Trailboss QTHD774L User manual

Towbar Fitting Instructions
To Suit HOLDEN COMMODORE ZB CL4
Part Number QTHD774L
Rating 2100/90 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
Post: PO Box 4050, Dandenong South VIC 3175
Rev: A Page 1 Issue Date: 03-10-2018
FOR TRAILER TOWING PURPOSES ONLY
For towing capacity details please refer to vehicle owner’s
manual or to the manufacturer. Overloading can void your
warranties.
WARNING:
1. Do not, drill, cut, weld or otherwise modify the tow bar.
2. If you are using electric welding on a motor vehicle, always check that the vehicle is not equipped with electronic engine or
instrument management equipment. Failure to do so could destroy any onboard computers. If in doubt, check with the
vehicle's manufacturer.
3. The high tensile fasteners supplied with this product were used to achieve the specified rating. If replacement is required
ensure that fasteners of the same rating & quality are used. Contact an authorised Trailboss dealer if further information is
required.
4. If TBM is used in inverted position tow ball may make contact with rear tailgate when lowered, which could cause damage.
General:
1. Ensure all hardware items have been included refer to assembly diagram.
2. It is recommended that the instructions are read through and completely understood before making any attempt to fit this
product.
3. Be wary of any changes to vehicle designs or other accessories that may conflict with the installation of this product.
4. Before drilling ensure that the area is clear of fuel, electrical & other components.
5. All holes drilled into the body panels shall have all burrs & swarf removed then coated with a suitable rust preventative paint.
6. For vehicles that require the bumper to be cut. Ensure cut out area is in correct position on the vehicle prior to cutting the
bumper.
7. The high tensile fasteners supplied with this product were used to achieve the specified rating. If replacement is required
ensure that fasteners of the same rating & quality are used. Contact an authorized Trailboss dealer if further information is
required.
8. Ensure that all hardware is fastened to torque list below check fasteners on regular basis.
9. Tow bar load rating sticker provided with this product shall be conspicuously located on inside rear end of the driver's door.
(See diagram below).
10. Trailboss recommends that you check your tow ball to ensure that it complies with the Australian standards AS 4177.2.
11. PLEASE NOTE: It is advised to remove your LUG or TBM when not actually towing so as to produce a clear view of the
vehicles registration plate if obscured, and to also provide maximum available departure angle
Tow bar Maintenance and Care.
Trailboss recommends that bolt torque’s, as listed below, are routinely and regularly inspected and checked for correct tension. Replace
any worn or defective parts.
We recommended to remove Tow Ball Mounts (TBM’s, tongues or lugs) when not being used for any considerable length of time.
So as to avoid injury, when not towing it is suggested that the tongue, Pull Pin and R-clip are removed then stored in a safe, clean and
dry place, away from excessive moisture.
Hitch Pull Pins and spring “R” clips are regularly checked for proper installation. Replace any worn or defective parts.
Place load rating sticker
inside driver’s door here
RECOMMENDED ASSEMBLY TORQUE LISTING
Diameter Grade 8.8 Bolt
M6 9.5 Nm
M8 21.7 Nm
M10 43.4 Nm
M12 77.3Nm
M14 146 Nm
M16 189.8 Nm

Towbar Fitting Instructions
To Suit HOLDEN COMMODORE ZB CL4
Part Number QTHD774L
Rating 2100/90 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
Post: PO Box 4050, Dandenong South VIC 3175
Rev: A Page 2 Issue Date: 03-10-2018
ITEM
DESCRIPTION
QTY
1
HOLDEN WAGON WELDED ASSY
1
2
SIDE ARM ASSY RH
1
3
SIDE ARM ASSY LH
1
4
BUMPER TAB
2
5
TRAILER BALL MOUNT
1
6
NUT HEX HD M10 X 1.25P G8
8
7
WASHER PLAIN M10 X 25 X 3
28
8
BOLT HEX HD M10 X 40 X 1.25P G10.9
8
9
TEK SCREW 14-10 HEX HD 25MM
2
10
NUT M10 NYLOC
4
11
SETSCREW HXHD M10X30X1.5P G8.8
4
12
BOLT M10 - 1.5 x 55MM
4
ITEM
DESCRIPTION
QTY
13
SET SCREW M6 x 20 GR 8.8 Z/P
2
14
WASHER FLAT M6x18x1.5
2
15
NUT NYLON LOCK HEX HD M4X0.7P G8
2
16
CLIP NUT 6MM
2
17
VE PLUG BRACKET
1
18
HITCH BOX COLLAR COVER
1
19
"D" SHACKLE 10MM
2
20
TOWBALL 50MM
1
21
SILENT HITCH PIN –SILVER
1
22
ACRYLIC COMPLIANCE LABEL
1
23
WIRING LOOM
1

