ARB 3432200 Bedienungsanleitung

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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

LAND ROVER DISCOVERY 4

ARB BULL BAR AND WINCH BAR

Not suitable for HSE & V8 models.

PART No 3432200 DISCOVERY 4 WINCH BAR

PART No 3232200 DISCOVERY 4 BULL BAR

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.

02-08-12 Page 2 of 22 3782929

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 BULL BAR COMPONENT, CONTACT YOUR

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.

Corporate Head Office

42-44 Garden St Tel: +61 (3) 9761 6622

Kilsyth, Victoria Fax: +61 (3) 9761 6807

AUSTRALIA 3137

Australian enquiries [email protected]

North & South American enquiries [email protected]

Other international enquiries [email protected]

www.arb.com.au

GENERAL CARE AND MAINTENANCE

By choosing an ARB set of side rails, you have bought a product that is one of the most sought after 4WD

products in the world. Your side rails are a properly engineered, reliable, quality accessory that represents

excellent value. To keep your side rails in original condition it is important to care and maintain it

following these recommendations:

Prior to exposure to the weather your bar should be treated to a Canuba based polish on all exposed

surfaces. It is recommended that this is performed on a six monthly basis or following exposure to salt,

mud, sand or other contaminants.

As part of any Pre Trip Preparation, or on an annual basis, it is recommended that a thorough visual

inspection of the side rails and bull bar is carried out, making sure that all bolts and other components

are torqued to the correct specification. Also check that all wiring sheaths, connectors, and fittings are

free of damage. Replace any components as necessary. This service can be performed by your local

authorized ARB Stockist.

02-08-12 Page 3 of 22 3782929

FITTING REQUIREMENTS

REQUIRED TOOLS FOR FITMENT OF PRODUCT:

POWER DRILL WITH 8 & 10MM BITS

SCREWDRIVER SET

METRIC SOCKET SET & SPANNERS

KEY HOLE SAW

TORX BIT SET

SHARP KNIFE & WHITE MARKER

SENSOR SAFE SILICONE

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.

FASTENER TORQUE SETTINGS:

SIZE

Torque Nm

Torque lbft

9Nm

7lbft

22Nm

16lbft

M10

44Nm

32lbft

M12

77Nm

57lbft

02-08-12 Page 4 of 23 3787827

USE

PART no

QTY

DESCRIPTION

IMPACT ABSORBER TO

CHASSIS

3758047L

CHASSIS MOUNT BRACKET ASSEMBLY

3758047R

CHASSIS MOUNT BRACKET ASSEMBLY

6151204

BOLT M10 x 35 x 1.5p HEX HEAD

6151321

NUT FLANGE M10 x 1.5

4581040

WASHER FLAT M10

4581048

WASHER SPRING M10

6151022

BOLT M8 x 25mm HEX HEAD

4581044

WASHER FLAT M8

4581046

WASHER SPRING M8

CR08

SPIRAL WRAP

BULL BAR TO IMPACT

ABSORBER

6151204

BOLT M10 x 35 x 1.5p HEX HEAD

6151321

NUT FLANGE M10 x 1.5

4581040

WASHER FLAT M10

4581048

WASHER SPRING M10

BUFFERS TO BULL BAR

3162470L

BUFFER 260 x 230 STANDARD

3162470R

BUFFER 260 x 230 STANDARD

6151128

NUT FLANGE M6

LICENCE PLATE TO BULL

BAR

6821116

NYLON PLUG

6151143

SCREW TEK 8-18 x 20mm

FOG LIGHTS, INDICATORS

AND SENSORS (IF FITTED)

