Trailboss KM23L User manual

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 1
Issue Date: 31-05-19
PRODUCT DETAILS:
Part Number:
KM23L
Maximum Towing Braked:
1200
kg
ECU Number:
04836
Maximum Towing Unbraked:
610
kg
Tail Harness Length Required:
04936
Maximum Static Ball Load:
75
kg
TBM/Lug Part Number:
07756
FITTING DETAILS:
Towbar Installation Time:
70 Mins.
RPA Disable/Other Notes:
YES
Total Installation Time:
70 Mins.
Note:
Bumper Cut Required:
Yes
RPA Disable - Harness 04936 must be used
and connected
Electric Brake Input Location: Near ECU
connector

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 2
Issue Date: 31-05-19
TRAILBOSS RECOMMENDS THAT INSTRUCTIONS ARE READ AND
UNDERSTOOD COMPLETELY PRIOR TO FITMENT.
BEFORE YOU START:
1. Check all hardware items have been included refer to assembly diagram.
2. Please ensure this towbar is only fitted to vehicle models as per Trailboss application guide.
3. Bumper Cuts
4. 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 Trailboss warranty.
5. 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).
6. 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 metal body panels shall have all burrs & swarf removed then coated with a suitable rust preventative
paint.
7. 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.
8. 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 Trailboss warranty.
9. Product Labels
a. Towbar load rating sticker provided with this product shall be conspicuously located on inside rear end of the driver’s door.
WARNING:
Do not, drill, cut, weld or otherwise modify the towbar.
FOR TOWING PURPOSES ONLY - This towbar is designed and tested by Trailboss to adhere to ADR 62/02 which
provides only for the expected load demands of towing.
1.
2.
3.
Figure 1
INCORRECT
CORRECT
Figure 2

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 3
Issue Date: 31-05-19
TOWBAR ASSEMBLY DIAGRAM
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
1
KIA CERATO WELDED ASSEMBLY
1
10
SPRING WASHER M16
2
2
RH SIDE ARM ASSEMBLY
1
11
LUG ASSY
1
3
LH SIDE ARM ASSEMBLY
1
12
NUT NYLON LOCK HEX M4X0.7P
2
4
BUMPER TAB
2
13
PLUG BRACKET
1
5
SET SCREW HEX HD M10x40x1.25P
10
14
10mm "D" SHACKLE
2
6
NUT HEX HD M10x1.25P
4
15
50mm TOWBALL
1
7
WASHER PLAIN M10
14
16
ACRYLIC COMPLIANCE LABEL
1
8
TEK SCREW 14-20 HEX HD 22mm
4
17
WIRING LOOM
1
9
SET SCREW HEX M16x40x2.0P
2

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 4
Issue Date: 31-05-19
1. Open boot and remove LH and RH side panel
trims from inside boot to expose rear of tail-light.
2. Remove 4 x hex nuts securing tail-light to vehicle.
Gently pull tail-light rearwards to dislodge and
unclip attached wiring from inside vehicle and
feed through rear panel. Set tail-light aside.
Repeat for opposite side.
3. Remove 1 x screw and 1 x scrivet from top of
bumper where tail-light was removed.
Repeat for opposite side.

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 5
Issue Date: 31-05-19
4. For single exhaust, remove trim from underside
of vehicle by removing 3 x scrivets and 3 x hex
nuts.
Set trim aside.
5. Inside rear wheel arch, remove 2 x screws and 2 x
scrivets (one on the underside of vehicle).
6. Remove 2 x hex head bolts on each side of vehicle
securing impact beam to rear panel. These can be
accessed from the underside of the vehicle.

