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Ironman4x4 BBR074 Installation Manual

Raid bull bar to suit isuzu d-max rg 2019+
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INSTALLATION
GUIDE
BBR074
RAID BULL BAR TO SUIT ISUZU D-MAX RG 2019+
• Ironman 4x4 BBR074 – Raid Bull Bar to suit Isuzu D-Max RG 2019+
• It will take approximately 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 2023 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 BBR074

  • Page 1 BBR074 RAID BULL BAR TO SUIT ISUZU D-MAX RG 2019+ • Ironman 4x4 BBR074 – Raid Bull Bar to suit Isuzu D-Max RG 2019+ • It will take approximately 5 hours to install. NOTE: This product has been tested for air bag compatibility...

  • Page 2: Before Installation

    Installation Guide Installation Guide BBR074 Before Installation PLEASE NOTE: • It is always good practice to disconnect the battery while working on 12 Volt systems. - Please check the owner’s manual for vehicle-specific requirements as some models may need battery backup.

  • Page 3: Optional Accessories

    Installation Guide Installation Guide BBR074 Optional Accessories • Winch extension cable WWB032 • Hidden control box mount kit WWBCP001 • Bull bar multi-Function light patch loom IBBPL074 (Suits non-halogen headlights) Optional centre light bar ILBSR002BW (Requires x1) If you are installing the centre light bar, you will need to purchase an IPL074 wiring harness...
  • Page 4 Installation Guide Installation Guide BBR074 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 as right and left sides for vehicle-specific fitment.

  • Page 5: Parts List

    Installation Guide BBR074 Parts List Bull Bar Channel Assembly Winch Cradle Qty1 Qty1 Outer Chassis Outer Chassis Inner Chassis Inner Chassis Headlight Lower Bracket LHS Bracket RHS Bracket LHS Bracket RHS Support Bracket Qty1 Qty1 Qty1 Qty1 Qty1 Headlight Lower...
  • Page 6 Installation Guide BBR074 Light Bar Mesh Zip Tie Hex Head Bolt (full thread) Hex Head Bolt (full thread) Hex Head Bolt (full thread) M12_120 Flat Washer M12_45 Flat Washer M12 M12_45 Flat Washer M12 M12 (12x32x3mm) Spring (12x32x3mm) (12x24x2.5mm) Washer M12 Hex Nut M12...

