Dobinsons Isuzu D-Max 2012 on

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document provides a comprehensive installation guide and maintenance instructions for the Dobinsons Bullbar, specifically designed for the Isuzu D-Max 2012 onwards. The bullbar is a robust accessory intended to enhance the vehicle's front-end protection and provide mounting points for additional equipment like winches and driving lights.

Function Description:

The Dobinsons Bullbar serves multiple functions:

Front-End Protection: It provides significant protection to the vehicle's front, including the bumper, grille, and headlights, against impacts from off-road obstacles, animal strikes, and minor collisions. This is crucial for vehicles used in demanding environments or for those frequently traveling on rural roads.
Accessory Mounting Platform: The bullbar is designed to integrate various accessories. It offers dedicated mounting points for:
- Winch: A winch can be installed within the bullbar's structure, providing recovery capabilities for off-road situations. The manual details the steps for winch installation, including routing wires and ensuring proper fitment.
- Driving Lights/Fog Lights: The bullbar includes provisions for installing auxiliary driving lights and fog lights, improving visibility during night driving or adverse weather conditions. The wiring diagram for fog lights is provided, along with instructions for connecting them to the vehicle's electrical system.
- Number Plate: The bullbar includes a designated area for re-installing the vehicle's number plate.
Aesthetic Enhancement: Beyond its functional aspects, the bullbar contributes to a more rugged and aggressive appearance for the Isuzu D-Max.

Important Technical Specifications:

The bullbar is identified by part numbers: BU21-3529, BU21-3685, and BU21-3681. These part numbers likely correspond to different variations or components of the bullbar system. The installation process involves various fasteners and components, including:

Chassis bracket (1 set)
Support bracket (2 set L,R)
Bracket (1 Pcs.)
Bolts: M12 x 1.5 x 35 (6 Pcs.), M10 x 1.25 x 80 (4 Pcs.), M10 x 1.25 x 30 (13 Pcs.), M8 x 1.25 x 20 (2 Pcs.), M6 x 1 x 20 (13 Pcs.)
Nuts: M12 x 1.5 (6 Pcs.), M10 x 1.25 (22 Pcs.), M8 x 1.25 (2 Pcs.), M6 x 1 (13 Pcs. - Fix nut)
Washers: Square M12 (12 Pcs.), DØ20 dØ11 (12 Pcs.), M10 (31 Pcs.), M8 (2 Pcs.)
U-Bolt M10 (4 Pcs.)
Under protection plates (Middle, RHS, LHS – 1 Pcs. each) The bullbar is designed to fit the Isuzu D-Max 2012 onwards models, with specific instructions for 4x4 and 4x2 high-rider models, and distinct steps for 4x2 lo-rider models, particularly concerning bumper cutting.

Usage Features:

Installation Time: The estimated installation time for this bullbar is approximately 3 hours, suggesting a moderately complex installation process that requires attention to detail.
Qualified Installation Recommended: The manual explicitly states that "Dobinsons BULLBARS should be installed by a qualified installer and it is the installer responsibility to ensure correct fitment." This highlights the importance of professional installation to ensure safety, proper alignment, and functionality.
Detailed Step-by-Step Instructions: The guide provides a comprehensive, numbered sequence of steps for installation, starting from removing existing vehicle components (number plate, grille, bumper, bash plate, bumper support brackets) to fitting the bullbar, wiring lights, and reassembling parts.
Model-Specific Instructions: It differentiates between 4x4/4x2 high-rider and 4x2 lo-rider models, especially regarding bumper modifications. For 4x2 lo-rider models, a template is provided for precise cutting of the bumper, emphasizing the need for accurate scaling during printing.
Winch Integration: Specific instructions are given for winch installation, including testing fitment, rotating the clutch handle/gearbox housing for accessibility, mounting the control box, and routing wires and breather hoses.
Lighting Wiring Diagrams: Detailed wiring diagrams are included for fog lights and indicator/parker lights, with two types of configurations (Type 1 and Type 2) to match different vehicle wiring setups. This ensures correct electrical connections for integrated lighting.
Alignment and Fitment: The instructions stress the importance of careful alignment of the bullbar to the vehicle, ensuring a minimum gap of 17mm between the bullbar wings and the vehicle quarter panel. Pinning holes are drilled to secure the bullbar in its final position.
Post-Installation Adjustments: The manual notes that headlight adjustment may be required after installation due to changes in ride height, and that vehicle handling characteristics may change.
Fog Light Characteristics: It explains that Dobinsons bullbars use Halogen bulbs for fog lights to provide yellow light for clear fog vision. It also clarifies that fog light assemblies are not sealed and have a small breather, which may lead to condensation. Customers are advised not to seal the rear breather if they choose to seal the lens.

Maintenance Features:

Regular Cleaning: To maintain the surface finish quality, it is recommended to wash and clean the bullbar regularly to prevent the build-up of dirt and contaminants. This is particularly important in coastal and high-dust areas.
Fastener Checks: All mounting fasteners on the bullbar should be checked after the first 1000 km of use to ensure they remain tight.
Winch Servicing: If a winch is installed, its servicing and care should be performed according to the winch's instruction manual.
Stainless Loop Care (for Deluxe Models): For bullbars with stainless steel loops (304-grade stainless steel), specific care instructions are provided:
- Cleaning: Clean regularly with regular car cleaning items (soft sponge, car wash, chamois), avoiding strong chemicals.
- Stain Removal/Polishing: If staining occurs over time due to weathering, the surface can be polished using an electric buffer or drill with a soft, finishing-type buffing wheel (e.g., Calico loose leaf style) and polishing compound.
- Polishing Technique: Detailed steps for polishing are given, including dressing the buff wheel with compound, gently buffing the work area with light pressure, and cleaning the surface after polishing.
- Warning: Crucially, it warns against using rough cutting type wheels or metal/harsh buffing pads, as these can damage the polished surface. Only soft, high-gloss buffing wheels should be used.
Polishing Compound: Dobinsons Spring and Suspension can supply a specific type of polishing compound, indicating that specialized products may be beneficial for optimal maintenance.