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Ironman4x4 BB067, Installation Manual

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Ironman4x4 BB067 Installation Manual Download Page 16

Page 16 of 16

BB067

Installation Guide

©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd

Wiring Diagrams

Parklight

Blue

Relay

Connector

Ground

Fuse

Red

30

85

86

87

87a

Red

Lamp

Black

Lamp

Battery

Ground

Ground

White

Switch

SPST

Positive power supply

at connector to factory fog light 

Blue

Relay

Connector

Ground

Fuse

Red

30

85

86

87

87a

Red

Lamp

Black

Lamp

Battery

Yellow

Red

Brown

Daytime Running Light

Park Light

Indicator Light

Ground

White

If vehicle is not fitted with DRL, leave red wire disconnected

PARK LIGHT & INDICATOR

FOG LIGHTS

WITHOUT FACTORY FOG LIGHTS

Summary of Contents for BB067

Page 1: ...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 BB067 180122 BB067 Copyright 2022 Ironman 4x4 Pty Ltd No part of this publication may be reproduced or replicated without the prior written consent of Ironm...

Page 2: ...25 M 12 x 1 5 8 8 Nm 10 5 25 49 88 ft lb 7 7 18 36 64 Bull Bar Parts List 1 Bull Bar QTY 1 2 Mounting Bracket QTY 1 3 Steel Skid Plate QTY 1 4 Steel Skid Plate L R QTY 2 5 Support Bracket 1 L R QTY 2 6 Support Bracket QTY 2 7 License Plate Bracket QTY 2 8 Skid Plate Bracket QTY 2 9 Bolt M12x1 25x90mm QTY 4 10 Bolt M10x1 25x40mm QTY 14 11 Bolt M12x1 25x40mm QTY 7 12 Bolt M6x1 0x25mm QTY 2 13 Bolt M...

Page 3: ...rap bull bar Check over riders and light assemblies are tight in bull bar before installation 3 Disconnect any bumper lights sensors and cameras Remove factory bumper bar grill assembly and factory protection plate from under radiator Remove washer bottle filler neck and bumper support panel 4 Temporarily mount bull bar cradle to front cross member using 4 captive nuts Ensure bracket is centralise...

Page 4: ...on may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd 6 Drill holes using a 21mm hole saw only through outer skin of chassis cross member Drill a pilot hole using the centre drill bit of the hole saw through the inner skin as shown 7 Open the inner holes to 12mm ...

Page 5: ...ent of Ironman 4x4 Pty Ltd 9 Insert crush tubes into holes previously drilled in front cross member HINT Use short bolts from fitting kit to temporarily hold crush tubes in position during istallation 8 Mount chassis support brackets to inner and outer faces of chassis using hardware provided Do not tighten Use trimmed washer for bolt on inside of tie down point ...

Page 6: ...ublication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd 10 Reinstall mounting cradle to vehicle centralise insert and tighten all mounting hardware 11 If fitting a winch horns will need to be moved to the rear of the mounting cross member as shown ...

Page 7: ...OE light recess Do not cut area mark top of light The horizontal part of the bumper remains in place do not cut above the light See image to right Continue cut line straight across bumper bar as indicated NOTE Leave top section of bumper in place to allow the grill to be clipped back in place Mark triangle template over chrome sections as indicated Triangle is 40mm H x 100mm W Re fit bumper bar an...

Page 8: ...th vehicle leaving a 10 15mm gap between wings and bumper bar and tighten all bolts 14 If applicable fit camera to bull bar through hole located above winch fairlead using supplied bolts and spacers 16 Once bull bar is aligned with vehicle and bolts tightened drill through pinning holes circled in yellow between bull bar and chassis bracket and secure with M10 bolts washers and nuts provided 17 If...

Page 9: ...supplied pump as shown Shorten factory hose and connect to washer pump Place washer bottle into cavity behind headlight Fit mounting bracket using body earth bolt Fit washer bottle to bracket and replace battery NOTE It is easier to connect indicators park lights and fog lights during this process as it allows easier access to the plugs Refer to wiring diagram on page 16 19 Fit supplied protection...

Page 10: ...Installation 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 1 Remove rubber grommets from sensor holes in bullbar 2 Remove blank from sensor holder and trim any excess plastic from inside openin...

Page 11: ...sor 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...

Page 12: ...d without the prior written consent of Ironman 4x4 Pty Ltd 5 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 bullbar 6 Remove protective film from one side of double sided tape and apply to mounting surface of sensor holder ...

Page 13: ...ication 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 ...

Page 14: ...tten consent of Ironman 4x4 Pty Ltd 1 Bolt winch to cradle Bolt fairlead to recess in front of bull bar using bolts washers and nuts provided Winch Installation 2 Fit bull bar to vehicle referring to steps of bull bar fitting instructions 3 Mount control box in desired location 4 Connect three colour coded cables to the corresponding poles on winch motor ...

Page 15: ...f winch motor 7 Connect positive and negative battery cables main battery of vehicle Not Auxilliary Battery 8 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 Refer back to step 18 of the Bull Bar fitting instructions on page 7 6 Run the positive and negative ...

Page 16: ...ector Ground Fuse Red 30 85 86 87 87a Red Lamp Black Lamp Battery Ground Ground White Switch SPST Positive power supply at connector to factory fog light Blue Relay Connector Ground Fuse Red 30 85 86 87 87a Red Lamp Black Lamp Battery Yellow Red Brown Daytime Running Light Park Light Indicator Light Ground White If vehicle is not fitted with DRL leave red wire disconnected PARK LIGHT INDICATOR FOG...

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