  • Page 7: Tools Required

    Installation Guide BBR074 Tools Required Bolt Tension Chart NOMINAL DIAMETER - COARSE THREAD Property Class TORQUE ma M6 x 1 M8 x 1.25 M10 x 1.25 M12 x 1.25 10.5 ft/lb Page 7 of 27 ©Copyright 2023 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 8 Installation Guide BBR074 Before installation, check bull bar application is compatible with your vehicle. Remove and retain the number plate, if fitted, to be reinstalled later. Also, remove the factory number plate holder. Disconnect the negative battery terminal if applicable.
  • Page 9 Installation Guide BBR074 Remove the four (4) remaining clips once the grille is removed. Unclip the inner guard clips and unbolt the inner bumper to guard liner bolts. Repeat on the opposite side. Unbolt the lower bumper bar bolts and the factory underbody plate.
  • Page 10 NOTE: The bar has air ducts to direct the air. 11. BBR074 is a bumper replacement; it is advised to paint below the inner guard and under the headlight as to give greater depth to the bar.
  • Page 11 Installation Guide BBR074 13. BBR074 is a bumper replacement; it is advised to paint below the inner guard and under the headlight as to give greater depth to the bar. Repeat on opposite side. 14. Unwrap the hardware. It is good practice to lay out all hardware and cross-reference against the parts list.
  • Page 12 Installation Guide BBR074 16. NOTE: 3 crush tube are used on the chassis brackets. N#5 inner chassis, N#3 outer bracket, N#13, N29 nut plate Hardware N3,22/46 & 35 N#6 inner chassis, N#4 outer bracket, N#14 N29 nut plate Hardware N3,22/46 & 35.
  • Page 13 Installation Guide BBR074 19. Find a fixed point on the vehicle, take measurements, and square up the cradle. Repeat on both sides until the cradle is centred. TIP: Use the inside edge of the headlight as a guide. Once centred, torque to torque settings on page...
  • Page 14 Installation Guide BBR074 23. Remove 8mm side-mounted Allen- head bolts, and with the hardware supplied, bolt the side bracket to the winch using the supplied spacer kit. NOTE: Mount can bolt over the electrical motor or gearbox side. 24. The electrical control box also has multiple mounting positions. Once the desired position is found, bolt down using supplied hardware.
  • Page 15 Installation Guide BBR074 26. BBR074 Is a bumper replacement. Install supplied bumper in fills with m6 hardware. Leave loose to adjust once bar is in place. NOTE: there is a right and left. N#15 LHS N#16 RHS 27. NOTE: if the vehicle doesn’t...
  • Page 16 Installation Guide BBR074 28. Remove the parking sensor wiring and parking sensors from the factory bumper taking note of the direction and position of each sensor. 29. The plastic sensor holder centre will need to be removed to install parking sensors.
  • Page 17 Installation Guide BBR074 32. 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. 33. Remove the protective film from one side of the double-sided tape and apply to the mounting surface of the sensor holder.
  • Page 18 Installation Guide BBR074 35. Assemble and install a light bar into the centre bar section using the brackets supplied with the bull bar fitting kit. The brackets provide some adjustments to ensure centralised positioning and the vertical aim of the light.
  • Page 19 IBBPL074 Non-Halogen headlight type. Wiring for fog lights, blinkers, and parkers, can now be IPL001P strip light plug and wired. Ironman4x4 recommends using a bull bar patch play loom. loom. Note: Depending on the blinker/parker light selection, NOTE: When mounting indicator park light strips, it is some wires may need to be cut, joined, and soldered.
  • Page 20 Installation Guide BBR074 41. See image. Parker Blinker 42. When mounting the bracket, you will need to mount it in its most forward position. 43. If you are not fitting the optional light bar, a mesh infill is supplied You will still need to use the light bar support brackets to install mesh.
  • Page 21 Installation Guide BBR074 44. Install license plate mount bracket onto bull bar. If a winch is being installed, fit the fairlead as well. N#23 45. Using the P-clips supplied, position them along the back side of the light bar, feed light bar, and parking sensor wiring through the hole.
  • Page 22 Installation Guide BBR074 47. The factory grille is in two pieces. The lower half needs to be separated from the factory bumper and cut. See image. Reinstall the lower and upper grilles before fitting the bull bar. 48. Install the bull bar into position, aligned to the chassis mounting holes.
  • Page 23 Installation Guide BBR074 49. Once the bull bar is aligned, drill and pin the bar into position using the M10 bolts supplied. 4 x N#40 50. Connect lights if applicable and parking sensor fog light harness. If the winch is fitted connect the extension harness to the control box.
  • Page 24 Installation Guide BBR074 53. Install both wing protection plate brackets with bolts provided, to the outer cradle. N#2 x 2 Bracket N#41 Hardware Repeat on the opposite side. 54. Hold the wing panel in position and mark the guard liner to be trimmed.
  • Page 25 Installation Guide BBR074 56. Install the factory centre plate, making sure to ????? You will need to install centre factory plate bracket. N#27 57. Install the Silver centre plate, with the M6 Allen key bolts. NOTE: The centre plate will need to be aligned with the other plates through the lower mount support bracket.

  • Page 26: Wiring Diagrams

    Installation Guide BBR074 Wiring Diagrams WITHOUT FACTORY FOG LIGHTS Ground Lamp Fuse Connector Relay Black Blue Battery Lamp Parklight Switch SPST Ground White Ground FOG LIGHTS Ground Lamp Fuse Connector Relay Black Blue Battery Lamp Positive power supply at connector to factory fog light Page 26 of 27 ©Copyright 2023 Ironman 4x4 Pty Ltd.
  • Page 27 Installation Guide BBR074 Once Bull Bar is Installed • Ensure all bolts are tensioned correctly • Doing a pre-trip check before heading away, or every 10,000 km is good practice. • Visually inspect bull bar and hardware, retention bull bar hardware or when needed.