ARB 3921120 Manual de usuario

03/07/2014 Page 1 of 9 3786418

If you have any queries regarding the installation of this product please contact the distributor from whom it was purchased, or alternatively the ARB office in your state.

Head Office –ARB Corporation Ltd VIC: 42-44 Garden Street, Kilsyth, Victoria, 3137 Tel: (03) 9761 6622 Fax: (03) 9761 6807

WA:(08) 9244 3553 NSW: (02) 9821 3633 ACT: (02) 6280 7475 SA: (08) 8244 5001 QLD: (07) 3872 3872 NT: (08) 8947 2262 TAS: (03) 6331 4190

ARB PRADO WINCH/NON WINCH BUMPER TO SUIT

GXL, VX AND GRANDE 2003 ONWARDS.

PART No 3921120

5100050 Top Tube Kit

5100160 Buffer Kit –With hole (required when fitting Top Tube)

5100170 Buffer Kit –With no hole

FITTING KIT NO: 6172356

WARNING

FOR VEHICLES EQUIPPED WITH SRS AIRBAG

WHEN INSTALLED IN ACCORDANCE WITH THESE INSTRUCTIONS, THE FRONT

PROTECTION BAR DOES NOT AFFECT OPERATION OF THE SRS AIRBAG.

TAKE NOTE OF THE FOLLOWING:

THIS PRODUCT MUST BE INSTALLED EXACTLY AS PER THESE INSTRUCTIONS

USING ONLY THE HARDWARE SUPPLIED.

IN THE EVENT OF DAMAGE TO ANY BAR COMPONENT, CONTACT YOUR NEAREST

AUTHORISED ARB STOCKIST. REPAIRS OR MODIFICATIONS TO THE IMPACT

ABSORPTION SYSTEM MUST NOT BE ATTEMPED.

DO NOT USE THIS PRODUCT FOR ANY VEHICLE MAKE OR MODEL, OTHER THAN

THOSE SPECIFIED BY ARB.

DO NOT REMOVE LABELS FROM THIS BAR.

THIS PRODUCT OR ITS FIXING MUST NOT BE MODIFIED IN ANY WAY.

OPTIONAL LIGHT SETS TO SUIT THIS PRODUCT:

- ARB 6821201 Fog Light Kit Suit 3163015

- Up to IPF 900 SERIES FOG OR DRIVING LIGHT SETS

Suits warn 9000lb and 9500lb High Speed winches

Tools Required For Bar Fitment: Basic Tool Kit, 17mm Tube Spanner, Cir-Clip pliers,

Drill, 10mm and 13mm Drill Bits.

18/04/13 Page 2 of 9 3786418

USE.

PART NO.

QTY

DESCRIPTION

Impact Absorber To Chassis

3756571

3756645R

3756645L

3193741

6151306

6151255

6151189

6151094

4581049

4581050

5846401

Bracket Mount Assembly

Bracket Mount Brace RHS

Bracket Mount Brace LHS

Captive Nut Plate

Nut Cage M12 x 1.75

Bolt M12 x 1.75 x 40mm

Nut M12 x 1.75

Bolt M12 x 1.25 x 30mm

Washer Flat ½”

Washer Spring ½”

Spacer 8mm

Bar To Impact Absorber

6151304

6151232

4581040

4581048

6151026

Nut Cage M10 x 1.5

Bolt M10 x 1.5 x 30mm

Washer Flat M10 x 2mm

Washer Spring M10

Nut M10 x 1.5

Stone Tray to Bar

6522036

6151300

6151180

4581084

4581036

Stone Tray

Nut Cage M6

Bolt M6 x 20mm

Washer Flat Panel M6

Washer Spring M6

Top Tube To Bar

(5100050)

6131516

6151255

4581049

4581050

Top Tube assembly

Bolt M12 x 1.75 x 40mm

Washer Flat ½”

Washer Spring ½”

Buffer To Bar

(5100160 Required if fitting Top

Tube)

6151128

3162153

3162154

Flange Nut M6

Buffer LHS

Buffer RHS

Buffer To Bar

(5100170 Required if not fitting

Top Tube)

