Hayman Reese 03299XW User manual

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03299XW
ISUZU D-MAX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 1Issue Date: 13-02-20
PRODUCT DETAILS:
Part Number:
03299XW
Maximum Towing Braked:
3500
kg
ECU Number:
04835
Maximum Towing Unbraked:
750
kg
Tail Harness Length Required:
1200mm
Maximum Static Ball Load:
350
kg
TBM/Lug Part Number:
21366
Wiring Part Number:
100055-WL
FITTING DETAILS:
Towbar Installation Time:
120 mins.
Vehicle Coding Required:
NO
Wiring Installation Time:
30 mins.
RPA Disable/Other:
NO
Total Installation Time:
150 mins
Bumper Cut Required:
No

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03299XW
ISUZU D-MAX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 2Issue Date: 13-02-20
ENSURE THAT INSTRUCTIONS ARE UNDERSTOOD PRIOR TO FITMENT.
BEFORE YOU START:
1. Hayman Reese recommends that instructions are read completely prior to fitment.
2. Check all hardware items have been included refer to assembly diagram.
3. Please ensure this towbar is only fitted to vehicle models as per Hayman Reese application guide
(www.haymanreese.com.au).
4. Bumper Cuts
5. Vehicle and bumper variations can and do occur during vehicle manufacture after initial towbar
design. Fitment of towbar to vehicle and accuracy of bumper cut must be assessed prior to any
bumper modifications made. Incorrect bumper cuts are not covered under Hayman Reese warranty.
6. NOTE: Bumper cuts need to be approached with care, refer to notes below.
Bumper centreline –where the centreline of the bumper needs to be determined, the installer
must assess centre point by measurement of bumper width or determining two symmetrical
reference points to give centreline.
Bumper edge –To assist with accurate bumper cut measurement, reference to the start of the
bumper edge is now being commonly used.
oMeasure from bottom edge along bumper and around corner to the 70 mm point
(Figure 1).
oDo not measure from visible bumper front of corner, upwards (Figure 2).
7. Drilling
For any required drilling during installation, ensure that the area is clear of fuel, electrical & other components that may be
damaged.
All holes drilled into the body panels shall have all burrs & swarf removed then coated with a suitable rust preventative paint.
8. Bolts/Fasteners
Ensure that all hardware is fastened to correct torque as specified in this fitting instruction.
All fasteners supplied with this product are used to achieve a specified clamp loading. If replacement is required ensure that
fasteners of the same grade and class are used.
9.
10. NOTE: Achieving correct torque is critical to proper installation and responsibility of the installer. Towbar failures attributed to
tension issues from over tightening or under tightening are not covered by Hayman Reese warranty.
11.
12. Product Labels
a. Towbar load rating sticker provided with this product shall be conspicuously located on inside rear end of the driver’s door.
b. Powertrain Control Module (PCM)/Body Control Module (BCM) upgrade warning label will be provided in towbar kit for
vehicles as required. Affix warning label in door and owner’s handbook.
WARNING:
1.
2. Do not, drill, cut, weld or otherwise modify the towbar.
3. FOR TOWING PURPOSES ONLY - This towbar is designed and tested by Hayman Reese to adhere to ADR 62/02 which provides
only for the expected load demands of towing.
Figure 1
INCORRECT
CORRECT
Place Vehicle PCM/ BCM upgrade
warning label in door AND on front
cover of owner’s service handbook
Place Load Rating
sticker inside driver’s
door here
Figure 2

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03299XW
ISUZU D-MAX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 3Issue Date: 13-02-20
TOWBAR ASSEMBLY DIAGRAM
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
1
ISUZU DMAX WELDED ASSEMBLY
1
21
XBAR COVER SPRING 60Lx10ODx1P
2
2
ISUZU DMAX SIDE ARM RHS
1
22
NUT HEX M10x1.5P
4
3
ISUZU DMAX SIDE ARM LHS
1
23
WASHER PLAIN M10x25x3
8
4
LHS STEP BRACKET
1
24
SET SCREW HEX HD M10x30x1.5P
4
5
RHS STEP BRACKET
1
25
NUT HEX M6x1.0P
2
6
NUT PLATE
2
26
WASHER PLAIN M6x12.5x1.2
4
7
FORGED TBM 65MM DROP 3.5T
1
27
SET SCREW HEX HD M6x25x1P
2
8
FORGED SIDE RECOVERY HOOK
2
28
SET SCREW HEX HD M12x45x1.25P
10
9
FORGED CENTRE RECOVERY HOOK
1
29
WASHER PLAIN 1/2x1-1/8x16
10
10
HR TOWBALL
1
30
CENTRE RECOVERY HOOK BOLT KIT
1
11
"D" SHACKLE 10mm
2
31
SIDE RECOVERY HOOK BOLT KIT
2
12
ANTI-RATTLE PULL PIN ASSY GOLD
1
32
NUT HEX FLANGE M12x1.25P
8
13
WIRING HOUSING
1
33
SET SCREW HEX HD FLANGE M12x45x1.25P
8
14
XBAR REAR COVER
1
34
NUT NYLOC HEX M4x0.7P
2
15
BUSH 15ODx8Lx5ID
4
35
SCREW PAN HD M4x16x0.7P
2
16
SET SCREW HEX HD M5x16x0.8P
4
36
SCREW PAN HD M3x20x0.7P
2
17
NUT NYLOC INS HEX M5x0.8P
4
37
NUT NYLOC HEX M3x0.7P
2
18
BOLT COACH M8x20x1.25P
2
38
XBAR LOGO STICKER
2
19
PLUG PLATE
1
39
ACRYLIC COMPLIANCE LABEL
1
20
NUT NYLOC HEX M8x1.25P
2
40
WIRING LOOM
1

