller cage on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 37 INTIMIDATOR XD 4 Fix the holder with the ledge to the roller cage by screws, washers, nuts and covers on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 38 INTIMIDATOR XD 4 Place the front ledge support holder onto the ledge welded holder and onto the front bottom ledge on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 39 INTIMIDATOR XD 4 Fix the support holder with the ledge and with the ledge holder by nut, washer and cover on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 40 INTIMIDATOR XD 4 Place the upper front ledge onto the roller cage and adjust to best position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 41 INTIMIDATOR XD 4 Place the strap-ring onto the front ledge and onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 42 INTIMIDATOR XD 4 Fix the strap-ring with the front ledge to the roller cage by screws, washers, nuts and covers and tighten these correctly. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 43 INTIMIDATOR XD 4 ELECTROINSTALLATION – WIPER SET 1. View onto the wiper motor with the cover and with the middle ledge. Place the washer onto the wiper longer pin. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 44 INTIMIDATOR XD 4 Place the washer onto shorter wiper pin. View onto installed washers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 45 Insert these washers onto the wiper’s pins and onto the glass from outer side. Fix the wiper motor with the front glass by included nuts and tighten these correctly. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...

  • Page 46: Front Panel

    INTIMIDATOR XD 4 FRONT PANEL Place the front window with the hinge to the front upper ledge. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 47 INTIMIDATOR XD 4 Fix the front window’s hinges with the hhinge’s bases to the front ledge by screws, washers, nuts and covers. Tighten these screws and nuts hard. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 48 INTIMIDATOR XD 4 ROOF Stick the self-glued seal onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 49 INTIMIDATOR XD 4 Place the roof onto the roller cage and adjust to correct position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 50 INTIMIDATOR XD 4 Place the roof holders onto the roof onto the front upper ledge and onto the roller cage on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 51 Fix the roof with the front ledge and with the roof holders to the roller cage by screws, washers, nuts and covers. Tighten these screws and nuts gently now. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 52 INTIMIDATOR XD 4 Fix the rear window with the roof by screws, washers, nuts and covers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 53 INTIMIDATOR XD 4 Adjust the roof and the front upper ledge with front window to best position and tighten all screws and nuts. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 54 XD 4 FRONT PANEL Install the gas spring onto the gas spring holder on both sides. It’s necessary to install the gas springs in same position like on picture. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 55 INTIMIDATOR XD 4 Open the window and install the gas spring into the gas spring metal holder. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 56 INTIMIDATOR XD 4 Fix the gas spring with the gas spring metal holder by nuts and cover on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 57 INTIMIDATOR XD 4 LEFT DOOR + RIGHT DOOR Lubricate the hinge’s pins and insert the washers onto the hinge’s pins. Insert the door onto the hinge’s pins. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 58 INTIMIDATOR XD 4 Loosen the door hinge’s screws. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 59 Adjust the door by hinges to best position. If you have some gapes between the door seal and the roller cage or UTV’s body, you can insert more washers 10 onto the hinges, or take out washer 10 from the hinges. Tighten the hinge’s screws and nuts correctly. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 60 If you close the door slowly and adjust the door stop correctly, you can hear 2 clear metalic click. After you adjusted the door stop to best position tighten all screws and nuts hard. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 61 XD 4 If you have some gapes between the EPDM and UTV’s body, loosen the bottom ledge’s nuts and adjust the EPDM to better position. Tighten these nuts correctly. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 62 INTIMIDATOR XD 4 Install the gas spring into the door base gas spring holder. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 63 INTIMIDATOR XD 4 Fix the gas spring with the gas spring holder by nut, washer and cover. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 64 INTIMIDATOR XD 4 Place the gas spring holder onto the door frame. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 65 INTIMIDATOR XD 4 Insert the gas spring into the holder and adjust the holder to best position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 66 INTIMIDATOR XD 4 Fix the gas spring holder with the door frame by TEX screws, washers and TEX covers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 67 INTIMIDATOR XD 4 Fix the gas spring with the holder by nut, washer and cover. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 68 Uninstall the screws from the door and place the mirror washer and the right rear mirror onto the door panel. Fix the mirror with the base to the door by screws from previous steps. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 69 INTIMIDATOR XD 4 Repeat previous steps with the left door and left parts. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 70 INTIMIDATOR XD 4 ELECTROINSTALLATION WIPER/WASHER ASSEMBLY Parts needed (Included) Washer tube Switch wiper/washer/off Harness and washer tank FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 71 Run the harness branch No.:1 around the roller cage to the wiper motor. Connect the harness branch No.:1 with the wiper motor and stretch the washer hose through the bushing. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 72 If you don’t find connection for connectors installed on harness branch, you can use other connectors (included). Fill the washer liquide into the washer tank before first usage. SEE NEXT PAGE FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 73 If you connect all harness connectors correctly, pin is turning. Find the ends of turning and install the wiper arm on correct position. Fix the wiper arm with the wiper motor pin by included nut. Insert plastic holder onto the wiper latch pin in correct position FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 74 INTIMIDATOR XD 4 View onto the installed plasstic holder. Insert the wiper arm hook onto the wiper latch plastic holder and press it into the correct position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 75 INTIMIDATOR XD 4 View onto installed wiper arm hook. Connect the washer hose from the harness with the washer hose from wiper arm by included tube. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 76 Parts needed (included) Heater with cover Bleeding valve Electric vent Tightening straps Air vent corner Air vent straight Small, medium and large Hot air hose AL tape “Y” coupling 14/18/14 FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 77 INTIMIDATOR XD 4 Y couplings El. Vent switch Heater switch assembly Heater harness Hot water hose Air vent grill holder Air vent grill FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 78 INTIMIDATOR XD 4 Exploded view to important parts FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 79 INTIMIDATOR XD 4 IMPORTANT IT IS ABSOLUTELY NECESSARY TO TAKE OUT THE RUBBER PLUGS FROM THE HEATER TUBES!!! FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 80 Install the heater with the heater holder to best position (where you like these) and fix these with the UTV’s body by correct screws. Connect harness branch No.: 3 with the heater connector. Connect the harness branch No.: 4 with the electromagnetic vent. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 81 Drill 1 hole ø 11,5-14mm (0,45-0,55 in) and 2 holes ø 2,5-4 mm ( 0,1- 0,16 in) into the dashboard in accordance with the ventilator switch base. Be very carefull to find best place for switches. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 82 Drill hole ø 21 mm for electromagnetic vent switch into the dashboard. Pull the harness branch No.: 2 throught the hole from previous page (bottom picture) and connect the branch with the switch. Detail of connection. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 83 Connect hot water hoses with the UTV’s cooling circuit near the cooler by pair of “Y” coupling (included). If you have detailed information about engine cooling circuite and you are sure about correct connection, you can make that. SEE NEXT PAGE FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 84 Repeat this procedure until heater/cooling system is completely bleeded out. The DFK Cab heater, like the heater in a car, generates heat from the vehicle’s engine. In nearly all cases, the heater should generate enough heat from your UTV, side by side, or tractor engine that you may need to turn the heater off periodically otherwise the air in the cabin may be too hot.