Ironman4x4 BBR074 User manual

Document Number: BBR074/070323
INSTALLATION
INSTRUCTIONS
BBR074
RAID BULL BAR TO SUIT ISUZU D-MAX
RG 2019+
This product has been tested for airbag compatibility
and therefore the mounting system MUST NOT be modified
©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
Document Number: BBR074/190523
NOTE
This bull bar requires parker/indicator lights.
These are not included and must be purchased separately.
No Bumper
Cut Required
SAFETY WARNING
Ironman 4X4 requires you read and understand the safety and pre-install
directions on page 2 and 3 before commencing installation of this product.
5 Hours
Approximately

Page 2 of 27
BBR074 Installation 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
Document Number: BBR074/190523
Pre-Installation Procedures
SAFETY WARNING
• 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.
• Auto electrical work should be carried out by a competent person. Vehicle wire colours are listed as a
guide only 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 should be soldered and then insulated with electrical tape or heat shrink.
• Grounding/Earth points must always be connected to the factory grounding points, not to the battery
negative terminal. See owner’s manual.
• Using only a LED test light, test all electrical components of the vehicle before and after wiring.
This is to ensure everything works correctly.
• Ironman 4x4 does not recommend the installation of large or light-coloured antennas or aerials to the
front of a bull bar as this may cause the lane departure system to malfunction.
NOTE
• Only a competent person should perform accessory installations. It is the responsibility of this person
to ensure correct fitment.
• Whilst working on this vehicle, always use appropriate safety equipment.
• Read and understand instructions fully before commencing fitment.
• Check the hardware supplied against the contents list on the following pages.
• 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,
or complete the information below and file with customer job card.
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 silicone spray or similar (non-acidic or alkaline based).
CUSTOMER INFORMATION
Customer Name: Date:
Contact:
Part Number: Batch Number:
(Located on label behind bull bar wing)
#

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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
Document Number: BBR074/190523
• Isuzu D-Max vehicles are equipped with blinker and parker lights in the factory bumper.
These will need to be fitted and positioned within the bull bar to comply with State and Federal road
laws.
• 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 point.
• Ensure all bolts are tightened to the specified torque.
• Do not remove warning labels from recovery points. (Some recovery points require the warning labels
to be installed, these are supplied and must be installed).
• It is advised to use an equalising or bridle strap. Failure to do so correctly can result in recovery point
fatigue or bending and void 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 an angle or sideways pull may
result in a reduction of the WLL.
NOTE
• This product has been tested for airbag compatibility; therefore, the mounting system MUST NOT
be modified.
• Fitting instructions are correct at the time of publication date and Ironman 4x4 cannot be held
responsible for any vehicle changes from the manufacturer. It is the responsibility of the installer
to ensure correct fitment.
Page 3 of 27
Installation Guide
Warning

