Ironman4x4 BBR074 User manual

RAID BULL BAR TO SUIT ISUZU D-MAX RG 2019+
INSTALLATION
GUIDE
• Ironman 4x4 BBR074 – Raid Bull Bar to suit Isuzu D-Max RG 2019+
• It will take approximately 5 hours to install.
IMPORTANT: Bull bar installations should only be done by a qualified person
and it’s 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
BBR074/030223
BBR074
©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 2 of 27
BBR074Installation Guide
©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
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.
• Caution: Auto electrical work should be carried out by a competent person.
Vehicle wire colours are listed as a guide and may vary on some makes and models.
• The function of each wire should be checked before any connections are made.
All wires tapped into the factory harness should be soldered and then insulated with
electrical tape or heat shrink.
• Using only a LED test light, test all electrical components of the vehicle before and after
wiring. This is to ensure that everything works correctly.
IMPORTANT:
• Only a competent person should do accessory installations, and it is the responsibility of this
person to ensure correct fitment.
• Whilst working on this vehicle, use appropriate safety equipment
• Read instructions fully before commencing fitment.
Check the hardware supplied against the contents list below.
• Do not use this product for any vehicle make or model other than specified in these
instructions.
• This product and or hardware must not be modified in any way. Do not remove labels from
this product.
• Recording the batch number on the customer’s job card is good practice for future
reference.
BULL BAR CARE INSTRUCTIONS:
• To maintain the finish of the product, wash regularly using a PH neutral Car wash,
hose off and chamois dry.
• Do not use acidic or alkaline cleaners.
• Plastic components can be maintained with a silicon spray or similar
(non-acidic or alkaline based).
Page 2 of 27
Before Installation
Installation Guide

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BBR074Installation Guide
©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
• 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
separately for some makes and models if you are not installing an IBBPL074
2 x Strip lights IPL001P (2 required)
Optional Cube lights: (can install up to x 2 cube lights)
• 20W Bright Cube, spot beam, white light - Part Number ILED20B
• 20W Bright Cube, spot beam, amber light - Part Number ILED20BA
• 20W Bright Cube, spot beam, white light - Part Number ILED20BF
• 20W Bright Cube, spot beam, amber light - Part Number: ILED20BFA
Page 3 of 27
Optional Accessories
Installation Guide

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BBR074Installation Guide
©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
• 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.
• Ironman 4x4 includes specific mounting hardware to ensure correct fitment to your 4WD.
The correct fitment of these components is critical for your safety.
• Do not use this recovery point for any other vehicle make or model other than the one
intended and specified by Ironman 4x4.
• Do not alter or modify the recovery point in any way. Doing so may compromise the
strength and integrity of the recovery points.
• Ensure that bolts are tightened to the specified torque.
• Don’t remove warning labels from the recovery point.
(Some recovery points require the warning labels to be installed, these must be installed)
• It is advised to use an equalising or bridle strap. Failure to do so correctly can result in
recovery point fatigue and bending and voiding your warranty.
• Never use a single recovery point combined with a side load pull.
• Recovery Points are designed for a straight-line pull, by pulling on and angle/ sideways pull
may result in a reduction of the WLL.
• Ford Ranger vehicles are equipped with BMS (Battery Monitoring System) - nothing should
be connected to this battery module. There is a spare post on the factory bus bar.
Please check the owner’s manual
• Grounding/Earth points must always be connected to the factory grounding points,
not to the battery negative terminal. See owner’s manual.
NOTE: This product has been tested for airbag compatibility; therefore, the mounting system
MUST NOT be modified.
Ironman 4x4 does not recommend the installation of large or light-coloured antennas or aerials
to the front of a bull bar as it may cause the lane departure system to malfunction.
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WARNING
Installation Guide

