This document is an installation guide for the Ironman 4x4 BB074 Bull Bar, designed to fit Isuzu D-Max models from 6/2019+ (MY20+). The installation is estimated to take approximately 4 hours and requires a qualified person to ensure correct fitment and maintain air bag compatibility, as the mounting system must not be modified.

Function Description:

The Ironman 4x4 BB074 Bull Bar serves as a protective accessory for the front of the vehicle, offering enhanced frontal impact protection and a mounting platform for additional accessories such as lights and a number plate. It is designed to be air bag compatible, ensuring the vehicle's safety systems remain functional after installation. The bull bar integrates with the vehicle's existing structure, requiring modifications to the bumper and chassis for proper fitment. It also includes provisions for park lights, indicators, and fog lights, with a wiring diagram provided for electrical connections.

Important Technical Specifications:

Compatibility: Isuzu D-Max 6/2019+ (MY20+).
Installation Time: Approximately 4 hours.
Air Bag Compatibility: Tested and confirmed; mounting system must not be modified.
Hardware: A variety of bolts, washers, and nuts are used for installation, including:
- M6 bolts (M6x1.0x25mm)
- M8 bolts (M8x1.25x25mm, M8x1.25x40mm)
- M10 bolts (M10x1.25x40mm, M10x1.25x120mm)
- M12 bolts (M12x1.25x40mm, M12x1.25x90mm, M12x1.25x120mm)
- Flat washers (M6, M8, M10, M12)
- Spring washers (M8, M10, M12)
- Nuts (M8, M10, M12)
- Captive nuts for number plate mounting.
Drilling Requirements:
- 1 x 12mm hole per side for rear outer support bracket.
- 4 x 12mm holes per side for inner and outer support brackets.
- 4 x 10mm holes for pinning points.
- Pilot hole for guard liner, enlarged to 6mm.
- 6mm hole through bumper lip and guard liner.
Electrical Components:
- Supplied 21W resistor for indicator wiring to ensure correct function.
- Wiring diagrams for Park Light & Indicator, and Fog Lights.
- Relay (85, 30, 87, 86, 87a terminals) for fog lights.
- SPST (Single-Pole, Single-Throw) switch for fog lights.
- Fuses for fog light circuit.
Bolt Tension Chart (Property Class 8.8):
- M6: 10.5 Nm (7.7 ft/lb)
- M8x1: 25 Nm (18 ft/lb)
- M10x1.25: 49 Nm (36 ft/lb)
- M12x1.5: 88 Nm (64 ft/lb)

Usage Features:

The bull bar provides a robust front-end solution for the Isuzu D-Max. It includes a steel skid plate for underbody protection and support brackets for secure mounting. The design allows for the integration of the vehicle's existing lighting functions (indicators, park lights) and adds provisions for fog lights. The bull bar is designed to maintain a minimum 20mm gap between itself and the bumper to allow for body movement, preventing contact and potential damage during vehicle operation. The inclusion of a license plate bracket ensures compliance with road regulations.

Maintenance Features:

While the manual primarily focuses on installation, the robust construction of the bull bar suggests minimal ongoing maintenance beyond periodic checks of bolt tension and general condition. The bolt tension chart provides specific torque values for different bolt sizes, which is crucial for ensuring the long-term integrity and safety of the installation. The use of various washers (flat and spring) helps distribute load and prevent loosening over time. The product is designed to be durable, but regular inspection for damage, corrosion, or loose fasteners would be advisable to ensure continued performance and safety. The electrical connections, particularly the resistor for indicators, should be checked periodically to ensure proper functioning of the lights. The guide emphasizes that installations should only be done by a qualified person, which implies that any subsequent maintenance or adjustments should also be performed by trained individuals to maintain the product's integrity and air bag compatibility.

Ironman4x4 BB074 - Page 4

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