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BBR074 Installation 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
Document Number: BBR074/190523
11 17
7
22
3
5
34
27
6
19
4
14
8
29
30
20
28
10
18
16
12
13
26
2
24 31 33
25
32
21
9
123
15
Parts List (Item)
No. Part Description Qty
1. Bull bar channel assembly 1
2. Winch cradle 1
3. Outer chassis bracket - LHS 1
4. Outer chassis bracket - RHS 1
5. Inner chassis bracket - LHS 1
6. Inner chassis bracket - RHS 1
7. Headlight lower support bracket - LHS 1
8. Headlight lower support bracket - RHS 1
9. M10 nut plate - LHS 1
10. M10 nut plate - RHS 1
11. Side wing protection plate - LHS 1
12. Side wing protection plate - RHS 1
No. Part Description Qty
13. Recovery point - LHS 1
14. Recovery point - RHS 1
15. Headlight infill - LHS 1
16. Headlight infill - RHS 1
17. Parker/indicator strip light bracket - LHS 1
18. Parker/indicator strip light bracket - RHS 1
19. 18mm P-clip 3
20. 25W Resistor (for indicator circuit if required) 2
21. 25 x 25mm Spacer 4
22. Cradle chassis bracket spacer 4
23. Number plate flip bracket 1
24. Lightbar mounting bracket 2
No. Part Description Qty
25. Crush tube (57.6mm) 4
26. Crush tube on wire 2
27. OEM skid plate support mount 1
28. Sensor holders (PSH074) 4
29. M10 T-bolt set 2
30. Recovery point warning sticker 2
31. Underbody protection plate 1
32. Protection plate bracket 1
33. Lightbar mesh 1
34. Zip ties 10
Any damage or 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
Document Number: BBR074/190523
35 36 37
38 39 40
41 42 43
44 45 46
47 48 49
50 51
Parts List (Item)
Any damage or losses caused by improper installation and application, goes beyond our quality warranty.
No. Part Description Qty
35.
Hex Head Bolt (full thread) M12 x 120mm
Flat Washer M12 (12 x 32 x 3mm)
Spring Washer M12
Hex Nut M12
2
36.
Hex Head Bolt (full thread) M12 x 45mm
Flat Washer M12 (12 x 32 x 3mm)
Spring Washer M12
Hex Nut M12
2
37.
Hex Head Bolt (full thread) M12 x 45mm
Flat Washer M12 (12 x 24 x 2.5mm)
Spring Washer M12
Hex Nut M12
2
38.
Hex Head Bolt (full thread) M10 x 110mm
Flat Washer M10 (10 x 30 x 2.5)
Spring Washer M10
4
39.
Hex Head Bolt (full thread) M10 x 35mm
Flat Washer M10 (10 x 30 x 2.5mm)
Spring Washer M10
10
40.
Dome Head Bolt M10 x 30mm
Flat Washer M10 (10 x 20 x 2mm)
Nyloc Nut M10
2
41. Flat Head Bolt M10 x 30mm 4
42.
Combo Hardware -
Hex Head Bolt, Spring Washer,
Flat Washer M8 x 25mm, Flat Washer M8
Hex Nut M8 (8 x 24 x 2mm)
8
43.
Hex Head Bolt (full thread) M6 x 20mm
Flat Washer M6 (6 x 12 x 1.6mm)
Nyloc Nut M6
3
44.
Dome Head Bolt, Spring Washer,
Flat Washer (OD 18mm) M6 x 20mm
Flange Nut M6
6
45.
Dome Head Bolt, Spring Washer,
Flat Washer (OD 18mm) M6 x 20mm
M6 Cage Nut
16
46. Dome Head Bolt, Spring Washer,
Flat Washer (OD 18mm) M6 x 20mm 8
47.
Hex Head Bolt (full thread) M10 x 45 x 1.25mm
Flat Washer M10 (10 x 30 x 2.5mm)
Spring Washer M10
Hex Nut M10 x 1.25
4
48.
Hex Head Bolt (full thread) M10 x 40 x 1.25mm
Flat Washer M10 (10 x 20 x 2mm)
Spring Washer M10
4
49. Allen Key S=6 1
50. Allen Key S=5 1
51. Flat Washer M10 (10 x 30 x 2.5mm)
(spare kits) 8

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BBR074 Installation 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
Document Number: BBR074/190523
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
Bolt Tension Guide
MANDATORY
Strip lights, Indicator - ILEDSL003B (2 required) and Parker - ILEDSL003P (2 required), or an equivalent
replacement option to ensure bull bar fitted to vehicle complies with all State and Federal road laws.
OR
Indicator and parking light combo - ILEDTURNPARK (2 required)
Either option must be ordered separately
OPTIONAL
• 20W cube lights (can install up to 2 x cube lights per side)
- White light spot - ILED20B - Amber light spot - ILED20BA
- White light flood - ILED20BF - Amber light flood - ILED20BFA
• 120W centre lightbar - ILBSR002BW (1 required)
If you are installing the centre lightbar, you will need to purchase an IPLS074 wiring harness
separately for some makes and models if you are not installing an IBBPL074 (high spec - LED)
• Bull bar multi-function light patch loom - IBBPL074L (low spec - halogen).
Strip lights and/or cube lights will require the additional fitting of harness - IBBPL001P
• Winch extension cable - WWB032
• Hidden control box mount kit - WWBCP001
Accessories
Metric Spanner Set Screwdriver Set Metric Socket Set Air Hacksaw Tape Measure Drill and Drill Bits

Page 7 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
Document Number: BBR074/190523
1. Before installation, unwrap the hardware.
Unwrap the bull bar, taking care not to
damage or scratch in the process. Inspect bar
for any damage.
Ensure bull bar application is compatible with
the vehicle.
TIP
It is good practice to lay out all hardware to
cross-reference against the parts list and to
record the Batch Number.
2. Remove and retain the number plate if fitted,
to be reinstalled later. Remove the factory
number plate holder.
Disconnect the negative battery terminal if
applicable.
NOTE
Check manufacturer’s handbook for any
recommendations.
Remove and retain the top plenum cover,
ensuring to keep all plastic clips.
Once the cover is removed, disconnect front
camera wiring (if applicable).
3. Once plenum cover is removed, remove the
top clips and unscrew the centre screw of the
grille.
NOTE
There are hidden screws.