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BBR074Installation Guide
©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
Parts List
1Bull Bar Channel Assembly
Outer Chassis
Bracket LHS
Outer Chassis
Bracket RHS
Inner Chassis
Bracket LHS
Inner Chassis
Bracket RHS
Headlight Lower
Support Bracket
LHS
Headlight Lower
Support Bracket
LHS
Nut Plate
M10 LHS
Nut Plate
M10 RHS
Side Protection
Plate LHS
Recovery Point
LHS
Recovery Point
RHS
Headlight Infill
LHS
Headlight Infill
RHS
Parker/Indicator
Strip Light Bracket
LHS
Parker/Indicator
Strip Light Bracket
RHS
Number Plate
Flip Bracket
Light Bar
Mounting Bracket
Crush Tube
(57.6mm)
Crush Tube
on Wire
OEM Skip Plate
Support Mount
PSH074 T-bolt M10_40
Flat Washer M10
(10x30x2.5mm)
Spring Washer M10
Hex Nut M19
Recovery Point
Warning Sticker
UBP Protection Plate
Bracket
Cradle-Chassis
Bracket Spacer
14mm P-clip 25W Resistor 25x25 Spacer
Side Protection
Plate RHS
Winch Cradle
Qty1
Qty1 Qty1 Qty1
Qty1
2
3
8
13
18
23
28
4
14
19
24
29
5
10
15
20
25
30
6
11
16
21
26
31
7
12
17
22
27
32
Qty1 Qty1
Qty1
Qty1
Qty1
Qty1
Qty4
Qty1
Qty1
Qty3
Qty2
Qty2
Qty1
Qty1
Qty1
Qty4
Qty2
Qty1
Qty1
Qty4
Qty2
Qty1
Qty1
Qty1
Qty4
Qty1
Qty1
9

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BBR074Installation Guide
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33 3534 36 37
38
43
48
39
44
49
40
45
50
41
46
51
42
47
Light Bar Mesh
Allen Key S=6 Allen Key S=5
Zip Tie
Qty1
Qty4
Qty4
Qty4
Qty10
Qty10
Qty10
Qty1
Qty2
Qty2
Qty16
Qty1
Qty2
Qty4
Qty8
Qty8
Qty2
Qty8
Qty8
Hex Head Bolt (full thread)
M12_120 Flat Washer
M12 (12x32x3mm) Spring
Washer M12 Hex Nut M12
Hex Head Bolt (full thread)
M12_45 Flat Washer M12
(12x32x3mm)
Spring Washer M12
Hex Nut M12
Hex Head Bolt (full thread)
M12_45 Flat Washer M12
(12x24x2.5mm)
Spring Washer M12
Hex Nur M12
Hex Head Bolt
(full thread)
M10_110- Flat Washer M10
(10x30x2.5)
Spring Washer M10
Hex Head Bolt
(full thread) M0_35
Flat Washer M10 (10x30x25mm)
Spring Washer M10
Hex Head Bolt
(full thread) M6_20
Flat Washer M6 (6x12x1.6mm)
Nyloc Nut M6
Hex Head Bolt
(full thread) M10_1.25_45
Flat Washer M10
(10x30x2.5mm)
Spring Washer M10
Hex Nur M10 x 1.25
Hex Head Bolt (full thread)
M10_1.25_40
Flat Washer M10 (10x20x2mm)
Spring Washewr M10
Flat Washer M10
(10x30x2.5mm)
(spare kits)
Dome Head Bolt M0_30
Flat Washer M10
(10x20x2mm)
Nyloc Nut M10
Dome Head Bolt,
Spring Washer, Flat Washer
(OD 18mm) M6_20
Flange Nut M6
Dome Head Bolt,
Spring Washer, Flat Washer
(OD 18mm) M6_20
M6 Cage Nut
Dome Head Bolt,
Spring Washer, Flat Washer
(OD 18mm) M6_20
Flat Head Bolt M10_30 Combo Hardware -
Hex Head Bolt,
Spring Washer, Flat Washer
M8_25
Flat Washer M8 (8x24x2mm)
Hex Nut M8
Any damages and losses caused by improper installation and application, goes beyond our
quality warranty.