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 6
Issue Date: 31-05-19
7. Carefully peel back bumper from corners to
remove. Disconnect wiring harness from rear
panel to free the bumper.
Set bumper safely aside.
8. Remove 5 x scrivets securing impact beam to
bumper.
Disconnect any wiring connections between the
impact beam and the bumper. Remove impact
beam from bumper with wiring still attached.
Remove all wiring from impact beam.
9. Re-attach removed wiring to bumper and secure
in place with cable ties (not supplied). Disconnect
antenna from impact beam. This will be
reattached to the towbar later.
Discard impact beam.
ANTENNA

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 7
Issue Date: 31-05-19
10. If required, remove exhaust from rear exhaust
hanger to allow better access for fitment.
Note: Repeat for opposite side if fitting a dual
exhaust model.
11.Attach supplied bumper tab brackets to front
face of towbar (refer to exploded diagram on
page 3) with 1 x tek screw per bracket.
12. Loosely secure side arm to outboard side of
chassis rail via 2 x M10 bolts complete with 1 x
M10 washer per bolt.
Repeat for opposite side.

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 8
Issue Date: 31-05-19
13. Loosely secure welded centre section to side arms
via 2 x M10 bolts complete with 2 x M10 washers
and 1 x M10 nut per bolt.
Secure side arms to weld nuts on centre section
via 1 x M10 bolt complete with 1 x M10 washer.
Repeat for opposite side.
Tighten all bolts to the following torques:
M10 x 1.25 –48 N.m
14. Re-fit the antenna removed in Step 9 to the two
holes located on the top of the cross-tube with 2
x tek screws supplied. Ensure to not overtighten
fasteners.
15. Identify the centre line of the bumper. Measure
100mm up from the bottom edge of the bumper.
From there, mark and cut a 100mm tall (up to the
first style line on the bumper) x 100 mm wide
square (as measured either side of the bumper
centreline).
Ensure to remove any sharp edges or burrs from
bumper after cut.
100mm
100mm
100mm

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 9
Issue Date: 31-05-19
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.
16. In the engine bay, disconnect the vehicle battery
negative terminal (1).
17. In the boot, remove the rear sunshade (1).
18. Fold down the rear seats (2).
19. Remove the floor carpet (3).
20. Remove the foam storage tray.

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 10
Issue Date: 31-05-19
21. Remove the rear scuff trim (1) by first removing the
trim clips (2), and then pulling in an upwards
direction.
22. Remove the RHS tool tray (1) by releasing the Phillip's
Head screws (2).
23. On the RHS trim, remove the caps (3) to expose the
10mm bolts.
24. Remove the 10mm bolts and trim clip (4).
25. Remove the final screw (under the RHS tool tray)
securing the RHS trim.
26. Dislodge the RHS trim.
27. On the RHS floor, locate the 25mm blanking grommet
(1).
28. Remove the blanking plug and drill hole out to 30mm.

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 11
Issue Date: 31-05-19
29. Route the white and blue connector on the larger
trailer patch harness (102111-WL) (1) from the inside
of the vehicle through the drilled grommet hole (2) to
the outside.
30. Seat grommet (2) in hole.
Note: Keep harness routing clear of all sharp edges,
moving parts and places of extreme heat.
Note: Ensure grommet is seated correctly and makes
a good seal.
31. At the RHS tail light, patch in the harness connectors
(1) in between the vehicle harness (2) and the tail
light harness (3).
32. Using the supplied M6 flange nut, secure the star ring
terminal (4) to the vehicle stud (5).
Note: Ensure the star ring terminal bites into the
chassis to provide a clean earth connection.
33. Using an alcohol wipe, clean a suitable sheet metal
area (1) and the underside of the ECU (04836) (2).
34. Connect the trailer patch 12-way connector (3) to the
ECU.
35. Apply double sided tape to the ECU (2) and secure it
to the vehicle sheet metal.
Note: Mount the ECU, ensuring the connector is
orientated downwards.

