Linhai 550 T Boss Kabina

INSTALLATION INSTRUCTIONS
LINHAI
550 T-BOSS EPS
.
LINHAI
550 T-BOSS EPS
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. 2
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 NOT wear loose clothing, gloves, neckties or jewelry if
using power tools to assemble this product.
Insert all nut covers after you finish installation.
Never drive your UTV with the cab front window in open position.
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)!!!
DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Za Olšávkou 391, Uherské Hradiště 686 01 Fax: +420 572 520 071
Czech Republic E-mail: dfk@dfk.cz
LINHAI
550 T-BOSS EPS
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.
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.)
3
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 cabin when the polycarbonate plates are heated by the sun.
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.

LINHAI
550 T-BOSS EPS
PREPARATION FOR INSTALLATION:

Uninstall all additional systems from the roller cages (work lights, rear
mirrors, drink holders etc.)
CAB PREVIEW

LINHAI
550 T-BOSS EPS
ELECTROINSTALLATION 1.
WIPER / WASHER OVERALL DIAGRAM
----- WIPER HARNESS
----- WASHER HARNESS
----- SUPPLY HARNESS
----- SWITCH HARNESS

LINHAI
550 T-BOSS EPS
Uninstall front dashboard cover and pull out the battery cover.
6
Place the supply harness into the front battery space.

LINHAI
550 T-BOSS EPS
IMPORTANT WARNING
Before you connect supply harness with original connector (next step)
you have to make yourself sure of wire polarity. Red wire in DFK power
supply harness connector must by conected to the plus pole and black
wire to the minus pole. Check polarity of the original connector wires and
swap wires in the DFK supply connector, if polarity don’t corespond.
Connect the supply harness with the original 12V ACC connector.

LINHAI
550 T-BOSS EPS
Push out the original switch cover and insert included switch with harness
into the original switch hole.
8
Install the washer tank with the holder under the right seat.

LINHAI
550 T-BOSS EPS
Run the washer harness through the floor central tunnel from the seat
space to the front dashboard. Connect the washer harness with the
switch harness and run the washer hose to the right front vehicle frame.
9
Place the wiper harness into the front dashboard space. Connect the
wiper harness with the switch harness. Run the wiper harness to the front
right vehicle frame.

LINHAI
550 T-BOSS EPS
Connect the wiper harness and washer harness with the supply harness.
10
Fill the washer liquid into the washer tank before first usage.

LINHAI
550 T-BOSS EPS
HEATER
Install the heater body onto the original tunnel cover.
11
Bottom side view.

LINHAI
550 T-BOSS EPS
Place the heater hose into the tunnel and run the hose to the rear part of
the vehicle.
Install the water pump and el. Valve onto the heater hose. 12
Make sure all tightening straps are tightened correctly.

LINHAI
550 T-BOSS EPS
View onto the heater hose with water pump in vehicle.
13
Run the heater hose to the engine space.
Install the heater tube “Y” onto the heater hose.

LINHAI
550 T-BOSS EPS
CAUTION
DO NOT MANIPULATE WITH ENGINE OR WITH ENGINE COOLING
SYSTEM IF THAT PARTS OF MACHINE IS HOT! WHEN ENGINE IS HOT,
ANY MANIPULATION CAN RESULT IN SERIOUS BODY INJURY!
Secure the original engine cooling hose by pliers or clamps (not included)
and cut original hose between the pliers. Insert the tightening straps onto
the original hose. Insert the heater tube “Y” into the original hose.
Tighten the tightening straps hard.
14

LINHAI
550 T-BOSS EPS
Place the heater hose into the central tunnel. Run the hose through the
tunnel to the front right wheel.
Secure the original engine cooling hose by pliers or clamps (not included)
and cut original hose between the pliers. Insert the tightening straps onto
15
the original hose. Insert the heater tube “Y” into the original hose.
Tighten the tightening straps hard.
Cut 2 holes ø 25mm into the tunnel cover.

LINHAI
550 T-BOSS EPS
Run the heater hoses through the holes. Install the heater hoses into the 16
heater.
Install the heater air hoses the heater by included al straps.

LINHAI
550 T-BOSS EPS
Two bottom hoses has to be shorter.
17
Detail view onto mounted heater air hoses.

LINHAI
550 T-BOSS EPS
Run two longer heater hoses from the heater to the front dashboard
cover.
18
Run two longer heater hoses from the heater to the front dashboard
cover.

LINHAI
550 T-BOSS EPS
Cut two hole ø 77mm into the upper dashboard cover.
Place the heater harness onto the central tunnel. Connect the heater with 19
the heater harness.

LINHAI
550 T-BOSS EPS
Run the heater harness from the heater to the supply harness.
20
Connect the heater harness with the supply harness.
Place back dashboard cover and run the air hose through the holes.
LINHAI
550 T-BOSS EPS
Install the air vents into the air hoses by included tightening straps.
Push the air vents into the holes.
Drill hole ø 20mm into the tunnel cover and run the heater harness
21
through the tunnel to the water pump.
Fix the tunnel cover to the vehicle by original screws on rear fixing points.
LINHAI
550 T-BOSS EPS
Place the front heater cover onto the vehicle tunnel.