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BBR074Installation Guide
©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
Bolt Tension Chart
Property Class TORQUE ma
NOMINAL DIAMETER - COARSE THREAD
M6 x 1 M8 x 1.25 M10 x 1.25 M12 x 1.25
8.8
Nm 10.5 25 49 88
ft/lb 7.7 18 36 64
Tools Required

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BBR074Installation Guide
©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
1. 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.
2. Remove and retain the top plenum
cover.
Ensure to keep all plastic clips.
Once the cover is removed,
disconnect the front camera wiring
(if applicable).
3. Once the plenum cover is removed,
remove the top clips, and unscrew
the centre screw of the grille.
NOTE: There is a hidden screw.
4. NOTE - There is a hidden screw.

Page 9 of 27
BBR074Installation Guide
©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
5. Remove the four (4) remaining clips
once the grille is removed.
6. Unclip the inner guard clips and unbolt
the inner bumper to guard liner bolts.
Repeat on the opposite side.
7. Unbolt the lower bumper bar bolts and
the factory underbody plate.
NOTE: There are also two (2) hidden
bolts up behind the lower inner guard.
Repeat on the opposite side.
8. Disconnect factory blinker wiring and
fog lights from behind the bumper.
If the vehicle is fitted with a front
camera, then disconnect it.
NOTE: The plug is located on the LHS
under the headlight area.
Remove the bumper by unclipping,
starting on the left corner unclipping
away from the headlight.

Page 10 of 27
BBR074Installation Guide
©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
9. Unbolt the factory lower bar
reinforcement and inner and outer
lower bar support brackets.
10. Trim the plastic air-dam as shown in
image.
TIP: Hold the centre cradle in position
as a guide for trimming.
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.
Repeat on opposite side.
12. Using the headlight retaining bracket,
install the bracket using the factory
middle bolt and headlight lower clip
with supplied Allen-head M6 bolt.
Repeat on opposite side.
N#7 & N#8

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BBR074Installation Guide
©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
14. Unwrap the hardware. It is good
practice to lay out all hardware and
cross-reference against the parts list.
Unwrap the bull bar.
15. Mount both the right and left chassis
support brackets to the inner and
outer faces of the chassis rail using
the hardware provided.
This is a 3-piece bracket assembly –
see image.
NOTE: A crush tube is used on inner
of chassis and rear support bolts of
bracket.
Do not tighten.
Use
• 1 x M12X
• 2 x M10X
• 1 x lower nut plate and M12
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.

Page 12 of 27
BBR074Installation Guide
©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
18. Now mount the centre winch cradle using the
four (4) factory OEM bolts.
The remaining cradle bolts used the M12
hardware supplied.
Repeat on opposite side.
N#2 cradle.
17. N#26 inner crush tube.
N#25 outer crush tubes.
16. NOTE: 3 crush tube are used on the chassis
brackets.
LHS
N#5 inner chassis, N#3 outer bracket, N#13,
N29 nut plate
Hardware N3,22/46 & 35
RHS
N#6 inner chassis, N#4 outer bracket, N#14
N29 nut plate
Hardware N3,22/46 & 35.

Page 13 of 27
BBR074Installation Guide
©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
21. Select the desired mounting position.
The top plate can be bolted into
multiple positions depending on space.
22. Once the chosen position is found,
screw the top and side brackets
together using the hardware supplied.
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
2.
NOTE: Tighten OEM bolts and check
measurements before torquing to specifications
on Page 7.
Proceed to tighten all other hardware to torque
specifications.
20. Winch option
NOTE: if you are installing a winch, mount the
control box bracket into the right-hand side of
the lower radiator support/inner guard.
Connect the optional winch control box
extension wiring loom.
• WWBCP001
• WWB031

Page 14 of 27
BBR074Installation Guide
©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
25. Install winch into the cradle.
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.
NOTE: Earthing/grounding points must always be connected to the factory grounding points
and not to the battery negative terminal. See the owner’s manual.