6151128

3162471L

3162471R

Flange Nut M6

Buffer LHS Sahara Bumper

Buffer RHS Sahara Bumper

Buffer Lower To Bar

6151128

3162155

Flange Nut M6

Buffer Lower

Indicators To Bar

3163015

6821152

6821151L

6821151R

Kit Surround For Fog & Indicator Lights

Turn signal / clearance light loom

Turn Signal/Clearance Light

Licence Plate To Bar

6151128

6781408

Nut Flange M6

Tape Double sided

Winch Cover To Bar

6522030

6151256

4581304

6151128

Panel Winch Cover Prado

Screw M6 S/S Button Head

Washer Flat M6 S/S

Nut Flange M6

18/04/13 Page 3 of 9 3786418

Winch To Bull Bar

EG50

3756499

6151021

4581044

6151132

BLB560

4581040

6151074

Rubber Grommet

Bracket Control Box

Bolt M8 x 20mm

Washer Flat M8

Nut Flange M8

Cable Black 560mm

Washer Flat M10 x 2mm

Bolt 1 ¾” x 3/8” UNC

Washer Bottle Guard

To Bar

6522031L

6522031R

6151234

4581045

6151132

Washer Bottle Guard For Sahara bar

Bolt M8 x 25mm Black

Washer Flat M8 Black

Nut Flange M8

Miscellaneous

6821132

6151128

180302

3162152

180701

Rubber Grommet 3/8” ID

Nut Flange M6

Cable Ties

Plastic Plug 16mm DIA

Scotch Lock

ASSEMBLY

1. Position the lower buffer and assemble using

the M6 flange nuts. (Do not over tighten)

1. Fit the buffers. Buffer studs fit through the

slots in the wings and the pan. Fasten

using M6 flange nuts.

Note: This applies to both blank buffers and for

those with the hole for optional frame.

CAUTION: DO NOT OVER TIGHTEN THE M6

NUTS AS YOU RISK PULLING THE STUDS OUT

OF THE BUFFERS.

18/04/13 Page 4 of 9 3786418

2. Fit cage nuts to the bull bar. M10’s to

the six square holes in the upright and

M6’s in the four square holes in the

lower part of the pan. Also fit the M12

cage nuts to the captive nut assembly.

3. Remove front bumper cover from

vehicle.

4. Remove front bumper reinforcing bar.

5. Remove side bumper supports from

both guards.

NOTE: Retain the 8 flange nuts removed

for fitment of the bull bar chassis mount.

6. Using the 13mm drill bit, drill out the M8

captive nut in the top of the chassis on

both sides of the vehicle.

7. Fit the chassis mount braces to the

vehicle using the M12 x 30mm fine

pitched bolt, M12 spring and flat

washers supplied in the lower hole. Use

a M12 flat washer as a spacer between

the brace and the chassis at the upper

hole and fix with a M12 x 40mm bolt

M12 spring and flat washers and M12 x

1.75 nut. Do not tighten the bolts.

Use a M12 flat

washer as a spacer

between chassis

and bracket.

18/04/13 Page 5 of 9 3786418

8. Insert the captive nut assembly through

the front of the chassis and line it up

with the hole at the end of the mount

brace. Fix in place with the M12 x 1.75

x 40mm bolt, M12 flat and spring

washers. Break off the end of the

captive nut plate. Do not tighten yet.

9. Hold the 8mm spacer against the

chassis mount brace forward facing

surface and position the brace so that

the spacers sit just below the surface of

the chassis front face. Tighten the bolts.

10. Fix the chassis mount bracket to the

chassis mount brace using M12 x

40mm bolts, M12 spring and flat

washers, the 8mm spacers and M12 x

1.75 nuts. Tighten bolts.

CAUTION: when fitting the Chassis

mounting bracket carefully bend the air-

conditioning pipe out of the way.

Position brace so spacer

won’t protrude from the

chassis forward surface

18/04/13 Page 6 of 9 3786418

BEFORE ROTATION

AFTER ROTATION

11. For ease of access the winch gearbox

handle needs to be rotated. To do this

undo all the cap screws and carefully lift

the gearbox clear of the winch body so

as not to damage the gasket. (Do not

lift the gearbox more than a couple

of millimetres) Rotate the gearbox

anti-clockwise three hole spaces. Re-fit

the caps-crews.