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03299XW
ISUZU D-MAX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 4Issue Date: 13-02-20
NOTE: Pre-assembly of X-Bar centre section can assist for vehicles with difficult access.
A. BOLT RECOVERY HOOKS TO TOWBAR
B. MOUNT PLUGS TO BRACKET
AFTER CHOOSING YOUR DESIRED PLUG
CONFIGURATION, INSTALL PLUGS AND WIRING
TO BRACKET USING FASTENERS PROVIDED
TIP: INSERT RECOVERY HOOK BOLTS
THROUGH HOOK AND SPACER TUBES
PRIOR TO FITTING BAR. THIS WILL HELP
LOCATE & GUIDE DURING ASSEMBLY
3 x M12 x 130mm BOLT
CRUSH TUBE
SPACER PLATE
WASHER
NUT
4 x M12 x 45mm BOLT
WASHER
NUT
TORQUE FASTENERS
TO 100 N.m
RAISED SIDE OF
RECOVER HOOK
MUST FACE TOWBAR

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03299XW
ISUZU D-MAX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 5Issue Date: 13-02-20
C. INSTALL WIRING HOUSING
D.ATTACH COVER TO HOUSING
4 x M5 BOLT
NYLON BUSH
NYLOC NUT
ROUTE TAIL HARNESS THROUGH EXIT
POINT BEST SUITED TO VEHICLE
USING 2 x M8 COACH BOLTS COMPLETE WITH 1 x
NYLOC NUT PER BOLT, SECURE THE WIRING HOUSING
AND PLUG BRACKET TO THE MAIN TOWBAR
ASSEMBLY THROUGH THE TAB HOLES AS SHOWN.
STEP IV: USE 1 x SPRING
PER SIDE TO ATTACH
HOUSING TO COVER PLATE
TORQUE FASTENERS
TO 22 N.m
NOTE: DO NOT OVERTIGHTEN
FASTENERS TO ENSURE COVER
ASSEMBLY CAN ROTATE FREELY &
TO PREVENT DAMAGE TO BUSHES
STEPS I, II & III
I. INSERT BUSHES INTO SLOTS
II. THEN PLACE COVER OVER HOUSING, LINING UP BUSHES
WITH SCREW HOLES
III. FINALLY FASTEN COVER TO HOUSING BY PUSHING
SCREWS THROUGH BUSHES AND SECURING WITH NUTS

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03299XW
ISUZU D-MAX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 6Issue Date: 13-02-20
1. Disconnect rear registration light plug connection.
2. Remove 3 bolts from LH & RH side step mounting
brackets and remove step.
3. Remove plastic skin from rear step. Remove &
discard factory step brackets.
4. Loosely attach supplied brackets (Item numbers 4
& 5 from pg. 3) with 2 x M10 bolts complete with
2 x washers and 1 x nut, and 1 x M8 bolt
complete with 2 x washers and 1 x nut for both
RH & LH side.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03299XW
ISUZU D-MAX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 7Issue Date: 13-02-20
5. Loosely secure towbar sidearm to vehicle chassis
rail using nut plate inserted into chassis rail and 2
x M12 x 45mm bolts complete with 1 x washer
per bolt.
Repeat for opposite side.
6. Lift step brackets to outside of sidearms and
loosely secure to sidearm and chassis rail with 3 x
M12 bolts, complete with 1 x washer per bolt.
7. Lift centre welded assembly up to side arms and
loosely secure with 4 x M12 flange bolts per side,
complete with 1 x M12 flange nut per bolt.
Repeat for opposite side.
If not already done, complete pre-assembly steps
A, B, C & D now.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03299XW
ISUZU D-MAX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 8Issue Date: 13-02-20
8. Torque step fasteners as follows:
M8 = 22 Nm
M10 = 44 Nm
Reattach plastic step skin.
9. Torque all remaining fasteners as follows:
IMPORTANT: Ensure all bolts are tightened to correct torques using a calibrated torque wrench.
Tighten side arms to chassis rail first in an even pattern/sequence. Repeat for centre section to side arms and finally
torque all other fasteners.
HINT: Tighten step bracket to towbar whilst holding the step up so that enough clearance is present between step
and hitch box.
10 x M12 central and side recovery
hook fasteners = 100 N.m
10 x M12 sidearm to chassis
fasteners = 125 N.m
8 x M12 flanged sidearm
to centre section
fasteners = 165 N.m