Page 15 of 27
BBR074Installation Guide
©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
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
have factory-fitted parking
sensors, the PSH will still
need to be installed.
IMPORTANT: For parking sensors to function correctly,
these instructions must be followed closely.
Before removing sensors from the original bumper bar,
note the location and orientation of each sensor. This is
so when they are fitted back into the bull bar their original
location can be replicated.
IMPORTANT:
Parking sensors are a delicate piece of the vehicle’s safety
system. More so, the centre “eye” of the sensor as it is
responsible for detecting objects within a safe distance.
Painting the Parking Sensor does not damage it, but
it inhibits the sensor’s ability to detect objects in its
surroundings causing a malfunction or premature detection.
Parking Sensors must only be painted once by the OEM, as
the more you paint them, the less effective they become.
Excessive paint thickness will adversely affect the operation
of the park assist system.
Ironman 4x4 highly recommends not colour-coding parking
sensors when installing a bull bar.

Page 16 of 27
BBR074Installation Guide
©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
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.
If the vehicle doesn’t have factory
parking sensors, leave the centre
complete.
30. Fit the sensor with the factory silicone
sleeve to the sensor holder. Use
the flat side of the clamping plate
to secure the sensor. The sensor
will false alarm if excess pressure is
applied to the sensor body.
31. Clean inside the bull bar, around
sensor holes, and the mounting
surface of parking sensor holders
using grease and wax remover.
NOTE: It is advised to lightly scotch
bright inside of the bull bar and the
sensor mounting face holder.

Page 17 of 27
BBR074Installation Guide
©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
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.
34. Run the factory harness cabling in
between brackets. Clip in parking
sensors into parking sensor housings.
NOTE: Don’t cable tie off yet, Leave
wiring loom loose.

Page 18 of 27
BBR074Installation Guide
©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
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.
NOTE: Do not use supplied light bar hardware from the retail package.
Light bar brackets N#24
36. If fitting a winch, bolt in the winch extension plug.
NOTE: Optional center light bar ILBSR002BW
An option IPL is available our IBBPL074 OR IBBPL074L has a build in IPL. It is advised
to contact the dealer or see the owner’s manual for more information.
• WWB031
37. Assemble and install Ironman 4x4
cube lights to the inner light pod. The
brackets provide some adjustments
to ensure centralized positioning and
the vertical aim of the light. The Cube
Light cable can be secured to the
inside edge of the bull bar using cable
ties.

Page 19 of 27
BBR074Installation Guide
©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
38. Optional add-ons:
Indicator + Parker lights
ILED20BA x2
- or -
ILEDSL003B X 2 (Blinker)
ILEDSL003P x2 (Parker)
Patch Looms
IBBPL074 LED headlight type.
IBBPL074 Non-Halogen
headlight type.
IPL001P strip light plug and
play loom.
NOTE: When mounting
indicator park light strips, it is
advised to mount the indicator
on the outside.
39. The outer light pod has provisions for required
park lights & indicators. (Strip lighting option
shown)
NOTE: D-Max has blinker and parker lights in
the factory bumper. These will need to be fitted
and positioned in the bull bar to meet state and
federal road loads.
40. Using the supplied bracket, bolt the strip light to
the bracket.
The cable will feed through the middle hole.
NOTE: You will need to de-pin or cut the wires to
feed through the bracket.
Blinker will need to be mounted to the outer
location and parker to the inner.
N#17 LHS N#18 RHS
Wiring for fog lights, blinkers, and parkers, can now be
wired. Ironman4x4 recommends using a bull bar patch
loom.
Note: Depending on the blinker/parker light selection,
some wires may need to be cut, joined, and soldered.

Page 20 of 27
BBR074Installation Guide
©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
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.
N#33
Parker
Blinker
41. See image.
42. When mounting the bracket, you will need to mount it in its most forward position.