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Ironman4x4 BBR085E Installation Manual

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INSTALLATION
GUIDE
BBR085E
RAID BULL BAR TO SUIT RAM DT
• Ironman 4x4 BBR085E Raid Bull Bar to suit Ram DT.
• It will take approximately 2.5 hours to install.
NOTE: This product has been tested for air bag compatibility
and therefore the mounting system MUST NOT be modified
IMPORTANT: Bull bar installations should only be done by a qualified person
and it's the responsibility of this person to ensure correct fitment.
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd

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Summary of Contents for Ironman4x4 BBR085E

  • Page 1 GUIDE BBR085E RAID BULL BAR TO SUIT RAM DT • Ironman 4x4 BBR085E Raid Bull Bar to suit Ram DT. • It will take approximately 2.5 hours to install. NOTE: This product has been tested for air bag compatibility and therefore the mounting system MUST NOT be modified IMPORTANT: Bull bar installations should only be done by a qualified person and it’s the responsibility of this person to ensure correct fitment.

  • Page 2: Before Installation

    Installation Guide Installation Guide BBR085E Before Installation PLEASE NOTE: It is always good practice to disconnect the battery while working on 12-Volt systems. Please check owner’s manual to see vehicle specific requirements as some models may need battery backup. Caution: Auto electrical work should only be carried out by a competent person. Vehicle wire colours are listed as a guide and may vary on some makes and models.
  • Page 3 Installation Guide Installation Guide BBR085E WARNING • Ironman 4x4 recovery points are FEA Tested during design and Destruction tested during development to establish the Working Load Limits. (WLL) • Ironman 4x4 recovery points have been designed as a matching pair, supplied in right, and left sides for vehicle specific fitment.

  • Page 4: Parts List

    Installation Guide BBR085E Parts List 1. Bull Bar 2. Winch Cradle 3. Light Bar Mesh QTY-1 QTY-1 QTY-2 4. Side Bash Plate LHS 5. Side Bash Plate RHS 6. UBP 7. Recovery Point LHS 8. Recovery Point RHS QTY-1 QTY-1...
  • Page 5 Installation Guide BBR085E Parts List 34. M12 Hex Nyloc Nut 35. Hex Nut M12 36. Hex Nut M8 37. Spring Washer M10 38. Spring Washer M12 QTY-6 QTY-10 QTY-2 QTY-4 QTY-16 39. Spring Washer M8 40. Flat Washer M10 41. Flat Washer M12 42.
  • Page 6 QTY- QTY- QTY- QTY- QTY- Installation Guide BBR085E Tools Required Parts List Tools Required Parts List Metric spanner set Metric socket set Air hacksaw Tape measure Drill and drill bits Screwdriver set Bolt Tension Chart Page 4 of 14 ©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd...
  • Page 7 Installation Guide BBR085E Before installation, check bull bar application is compatible with your vehicle. Remove and retain number plate, if fitted, to be reinstalled later. Disconnect negative battery terminal. Please check owner’s manual to see vehicle specific requirements as some models may need battery backup.
  • Page 8 Installation Guide BBR085E If the vehicle is fitted with factory aero. Unplug aero harness off the motor and remove 4 x 13mm nuts. Remove aero dame. Unbolt, and remove factory chrome recovery points. 2 x 18mm and 2 x 21mm.
  • Page 9 Installation Guide BBR085E 10. Unwrap the hardware. It is good practice to lay out all hardware and cross reference against the parts list. Mount recovery points using the factory OEM hardware. Using 1Xm12x50mm and 1Xm12x40mm. 11. Unwrap winch cradle, bar brackets.
  • Page 10 Installation Guide BBR085E 15. Loosely Bolt up 4 x N#35 (M12x1.5x40mm washer, spring washer and nut) through the inner winch cradle holes and side brackets. 16. Find a fixed point on the vehicle, take measurements, square up the cradle. Repeat on both sides until cradle is centred.
  • Page 11 Installation Guide BBR085E 20. NOTE: If installing the control box with supplied bracket, it is advised to drill a 6mm drain hole in the lower control box housing. Making note to not damage internal components. IMPORTANT: For parking sensors to function correctly these instructions must be followed closely.
  • Page 12 Installation Guide BBR085E 24. Apply adhesion promoter to mounting surfaces around sensor holes and on sensor holders. This step is important to ensure sensor holders adhere properly to the bull bar. 25. Remove protective film from one side of double-sided tape and apply to mounting surface of sensor holder.
  • Page 13 Installation Guide BBR085E 28. Assemble and install light bar into the centre bar section using the supplied brackets and hardware. The brackets provide some adjustment to ensure centralized positing and vertical aim of the light. Light bar cable can be...
  • Page 14 Installation Guide BBR085E 32. Install Ironman 4x4 Raid bumper into position, aligned to the chassis mounting holes. We recommend 2 people when lifting the bumper into position to avoid injury or damage to the vehicle and components. NOTE: bar will need to be feed between the recovery points to align.
  • Page 15 Installation Guide BBR085E 35. Note: This bar has been supplied with Taptite Bolts. (These don’t require a washer or nut to mount) Installation: The M10 taptite bolt supplied requires a 9mm hole. Drill the 9mm hole, then add lock tight to thread of the Taptite.
  • Page 16 Installation Guide BBR085E 40. Bolt number plate to the vehicle with M6 hardware supplied. 41. Tuck guard liners in place behind side wing protection plates, drill 2 holes as shown and bolt into place. 42. Connect negative battery terminal if removed.

  • Page 17: Wiring Diagrams

    Installation Guide BBR085E Wiring Diagrams FOG LIGHTS Ground Lamp Fuse Connector Relay Black Blue Battery Lamp Parklight Switch SPST Ground White Ground WITHOUT FACTORY FOG LIGHTS Ground Lamp Fuse Connector Relay Black Blue Battery Lamp Positive power supply at connector to factory fog light Page 17 of 18 ©Copyright 2022 Ironman 4x4 Pty Ltd.
  • Page 18 Installation Guide BBR085E Once Bull Bar is Installed Ensure all bolts are tensioned correctly, it is good practice to do a vehicle pre trip check before heading away or every 10k kms. Visually inspect the Raid bar and hardware, retention the bar hardware or when needed.