TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122, BG41SY FITTING INSTRUCTINS REPLACES: 10.01.06 REVISED: 08.08.10 GMC SIERRA 9/04-2500 4X4 BIG TUBE PRTECTIN BAR T SUIT 15000Lb WARN ELECTRIC WINCH VEHICLE FRNTAL PRTECTIN SYSTEM (VFPS) FR AIR BAG & ADR CMPLIANT VEHICLES Check installation hardware before commencing. 1. Lift bonnet. 2. Remove plastic cover from top of radiator to grille, seven plastic clips. See figure 1. Remove one 10mm head bolt from top of grille then release one clip (each side) near headlight and pull grille slightly forward at top to access two 15mm head bumper bracket bolts (each side). Use 15mm socket with long extension bar. Remove three 15mm head bolts (each side) from bumper side supports. Discard side supports. Disconnect fog lights (if fitted) and slide bumper bar forward off vehicle. Refit grille and plastic cover. 3. Remove lower and outer side tow hook bolts from chassis (two each side). Remove two bolts from pipe cross member where plastic guard is bolted. See figure 2. 4. Remove bumper brackets from inside of chassis rail. Use oxy/acy or grinder, grind smooth and paint exposed metal with a rust inhibitor. See figures 3 and 4. 5. Place M12 x 50 x 1.75 bolts with flat and spring washers (supplied) through lowest hole on steel mounting plates. Attach 50 x 6 spacer plate (supplied) over bolt. See figure 5. Attach steel mounting plate (supplied) to outside of chassis into original tow hook hole. FINGER TIGHTEN NLY. 6. Level steel mounting plate off front, clamp in position then TIGHTEN M12 x 75 bolt, then remove clamp. See figure 6. 7. Fit winch and roller fairlead to winch mount. NTE: Roller fairlead top holes are used and must be elongated approximately 5-6mm toward drivers side to align with protection bar as winch sits offset to driver s side. Use die grinder. Treat all exposed metal with a rust inhibitor or similar. Measure roller fairlead from each side of steel winch mount to ensure roller fairlead is centred. See figure 7. Use original winch bolts with heavy duty flat and spring washers (supplied). FINGER TIGHTEN NLY. NTE: Feed winch cable through roller fairlead as installing. See figure 7. 8. Fit control box bracket to inside of winch mount. Use M8 x 30 bolts, nuts and washers (supplied). Fit control box to control box bracket. NTE: Control box must be fitted upside down for wiring to reach winch motor. Use original nuts. Note: Discard original warn control box bracket. Level control box and TIGHTEN ALL BLTS/NUTS. See figure 8. 9. Position winch mount and winch on a trolley jack or similar and position on chassis. Use two M12 x 40 x 1.75 bolts, flat washers and spring washers (supplied) for lower chassis into tow hook. Use two M12 x 40 x 1.75 bolts, flat washers and spring washers (supplied) for top chassis captive nuts and two M10 x 40 x 1.5 bolts, flat washers and spring washers (supplied) for pipe cross member brackets. FINGER TIGHTEN NLY. See figures 9, 10 and 11.. Copyright ECB Pty Ltd 2010 1
TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122, 10. Because of the length of the winch motor, the winch may sit approximately 5mm off centre toward driver s side and may just contact passenger side chassis. TIGHTEN winch to winch mount. TIGHTEN winch mount to chassis. Check roller fairlead is central on winch mount. See figure 12. TIGHTEN IN PSITIN. 11. Ensure top hole on winch mount is aligned with hole in steel mounting bracket. See figure 13. 12. Drill two 13mm holes (each side) through chassis using holes in steel mounting plates as a guide. Treat exposed metal with rust inhibitor or similar. Use ½ x 1¾ bolts, nuts, flat and spring washers (supplied). TIGHTEN ALL NUTS/BLTS. See figures 14 and 16. 13. Drill one 13mm hole (each side) through lower chassis rail. Use winch mount as a guide. Treat all exposed metal with a rust inhibitor. Use ½ x 1 ½ bolt with flat washer and spring washer (supplied). Use ½ nut and flat washer on 200mm wire (supplied) to access bolt. See figures 15 and 16. 14. Route winch cables to positive and negative. Use cable ties (supplied) to ensure cable will not rub through on vehicle. 15. Test winch operation. 16. Splice ECB indicator / park light wiring into original wiring. Remove headlight to access park light wiring. Turn and lift two pins at top of lights. See figures 17 and 18. Use six cable locks (supplied). NTE: Turn indicator bulb holders to unlock, remove bulb holders from lights to access wiring. 17. Cut plug from original fog light wiring and splice ECB fog light wiring (supplied) to original fog light wiring. Use four cable locks (supplied). 18. Fit ECB LED indicator / park lights into protection bar as per instructions supplied with the LED indicator kit. NTE: Ensure park light is to outside. See figure 19. 19. Fit ECB fog lights into protection bar. TIGHTEN FIRM NLY for later adjustment. Use M6 x 20 bolt with 6mm nut on 100mm wire (supplied). See figure 20. Do not fit ECB fog light trims (supplied) to protection bar at this point. 20. Fit ECB 6mm black clip lock trim to rear of protection bar. NTE: Trim off lower edge on an angle so trim will sit flush with end of protection bar. See figures 21, 22 and 23. Fit black clip lock trim (supplied) to skirt roller fairlead cut out. See figure 24. 21. Fit ECB protection bar to outside of steel mounting plates. Use ½ x 1¾ bolts, nuts, flat and spring washers (supplied) for forward most holes and ½ x 2 bolts, nuts, flat and spring washers for rear winch mount holes. 22. Align protection bar with vehicle. Approximately 30-40mm below guards at sides and approximately 6mm in front of grille is desirable position. See figures 25 and 26. TIGHTEN ALL BLTS AND NUTS. 23. Connect indicator / park lights and CHECK PERATIN. 24. Connect fog lights and CHECK PERATIN. 25. Aim fog lights with low beam. TIGHTEN fog light bolts. Fit fog light trims (supplied) to protection bar. Note: wider part of the trim faces toward centre.. Copyright ECB Pty Ltd 2010 2
TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122, 26. Tidy all wiring zip tie to vehicle. 27. Trim ends of plastic inner guard to match protection bar (if desired). See figure 27. ENSURE NUMBER PLATE IS CLEARLY VISABLE Note: When fitting/refitting the licence plate to the vehicle, ensure there is no obstruction to licence plate vision in accordance with local authorities. If required relocate licence plate to an alternate location. Further VFPS Notes: a) Do not attach VFPS to the vehicle using anchorages not intended for this purpose (e.g. engine mounting bolts). b) Do not use this product for any vehicle make or model, other than those specified by the VFPS manufacturer. c) Do not remove the plaque or label from the VFPS. d) Do not modify the structure of the VFPS in any way. e) No accessory or fitment should project forward of the VFPS forward profile. f) ENSURE THESE INSTRUCTINS ARE LEFT WITH VEHICLE WNER AND/R PERATR. IMPRTANT INFRMATIN Periodically check bolts and nuts for correct tightness, especially if travelling on rough roads FITTING KIT 1 Steel winch mount. 2 M8 x 30 bolts and nuts. 1 Steel control box bracket. 4 M8 flat washers. 2 Steel mounting plates. 2 M8 spring washers. 2 50 x 6 mm round alloy spacer plates with 13mm hole 1 Pair ECB fog lights and wiring. 2 ½ x 2 bolts and nuts. 4 ECB fog light trims (2 for winch access). 8 ½ x 1 ¾ bolts and nuts. 2 M6 x 20 bolts. 2 ½ x 1 ½ bolts. 2 M6 flat washers. 2 ½ nut and washer on 200mm wire. 2 M6 spring washers. 2 M12 x 50 x 1.75 bolts. 2 M6 nuts on 100mm wire. 4 M12 x 40 x 1.75 bolts 1 ECB LED Indicator / Park light kit 28 ½ flat washers. 10 Cable locks 18 ½ spring washers. 1 2400mm length 6mm black clip lock trim. 2 M10 x 40 x 1.5 bolts. 2 190mm lengths 6mm black clip lock trim. 2 M10 flat washers. 8 200mm long zip ties. 2 M10 spring washers.. Copyright ECB Pty Ltd 2010 3
TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122, Plastic cover being removed Figure 1 Figure 2 Remove this bracket Figure 3 Passenger side shown Figure 4 Drivers side shown with bracket removed 50 x 6 spacer on M12 x 50 x 1.75 bolt Figure 5 Figure 6. Copyright ECB Pty Ltd 2010 4
TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122, Figure 7 Figure 8 Figure 9 Driver s side rear lower bolt shown Figure 10 Top driver s side bolt shown Figure 11 Lower pipe cross member bolt Figure 12 - Measure edge of roller fair lead to steel mounting bracket each side to check if centred.. Copyright ECB Pty Ltd 2010 5
TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122, Figure 13 Figure 14 ½ x 1 ¾ bolts in drilled holes Headlight locking pins Figure 15 ½ nut/washer on wire Figure 16 Drivers side shown Figure 17 Figure 18. Copyright ECB Pty Ltd 2010 6
TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122, Stainless steel self-tappers M6 bolt Figure 7 Figure 20 Top 6mm Black clip lock trim Figure 21 Figure 22 Trim lower edge on an angle Fit clip lock here Black clip lock trim Figure 23 Indicative photo only Figure 24. Copyright ECB Pty Ltd 2010 7
TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122, Figure 25 30-40mm Figure 26 Tuck inside protection bar here Figure 27 Trim here. Copyright ECB Pty Ltd 2010 8
TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122, We value your comments Dear Fitter, ECB would like to know how you went with the installation of this product. We value your comment and may need to contact you to clarify some details so please complete your contact details clearly. We would appreciate if you could complete as many of the following details as possible. Your Name: Product Part No. Product Description: Your contact No. Product Invoice No. Make, model, and year of vehicle: Product Work rder No. Company your from/company product purchased from: Date of Fitment: / / Was the fitting hardware supplied complete? Yes No If no what was not supplied Yes No Did the installation go well? Please provide comments Please draw diagrams if you need to. Post to Fax to Reply Paid 122 (07) 3283 1168 P Box 122 Margate QLD 4019. Copyright ECB Pty Ltd 2010 9
TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122,. Copyright ECB Pty Ltd 2010 10
TELEPHNE: (07) 3897 5700 FAX: (07) 3283 1168 CLNTARF, BRISBANE. P.. Box 122, DESPATCH CHECKLIST BG41SY Work rder # Finish: Transport: Due Date: 1 Steel winch mount 1 Steel control box bracket 2 Steel mounting plates 1 Bolt Kit 1 LED ECB indicator / park light kit. 1 Pair ECB Fog lights and wiring 2 Fog light surrounds 1 2400mm length 6mm clip lock 2 190mm lengths 6mm clip lock 2 ECB verriders Fitted to Bar 2 Round cut out surrounds Fitted to Bar 2 6mm Air Scoops Fitted to Bar All parts checked and completed by: Nut and bolts: rder control: Final wrap check: Date / / Date / / Date / /. Copyright ECB Pty Ltd 2010 11