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 12
Issue Date: 31-05-19
36. From the RHS passenger door, remove a small section
of the weather seal (1).
37. Dislodge the trim (2) covering the rear passenger
seatbelt.
38. Route the power wire from the boot towards the
front of the vehicle.
Note: Use the supplied Cable Ties to secure the
harness away from the seat belt.
39. Continue routing the power wire (1) towards the fuse
box (2) at the RHS kick panel, tucking the wire under
the trim.
40. Dislodge the RHS kick panel trim (1) and the fuse box
cover (2).

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 13
Issue Date: 31-05-19
41. Remove Vehicle 20 amp fuse from location Fuse 14.
42. Insert the supplied 20 amp fuse (1) into the Add- A-
Fuse (2) top slot and then insert the vehicle fuse (3)
into the bottom slot.
43. Insert the Add-A-Fuse (2) to the blank fuse location in
the orientation shown (4).
44. Connect the Add-A-Fuse (2) to the main harness (5).
Note: To maintain correct electrical operation,
ensure you insert the fuse adaptor into the allocated
slot and in the orientation shown.
45. Connect the small T-patch harness in between the
bumper connector and vehicle connector.
46. With the rear bumper removed, secure tail harness
and small T-patch to towbar.
47. Route tail harness and T-patch along towbar to the
RHS.
Keep harness routing clear of all sharp edges,
moving parts and places of extreme heat.
48. Connect the tail harness (part number 04936) 8-way
connector (1) to the trailer patch mating 8-way
connector (2).
49. Connect the T-patch harness 3-way connector to the
trailer patch mating 3-way connector.
50. Cut-off, crimp the tail harness GREY and GREY/BLACK
wires (3) to the trailer patch matching WHITE and
GREY/BLACK wires (4).
51. Apply silicone grease (not supplied) (5) to waterproof
the blue connector.

TOWBAR INSTALLATION INSTRUCTIONS
PART NUMBER KM23L
KIA CERATO BD CL2
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 14
Issue Date: 31-05-19
52. Secure all harnesses using supplied Cable Ties.
53. Test the trailer patch function using a light board or
multi-meter.
54. Re-fit all removed parts and secure all fasteners,
ensuring there are no squeaks or rattles.
55.Mark out and drill 2 x ø5mm holes 69mm apart on
bumper skin to support plug bracket.
56.Remove centre bumper tab from bumper.
57.Refit all removed components. Attach bumper to
towbar tabs via 2 x scrivets accessed from the
underside of the vehicle.
58. Place the fitting instructions in the glove box after
fitment.

49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 15
Issue Date: 31-05-19
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
THANK YOU FOR PURCHASING TRAILBOSS. WITH CORRECT MAINTENANCE AND CARE
THIS PRODUCT WILL PROVIDE A LIFETIME OF TROUBLE-FREE OPERATION.
TOWBAR MAINTENANCE AND CARE:
1.
Trailboss recommend that the towbar LUG or TBM (Trailer Ball Mount) Pull Pin and R-clip are
removed and stored when not in use. Removal of LUG or TBM (Trailer 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.
Trailboss 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:
Trailboss 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 contact customer service on 1800 812 017.

49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
REV A
Page 16
Issue Date: 31-05-19
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
PRO SERIES SILENT ANTI-RATTLE HITCH PIN
Your Trailboss towbar is equipped with a Pro Series Silent Anti-Rattle Hitch 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 Silent Anti-Rattle Hitch Pin. 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 hitch pin nut is installed and tensioned.
Replacement parts are available from your Pro Series 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 Silent Anti-Rattle Hitch 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 Silent Anti-Rattle Hitch Pin (f) onto
Smart Pin (g); tighten Smart Pin Nut until finger
tight, ensuring TBM is restrained from up and
down movement.
STEP 4
Tighten Silent Anti-Rattle Hitch 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 Silent Anti-Rattle Hitch 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
SILENT ANTI-RATTLE HITCH PIN NUT
(f)
SILENT ANTI-RATTLE
HITCH PIN NUT
(e)
Fig. 2
R-CLIP
(g)