Dobinsons BU59-3545 Installation Manual

Bullbar Installation Guide ENSURE PAGE SCALING IS TURNED OFF WHEN PRINTING. CHECK TEMPLATE SCALE LINE FIRST Part Number: BU59-3545 & BU59-3714 & BU59-3716 Fits: Toyota Landcruiser 200 Series Mid-2015 on This Bullbar will take approximately 4 hours to install Tools required are • Spanners and socket set. • Pneumatic hacksaw. • Screwdrivers • Pliers and side cutters Dobinsons BULLBARS should be installed by a qualified installer and it is the installer responsibility to ensure correct fitment. Fully read and understand the instructions before beginning the installation

Fitting Guide 1. Remove the number plate. 2. Remove the grill top cover by removing the clips. 3. Remove the 2 out bolts attaching the top of the grill to the vehicle and reach in behind the grill and remove the pop clips attached the bumper and grill to the chassis support. 4. Remove all the fasters along the wheel arch edge of the bumper and the bottom of the bumper that attach the bumper to the vehicle. Reach in behind the bumper and disconnect the fog lights. 5. With help from another person starting at the outer edge of the bumper at the wheel arch on each side, pull away the wheel arch splash liner and gently unclip the bumper from its fixings. The bumper and grill should come off in once piece, take care, if it seems to difficult there may still be fixings you have missed.

6. Remove the foam bumper support, aluminium bumper mount, aluminium crush can mounts (keep the bolts nuts), the bumper support brackets and the tow hooks. 7. Install the chassis bracket to the chassis. This will require the plastic air dams to be trimmed with an air-hacksaw or similar to allow clearance to the bracket. 8. The Original flange nuts can be used on the chassis studs. Re-install the tow hooks under the chassis bracket. With everything loose centralise the bracket and tighten all fasteners. 9. The longer flat plates can be fitted later – these are the outer bulbar winch supports as seen in the picture above. It is best to leave these off for now until the bullbar is fitted. 10. Take the template from the end of this manual and first measure the scale line on each sheet to ensure each sheet has been printed at the full size, not scaled down. If this is not correct contact your dealer for another copy. 11. Once confirmed hold the 2 pages against a window so you can align both alignment marks directly on top of each other and tape together. Cut out the template. 12. Tape the outer edges of the bumper to prevent scratching and to allow a suitable

surface to mark the cutting line. This does not have to be exact. 13. Align the template onto the bumper, aligning the wheel arch edge, the top edge and then carefully hold the template down against the bumper, keep it straight and align the template to the bumper fold edge and also align the inner bottom corner with the top of the recess in the bumper. 14. Tape the template down, mark the cut edge and remove the template. 15. Flip the template upside down and mark the other side. 16. Mask a line across the bumper from the bottom cut edge on each side (at the top of the fog light recess) across the centre of the bumper across the top of the registration number plate screw clips.

17. Have another person help to hold the bumper, and carefully cut along the bumper cut line marked in the previous steps with an air hacksaw or similar. Take time to ensure the cuts are as neat as possible. 18. The installer may choose to install rubber edging to the cut or not depending on how neat the cut edge is. 19. Carefully un-wrap the bulbar taking care not to scratch it especially on the top loops. Reinstall the number plate. If installing driving lights to the bullbar it is easiest to install now. 20. If not installing a winch skip to step 30. 21. See the Installation section of your Dobinsons 4x4 Winch manual for specific detailed fitting instructions. For a brief overview see the following steps. 22. Test fit your winch to the mounting bracket and do up loosely with the clutch handle on the left hand side of the vehicle. 23. You may have to cut and bend the centre brace to allow clear the winch drum as seen below. 24. This may require the clutch handle and gear- box housing to be rotated forward a few bolt holes to allow easy access through the bulbar holes. See instructions in winch user manual. 25. Determine where the winch control box will be located and mount the control box. See instructions in winch user manual for control box mounting options. If mounting to the top of the bullbar using the supplied bracket, check clearance of control box to grill and also check where the wires will route as if the wires are passing through the holes in the top of the bullbar the control box may not be able to be wired until the bullbar has been fitted as below. 26. Now test fit the bumper to the vehicle again and you will see that you need to cut away the centre section of the bumper to clear the winch, control box and clutch handle as seen below. Take small amounts away each time until you are happy with the access.

27. Wire the winch up as per the winch instruction manual and bolt the winch to the mounting bracket, ensure the mounting bolts are not too long and tighten correctly. Route the wires and connect to battery and also route the breather hose. 28. Reinstall the bumper and grill and the grill cover. 29. Unwind some cable from the winch, and pass the cable through the fairlead hole in the bullbar and through the roller fairlead. This may require removing a circlip from the fairlead and re installing once the cable is passed through. 30. Install the fairlead into the bulbar. 31. Check the poly bulbar over riders, fog light and top loop bolts are tight (Do not over tighten the stainless steel loop mounting bolts. Do not over tighten the poly bullbar over riders as they will pull the over riders out of shape). 32. With help, fit the bulbar onto the mounting bracket and loosely fit the mounting hardware supplied. 33. Align the bulbar to the vehicle and tighten the mounting bolts. Leave a a gap of around 12 – 15mm on the wing tips to the bumper 34. Once happy with the alignment of the bullbar drill pinning holes on each side of the bullbar drilling through both the pinning holes predrilled in the bulbar bracket into the bulbar mounting plates. Fit bolts and nyloc nuts to keep the bullbar in its position. 35. Install the outer bulbar wing support brackets from the chassis bracket to the bracket on the inside of the bulbar wings and tighten. 36. Wire up the lights. Using a multimeter or test light first locate the earth wire, parker positive and indicator positive wires from the wiring on the back of the original vehicle lights on each side. 37. Unclip the wiring from the indicator/parker lights. Check that the wiring will be long enough to reach the new bullbar indicator/parker lights and extend if required. Using the diagram at the end of this manual, join the corresponding wires to original vehicle wires located in the previous step. The wires can be joined by either using good quality snap lock crimp connectors or by soldering. Ensure the connection is secure and is sufficiently insulated. 38. If fitting a bullbar with fog lights, the fog lights can be connected using the original vehicle fog light wires if fitted. If required, cut the old fog light wiring plugs off and cut the new fog light wiring plugs and join. If the vehicle is not fitted with OEM fog lights the wiring loom supplied can be used. Follow the wiring diagram at the end of this manual.

