Dobinsons Isuzu D-Max 2012 on User manual

Dobinsons Springs and Suspension www.dobinsonsprings.com
Bullbar Installation Guide
ENSURE PAGE SCALING IS TURNED TO
NONE OR OFF WHEN PRINTING
Part Number: BU21-3529, BU21-3685, BU21-3681
Fits:
Isuzu D-Max 2012 on
This Bullbar will take approximately 3 hours to install
Tools required are
•Spanners and socket set.
•Pneumatic hacksaw (For 4x2 lo-rider models)
•Screwdrivers
•Pliers and side cutters
•Torx-bit Screwdriver Set
Dobinsons BULLBARS should be installed by a qualified installer and it is
the installer responsibility to ensure correct fitment.
Fully read and understand the instructions before beginning the installation

Dobinsons Springs and Suspension www.dobinsonsprings.com

Dobinsons Springs and Suspension www.dobinsonsprings.com

Dobinsons Springs and Suspension www.dobinsonsprings.com
Fitting Guide
1. Remove the number plate.
2. Remove the screws and bolts from the top of
the grill.
3. Reach down in behind the bottom of the grill
and carefully unclip the grill from the top of
the bumper (red arrows shown below), then
remove the grill. Remove the clips from the
top of the bumper (blue arrows).
4. Remove the clips along the inside edges of the
wheel arches on both sides.
5. Remove all the fasteners securing the bottom
edge of the bumper to the vehicle.
6. Starting from each edge of the top of the
bumper, gently unclip the bumper.
7. Carefully remove the bumper from the
vehicle, and remove the bumper re-
enforcement bar.
8. Remove the lower bash plate and put aside
for re-fitment later.
9. Remove the inner and outer “L” shaped
bumper support brackets, 4 in total.
10. Loosely 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). Ensure
that the U-bolts do not pass over any wiring.
Note: Ensure clearance to the radiator
supports and these brackets, grind a small
amount away if necessary.

Dobinsons Springs and Suspension www.dobinsonsprings.com
11. Fit the bullbar mounting bracket.
12. Ensure the bullbar mounting bracket is central
to the vehicle and as low as possible and
tighten all fasteners.
For 4x4 and 4x2 high rider skip to step 17
For 4x2 Lowriders see steps 13-16
13. Ensure that page scaling was turned off when
printing this guide, cut out both parts of the
template at the end of this guide and measure
the scale line. It should be within 1 or 2mm.
14. Align the alignment marks directly on top of
each other and tape together. Align the
template on the vehicle bumper as per
instructions on the template and mark the cut
lines. The template can then be flipped upside
down to mark the other side.
15. Masking tape the top side of the cut lines to
prevent damage to the bumper and carefully
cut along the cut line.
16. Re-install both of the small bumper cut out
panels to the vehicle ensuring they are
clipped in properly at the front. Skip to step
19.
17. On 4x4 and 4x2 High rider models remove
the plastic bumper mounts at the ends of the
bumpers. (Do not remove on 4x2 lo-rider
models as these clip the bumper panels).
18. 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
bullbar it is easiest to install now.
19. If not installing a winch skip to step 27.
20. See the Installation section of your Dobinsons
4x4 Winch manual for specific detailed fitting
instructions. For a brief overview see the
following steps.
21. Test fit your winch to the mounting bracket
and do up loosely with the clutch handle on
the left hand side of the vehicle.
22. 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.
23. Determine where the winch control box will
be located and mount the control box. See
instructions in winch user manual for control
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

Dobinsons Springs and Suspension www.dobinsonsprings.com
to be wired until the bullbar has been fitted as
below.
24. 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.
25. 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.
26. Install the roller fairlead into the bulbar.
27. Check the poly bulbar over riders, fog light
and top loop bolts are tight (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).
28. 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.
29. 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.
30. 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
fitted with OEM fog lights the wiring loom
supplied can be used. Follow the wiring
diagram at the end of this manual.
31. Re-install the grill.
32. Paint a small section approx. 150mm high and
250mm wide on the ends of the vehicle body
satin black with a spray pack on both sides.
33. Install the under-headlight rubber fill in pieces
to the bar.
34. With help, fit the bulbar into position and
install nuts and bolts supplied.
35. Align the bar, leaving as big of a gap as
possibly between the top of the bullbar wings
and the vehicle quarter panel, this gap must
be a minimum of 17mm on each side at the
back of the wing tip of the bulbar.
Shown Below on 4x4 and 4x2 high rider
Shown Below on 4x2 Lowrider (note the bar
wings sit on the outside of panel)

Dobinsons Springs and Suspension www.dobinsonsprings.com
36. Once you are happy with the alignment
tighten the nuts and bolts on each side.
37. Once 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 chuck from the outside.
38. 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.
39. Fit the under bar protection kit now with the
bolts supplied. Fit the centre piece first
loosely fitting the front bolts. Then install the
remaining 2 bolts and washers from the
bracket fitting kit into through the rear of the
plate into the cross bar fitted earlier. Only
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.
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/vehicle body 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 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

Customer Copy: Bullbar Care Instructions
To ensure the surface finish quality it is recommended that the
bullbar be washed and cleaned regularly to prevent build up of
dirt and contaminants which when exposed to the elements can
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 surface using simple tools and cheap readily
available polishing items.
Tools Required:
•Electric buffer or Electric drill (an electric/cordless drill is generally more convenient).
•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.
•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.

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.
3. 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 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.
B). Gently buff the work area with the buffing wheel and with light pressure move back and forth across the
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