TO BULL BAR

6151300

CAGE NUT M6

6821116

NYLON PLUG

3758046L

FOG LIGHT BRACKET

3758046R

FOG LIGHT BRACKET

3756778L

COVER MOUNT BRACKET

3756778R

COVER MOUNT BRACKET

3758092

BRACKET OUTER SENSOR MOUNT

3758093

BRACKET INNER SENSOR MOUNT

6821151L

INDICATOR COMBINATION LAMP

6821151L

INDICATOR COMBINATION LAMP

6821152

COMBINATION LAMP WIRING LOOM

180701

SCOTCH LOCK

6151309

CAPTIVE U-TYPE NUT

3162468

FOG LIGHT INSERT

6151317

SCREW 8-18 x 5/8 PAN HEAD

6151213

BOLT M6 x 20mm BLACK ZINK

4581082

WASHER FLAT M6 x 20 BLACK ZINK

4581287

WASHER SPRING M6 BLACK ZINK

6151128

NUT FLANGE M6

6151308

SCREW 8-AB X 1” PAN HEAD

6151460

SCREW SELF TAPPING

3787854

DRILLING TEMPLATE OUTER

3787855

DRILLING TEMPLATE INNER

6821198

INDICATOR LOOM KIT

WINCH TO BULL BAR

(SUPPLIED WITH FITTING

KIT 6171975 ONLY)

3756499

CONTROL BOX MOUNT

BLB850

WINCH LEAD 850mm BLACK

6151074

BOLT 3/8” x 1 ¾” HEX HEAD

6151073

BOLT 3/8” x 1 ½” HEX HEAD

4581040

WASHER FLAT M10

4581048

WASHER SPRING M10

02-08-12 Page 5 of 23 3787827

6151021

BOLT M8 x 20mm

6151132

NUT FLANGE M8

4581044

WASHER FLAT M8

180302

CABLE TIES

USE

PART No

QTY

DESCRIPTION

WASHER BOTTLE

SUPPORT TO IMPACT

ABSORBERS

3756801

WASHER BOTTLE SUPPORT BRACKET

6151301

CAGE NUT M8

6151021

BOLT M8 x 20mm HEX HEAD

4581044

WASHER FLAT M8

4581046

WASHER SPRING M8

6151300

CAGE NUT M6

6151213

BOLT M6 x 20mm BLACK ZINK

4581082

WASHER FLAT M6 x 20 BLACK ZINK

4581287

WASHER SPRING M6 BLACK ZINK

STONE TRAY & FAIRLEAD

COVER TO BULL BAR

6542109

STONE TRAY

3758045

FAIRLEAD COVER

6151357

BOLT M10 SEMS

6151304

CAGE NUT M10

6151300

CAGE NUT M6

6151213

BOLT M6 x 20mm BLACK ZINK

4581082

WASHER FLAT M6 x 20 BLACK ZINK

4581287

WASHER SPRING M6 BLACK ZINK

WASHER BOTTLE STONE

TRAYS TO BULL BAR

6542110L

WASHER BOTTLE TRAY

6542110R

WASHER BOTTLE TRAY

6151301

CAGE NUT M8

6151300

CAGE NUT M6

6151262

BOLT M8 x 20mm BLACK ZINK

4581045

WASHER FLAT M8 BLACK ZINK

4581047

WASHER SPRING M8 BLACK ZINK

6151213

BOLT M6 x 20mm BLACK ZINK

4581082

WASHER FLAT M6 x 20 BLACK ZINK

4581287

WASHER SPRING M6 BLACK ZINK

RETAINING FENDER

LINERS TO WASHER

BOTTLE TRAYS

6151300

CAGE NUT M6

6151213

BOLT M6 x 20mm BLACK ZINK

4581082

WASHER FLAT M6 x 20 BLACK ZINK

4581287

WASHER SPRING M6 BLACK ZINK

MISCELLANEOUS

180302

CABLE TIES

3162152

ARIAL PLUG

6191009

PLASTIC SIDE MOULDING

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VEHICLE PREPARATION

1. Remove the grill and then the headlights

from the vehicle.

2. Remove the flares from the vehicle.

3. Remove the bumper bar from the vehicle.

NOTE: Be prepared to block or clamp off

the washer bottles lines to prevent water

leaking on the ground.

4. Remove the two bolts attaching the

bumper cross bar to the washer bottle.

5. On air suspension models, remove the

solenoid pack attached to the right hand

side of the crossbar.

