Ironman Fitness BB064 User manual

INSTALLATION
GUIDE
TO SUIT TOYOTA PRADO 150
12/2017+/MY2020 FACELIFT
BB064
• Ironman 4x4 BBP / BBT Bull Bar to suit a Toyota Prado 150 12/2017+ / MY 2020
• It will take about 4 hours to install
• All bolts, washers, spring washers and nuts are supplied unless otherwise indicated
• All drilled holes must have anti-corrosion treatment applied
If your vehicle has front parking sensors and you wish to refit them, refer to fitting
diagram on back pages of this instruction manual
IMPORTANT: Bull Bar installations should only be done by a qualified person
and it is the responsibility of this person to ensure correct fitment.
NOTE: This product has been tested for air bag compatibility
and therefore the mounting system MUST NOT BE modified
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
BB064081220

Page 2 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Bull Bar Parts List
Bolt Tension Chart
1. Bull Bar
QTY-1
2. Park Light Loom
QTY-1
3. Mounting Bracket with Kits Box
QTY-1
4. Side protection L-R
QTY-2
5. Centre Protection
QTY-2
6. Support Bracket L-R
QTY-2
7. Support Bracket L-R
QTY-2
8. Bracket
QTY-2
9. License Plate Bracket
QTY-1
10. Pinch Weld 1m
QTY-1
17. STL Bottle Opener
QTY-1
16. Logo
QTY-1
13. Parking Sensor Set
QTY-17
14. Bolt M12x1.25x40mm
QTY-2
15. Bolt M12x1.25x40mm
QTY-14
16. Bolt M8x1.25x20mm
QTY-18
17. Bolt M10x1.0x30mm
QTY-4
18. Bolt M12x1.25x100mm
QTY-4
19. Bolt M8x1.25x25mm
QTY-4
20. Cage Nut M6x1
QTY-2
21. Bolt M8x1.25x25mm
QTY-2
22. Bolt M8x1.25x25mm
QTY-2
23. Bolt M10x1.25x30mm
QTY-12
24. Bolt M8x1.25x35mm
QTY-2
25. Special Washer
OD 30mm ID 11mm
QTY-2
25. Bolt M12x1.25x90mm
QTY-2
27. Washer M12
QTY-2
28. Special Plate Washer
25x80mm
QTY-2
29. Primer
QTY-1
Property Class TORQUE ma
NOMINAL DIAMETER - COARSE THREAD
M6 M 8 x 1 M 10 x 1.25 M 12 x 1.5
8.8
Nm 10.5 25 49 88
ft/lb 7.7 18 36 64

Page 3 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
1. Before installation check bull bar application is compatible with your vehicle. Before making
any cuts, please refer to bumper cutting instructions applicable to your vehicle model.
3. Remove grill, front bumper, bumper bar
reinforcement, bumper bar support brackets and
front protection plate from under chassis.
4. Only applicable to MY 2020 carefully lever
chrome trims away from inside top corners of
headlights using a soft tool to prevent damage.
5. Only applicable to MY 2020 carefully remove
2 clips retaining the outer ends of the rubber
attached to the top of the grill.
6. Only applicable to MY 2020 disconnect the
radar located behind the centre grill badge if
applicable.
2. Unwrap bull bar. Check over riders and light
assemblies are tight in bull bar before installation.

Page 4 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
7. Only applicable to MY 2020 remove the
retaining screws from the top of the grill,
carefully release the clips and remove the grill.
8. Attach inner and outer chassis support brackets
using the following:
• 2 x M12 x 1.25 x 100 mm through holes A and B
with flat washers, spring washers and M12 nuts
• 1 x M12 x 1.25 x 90 mm bolt through hole C with
spring washer, flat washer and channel nut
• Black M8 bolt through hole D with spring washer
and flat washer
• 1 x M12 x 40 mm bolt through hole E with spring
and flat washer
A
D
B
E
C

Page 5 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
9. Carefully adjust A/C hose bracket towards A/C
condenser to allow clearance for winch cradle.
10. Centralise bracket to the body of the vehicle and
tighten all bolts.
11. Attach winch cradle to chassis using 6 x M10 x
1.25 x 30 mm bolts, spring washers and plate
washers to outside holes with captive nuts. 2 x
M10 x 1.25 x 40 mm bolts, 16 flat washers, 8 x
spring washers and 8 x M12 nuts to remaining
holes.