22

LINHAI
550 T-BOSS EPS
Fix the cover with the vehicle by original screw.
23
SEE NEXT PAGES

LINHAI
550 T-BOSS EPS
Connect ventilator switch branch to the ventilator switch.
24
Connect the electromagnetic vent branch to the electromagnetic vent
switch. Detail of connection.

LINHAI
550 T-BOSS EPS
Run the air hose through the cover hole. Install the air vent into the air
hose by included tightening strap. Push the vent into the hole.
25
Place the rear heater cover onto the tunnel. SEE NEXT PAGE

LINHAI
550 T-BOSS EPS
Run the air hose through the cover hole. Install the air vent into the air
hose by included tightening strap. Push the vent into the hole.
26
Fix the cover with the vehicle by original screws on front fixing points.

LINHAI
550 T-BOSS EPS
Fix the front cover with the rear cover by included screws.
27

LINHAI
550 T-BOSS EPS
Connect the el. pump harness with the el. valve (detail view).
28
Connect the heater harness branch with the el. pump harness (detail
view).

LINHAI
550 T-BOSS EPS
BLEEDING INSTRUCTIONS
 After installing the heater circuit, open the radiator and
coolant reservoir of the vehicle and add coolant to both the
coolant reservoir and radiator level is up to the MAX line.
 Install coolant reservoir and radiator caps.
 Activate heater fan, turn on the electromagnetic valve and
put the heating level to maximum.
 Run engine at idle with coolant reservoir cap ON until the
cooling fan cycles two times.
 If a DFK bleeding valve is is included in the heater assembly,
open it at nominal RPM until a continuous stream of fluid
flows out of it.
29
 Bleed even after the engine has warmed up to operating

engine temperature and repeat several times until full flow,
without air bubbles, escapes from the bleed plug holes.
 Check for heat coming out of the heater unit.
 Turn the ingnition switch off and allow the engine to cool
down.
 After the engine cools down check the coolant level in the
radiator reserve tank.
 Close all coolant containers and bleeding valve before driving.
 After the test drive, check the coolant level in the radiator
reserve tank and add coolant as necessary.
 Check for leaks in the entire heating circuit. Leaks can cause
additional aeration.
REAR PANEL
LINHAI
550 T-BOSS EPS
Uninstall the original screws from the rear central frame and uninstall the
upper seat from the vehicle. Loose the rear bottom plastic cover.
30

LINHAI
550 T-BOSS EPS
Insert the bottom rear cover onto the vehicle frame from inner side.
31

LINHAI
550 T-BOSS EPS
Fix the bottom cover with the frame by original screws.
32

LINHAI
550 T-BOSS EPS
Detail view onto the mounted rear bottom cover.
33

LINHAI
550 T-BOSS EPS
Place the rear upper ledge onto the vehicle frame.
34

LINHAI
550 T-BOSS EPS
Fix the rear upper ledge with the frame by included screws, washers and
covers on both sides.
35

LINHAI
550 T-BOSS EPS
Loose the holder screws and turn holders to the neutral position.
36

LINHAI
550 T-BOSS EPS
Place the rear window assembly onto the upper ledge and onto the
vehicle frame.
37

LINHAI
550 T-BOSS EPS
Fixed part of safety belts has to lay between the rear window and rear
bottom cover.
38
IMPORTANT!!!
Movable part of the safety belts has to be in inner cabine space and has
to go smoothly.

LINHAI
550 T-BOSS EPS
Fix the rear window with the upper ledge by included screws, washers,
tubes, nuts and covers.
39

LINHAI
550 T-BOSS EPS
Turn the holders to the correct position and tighten holder screws.
40

LINHAI
550 T-BOSS EPS
FRONT PANEL
Place the front upper ledge onto the vehicle frame.
41

LINHAI
550 T-BOSS EPS
Fix the ledge with the frame

by included screws, washers, nuts and covers.
42

LINHAI
550 T-BOSS EPS
Loose the holder screws and turn the holders to the neutral position.
43

LINHAI
550 T-BOSS EPS
Place the front window onto the upper ledge and onto the vehicle.
44

LINHAI
550 T-BOSS EPS
Fix the window to the upper ledge by included screw, washers, tube, nut
and cover on both side.
45

LINHAI
550 T-BOSS EPS
Turn the front holders to the correct position and tighten holder screws.
46

LINHAI
550 T-BOSS EPS
ROOF
If you have original roof, follow next steps.
If you do not have original roof skip to page 52.
Place the front cover ledge onto the front upper ledge.
47

LINHAI
550 T-BOSS EPS
Fix the cover ledge with the upper ledge by included screws, washers,
nuts and covers.
48

LINHAI
550 T-BOSS EPS
Place the rear cover ledge onto the rear upper ledge.
49

LINHAI
550 T-BOSS EPS
Fix the cover ledge with the upper ledge by included screws, washers,
nuts and covers.
50

LINHAI
550 T-BOSS EPS
Place selfglued sealing onto the roof. The sealing is delivered with the
doors. Place first layer which is red marked and blue marked second
layer.
51

LINHAI
550 T-BOSS EPS
Place the original roof onto the vehicle frame and fix by original fixing
assembly.
52

LINHAI
550 T-BOSS EPS
If you do not have original roof,

place the included roof onto the vehicle frame.
53

LINHAI
550 T-BOSS EPS
Fix the roof with the vehicle frame by included screws, washers, nuts and
covers on front side fixing points.
54

LINHAI
550 T-BOSS EPS
Fix the roof with the vehicle frame by included screws, washers, nuts and
covers on rear side fixing points and front central fixing point.
55

LINHAI
550 T-BOSS EPS
LEFT DOOR + RIGHT DOOR 1.

