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

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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
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.