Page 6 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
12. Install supplied park light loom as shown.
13. Run green wire through firewall.
Remove panel containing mirror controls.
14. Solder green wire onto dash light wire using
tester to locate correct wire.
Insulate soldered wire and re-install panel.
Correct wire will be green or blue depending on
model.
15. Connect indicator wiring to connector shown
in photograph. Using an LED test light check
for correct connection points or refer to your
workshop manual if you are unsure.
Parker light Parker light
Battery +
Earth
Relay
Through firewall
Wiring Instructions

Page 7 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
16. Mask ends of bumper as shown and mark cut
lines using template provided. Mask a horizontal
line across the bumper 20 mm below grill recess
and align with cut lines previously marked.
Cut along lines previously marked, remove lower
section of bumper.
20mm from the bottom
of the grill to cut line
17. Re-fit bumper bar and grill to the vehicle
using factory mounting hardware.
18. Remove parking sensors from bumper bar and fit
to bull bar making sure they are centrally located
to the holes.

Page 8 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
IMPORTANT: For parking sensors to function correctly these instructions must
be followed closely.
Before removing sensors from original bumper bar, note the location and
orientation of each sensor so when they are fitted the bullbar this can be
duplicated.
Universal Parking Sensor Installation
1. Remove rubber grommets from
sensor holes in bullbar.
2. Remove blank from sensor holder
and trim any excess plastic from
inside opening if applicable.

Page 9 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
3. Fit sensor with factory silicone
sleeve to the sensor holder and
secure using clamping plate and
screws provided. Do not over
tighten. Clamping plate has a flat
side for thicker sensors and a
raised section on the other side for
thinner sensors. It is important that
clamping plate is the correct way
around as sensor will false alarm
if excess pressure is applied to the
sensor body.
4. Clean inside of bullbar around
sensor holes and mounting surface
of sensor holders using wax and
grease remover.

Page 10 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
5. Apply adhesion promoter to
mounting surfaces around sensor
holes and on sensor holders.
NOTE:
This step is important to ensure
sensor holders adhere properly to
the bullbar.
6. Remove protective film from one
side of double-sided tape and
apply to mounting surface of
sensor holder.

Page 11 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
7. Remove protective film from
double-sided tape and apply
sensor holder/sensor to bullbar
making sure sensors are in the
same positions as they were in the
original bumper and in the same
orientation.
The two outer wing parking
sensors will require the extra
‘O’ ring placed over the silicone
sleeve.
NOTE:
Sensor nuts only need to be
‘nipped’ up. Do not overtighten
or sensor will not function as
intended.

Page 12 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
19. Fit bull bar to chassis brackets using 6 x M12
x 40 mm bolts, 12 x flat washers, 6 x spring
washers and 6 x M12 nuts provided.
20. Align bull bar with vehicle, leaving a 20 mm
gap for body movement.
21. Once bull bar is aligned with vehicle and
tightened, drill through pinning holes (circled in
yellow) between bull bar and chassis bracket and
secure with 4 x M10 x 1.25 x 30 mm bolts, 8 x
flat washers, 4 x spring washers, 4 x 10M flat
washers and nuts provided.