39. Plug the wires into the indicator, parker light plug and fog lights. Test all lights and adjust the position of the fog lights if required. 40. Check over all bolts to ensure they are tight. 41. Using the fastening hardware supplied fit the under bar protection kit. 42. Trim the left hand and right hand mud guard liners flush with the bottom of the under protection plates and secure to the under protection plates. 43. Check over all parts removed during installation. 44. IMPORTANT NOTES: It is important to inform the customer that headlight adjustment may also be required due to the change in ride height. It is also important to inform the customer that there will be a change in vehicle handling characteristics. It is also important to note that due to their nature fog lights are required to provide a yellow light to allow clear fog vision. For this reason Dobinsons bullbars utilise a Halogen bulb. Halogen bulbs generate a considerable amount of heat to achieve the yellow colour and this causes the air inside the fog light lens to expand and contract. For this reason the fog light assembly cannot be sealed and has a small breather on the back. In some cases this may cause condensation to form inside the fog light. The customer may choose to seal the lens of the fog light but must not seal the rear breather.

CUT CUT ALIGN WITH TOP BUMPER EDGE ALIGN WITH WHEL ARCH EDGE ALIGN WITH BUMPER TO GUARD JOIN EDGE ALIGNMENT MARKS 200 SERIES TOYOTA LANDCRUISER MID 2015 ON. CHECK SCALE LINE BEFORE CUTTING!!!!!!!

ALIGN WITH BUMPER RECESS TOP EDGE CUT CUT CUT ALIGN WITH BUMPER FOLD EDGE ALIGNMENT MARKS 200 SERIES TOYOTA LANDCRUISER MID 2015 ON. CHECK SCALE LINE BEFORE CUTTING!!!!!!!

To ensure the surface finish quality it is recommended that the bullbar be washed and cleaned regularly to prevent build up of dirt and contaminants which when exposed to the elements can degrade the surface finish. It is highly recommended to use a quality Carnauba wax on the bullbar powder-coat once a year to ensure a long lasting quality finish. It is also recommended that the mounting fasteners on the bullbar be checked after 1000km’s. Winch servicing and care should also be carried out as per the winch instruction manual. Stainless Loop Deluxe Bullbar Loop Care and Maintenance (Customers with Stainless Loop Deluxe Models Only) The top loops on your Dobinsons Stainless Loop Deluxe steel bullbar are manufactured from high quality 304 grade stainless steel. Once formed and welded it is highly polished to provide a high gloss finish. Whilst the material is a high quality stainless steel, like any other exterior polished surface, care and some maintenance is required to ensure the surface finish quality. It is recommended that the stainless loops be kept as clean as possible and is thoroughly washed and dried regularly to prevent build up of dust and contaminants. This is especially important in coastal and high dust areas. The loops can simply be cleaned with most regular car cleaning items like a soft sponge, car wash and a chamois, avoid strong cleaning chemicals. Like many other highly polished exterior metals, over extended periods of time and heavy weathering can cause some staining of the surface may occur. If this occurs the surface can be simply polished using the following methods to remove the stains and restore the high gloss surface using simple tools and cheap readily available polishing items. Tools Required: • Electric buffer or Electric drill (an electric/cordless drill is generally more convenient). • Polishing compound – This can be supplied by Dobinsons Spring and Suspension. Please contact head office on the details below for polish, as a specific type is used. • Soft finishing type buffing wheel – The buffing wheel should be a soft, finishing type/Calico loose leaf style to allow the surface to be polished to a high gloss without further marking the surface. The 2 types of discs shown below are readily available from most hardware stores (Australian customers – Bunnings etc). The brand below is Josco, and if purchasing a twin pack ensure that only the finishing buff is used and not the cutting buff. DO NOT USE METAL OR HARSH BUFFING PADS.

cordless drill this is not a necessity. If removing the loops, do not over tighten the loop retaining bolts when re fitting. 2. Ensure the loops are first completely clean and dry. 3. Fit the polishing buff wheel to the drill or buffing tool –take note of the maximum wheel speed and rotation direction. 4. It is recommended to follow specific instructions on the packaging of the buffing wheel for best results. However if no instructions are provided the following guidelines can be used: A). Carefully dress the buff wheel with the compound across the rotating wheel for a few seconds, taking care not o apply too much compound, it is better to apply a little compound more frequently than to overdress the buff. B). Gently buff the work area with the buffing wheel and with light pressure move back and forth across the job. C). After polishing use a soft, clean, dry rag to clean the surface and inspect in the light for an even finish. D). Once complete clean thoroughly again with a sponge and warm water. Dobinsons Spring and Suspension www.dobinsonsprings.com