Bullbar Installation Guide - Dobinsons Spring & Suspension
Contents
1. Bullbar Installation Guide Dobinsons Part Number BU21 3532 BU21 3687 BU21 3684 gt ACCESSORIES Fits Holden Colorado RG amp Colorado 7 Trailblazer 2012 on This Bullbar will take approximately 3 hours to install Tools required are e Spanners and socket set e Pneumatic hacksaw e Screwdrivers e Pliers and side cutters e Torx bit Screwdriver Set Fully read and understand the instructions before beginning the installation Dobinsons Springs and Suspension www dobinsonsprings com Dobinsons ACCESSORIES Nut M8 x 1 25 2 Pcs Bolt M6 x 1 x 20 11 Pcs Fix nut M6 x 1 11 Pcs Dobinsons Springs and Suspension www dobinsonsprings com Dobinsons e lt ACCESSORIES www dobinsonsprings com Dobinsons Springs and Suspension Fitting Guide 1 Remove the number plate 2 Remove the 8 torx head screws and 2 bolts from the top of the grill K aw E mg e gp 3 Remove the 2 lower screws along the inside edges of the wheel arches on both sides Zi 4 Remove all the fasteners securing the bottom edge of the bumper to the vehicle 5 Starting from each edge of the top of the bumper gently unclip the bumper The clips on the vertical join of the bumper can be quite difficult to unclip a small flat blade screw driver wrapped in a clean rag can be used to assist this take extreme care not to scratch the bumper of the quarter panel 6 Carefully remove the bumper from th2. there will be a change in vehicle handling characteristics It is also important to note that due to their nature fog lights are required to provide a yellow light to allow clear fog vision For this reason Dobinsons bullbars utilise a Halogen bulb Halogen bulbs generate a considerable amount of heat to achieve the yellow colour and this causes the air inside the fog light lens to expand and contract For this reason the fog light assembly cannot be sealed and has a small breather on the back In some cases this may cause condensation to form inside the fog light The customer may choose to seal the lens of the fog light but must not seal the rear breather Dobinsons Springs and Suspension www dobinsonsprings com FOG LIGHT lt WIRING DIAGRAM LAMP kur egen I RE O O O O O O D BATTERY BEGUN CHECK THE PARKER INDICATOR WIRING LIGHT CONFIGURATION AND USE THE CORRECT WIRING DIAGRAM AS SEEN BELOW ACCESSORIES O E PARKER SWITCH WIRE POSITIVE B IN CAB SWITCH TYPE 1 YELLOW BLACK WHITE TYPE 2 YELLOW WHITE BROWN FROM LIGHT FROM LIGHT AND CONNECTOR BLACK WHITE RED FROM CONNECTOR PARK LIGHT PARK LIGHT YELLOW INDICATOR PARK LIGHT CIRCUIT CIRCUIT mm VEHICLE GROUND PARK LIGHT CIRCUIT INDICATOR e CIRCUIT z Customer Copy Bullbar Care Instructions Dobinsons To ensure the surface finish quality it is recommended that the dirt and contamin
3. ants which when exposed to the elements can lt lt EEN RES ra l bullbar be washed and cleaned regularly to prevent build up of degrade the surface finish It is also recommended that the mounting fasteners on the bullbar be checked after 1000km s Winch servicing and care should also be carried out as per the winch instruction manual Stainless Loop Deluxe Bullbar Loop Care and Maintenance Customers with Stainless Loop Deluxe Models Only The top loops on your Dobinsons Stainless Loop Deluxe steel bullbar are manufactured from high quality 304 grade stainless steel Once formed and welded it is highly polished to provide a high gloss finish Whilst the material is a high quality stainless steel like any other exterior polished surface care and some maintenance is required to ensure the surface finish quality It is recommended that the stainless loops be kept as clean as possible and is thoroughly washed and dried regularly to prevent build up of dust and contaminants This is especially important in coastal and high dust areas The loops can simply be cleaned with most regular car cleaning items like a soft sponge car wash and a chamois avoid strong cleaning chemicals Like many other highly polished exterior metals over extended periods of time and heavy weathering can cause some staining of the surface may occur If this occurs the surface can be simply polished using the following methods to remove the stains and restore the high gloss s
