Dobinsons BU59-3541 User manual

Bullbar Installation Guide
Part Number: BU59-3541 & BU59-3706 & BU59-3707
Fits:
Toyota Hilux Revo 2015 on
This Bullbar will take approximately 3.5 hours to install
Tools required are
•Spanners and socket set.
•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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Fitting Guide
1. Remove the number plate.
2. Remove the screws and clips in the top of the
grill to radiator cover.
3. Remove the screws and bolts attached the
top of the grill.
4. Reach down in behind the grill and gently
unclip the lower grill tabs and slide the grill
forward to remove it from the vehicle.
5. Remove the screws and clips along both
wheel arch edges of the bumper and also
along the bottom edges of the bumper that
attached the bumper to the vehicle.
6. Remove the top clips that attached the under
grill air damn to the top of the bumper.
7. Unclip the fog light wiring plugs if fitted.
8. Starting from either side of the vehicle gently
unclip the bumper from the edge of the guard
and headlight.
9. Remove the bumper.
10. Remove the front horizontal air dam and the
LH and RH vertical air dam, keeping aside for
re-fitment later.
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11. Remove the front plastic bumper support by
sliding sideways to release from the clips and
remove the steel bumper mount. Keep the
original bolts for fitment of the bullbar
bracket. Remove the small plastic air dams
also.
12. Remove the lower bash plate and keep aside
for re-fitment.
13. Remove the 2 outer bumper support brackets.
14. Install the inner and outer bullbar bracket
supports to each side of the chassis using the
M12 fine bolts with washers for the rear 2
outer mounting points. The longer bolts pass
through the chassis through both brackets.
Use a washer on each side. Leave bolts loose
for now.
15. Install the bullbar bracket using the nuts, bolts
and washers supplied. Use the original bolts
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with the washers supplied in the original bolt
position.
16. Centralise the bracket to the vehicle and
tighten all fasteners.
17. Trim the original LH and RH vertical air dams
as seen in the photo below to clear the new
mounting bracket and bullbar.
18. Re-install the air dams to the vehicle.
19. Remove the plastic screw clips from the
original bumper mounts near the inner lower
corners of the headlights.
20. Drill a small hole in the air damns just in front
of this to attach a cable tie to, and cable tie it
to stop movement.
21. Install the new grill support bracket. It is
recommended to remove the screw plug and
use a nut and bolt to tighten it correctly.
22. Re-install the grill inserting the centre 2 tabs
into the new bracket and re-install the upper
bolts and screws. It is also recommended to
drill a hole in the outer lower tabs on each
side at the base and cable tie to the holes
drilled in step 20 to secure the grill.
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23. Now a good time to run the wiring for the
new parker lights and indicators.
24. In the base of the headlight you will see a light
grey and dark grey wire connector this will
slide out from the headlight and the plug can t
then be disconnected.
25. It is recommended to take the earth directly
off the vehicle body.
26. For the parker light positive feed it can be
taken from the vehicle side of the wiring loom
(the light grey plug) and taken from the grey
wire on the right hand side and green wire on
the left hand side (Australian vehicles) NOTE:
you must double check this with a multimeter
or test light to confirm.
27. For the indicator positive feed, there is a small
conduit that goes up into the back of the
indicator, this can be pulled down below the
headlight and the red wire on the right hand
side used, and the yellow on the left hand side
(Australian vehicles) NOTE: you must double
check this with a multimeter or test light to
confirm.
28. 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 (soldering recommend. Ensure the
connection is secure and is sufficiently
insulated.
29. If fitting a bullbar with fog lights, the fog lights
can be connected using the original vehicle
fog light wires if fitted but this will require
cutting and joining the fog light plugs from the
loom supplied. 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.
30. 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.
31. If not installing a winch skip to step 39.
32. See the Installation section of your Dobinsons
4x4 Winch manual for specific detailed fitting
instructions. For a brief overview see the
following steps.
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33. Test fit your winch to the mounting bracket
and do up loosely with the clutch handle on
the left hand side of the vehicle.
34. This may require the clutch handle and gear-
box housing to be rotated forward one or 2
bolt holes to allow easy access through the
bulbar holes. See instructions in winch user
manual.
35. 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.
36. 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.
37. 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.
38. Install the roller fairlead into the bulbar.
39. 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).
40. Fit the rubber headlight to bumper inserts on
the top of each bar and tighten (Do not over
tighten).
41. With help, fit the bulbar into position and
install nuts and bolts supplied.
42. Align the bar with the vehicle into its correct
position leaving a gap of about 15mm
between the bullbar wing and the bottom of
the quarter panel.
43. Once you are happy with the alignment
tighten the 3 nuts and bolts on each side.
44. Once happy with the alignment of the bullbar
drill through the pinning holes on each side of
the bullbar bracket mounting plate. Fix with
bolts and nyloc nuts the same diameter as the
pinning hole to keep the bullbar in its
position.
45. Plug the wires into the indicator and parker
light plug. Test all lights and adjust the
position of the fog lights if required.
46. Fit the under bar protection kit now with the
bolts supplied.
47. Cut along the bottom of both wheel arch
splash guard so that they are flush with the
bottom of the side protection plate ensuring
you do not cut into washer bottle bracket on
the LH side and secure to the back side of the
bash plates. For the LH side you may need to
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cut them longer and bend it in place to reach
the back of the guard.
48. Check over all items removed during
installation.
49. 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.
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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.
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