ARB 3410100 User Manual

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Part Number: 3410100 Description: ARB “DAKAR” WINCH BAR TO SUIT TOYOTA LAND CRUISER

60 SERIES

WARNING

♦ When installed in accordance with these instructions, the front protection bar does not

affect operation of the SRS airbag.

♦ This product must be installed exactly as per these instructions using only the hardware

supplied.

♦ In the event of damage to any bull bar component, contact you’re nearest authorised ARB

stockist. Repairs or modifications to the impact absorption system must not be attempted.

♦ Do not use this product for any vehicle make or model, other than those specified by ARB.

♦ Do not remove labels from this bull bar.

♦ This product or its fixing must not be modified in any way.

♦ The installation of this product may require the use of specialized tools and/or techniques

♦ It is recommended that this product is only installed by trained personnel

♦ These instructions are correct as at the publication date. ARB Corporation Ltd. cannot be

held responsible for the impact of any changes subsequently made by the vehicle manufacturer

♦ During installation, it is the duty of the installer to check correct operation/clearances of all

components

♦ Work safely at all times

♦ Unless otherwise instructed, tighten fasteners to specified torque

www.arb.com.au

Corporate Head Office

42-44 Garden St Tel: +61 (3) 9761 6622 Kilsyth, Victoria Fax: +61 (3) 9761 6807 AUSTRALIA 3137

Last Rev Date: 26/05/2006 Page 1 of 9 Fitting instructions# 3783204

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FITTING REQUIREMENTS

REQUIRED TOOLS FOR FITMENT OF PRODUCT:

Basic tool kit Drill and 10mm drill bit

Test lamp

HAVE AVAILABLE THESE SAFETY ITEMS WHEN FITTING PRODUCT:

Protective eyewear

Hearing protection

NOTE: ‘WARNING’ notes in the fitting procedure relate to OHS situations, where to avoid a potentially hazardous situation it is suggested that protective safety gear be worn or a safe work procedure be employed. If these notes and warnings are not heeded, injury may result.

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WHERE USED PART No QTY DESCRIPTION

CHASSIS BRACKETS TO

CHASSIS

BULL BAR TO CHASSIS

BRACKETS

NUMBER PLATE AND INDICATORS TO BAR

3756862L 1 Chassis bracket assembly LHS

3756862R 1 Chassis bracket assembly RHS

5846279 4 Spacer chassis 32 x 14 x 24mm

6151100 8 Bolt ½” x 1 ½” hex head

6151101 4 Bolt ½” x 2” hex head

4581049 24 Washer flat ½”

4581050 12 Washer spring ½”

6151138 12 Nut ½” hex

6151100 4 Bolt ½” x 1 ½” hex head

4581049 8 Washer flat ½”

4581050 4 Washer spring ½”

6151232 2 Bolt M10 x 1.5 x 30mm

4581040 4 Washer flat M10

4581048 2 Washer spring M10

3751451 1 Bracket number plate

6151017 4 Bolt M6 x 16mm

6151046 4 Washer flat M6

6151128 4 Nut flange M6

WINCH AND CONTROL BOX

TO BAR

3500080 1 Universal indicator kit

3756209 1 Bracket winch control box

6151021 2 Bolt M8 x 20mm

4581044 2 Washer flat M8

6151132 2 Nut flange M8

6151074 2 Bolt 3/8” x 1 ¾” hex head

6151073 2 Bolt 3/8” x 1 ½” hex head

4581040 4 Washer flat M10

4581048 4 Washer spring M10

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FITTING PROCEDURE

1. Place the bull bar on a suitable surface or stand and fit the indicators using the hardware provided in the indicator kit.

2. Fit the licence plate bracket to the bull bar using two M6 x 16mm bolts, M6 flat washers and M6 flange nuts.

3. Remove the existing bumper bar or bull

bar from the vehicle.

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FITTING PROCEDURE

New position

Old position

NOTE: IF NOT FITTING A WINCH PROCEED TO STEP 11

3. For low mount winches below 10000lb capacity, remove the ten cap screws from the gearbox and carefully lift and rotate the gearbox 72 degrees counter clockwise. (two hole spaces) Re-insert and tighten the cap screws.

Note: For high mount winches go to step 5.

4. When fitting a low mount winch, fit the control box bracket to the bar. Fit using two M8 x 20mm bolts, M8 flat washers and M8 flange nuts.

5. Lay the winch on a bench or stand with the legs facing upwards. With the help of an assistant, carefully place the bull bar over the top of the winch so that the holes line up with the winch mounting holes.

6. Fit the winch to the bar with two 3/8” x 1 ½” bolts with M10 flat washers and M10 spring washers to the two top holes.

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FITTING PROCEDURE

Drill the new hole 20mm below original

7. Using a 12mm drill bit, drill two new holes in the roller fairlead 20mm below the original holes.

Original

New hole

8. Fit the roller fairlead to the bar using two 3/8” x 1 ¾” bolts, M10 flat and spring washers. Tighten all winch bolts.

9. Fit the control box to the control box bracket using the nuts and washers that came with the winch kit.

10. Wire the control box to the winch according to the instructions provided with the winch.

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FITTING PROCEDURE

11. Fit the licence plate to the bull bar using two M6 x 16mm bolts, M6 flat washers and M6 flange nuts.

12. Fit the left and right hand bull bar mounting brackets to the appropriate chassis rails.

Note

: Due to the age of the vehicles the use of a hammer may be necessary, if so use a piece wood against the part. Do not hit the part directly with the hammer.

13. If necessary use the 25mm spacers

provided in the fitting kit between the mounting bracket and the out riggers of the chassis. Fix in place with ½” x 2” bolts, ½” flat washers, ½” spring washers and ½” nuts. Do not tighten.

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FITTING PROCEDURE

14. Fix the mounting bracket to the chassis

using four ½” x 1 ½” bolts, eight ½” flat washers, four ½” spring washers and four ½” nuts. When happy with the alignment of the brackets tighten all the bolts.

15. With the help of an assistant, lift the bar

onto the mounting brackets. Align the holes in the bull bar with the holes in the mounting bracket to the desired height. (see diagram opposite)

16. Fix the bull bar in place using two ½” x 1

2” lift 1” lift STD

½” bolts, four ½” flat washers, two ½” spring washers and two ½” nuts for each side.

17. Using the hole in the mounting bracket

as a guide, drill a 10mm hole through the bull bar upright for the pinning bolt.

18. Pin the bar using a M10 x 30mm bolt,

two M10 flat washers, M10 spring washer and M10 nut. Tighten the bolt. Repeat for the other side.

Note: There are two holes provided for pinning depending on what height the bull bar has been set at.

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19. With the bull bar fitted and all bolt tightened, wire the indicators and winch. (if fitted) Use a test lamp to find the correct wires for the indicators to tap into and use the scotch locks provided to join the wires together. Refer to the winch fitting instructions for correct wiring of the winch. Make sure all wiring is clear of hot, moving or sharp objects.

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