ARB 341 4460 - User Manual

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Summary

Product Information and Safety

Product Identification and Fitting Kits

Lists product codes for different bull bar variants and fitting kit part numbers.

Important Safety and Installation Notes

Provides crucial instructions for safe installation and product usage, emphasizing adherence to guidelines.

General Care, Maintenance, and Tools

Care and Maintenance Recommendations

Outlines recommended practices for maintaining the bull bar's condition and appearance.

Required Safety Items

Lists essential safety equipment to be used during product installation.

Fastener Torque Specifications

Details torque values in Nm and lb/ft for various fastener sizes used in installation.

Required Tools for Installation

Bull Bar Assembly and Installation Procedure

Vehicle Preparation and Component Removal

Steps for removing the original bumper, grill, headlights, and associated brackets.

Initial Component and Wiring Installation

Covers fitting the grill bracket, indicator wiring, buffers, fog lamps, and relay loom.

Winch Preparation and Mounting

Details gearbox rotation, control box setup, and mounting the winch to the bull bar.

Bull Bar Mounting and Chassis Attachment

Procedure for positioning the bull bar, mounting to chassis, and final adjustments.

Accessory Fitting and Final Touches

Instructions for fitting stone guards, optional lights, number plate, and jack provision.

Wiring Diagram and Connections

Indicator and Relay Loom Schematics

Detailed schematic showing connections between indicator looms, relay loom, and vehicle wiring.

Power and Earth Wiring Layout

Illustrates the connection of the main battery positive and earth terminals to the system.

Summary

Product Information and Safety

Product Identification and Fitting Kits

Lists product codes for different bull bar variants and fitting kit part numbers.

Important Safety and Installation Notes

Provides crucial instructions for safe installation and product usage, emphasizing adherence to guidelines.

General Care, Maintenance, and Tools

Care and Maintenance Recommendations

Outlines recommended practices for maintaining the bull bar's condition and appearance.

Required Safety Items

Lists essential safety equipment to be used during product installation.

Fastener Torque Specifications

Details torque values in Nm and lb/ft for various fastener sizes used in installation.

Required Tools for Installation

Bull Bar Assembly and Installation Procedure

Vehicle Preparation and Component Removal

Steps for removing the original bumper, grill, headlights, and associated brackets.

Initial Component and Wiring Installation

Covers fitting the grill bracket, indicator wiring, buffers, fog lamps, and relay loom.

Winch Preparation and Mounting

Details gearbox rotation, control box setup, and mounting the winch to the bull bar.

Bull Bar Mounting and Chassis Attachment

Procedure for positioning the bull bar, mounting to chassis, and final adjustments.

Accessory Fitting and Final Touches

Instructions for fitting stone guards, optional lights, number plate, and jack provision.

Wiring Diagram and Connections

Indicator and Relay Loom Schematics

Detailed schematic showing connections between indicator looms, relay loom, and vehicle wiring.

Power and Earth Wiring Layout

Illustrates the connection of the main battery positive and earth terminals to the system.

This document provides fitting instructions for the ARB Bull Bar designed for the Toyota Hilux, 2011 onwards models, specifically those equipped with SRS Air Bags.

Function Description:

The ARB Bull Bar is a robust accessory for the Toyota Hilux, offering enhanced front-end protection, particularly for off-road driving and in the event of animal strikes. It is designed to integrate with the vehicle's SRS Air Bag system, ensuring continued safety functionality. The bull bar can be configured in several ways:

Winch Bull Bar: Available for both flared (Product No. 341 4460) and non-flared (Product No. 341 4450) vehicles. This version accommodates a winch, providing recovery capabilities.
Non-Winch Bull Bar: Available for both flared (Product No. 321 4460) and non-flared (Product No. 321 4450) vehicles. This version provides protection without winch integration.

The bull bar system includes provisions for various accessories such as indicators, fog lamps, and optional driving lights. It also features impact absorbers and chassis stiffening plates to distribute impact forces and maintain structural integrity.

Important Technical Specifications:

The fitting kit numbers are:

6173152: For winch bull bars (341 4450/60)
6173155: For non-winch bars (321 4450/60)

The document specifies various fasteners and components used in the installation, including:

