Dobinsons BU59-3545 User manual

Dobinsons Springs and Suspension www.dobinsonsprings.com
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

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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.

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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

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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.

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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.

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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.

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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.

100MM SCALE LINE
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!!!!!!!

100MM SCALE LINE
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!!!!!!!

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 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.

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