6. Remove the crossbar from the vehicle.

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VEHICLE PREPARATION

7. If fitting a winch the plastic air ram will

need to be removed.

Short loom .

Longer relay loom .

8. To wire up the indicators from the bull

bar to the vehicle indicators a short loom

must be fitted .

A longer loom with two relays is also to be

fitted in conjunction with the short turn

signal loom .

9.Open the bag containing the long wiring

loom with relays .

Lay the loom across the engine bay from

headlamp to headlamp with the relays on

the Left Hand ( battery ) side of

the vehicle .

Place the relays on the inner guard ( as

shown ) as close as possible to the

battery .

Using a drill and a Phillips head bit attach

the relays to the vehicle with the screws

provided .

Note :- Ensure wiring will not rub on

any metal part or sharp edges .

02-08-12 Page 8 of 23 3787827

VEHICLE PREPARATION

10. Find the clearance , indicator and earth

wires for each headlight using a test lamp.

Removal of the headlamp will make this

easier . Wire the park lamp wire ONLY AT

THIS STAGE from the short indicator looms

into the head light looms using the scotch

locks provided .

WIRING TABLE FOR SHORT LOOM

FUNCTION

INDICATOR

HARNESS

VEHICLE COMBINATION LAMP

RIGHT

LEFT

INDICATOR

GREEN

GREEN / WHITE

GREEN / RED

EARTH

BLACK

PARK LAMP

RED

RED / ORANGE

RED / BLACK

11. The remaining wires from the short loom

( tabled above ) will now in conjunction with

the longer loom - will be both wired into the

vehicles headlamp loom . The table below

lists the colour & function of the longer relay

loom .

WIRING TABLE FOR LONG LOOM

FUNCTION

RELAY

HARNESS

SHORT INDICATOR HARNESS

RIGHT

LEFT

BATTERY

POSITIVE

RED

-------

------

BATTERY

EARTH

BLACK

-------

------

VEHICLE RH

INDICATOR

GREEN /

BLACK

------

BULL BAR

INDICATOR

GREEN

BULL BAR

INDICATOR

BLACK

VEHICLE LH

INDICATOR

YELLOW /

BLACK

------

BULL BAR

INDICATOR

YELLOW

GREEN

BULL BAR

INDICATOR

BLACK

12. The two wires for each common function

from both looms can now be combined and

scotch locked to the appropriate wire in the

vehicles head lamp loom . Replace the

headlamps back into the vehicle if removed

13. Wire the positive wire to the battery and the

earth wire to the negative as shown .

BLACK WIRE TO

BATTERY NEGATIVE

TERMINAL

RED WIRE TO

BATTERY POSITIVE

TERMINAL

02-08-12 Page 9 of 23 3787827

VEHICLE PREPARATION

14. With all the wiring connections now

made , feed the harness down so that it

sits neatly and retain in place with the

cable ties provided .

Note :- Ensure all wiring will not rub or

touch on any metal parts , sharp

edges and hot or moving parts .

15.Replace the headlight to gain a visual

reference of the line to be cut. Mask the

flare along the line of the headlight.

16.Remove the headlight and remove the

flare.

17.Cut the flare along the line of the

masking tape.

NOTE: Be careful not to cut too much off

the inner tab that attaches the flare to the

guard.

18.Replace the flares making sure to

replace the screw at headlight level.

19.Bend the tag that hangs down below the

line of the guard up and out of the way.

Bend tag

Replace screw

02-08-12 Page 10 of 23 3787827

VEHICLE PREPARATION

20.Once satisfied with the cut of the flare,

replace the headlight and the grill.

21.Clean the flare where it has been cut

and attach the plastic side moulding to

the flare.

22.Cut the plastic side moulding with a

Stanley knife along the back edge of the

flare.

23.It is recommended that the lower portion

of the bodywork below the flare cut off

be painted black. Clean the surface with

prep wash then mask the surrounding

area.

If fog lights not fitted go to step 26

24.Using a TORX bit, remove the fog lights

from the bumper bar and keep the six

retaining screws.

25.Remove the fog light wiring loom from

the bumper bar.

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