Control Box Fitment (Winch Only): Control box bracket (3756499), M8x1.25x25 long black bolts (6151234), flat M8 black washers (4581045), M8 flange nuts (6151132), rubber grommets (EG50), and cable ties (180302).
Winch (8000/9000/9500 LB): Flat 3/8" washers (4581040), UNC 3/8"x1 3/4" bolts (6151074), and 850mm black cable (BLB850).
Impact Absorber to Bull Bar: M10 cage nuts (6151304), flat M10 washers (4581040), oversized flat M10 washers (4581288), spring M10 washers (4581048), M10x1.5x30 long bolts (6151232), and M10x1.5 hex nuts (6151026).
Buffers to Bull Bar: RH buffer (3162470R), LH buffer (3162470L), and M6 flange nuts (6151128).
Number Plate to Bull Bar: Round flat grommets (6821189) and 5x16mm pan head phil black screws (6151384).
Indicators to Bull Bar: RHS indicator kit (6821151R), LHS indicator kit (6821151L), nylon plugs (6821116), self-tapping screws (6151308), wiring loom (6821152), and indicator relay loom (6821198).
Wing Trim Fitment: LH wing trim (3163052R), RH wing trim (3163052L), M6 flat black washers (4581082), 5x16mm BZ pan head screws (6151384), and M6x1 nyloc nuts (6151162).
Impact Absorber to Chassis: Chassis mount bracket (3756721), flat M10 washers (4581040), spring M10 washers (4581048), and M10x1.25 nuts (6151133).
Chassis Stiffening Plate to Chassis & Impact Absorber: RH chassis plate (3199756R), LH chassis plate (3199756L), M10x1.25x35 long bolts (6151088), flat M10 washers (4581040), spring M10 washers (4581048), and M10x1.25 nuts (6151133).
Lower Grill Bracket: Grill mount bracket (3758129), M8x1.25x25 long black bolts (6151234), flat M8 black washers (4581045), spring M8 black washers (4581047), and M8 flange nuts (6151132).
Fog Lamps to Bull Bar: RHS fog lamp surround (3163006), LHS fog lamp surround (3163005), and fog lamp loom (6821183).
Centre Stone Deflectors: Upper stone guard panel (6522649), lower stone guard panel (6522650), M8 cage nuts (6151303), flat M8 black washers (4581045), spring M8 black washers (4581047), and M8x1.25x25 long black bolts (6151234).
Wing Stone Deflectors: RH wing panel (6522816R), LH wing panel (6522816L), M6 cage nuts (6151315), flat M6 black washers (4581082), spring M6 black washers (4581287), M6x1.0x20 black bolts (6151213), M12x1.25x30 long bolts (6151094), flat M12 washers (4581049), spring M12 washers (4581050), M8x1.25x25 long black bolts (6151234), M8 cage nuts (6151303), flat M8 black washers (4581045), spring M8 black washers (4581047), RH wing stone shield bracket (3758190R), and LH wing stone shield bracket (3758190L).

Fastener Torque Settings:

M6: 9 Nm (4 lb/ft)
M8: 22 Nm (16 lb/ft)
M10: 44 Nm (32 lb/ft)
M12: 77 Nm (57 lb/ft)

Usage Features:

Winch Integration: For winch-compatible bull bars, the instructions detail how to rotate the winch gearbox (72° counterclockwise) for proper fitment and how to install the control box, including repositioning solenoids for a centralized fit.
Lighting: The bull bar accommodates factory fog lamps and includes indicator kits. Wiring diagrams are provided for connecting indicator and relay looms to the vehicle's existing wiring. Optional driving lights can also be fitted.
Protection: Stone guards (centre and wing) are installed to protect the vehicle's underside and engine bay from debris. Impact absorbers and chassis stiffening plates are critical for distributing impact loads.
Number Plate Mounting: Provisions are made for mounting the number plate, with different positions shown for winch and non-winch bars.
High-Lift Jack Points: The bull bar includes provision for a high-lift jack on both sides, aiding in vehicle recovery.

Maintenance Features:

General Care: The bull bar should be treated with a Canuba-based polish on all exposed surfaces every six months or after exposure to salt, mud, sand, or other contaminants.
Pre-Trip/Annual Inspection: A thorough visual inspection is recommended as part of any pre-trip preparation or annually. This includes checking that all bolts and components are torqued to the correct specification and that all wiring sheaths, connectors, and fittings are free of damage. Any damaged components should be replaced. This service can be performed by an authorized ARB Stockist.
Repairs/Modifications: Repairs or modifications to the impact absorption system are explicitly not to be attempted. In case of damage to any bull bar component, contact an authorized ARB stockist.
Painting Exposed Metal: During installation, any exposed metal (e.g., after drilling or cutting) should be spray painted to prevent rusting.
Relay Mounting: The relay should always be mounted upright to help prevent water ingress.
Cable Management: All cables must be installed clear of hot, sharp, or moving surfaces and secured with cable ties.

Safety Precautions:

OHS Warnings: The document emphasizes the importance of heeding 'WARNING' notes, which relate to Occupational Health and Safety (OHS) situations. These suggest wearing protective safety gear (e.g., protective eyewear, hearing protection) or employing safe work procedures to avoid hazardous situations and potential injury.
Trained Personnel: It is recommended that this product is only installed by trained personnel.
Correct Installation: The product must be installed exactly as per the instructions using only the supplied hardware.
Vehicle Compatibility: Do not use this product for any vehicle make or model other than those specified by ARB.
No Modifications: The product or its fixings must not be modified in any way.
Labels: Do not remove labels from the bull bar.
Component Clearance: During installation, the installer must check for correct operation and clearances of all components.
Winch Gearbox: When rotating the winch gearbox, do not lift it more than a couple of millimeters.
Fastener Tightening: Unless otherwise instructed, tighten fasteners to specified torque. Specific instructions like "DO NOT OVER TIGHTEN" are provided for certain steps (e.g., buffers, control box cover).