ECB BIG TUBE BT82SY User manual

.© Copyright – ECB Pty Ltd – 2010 1
REPLACES: 30.09.04
REVISED: 15.07.10
BT82SY
FITTING INSTRUCTIONS
LANDCRUISER 100 SER IFS BIG TUBE™ PROTECTION BAR
with 9000LB WARN WINCH MOUNTING BRACKET
VEHICLE FRONTAL PROTECTION SYSTEM (VFPS)
FOR AIR BAG and ADR COMPLIANT VEHICLES
Check installation hardware before commencing.
NOTE: Ensure any exposed ends of clip lock trim are sealed with silicone or similar to prevent corrosion.
1. Lift Bonnet. Remove grille, three PK screw at top and two plastic clips at bottom. Remove bumper cover. Three
plastic clips behind bottom of grille area, See figure 1, one 10mm head PK screw (each side at top of bumper side
returns and four to six 10mm head bolts (depending on model) along bottom of bumper.
2. Remove foam from bumper sub-frame to access sub-frame bolts.
3. Remove bumper sub-frame.
4. Remove tow hook tie and down brackets.
5. Bend bumper cover locating tab under headlight downwards (98-9/02 models only).
6. Remove indicators from vehicle (1 PK screw under bonnet, top outside of headlight) push out from under guard.
Splice ECB wiring into original indicator wiring loome. Use cable locks (supplied). Splice ECB park light wiring
into original park light wiring. Refit original indicators.
7. Attach the 200mm lengths of 6mm black clip (supplied) to each side of the roller fairlead cut out, trim to edge of
skirt. See figure 2.
8. Attach infill trim (supplied) to top sides of ECB protection bar. NOTE: Trim 30mm off lower edge so trim will
sit over end of protection bar. See figures 3 and 4. Trim excess off end to follow protection bar. See figure 5.
NOTE: Seal any exposed edges of trim with silicone or similar to avoid corrosion of inner steel.
9. Fit ECB LED indicator / park lights into protection bar as per instructions supplied with the LED indicator kit.
NOTE: Ensure park light is to outside. See figure 6.
10. Attach round cut out surrounds (supplied) into the round cut outs on the front of the protection bar. NOTE: Wider
part of trim faces to bottom side of cut out.
11. Attach ECB steel mounting brackets (supplied) to vehicle. NOTE: Tilt steel mounting brackets slightly in
towards centre and feed onto chassis. Use M10 x 30 high tensile bolts (supplied) for front holes. FINGER
TIGHTEN ONLY. Do not fit lower tow hook bolts. See figures 7 and 8.
12. Insert ½ x 6 bolts (supplied) vertically through mount hole at front of chassis. Place 40mm round spacer
(supplied) between mount and top of chassis. Use nuts/washers (supplied). DO NOT TIGHTEN. See figure 8.
NOTE: Ensure all air conditioning lines are clear of nut/bolt on passenger side. Bend slightly to clear if
necessary.

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13. Attach fairlead to ECB winch mount. Use ⅜x 1 ¼ bolts/washers and nuts (supplied). TIGHTEN FIRM ONLY
AS HIGH AS POSSIBLE ON WINCH MOUNTING BRACKET.
14. Loosely bolt winch to winch frame. Use bolts and spring washers supplied with winch along with ⅜flat washers
(supplied). See figures 9 and 10. NOTE: Feed winch cable through roller fairlead as installing.
15. Attach control box cables to winch. TIGHTEN CABLES – loosely sit control box on top of winch See figure
10.
16. Place winch mount and winch onto trolley jack or similar. Ensure all cables are at top of winch and not at back.
17. Jack winch mount/ winch up onto chassis rails. See figure 11.
18. Reattach tow hook on drivers side and tie down brackets on drivers and passengers side over winch mount. DO
NOT TIGHTEN. Use original bolts.
19. Position control box bracket on inside of winch mounting bracket. Use 3/8 x 1 ¼ bolt/nut and washers (supplied).
FINGER TIGHTEN ONLY. See figure 12.
20. Attach control box to control box bracket. Use ¼ flat washer (supplied) each side of control box bracket. Position
control box socket approximately 2-5mm in front of grille panel and top of socket 20-30mm from with underside
of grille panel. TIGHTEN ALL BOLTS/NUTS. See figure 13 and 14.
21. Route positive and negative cables to battery and connect as per winch instructions.
22. Refit grille to vehicle.
23. Attach ECB protection bar to inside of steel mounting brackets using ½ x 1 ½ bolts and nuts (supplied). DO NOT
TIGHTEN.
NOTE: Use ½ x 1 ¾ bolts (supplied) for lower protection bar mount hole. Pass bolt through winch mount, steel
protection bar mount, alloy mount and winch mount.
24. TIGHTEN M10 x 30 x 1.25 bolts and ½ x 6 bolts/nuts on Protection bar steel mounts.
25. Align protection bar with vehicle – adjust on slot holes for protection bar to sit neatly around grille and headlight
under panels. Adjust at side returns so protection bar infill trim just makes contact with vehicle guards. See figure
15. TIGHTEN FOUR UPPER PROTECTION BAR BOLTS/NUTS ONLY TO 130 N-m (100ft/lb)
26. Position winch frame on slot holes so that winch frame is clear of protection bar and chassis cross member.
TIGHTEN ALL BOLTS. Including lower protection bolts/nuts.
27. Align winch in winch frame and TIGHTEN four winch bolts.
28. Realign roller fairlead if necessary. TIGHTEN IN POSITION.
29. Connect ECB wiring to ECB indicators / park lights. Use cable lock (supplied). CHECK FOR CORRECT
OPERATION.
ENSURE NUMBER PLATE IS CLEARLY VISABLE