12. Remove the three screws from the

control box and remove the cover.

13. Replace the two cables marked “A” and

“F1” and replace them with the two

cables (BLB560) supplied with the

fitting kit. Label the cables the same as

the original to assist in the wiring of the

winch.

14. Place the winch on a table with the feet

facing up and using an assistant,

carefully lift the bar on top of the winch.

15. Attach the winch to the bar using two 1

½” x 3/8” bolts from the winch fitting kit,

3/8” spring washer and 3/8” flat

washers in the top holes.

NOTE: Winch must be assembled so that

the wire rope spools from the bottom and

the gearbox is on the passenger side.

16. Position the roller fairlead, and remove

the circlips from the lower of the verticle

rollers and push the pins up to give

access to the lower bolts.

17. Fix the roller fairlead to the bar using

the 1 ¾” x 3/8” bolts, spring and flat

washers.

18/04/13 Page 7 of 9 3786418

18. Fit the control box bracket to the bar

using two M8 x 20mm bolts, M8 flat

washers and M8 flange nuts.

19. Fit the control box to the control box

bracket and connect the power cables

to the winch as per the winch

instructions.

20. Connect the ground wire to the tension

bar of the winch.

CAUTION: Cable-tie all cables together

and keep all cables clear of sharp edges

and all moving parts.

With winch

Without winch

21. Place the double-sided tape along the

top edge of the licence plate. Using the

original licence plate screws and M6

flange nuts supplied in the fitting kit,

attach the licence plat to the bar.

22. Mask the area around the headlight and

the front guard and paint the lower

section under the front guard black.

Paint this section on both sides black.

23. With the help of an assistant position

the bar on the chassis bracket and fix

with six M10 x 30mm bolts, M10 spring

and flat washers.

Do not tighten the bolts yet.

18/04/13 Page 8 of 9 3786418

If fitting Top Tube

24. Attach the tube to the bar by pushing

through the holes in the buffers, fix

using two M12 x 1.75 x 40mm bolts, ½”

flat and spring washers.

25. Position the bar so that there is an even

gap along the headlights and the

guards of 25mm. tighten all the bolts.

25mm gap

26. With the bar in position drill a 10mm

hole through the upright on both sides

using the hole in the chassis bracket as

a guide.

27. Fix in place using two M10 x 30mm

bolts, M10 spring washers, M10 Flat

washers and M10 x 1.5 nuts.

28. Remove the front stone tray from the

vehicle and remove the tags at the front

of the tray. Refit the stone tray fixing in

place with the rear bolts only.

Attach tube

inside wing

NOTE:

Torque these M12 fasteners to

44Nm only (Critical)

18/04/13 Page 9 of 9 3786418

29. Fit the bull bar stone tray by sliding the

tray under the front of the vehicles

original stone tray and fixing in place

with the original bolts from the vehicles

stone tray.

30. Fit the front of the stone tray to the bull

bar with four M6 x 16mm bolts, M6

large panel washers and M6 spring

washers.

31. Fit the washer bottle guard with five M8

x 25mm black bolts, M8 black flat

washers and M8 flange nuts.

32. After fitting the washer bottle guard, trim

the plastic inner guard liner so that it

doesn’t sit below the line of the washer

bottle guard

33. Attach the inner guard to the washer

bottle guard with cable ties.

Repeat step 33 for the opposite side.

34. Assemble and install combination light

surrounds (p/n 3163015) as per

instructions no. 3786421 supplied with

surround kit. Note: Optional fog lamps

can be installed at this point as per

fitting instruction no. 3783315 supplied

with fog lamp kit no. 6821201.

35. Wire the combination lamp to the

vehicles indicator and clearance lamps.

CAUTION: Cable-tie all cables together

and keep all cables clear of sharp edges

and all moving parts.

When finished make sure that all bolts are tightened and that all wiring is clear of hot, sharp and

moving parts.

Also supplied in the kit are two 3/8” rubber grommets and two 16mm plugs. The rubber

grommets are for the two holes in the top pan if lights are being fitted. The two plastic plugs are

for the holes in the top surface of the wings if no CB aerials are going to be connected.

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