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03299XW
ISUZU D-MAX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 9Issue Date: 13-02-20
IMPORTANT
Due to possible vehicle variations, always confirm any noted
vehicle colour wires with a multi-meter to ensure the correct
function is identified before soldering or scotch locking. For
vehicle wires denoted with two colours (example;
RED/GREEN) the first colour will always be the main wire
colour while the second colour is the thinner trace colour on
the wire.
10. Underneath the rear of the vehicle, locate and
disconnect the LHS vehicle trailer break-out
connector (1).
11. Connect the Trailer Patch Harness (part no. 100055-
WL) to the LHS break-out connector (1).
12. Route Tail Harness (length 1200mm) (2) towards the
Trailer Patch Harness and connect the Trailer Patch
Harness to the Trailer tail Harness.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03299XW
ISUZU D-MAX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 10 Issue Date: 13-02-20
13. Secure the Trailer Patch Harness relays (1) onto the
interior vehicle sheet metal as shown using tech
screws.
14. Secure the vehicle patch harness and Tail Harness
connectors (2) using cable ties (not supplied).
15. Test the Tail Harness socket using a light board or multimeter.
16. Secure all harnesses using cables ties (not supplied).
17. Re-fit all removed parts and secure all fasteners ensuring there are no squeaks or rattles.
18. Place instructions in glove box after fitment.

49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
Rev: APage 11 Issue Date: 13-02-20
THANK YOU FOR PURCHASING HAYMAN REESE.
WITH CORRECT MAINTENANCE AND CARE THIS PRODUCT WILL PROVIDE A
LIFETIME OF TROUBLE-FREE OPERATION.
TOWBAR MAINTENANCE AND CARE:
1.
Hayman Reese recommend that the towbar LUG or TBM (tow ball Mount) Pull Pin and R-clip are removed
and stored when not in use. Removal of LUG or TBM (tow ball mount) is advisable when not in use to
assist with any of the following.
Ensure rear number plate is not obscured.
Allow maximum available departure angle and prevent any potential interference.
Prevent possible interference with vehicles reverse sensors or camera detecting a tow ball mount
as an obstruction during reversing.
Removes towball mount as an obstruction for when moving around the rear of the vehicle.
2.
Hayman Reese recommends routine inspection of your towbar to ensure trouble free towing.
Bolt security and tension should be regularly inspected and checked for correct tension. Replace
any worn or defective parts with suitable grade & class fasteners. Inspection should be requested
to coincide with vehicle major services.
3.
It is the owner’s responsibility to ensure towing and down ball weight capacities of the towing vehicle are
not exceeded.
Towing and down ball weights allowable may differ according to model variations. Please refer to
owner’s manual or vehicle dealer to confirm exact rating for your vehicle model variant.
It is not uncommon for the vehicle tow rating to differ from the towbar rating. When this occurs,
the lesser rating must be adhered to.
For vehicles fitted with enhanced vehicle functions that may be altered/changed when towing i.e
Trailer sway mitigation, blind spot detection, adaptive cruise control etc. Please consult owner’s
manual to understand changes enabled when towing and after towing.
WARRANTY INFORMATION:
Hayman Reese Towbars are covered by a Lifetime Warranty.
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are
entitled to a replacement or refund for a major failure and for compensation for any other reasonably
foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to
be of acceptable quality and the failure does not amount to a major failure.
For further details please visit www.haymanreese.com.au/warranty or contact customer service on
1800 812 017 or [e-mail].

49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
Rev: APage 12 Issue Date: 13-02-20
HAYMAN REESE SMART PIN
Your Hayman Reese towbar is equipped with Smart Pin technology to help reduce towbar tongue rattle in most
driving conditions. Please ensure below instructions are understood and routine maintenance is carried out to
ensure best towing experience.
Regularly inspect for wear and check the tightness of the Smart Pin Nut. Follow instructions below to re-
tighten the nut as necessary when movement and noise in the tow ball mount is noted.
Before towing, ensure R-Clip is properly installed and Smart pin nut is installed and tensioned.
Replacement parts are available from your Hayman Reese Distributor.
TOWBALL MOUNT REMOVAL/INSTALLATION
STEP 1
Insert Trailer Ball Mount (TBM) (a) into towbar
hitchbox (b), aligning hole in TBM shank (c) with
hole in hitchbox (d) (Fig. 1)
STEP 2
Insert Smart Pin (e) through hole in hitchbox and
hole in TBM shank (g); ensure the locators are
inserted into the notches in the hitchbox (Fig. 2)
STEP 3
Screw Smart Pin Nut (f) onto Smart Pin (g); tighten
Smart Pin Nut until finger tight, ensuring TBM is
restrained from up and down movement.
STEP 4
Tighten Smart Pin Nut by turning nut a further
1/8th of a turn in the clockwise direction using a
24mm spanner (Fig. 4).
STEP 5
Install Smart Pin R-Clip through the hole that
provides best clearance or easiest access. (Fig. 5)
Fig. 1
Fig. 4
(d)
HITCHBOX
(b)
Fig. 5
TRAILER BALL
MOUNT
(a)
(c)
Fig. 3
SMART PIN NUT
(f)
SMART PIN
(e)
Fig. 2
R-CLIP
(g)