Uninstall upper holder from the door base.
56

LINHAI
550 T-BOSS EPS
Place the door base onto the vehicle.
57

LINHAI
550 T-BOSS EPS
Fix the base with the vehicle frame

by included screw, washers, tube, nut and cover.
58

LINHAI
550 T-BOSS EPS
Fix the base holder with the frame by included screw, washers, nut and
covers.
59

LINHAI
550 T-BOSS EPS
Place the upper holder onto the door base.
60

LINHAI
550 T-BOSS EPS
Fix the holder with the frame by included screw, washers, nut and covers.
61

LINHAI
550 T-BOSS EPS
Fix the holder with the base by included screw, washer, nut and cover.
62

LINHAI
550 T-BOSS EPS
Adjust the door base to the best position and tighten base screws hard.
63

LINHAI
550 T-BOSS EPS
Lubricate the hinge pins and place the door onto the hinge pins.
64

LINHAI
550 T-BOSS EPS
Adjust the door to the best position by hinges

and tighten the hinge screws hard.
65

LINHAI
550 T-BOSS EPS
Place the left door stop assembly onto the front vehicle frame.
66

LINHAI
550 T-BOSS EPS
Fix the holder with the frame by included screws, washers and covers.
67

LINHAI
550 T-BOSS EPS
Place the left front cover onto the door stop assembly and onto the
vehicle.
68

LINHAI
550 T-BOSS EPS
Fix the cover with the holder by included screw, washer, tube, nut and
cover.
69

LINHAI
550 T-BOSS EPS
Adjust the door stop assembly to the correct position. If you adjust door
stop correctly and close the door slowly, you can hear two metallic click.
70

LINHAI
550 T-BOSS EPS
Install gas spring pins into the holders. Fix the pins with holders by
included nuts, washers and covers. Install gas spring onto the pins.
71

LINHAI
550 T-BOSS EPS
Gas spring has to be installed in same orientation like on picture.
72

LINHAI
550 T-BOSS EPS
Uninstall screws and washers from the door.

Place the side mirror onto the door panel. Fix the mirror holder to the
door by screws and washers from previous steps.
73

LINHAI
550 T-BOSS EPS
ELECTROINSTALLATION 2.
Place the wiper assembly onto the front glass from inner side.
Fix the wiper motor with the front glass by included washers and nuts.
Tighten the fixing assemblies correctly.
SCHEME OF THE WIPER MOTOR FIXING ASSEMBLY
74
Install wiper arm and wiper blade onto the wiper motor.
Run the wiper harness and the washer hose around the vehicle frame.
LINHAI
550 T-BOSS EPS
Connect the wiper harness with the wiper motor and connect the washer
hoses with the washer jet. 75

LINHAI
550 T-BOSS EPS
76

Declaration of Conformity
DFK Cab, s.r.o.

Za Olšávkou 391
686 01 Uherské Hradiště
Česká republika / Czech Republic

Linhai 550 T Boss Kabina

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Linhai 550 T Boss Kabina

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INSTALLATION INSTRUCTIONS

READ PROPERLY COMPLETE ASSEMBLY INSTRUCTIONS BEFORE

Install all parts indicated in assembly instructions. Failure to fully assemble

Assembly of product requires use of hand or power tools.

Some parts contain sharp edges, wear protective gloves if necessary.

Insert all nut covers after you finish installation.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

MAINTENANCE AND CLEANING

The recommended frequency of cleaning of polycarbonate part

Do not use detergents that could scratch the surface plates.

Do not use the squeegee, it could be scratched surface plates.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

PREPARATION FOR INSTALLATION:

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

----- WIPER HARNESS

----- WASHER HARNESS

----- SUPPLY HARNESS

----- SWITCH HARNESS

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

View onto the heater hose with water pump in vehicle.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Cut 2 holes ø 25mm into the tunnel cover.

Install the heater air hoses the heater by included al straps.

Two bottom hoses has to be shorter.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Cut two hole ø 77mm into the upper dashboard cover.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Place the front heater cover onto the vehicle tunnel.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Fix the cover with the vehicle by original screw.

SEE NEXT PAGES

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Connect ventilator switch branch to the ventilator switch.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

 Bleed even after the engine has warmed up to operating

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Fix the bottom cover with the frame by original screws.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Detail view onto the mounted rear bottom cover.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Place the rear upper ledge onto the vehicle frame.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz