Dobinsons BU45-3505 User manual

Dobinsons Springs and Suspension www.dobinsonsprings.com
Bullbar Installation Guide
Part Number: BU45-3505, BU45-3691, BU45-3655
Fits:
Nissan Patrol GU Series 4 on
This Bullbar will take approximately 2.5 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

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Dobinsons Springs and Suspension www.dobinsonsprings.com

Dobinsons Springs and Suspension www.dobinsonsprings.com
Fitting Guide
1. Remove the number plate.
2. Remove the bumper bar or factory bullbar if
fitted.
3. Install the bullbar mounting brackets and
cross brace as per the diagram on page 3.
4. Install all bolts and tighten. The bolts at the
top rear section of the outer brackets may
need to be drilled through the chassis and
installed.
5. Carefully un-wrap the bulbar taking care not
to scratch it especially on the top loops.
Reinstall the number plate to the bullbar as it
is easier now. If installing driving lights to the
bullbar it is easiest to install now.
6. If mounting a winch see steps 7 – 16.
7. The winch mounts directly to the rear of the
bullbar. If fitting a Dobinsons Winch the
clutch handle will be on the left hand side of
the vehicle, with the wire spooling from the
bottom of the winch.
8. See the Installation section of your Dobinsons
4x4 Winch manual for specific detailed fitting
instructions. For a brief overview see the
following steps.
9. This will require the clutch handle and gear-
box housing to be rotated forward 2 bolt
holes to allow easy access through the bulbar
holes. See instructions in winch user manual.
10. Determine where the winch control box will
be located and mount the control box; it is
easiest to mount to the top of the bar.
11. Sit the winch behind the bullbar and un wind
about a metre of cable and pass through the
fairlead hole in the bullbar.
12. With the fairlead sitting in front of the bullbar
pass the winch cable through the roller
fairlead. This may require removing a circlip
from the fairlead and re installing once the
cable is passed through.
13. With help from another person, hold the
fairlead in position at the front of the bullbar
and the winch in position at the rear of the
bullbar and bolt the winch and fairlead to the
bullbar using the lower bolts.
14. Install the top winch mounting bolts.
15. Tighten the winch bolts and ensure the winch
bolts are not too long and tighten correctly.
16. Wire the winch up as per the winch
instruction manual and bolt the winch to the
mounting bracket. Route the wires and
connect to battery and also route the
breather hose.
17. 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.
18. 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.
19. 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.
20. For a better finish the lower outer sections of
the front wheel arch panel can be painted
satin black.
21. With help, fit the bulbar into position and
install nuts and bolts supplied. The
adjustment stopper bolts on the front of the
bullbar (item 3) touch against the front of the
chassis. Depending on the exact alignment of
the bar these may need to be cut a little
shorter.

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22. Align the bar with the vehicle into its correct
position, leaving an even gap between the top
of the bullbar and the bottom of the
flare/headlight/grill of about 10-20mm.
23. Once you are happy with the alignment
tighten the nuts and bolts on each side.
24. Tighten the adjustment stopped bolts so they
are firm against the front of the chassis.
25. Using a 10mm drill bit, drill 10mm holes
through the bullbar mount into the mounting
bracket as seen below. This only drills through
the outer plate on the mounting face of the
mounting bracket.
26. Install 10mm x 25mm high tensile bolts into
the pinning holes. Slide an 10mm nyloc nut
into the space between the 2 bracket plates
and align with the nut and tighten. This must
be done to prevent the bullbar moving when
winching.
27. 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.
28. Fit the under bar protection kit now with the
bolts supplied. The original plastic splash
guard can be secured to the rear of the new
bash plate.
29. Trim the wheel arch mud guard liners back so
they are not visible from the front of the
vehicle.
30. Check over all items removed during
installation.
31. 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.

Customer Copy: Bullbar Care Instructions
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 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.

Method
1. The stainless loops may be removed from the bullbar if this makes it easier to work on, however if using a
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