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Note: When fitting/refitting the licence plate to the vehicle, ensure there is no obstruction to licence plate vision in
accordance with local authorities. If required relocate licence plate to an alternate location.
Further VFPS Notes:
a) Do not attach VFPS to the vehicle using anchorages not intended for this purpose (e.g. engine mounting bolts).
b) Do not use this product for any vehicle make or model, other than those specified by the VFPS manufacturer.
c) Do not remove the plaque or label from the VFPS.
d) Do not modify the structure of the VFPS in any way.
e) No accessory or fitment should project forward of the VFPS forward profile.
f) ENSURE THESE INSTRUCTIONS ARE LEFT WITH VEHICLE OWNER AND/OR OPERATOR.
IMPORTANT INFORMATION
Periodically check bolts and nuts for correct tightness, especially if travelling on rough roads
FITTING KIT
1 – Winch mounting plate. 8 – ½ spring washers.
1 – Control box bracket. 4 – ½ x 1 ½ bolts and nuts.
2 – Steel mounting brackets. 2 – ½ x 1 ¾ bolts.
2 – 40mm alloy washers c/w 13mm round holes. 16 – ½ flat washers.
4 – M10 x 30 x 1.25 bolts. 1 – ECB LED Indicator / Park light kit
4 – 3/8 x 1 ¼ bolts and nuts. 6 – Cable locks.
16 – 3/8 flat washers. 1 – 2500mm length 6mm black infill trim.
8 – 3/8 spring washers. 2 – 200mm lengths 6mm black clip lock.
2 – ½ x 6 bolts and nuts. 2 – Round cut out surrounds.
3
p
lastic cli
p
s
Figure 1 Figure 2
Attach 6mm black clip lock to each side of
roller fairlead cut out

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Figure 3 Figure 4
Infill trim flush with end
Figure 7
Figure 6
Stainless steel self-tappers
Figure 5
Note: Example only angle on bar maybe different to the above
Figure 8
M10 x 30 x 1.25
bolts.
Attach infill trim
Trim to follow protection bar angle
Trim 30mm off
lower edge
½ x 6 bolt/nut

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Figure 9 Figure 10
Control box bracket
Figure 11
Figure 13 Figure 14
Control box socket 20-30mm under panel
Figure 12

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Infill trim
Figure 15

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We value your comments
Dear Fitter,
ECB would like to know how you went with the installation of this product. We value your comment and may need to contact
you to clarify some details so please complete your contact details clearly.
We would appreciate if you could complete as many of the following details as possible.
Your Name:
Your contact No.
Product Part No.
Product Invoice No.
Product Description:
Make, model, and year of vehicle:
Product Work Order No.
Company your from/Company product purchased from:
Date of fitment: ____/_____/____
Yes No
Was the fitting hardware supplied complete?
If no what was not supplied
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Yes No
Did the installation go well?
Please provide comments
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
Please draw diagrams if you need to.
Post to Fax to
Reply Paid 122 (07) 3283 1168
PO Box 122
Margate QLD 4019

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DESPATCH CHECKLIST
BT82SY
Work Order #
Finish:
Transport:
Due Date:
O2 – Steel mounting brackets.
O1 – Winch mounting plate.
O1 – Control box bracket.
O1 – Bolt Kit.
O1 – LED ECB indicator / park light kit.
See other side of
this page for
photos of all
mounts
O1 – 2500mm length 6mm clip lock.
O2 – 200mm lengths 6mm clip lock.
O2 – Round cut out surrounds.
O2 – ECB Overriders – Fitted to Bar
O2 – 6mm Air Scoops – Fitted to Bar
Is this product “the best it can be” Yes ______/______
Wrapper’s initials / Checker initials
If NO fix before continuing
All parts checked and completed by:
Nut and bolts: __________________________Date__/__/__
Order control: __________________________Date__/__/__
Final wrap check: __________________________Date__/__/__

.© Copyright – ECB Pty Ltd – 2010 10