Ironman4x4 BBT045 User manual

BBT045/ BBC045/ BBCD045
NW PAJERO
(2011 - )
INSTALLATION
GUIDE
• Ironman 4x4 BBT/ BBC/ BBCD045 Bull Bars
fit to a NW Pajero.
• It will take about 3 hours to install.
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

Page 2 of 11
1. Before installation check bull bar application
is compatible with your vehicle.
2. Remove number plate and grill and radiator
protection plate and store in a safe place for later
re-fitment.
3. Locate and cutout cutting template at the end of
this Instruction Guide.
4. Mask outer ends of bumper bar and place cutting
template in position as shown.
5. Mark cut line and repeat for other side.
6. Carefully unclip flares from bumber.

Page 3 of 11
8. Remove bumper bar.
7. Mask a cut line across the bumper from the lines
previously marked, above the foglight openings
and below the original numberplate mounting.
Only make cut after removing bumper bar
9. Cut bumper bar to remove lower section.
10. If winch is being installed, remove section of
bumper bracket as marked in photo

Page 4 of 11
11. Place winch cradle in position on vehicle and
secure in place with strengthening plates as
shown (do not tighten)
12. Using strengthening brackets as a guide, drill
through sub frame and secure in place using
long bolts, washers and nuts provided and tighten
all mounting hardware.
13. Re-fit top section of bumper bar and cut flares as
shown. Install pinchweld.
If winch is being installed, refer to winch installation
instructions, Pages 6 - 7

Page 5 of 11
16. Align bull bar with vehicle and tighten all bolts.
17. Once bull bar is aligned with vehicle and
tightened, drill through pinning holes (circled in
red) between bull bar and chassis bracket and
secure with bolts, washers and nuts provided.
18. Connect park lights, indicators and fog lights
as per wiring diagrams at the back of fitting
instruction manual.
15. Fit bull bar to chassis brackets using M12 bolts,
flat washers, spring washers and nuts provided.
14. Unwrap bull bar. Check over riders and light
assemblies are tight in bull bar before installation.

Page 6 of 11
20. Trim guard liners and secure to radiator support
panel with bolts and washers as shown.
19. Fit protection plates underneath the bull bar
using M8 bolts, spring washers and flat
washers provided.

Page 7 of 11
2. 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.
3. Bolt fairlead to recess in front of bull bar using
bolts, washers and nuts provided.
4. Fit bull bar to vehicle referring to steps 12 - 17 of
bull bar fitting instructions.
5. Mount control box in desired location.
Winch Installation
1. Before winch can be installed a section of the
bumper bar will need to be removed. To do
this, place winch on mounting cradle and mark
bumper bar as shown.

Page 8 of 11
9. 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.
8. Run the positive and negative battery cables into
the engine bay taking care to secure cables away
from any sharp or moving objects.
7. Connect the thin black earth wire and negative
battery cable to the earth connection on the
opposite side of winch motor.
6. Connect three colour coded cables to the
corresponding poles on winch motor.

Page 9 of 11
Wiring Diagrams
Parklight
Blue
Relay
Connector
Ground
Fuse
Red
3085
86
87
87a
Red Lamp
Black
LampBattery
Ground
Ground
White
Switch
SPST
Park Light Indicator
Ground Ground
Indicator
Circuit
Park Light
Circuit Black
YellowWhite
Black
PARK LIGHT & INDICATOR
FOG LIGHTS

NW PAJERO 2011 -
BBT045/ BBC045/ BBCD045
BULL BAR TEMPLATE
PAGE 2/2
PAGE 1/2
NW PAJERO 2011 -
BBT045/ BBC045/ BBCD045
BULL BAR TEMPLATE
0
10 20 30 40 50 60 70 80 90
100
MM
0
10 20 30 40 50 60 70 80 90
100
MM
HEADLIGHT
FLARE
HEADLIGHT
FLARE

NW PAJERO 2011 -
BBT045/ BBC045/ BBCD045
BULL BAR TEMPLATE
PAGE 2/2
PAGE 1/2
NW PAJERO 2011 -
BBT045/ BBC045/ BBCD045
BULL BAR TEMPLATE
0
10 20 30 40 50 60 70 80 90
100
MM
0
10 20 30 40 50 60 70 80 90
100
MM
HEADLIGHT
FLARE
HEADLIGHT
FLARE