4. best results However if no instructions are provided the following guidelines can be used A Carefully dress the buff wheel with the compound across the rotating wheel for a few seconds taking care not o apply too much compound it is better to apply a little compound more frequently than to overdress the buff job C After polishing use a soft clean dry rag to clean the surface and inspect in the light for an even finish D Once complete clean thoroughly again with a sponge and warm water Dobinsons Spring and Suspension www dobinsonsprings com
5. binsons Springs and Suspension will need to be cut away to allow clearance to Dobinsons the top of the bullbar mounting bracket A section of approximately 80mm x 80mm will be required to be removed Also check the gt ACCESSORIES clearance of the bumper to the mounting bracket and trim if required to clearing bullbar mounting tabs 21 Carefully un wrap the bulbar taking care not to scratch it especially on the top loops Reinstall the number plate to the bullbar as it is easier now If installing driving lights to the e bullbar it is easiest to install now 17 Once there is sufficient clearance re fit the 22 If not installing a winch skip to step 30 bumper to the vehicle installing all screws and 23 See the Installation section of your Dobinsons bolts along the top section and side 4x4 Winch manual for specific detailed fitting 18 Fit the bullbar mounting bracket instructions For a brief overview see the er E following steps 24 Test fit your winch to the mounting bracket and do up loosely with the clutch handle on the left hand side of the vehicle Installing a winch may also require you to trim away the centre of the bumper more too allow clearance for the winch The lower bumper grill can be removed if desired and the section ee ie s at the bottom where the grill was trimmed off i ge P to allow clearance 19 Ensure the bullbar mounting bracket is central to the vehicle a
6. e vehicle Dobinsons Springs and Suspension Dobinsons e Zeg ACCESSORIES 7 Remove the lower bash plate and put aside for re fitment later e m 8 Remove the bumper bar mounting beam and discard 9 The lower outer edges of the front metal splash guards can be painted satin black www dobinsonsprings com 10 Remove the number plate mounting bracket from the lower section of the bumper y Dobinsons 13 Carefully cut away the lower section of the aw oe bumper For Colorado Ute See Below or for Colorado7 Chevrolet Trail blazer Ref Step 14 11 Mask a line along the rib on the outside of the air ducts through the centre rib of the air duct to the inside corner of the air ducts on both sides For Colorado7 Chevrolet Trail blazer See Below 14 Mark the bumper as seen below by following the bumper mould line on each side across the centre of the vehicle again staying about 2 3cm s below the bottom of the chrome on the grill COLORADO d zg Se e _ KS 12 Then continue this line across to the centre of the bumper about 2 cm s below the chrome of the grill 15 Install the bullbar support brackets item 2 to either side of the chassis on both sides as per the diagram on page 3 and the under protection cross beam item 3 16 Test fit the bullbar mounting bracket to the chassis Small sections of the radiator air ducts Do
7. e happy with the alignment of the bullbar drill 2 x 8mm pinning holes on each side of the bullbar drilling through both the mounting bracket mounting plate and bullbar mounting plate Fix with 8mm bolts and nyloc nuts to keep the bullbar in its position This may be easiest performed by drilling with a small bodied drill from the inside or a right angle drill from the outside Plug the wires into the indicator parker light plug and fog lights Test all lights and adjust the position of the fog lights if required Fit the under bar protection kit now with the bolts supplied Fit the centre piece first www dobinsonsprings com loosely fitting the front bolts Then install the remaining 2 bolts and washers from the bracket fitting kit into through the rear of the gt lt plate into the cross bar fitted earlier Only ACCESSORIES thread these bolts in a few turns Then slide the original vehicle bash plate over the bolt heads and washers and install the rear original bolts e F 40 Install the side plates and tighten all nuts and bolts in all under protection plates 41 Check over all items removed during installation 42 Trim the wheel arch splash guards level with the bottom of the under protection plates and secure 43 IMPORTANT NOTES It is important to inform the customer that headlight adjustment may also be required due to the change in ride height It is also important to inform the customer that