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BBR074 Installation 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
Document Number: BBR074/190523
4. Remove the four (4) remaining clips once the
grille is removed.
5. Unclip the guard bumper clips and unbolt the
inner bumper to guard liner bolts (1).
Unclip top corner bumper clip and remove
inner guard liner screws (2).
Repeat procedure on opposite side.
6. Unbolt the lower bumper bar bolts and factory
underbody plate.
NOTE
There are two (2) hidden bolts up behind the
lower inner guard.
7. Disconnect factory blinker wiring and fog
lights from behind the bumper.
If vehicle is fitted with a front camera or
parking sensors, disconnect these now.
NOTE
The plug is located on the LHS under the
headlight area.
Remove the bumper by unclipping starting
on the left corner, moving away from the
headlight. Place OE bumper to the side, do
not remove Parking Sensors at this point.
1.
2.

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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
Document Number: BBR074/190523
8. Unbolt the factory lower bar reinforcement
and inner and outer lower bar support
brackets.
9. Trim the plastic air-dam as shown in image.
TIP
Hold the centre cradle in position as a guide for
trimming.
NOTE
The new bull bar has air ducts to direct the air.
10. Remove OE bumper bar retaining clips and
bumper retaining bracket from side guard.
Repeat procedure on opposite side.
11. Using the headlight retaining bracket, install
the bracket using the factory middle bolt and
headlight lower clip with supplied Allen-head
bolt.
Repeat procedure on opposite side.
Item: 7 and 8

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BBR074 Installation 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
Document Number: BBR074/190523
13. 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
lower image.
A crush tube is used on inner of chassis
and rear support bolts of bracket.
Do not tighten.
NOTE
3 crush tubes are used on each chassis
bracket.
LHS
Item: 5 and 3
Item: 13 and 9
Item: 22
RHS
Item: 6 and 4
Item: 14 and 10
Item: 22
12. It is advised to paint below the inner guard
and under the headlight as to give greater
depth to the bar once fitted.
Repeat procedure on opposite side.

Page 11 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
Document Number: BBR074/190523
15. Mount the centre winch cradle using the four
(4) factory OEM bolts.
The remaining cradle bolts use hardware
supplied.
Leave all hardware loose at this point.
Repeat procedure on opposite side.
Item: 2
16. Find a fixed point on the vehicle and opposing
side of cradle as shown. Take measurement
to square up and centre cradle.
Repeat from left and right fixed points until
the cradle is centred.
TIP
Use the inside edge of the headlight as a guide.
Tighten OEM bolts, check measurements and
readjust if neccessary.
Once centred, tighten chassis through bolt to
pull unit together. Tighten forward facing bolts
to torque guide specifications. Refer page 6.
Proceed to tighten all other bolts to torque
guide specifications. Refer page 6.
Paint mark all bolt heads.
14. Insert crush tubes into end of the chassis rail
Item: 26 and 25
Repeat procedure on opposite side.

Page 12 of 27
BBR074 Installation 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
Document Number: BBR074/190523
18. Select the desired mounting position. The top
plate can be bolted into multiple positions
depending on space available.
20. 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
Control box bracket can bolt over the
electrical motor or gearbox side.
19. Once the chosen position is found, screw
the top and side brackets together using the
hardware supplied.
17. Winch option
If installing a winch, you can use the optional
winch control box bracket and control box
extension wiring loom.
P/N: WWBCP001 / P/N: WWB031

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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
Document Number: BBR074/190523
22. Install winch into the cradle using bolts
supplied with the winch.
Connect winch power cables, colour to colour
to the winch.
21. 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 14 of 27
BBR074 Installation 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
Document Number: BBR074/190523
23.
NOTE
If the vehicle doesn’t have factory-
fitted parking sensors, the Parking
Sensor Holders will still need to be
installed into the new bull bar to fill
sensor provision holes.
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:
Do Not Paint Parking Sensors
Parking sensors are a delicate piece of the
vehicle’s safety system. The centre “eye” of the
sensor is responsible for detecting objects within a
specified distance of the vehicle.
Painting a Parking Sensor does not damage it, but
inhibits the sensor’s ability to detect objects in its
surroundings, causing a malfunction or premature
detection.
Parking Sensors should only be painted once by
the OEM, as the more you paint them, the less
effective they become.
Ironman 4x4 highly recommends not colour-coding
parking sensors when installing a bull bar as
excessive paint thickness will adversely affect the
operation of the park assist system.
24. Remove the parking sensor wiring and
parking sensors from the factory bumper
taking note of the position order and
orientation of each sensor.
25. The centre of the plastic sensor holder will
need to be removed to install parking sensors.
If the vehicle doesn’t have factory parking
sensors, leave the centre complete.