Page 13 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
23. Connect park lights, indicators and fog lights.
22. Fit side wing supports to both sides using bolts
provided - 2 x black M8 bolts, spring washers
and flat washers per side and 1 x M10 x 30 mm
bolt, spring washer and flat washer per side.
24. If applicable, fit camera and parking sensor
wiring loom. The wiring loom to the sensors will
be long enough without lengthening but may
have to be removed from factory conduit in order
for it to reach. Replace conduit as required.
Do not cut wiring.

Page 14 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
25. Attach centre protection plate to bull bar followed
by side plates using M8 bolts, spring washers,
flat washers and nuts. Trim guard liners to suit.

Page 15 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
1. Bolt winch to cradle with gearbox to the left hand
side of vehicle and cable spooling from bottom of
the cable drum using bolts and washers provided.
2. Bolt fairlead to recess in front of bull bar using
bolts, washers and nuts provided.
3. Fit bull bar to vehicle referring to steps of bull bar
fitting instructions.
4. Mount control box in desired location.
5. Connect three colour coded cables to the
corresponding poles on winch motor.
Winch Installation

Page 16 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
8. Connect positive and negative battery cables
main battery of vehicle (Not Auxilliary Battery).
9. Attach breather hose to barb fitting on winch
motor. Run hose to the highest available point
in engine bay and cable tie in position. Cable tie
hose away from any sharp, hot or moving objects.
7. Run the positive and negative battery cables into
the engine bay taking care to secure cables away
from any sharp or moving objects.
6. Connect the thin black earth wire and negative
battery cable to the earth connection on the
opposite side of winch motor.

Page 17 of 20
BB064Installation Guide
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Bull Bar Parklight
Blue
Relay
Connector
Ground
Fuse
Red
3085
86
87
87a
Red Lamp
Black
LampBattery
Ground
Ground
NOTE: Do not use
factory parker light
wiring. Use bull bar
parker light when
wired with loom in
step 8 of the bull bar
fitting instructions.
White
Switch
SPST
Yellow
Red
Brown
Daytime Running Light
Park Light
Indicator Light
Ground
White
If vehicle is not tted with DRL, leave red wire disconnected
PARK LIGHT & INDICATOR
WITHOUT FACTORY FITTED FOG LIGHTS
WITH FACTORY FITTED FOG LIGHTS
Blue
Relay
Connector
Power from existing factory fog light
Ground
Fuse
Red
3085
86
87
87a
Red Lamp
Black
LampBattery
Wiring Instructions

PAGE 1/3
270720
BBP064 / BBT064
BULL BAR TEMPLATE
TO SUIT TOYOTA PRADO 150 SERIES 2017+
UNDER HEADLIGHT
0
10
20
30
40
50
60
70
80
90
100
MM
TOWARD CENTRE OF VEHICLE
JOIN HERE
JOIN HERE
DISABLE PAGE SCALING WHEN
PRINTING
CHECK RULER DIMENSIONS TO
ENSURE ACCURACY BEFORE CUTTING

PAGE 2/3
BBP064 / BBT064
BULL BAR TEMPLATE
TO SUIT TOYOTA PRADO 150 SERIES 2017+
UNDER HEADLIGHT
FRONT GUARD
CUT LINE
270720
0
10 20 30 40 50 60 70 80 90
100
MM
JOIN HERE
JOIN HERE
JOIN HERE
DISABLE PAGE SCALING WHEN PRINTING
CHECK RULER DIMENSIONS TO ENSURE ACCURACY BEFORE CUTTING
DISABLE PAGE SCALING WHEN
PRINTING
CHECK RULER DIMENSIONS TO
ENSURE ACCURACY BEFORE CUTTING

PAGE 3/3
BBP064 / BBT064
BULL BAR TEMPLATE
TO SUIT TOYOTA PRADO 150 SERIES 2017+
FRONT GUARD
270720
0
10 20 30 40 50 60 70 80 90
100
MM
JOIN HERE
DISABLE PAGE SCALING WHEN PRINTING
CHECK RULER DIMENSIONS TO ENSURE ACCURACY BEFORE CUTTING