8. ght Do not over tighten the stainless steel loop mounting bolts Do not over tighten the poly bullbar over riders as they will pull the over riders out of shape Wire up the lights Using a multimeter or test light first locate the earth wire parker positive and indicator positive wires from the wiring on the back of the original vehicle lights on each side Unclip the wiring from the indicator parker lights Check that the wiring will be long enough to reach the new bullbar indicator parker lights and extend if required Using the diagram at the end of this manual join the corresponding wires to original vehicle wires located in the previous step The wires can be joined by either using good quality snap lock crimp connectors or by soldering Ensure the connection is secure and is sufficiently insulated If fitting a bullbar with fog lights the fog lights can be connected using the original vehicle fog light wires if fitted If required cut the old fog light wiring plugs off and cut the new fog light wiring plugs and join If the vehicle is not Dobinsons Springs and Suspension 34 35 36 37 38 39 Dobinsons fitted with OEM fog lights the wiring loom supplied can be used Follow the wiring diagram at the end of this manual With help fit the bulbar into position and install nuts and bolts supplied Align the bar Once you are happy with the alignment tighten the nuts and bolts on each side Onc
9. nd tighten all fasteners 20 Trim the bottom of the mudguard liners level with the bottom of the splash panel 25 This may require the clutch handle and gear box housing to be rotated forward one or 2 bolt holes to allow easy access through the bulbar holes See instructions in winch user manual 26 Determine where the winch control box will be located and mount the control box See instructions in winch user manual for control Dobinsons Springs and Suspension www dobinsonsprings com 27 28 29 30 31 32 33 box mounting options If mounting to the top of the bullbar using the supplied bracket check clearance of control box to grill and also check where the wires will route as if the wires are passing through the holes in the top of the bullbar the control box may not be able to be wired until the bullbar has been fitted as below Wire the winch up as per the winch instruction manual and bolt the winch to the mounting bracket ensure the mounting bolts are not too long and tighten correctly Route the wires and connect to battery and also route the breather hose Unwind some cable from the winch and pass the cable through the fairlead hole in the bullbar and through the roller fairlead This may require removing a circlip from the fairlead and re installing once the cable is passed through Install the roller fairlead into the bulbar Check the poly bulbar over riders fog light and top loop bolts are ti
10. urface using simple tools and cheap readily available polishing items Tools Required e Electric buffer or Electric drill an electric cordless drill is generally more convenient e Polishing compound This can be supplied by Dobinsons Spring and Suspension Please contact head office on the details below for polish as a specific type is used e Soft finishing type buffing wheel The buffing wheel should be a soft finishing type Calico loose leaf style to allow the surface to be polished to a high gloss without further marking the surface The 2 types of discs shown below are readily available from most hardware stores Australian customers Bunnings etc The brand below is Josco and if purchasing a twin pack ensure that only the finishing buff is used and not the cutting buff DO NOT USE METAL OR HARSH BUFFING PADS AVOID USING THE ROUGH CUTTING TYPE WHEELS USE THIS SOFT TYPE CALICO HIGH GLOSS BUFFING WHEEL ONLY Method 1 The stainless loops may be removed from the bullbar if this makes it easier to work on however if using a cordless drill this is not a necessity If removing the loops do not over tighten the loop retaining bolts when re fitting 2 Ensure the loops are first completely clean and dry Fit the polishing buff wheel to the drill or buffing tool take note of the maximum wheel speed and rotation direction 4 It is recommended to follow specific instructions on the packaging of the buffing wheel for
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