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
Document Number: BBR074/190523
26. 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.
27. 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.
28. Apply adhesion promoter to the mounting
surfaces around the sensor holes and on the
sensor holders.
This step is important to ensure sensor
holders adhere properly to the bull bar.

Page 16 of 27
BBR074 Installation 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
Document Number: BBR074/190523
29. Remove the protective film from one side
of the double-sided tape and apply to the
mounting surface of the sensor holder.
30. 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.
31. BBR074 is a bumper
replacement. Install supplied
bumper infills with hardware.
Leave loose to adjust once
bar is in place.
Item: 15 and 16
NOTE
There is a left and right.

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
Document Number: BBR074/190523
32. Bypass this step if not installing a lightbar. Refer to step 40 for mesh infill fitting.
Assemble and install a lightbar into the centre bar section using the brackets supplied with
the bull bar fitting kit. Item: 24
The brackets provide some adjustments to ensure centralised positioning and the vertical
aim of the light.
NOTE
Do not use supplied lightbar hardware from the retail package.
33. If fitting a winch, bolt in the optional winch extension plug. P/N: WWB031
NOTE
Optional centre lightbar P/N: ILBSR002BW (requires P/N IPLS074 if not installing an IBBPL)
Ironman 4x4 have an optional IBBPL available, P/N: IBBPL074 (high spec - LED) or
PN: IBBPL074L (low spec - halogen) as reference. Both these have a built-in IPL.
It’s advised to contact the dealer or see the owner’s manual for more information.
34. Assemble and install Ironman 4x4 cube lights
to the inner light pod. The brackets provide
some adjustments to ensure centralised
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.
Spacer may be required. Item 21

Page 18 of 27
BBR074 Installation 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
Document Number: BBR074/190523
35. Optional add-ons:
Indicator / Parker lights
P/N: ILEDTURNPARK x 2
(Indicator/Parker Combo)
- or -
P/N: ILEDSL003B x 2 (Indicator)
P/N: ILEDSL003P x 2 (Parker)
Patch Looms
P/N: IBBPL074
(high spec - LED).
P/N: IBBPL074L
(low spec - halogen).
P/N: IPL001P strip light plug and
play loom.
NOTE
When mounting indicator/park
strip lights, it is advised to mount
the indicator on the outside.
P/N: ILEDTURNPARK
P/N: ILEDSL003B
P/N: ILEDSL003P
36. The outer light pod has provisions for required
park lights and indicators. (Strip lighting option
shown)
WARNING
D-Max has indicator and parker lights in the
factory bumper. These will need to be fitted and
positioned in the bull bar for the vehicle to meet
State and Federal road laws.
37. Using the supplied bracket, bolt the strip light to
the bracket.
The cable will feed through the side slots.
Indicator will need to be mounted to the outer
location and parker to the inner.
Item: 17 and 18
Wiring for fog lights, indicators, and parkers, can
now be wired. Ironman 4x4 recommends using a
bull bar patch loom.
NOTE
Depending on the indicator/parker light
selection, some wires may need to be cut,
joined, and soldered.

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
Document Number: BBR074/190523
40. If you are not fitting the optional
lightbar, a mesh infill is supplied and
fitted at this stage. Use the lightbar
support brackets to install mesh.
Item: 33
39. When mounting the bracket, you will need to mount it in its most forward position.
PARKER
INDICATOR
(to outside)

Page 20 of 27
BBR074 Installation Guide
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Document Number: BBR074/190523
41. Install license plate mount bracket onto bull
bar.
If a winch is being installed, fit the fairlead
as well.
Item: 23
42. Using the P-clips supplied, position them
along the back side of the lightbar, feed
lightbar, and parking sensor wiring through
the hole.
Using bolts supplied, feed into the lightbar
and bolt down. Cable tie remaining cables.
Item: 19
44.
NOTE
To aid in fitting the bar it is advised to tape nut plate to cradle as shown.
Item: 9 and 10
43. Clip in speed clips along the underside of
bull bar in preparation of attaching wing
protection plates later.
Item: 45