Towbar Fitting Instructions
To Suit HOLDEN COMMODORE ZB CL4
Part Number QTHD774L
Rating 2100/90 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
Post: PO Box 4050, Dandenong South VIC 3175
Rev: A Page 3 Issue Date: 03-10-2018
1. In wheel arch, remove 4 x Torx screws.
Repeat for other side
2. In the wheel arch peel back the trim and remove
the exposed 1 x Screw.
Repeat for other side.
3. Under bumper, remove 2 x screws.

Towbar Fitting Instructions
To Suit HOLDEN COMMODORE ZB CL4
Part Number QTHD774L
Rating 2100/90 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
Post: PO Box 4050, Dandenong South VIC 3175
Rev: A Page 4 Issue Date: 03-10-2018
4. Remove the Number Plate and remove the
exposed 2 x screws securing the bumper to the
back panel.
5. Peel away bumper from the sides and remove
from vehicle. Ensure to disconnect the electrical
harness (RH side).
Set bumper aside in a safe location.
6. Remove the 4 x Nuts on the top and 4 x Bolts on
the bottom that secure the impact beam and the
exhaust brackets.
Discard the impact beam along with the
fasteners.

Towbar Fitting Instructions
To Suit HOLDEN COMMODORE ZB CL4
Part Number QTHD774L
Rating 2100/90 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
Post: PO Box 4050, Dandenong South VIC 3175
Rev: A Page 5 Issue Date: 03-10-2018
7. Lower the LH and RH mufflers.
8. Remove the LH and RH heat shields secured
with screw on retainers to gain access to the
chassis rails.
9. Insert the LH side arm assembly into the chassis
rail and loosely secure with 2 x M10 bolts
complete with 1 x washer per bolt.
10. Loosely secure (only) the top side arm mountings
with 2 x Nylocs complete with 1 x washer per
nyloc.
Repeat for other side.
11. Lift cross tube to the side arms and loosely
secure with 8 x M10 bolts complete with 2 x
washers and 1 x nut per bolt.

Towbar Fitting Instructions
To Suit HOLDEN COMMODORE ZB CL4
Part Number QTHD774L
Rating 2100/90 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
Post: PO Box 4050, Dandenong South VIC 3175
Rev: A Page 6 Issue Date: 03-10-2018
12. Tighten the 2 x M10 bottom fasteners.
Torque to 44Nm.
Repeat for other side.
13. Refit the 2 x heat shields removed in step 8.
14. Raise the muffler and loosely secure the muffler
brackets along with the bottom holes on the side
arm brackets with 2 x M10 bolts complete with 1
x washer per bolt to the back panel.
Repeat for other side.
15. Tighten all the fasteners to the torques as
specified:
Cross tube to side arms M10 (10.9) : 68Nm
M10 Nyloc : 44Nm
M10 Bolt to rear panel : 44Nm
16. Working on the outside of the bumper panel,
locate the centre, mark off and cut out 100mm
wide and 160mm long as measured from the
edge of the bumper. (The cut should stop at the
first style line)
NOTE: The bumper has an inner skin panel that
requires some material removal.
100mm
160mm

Towbar Fitting Instructions
To Suit HOLDEN COMMODORE ZB CL4
Part Number QTHD774L
Rating 2100/90 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
Post: PO Box 4050, Dandenong South VIC 3175
Rev: A Page 7 Issue Date: 03-10-2018
17. Fit the clip nuts to the 2 x bumper brackets and
loosely secure to the inside of the bumper with 1x
M6 bolt complete with 1 x washer.
18. At an appropriate position on the bumper, mark
out and drill 2x ø5mm holes 69mm apart on
bumper skin to support plug bracket. Feed
bracket threads through drilled holes prior to
reinstalling bumper.
19. Refit the bumper to the vehicle.
20. Secure the bumper brackets to the cross tube
with 2 x tek screws.
21. Refit all removed fasteners following steps 1-4 in
reverse.

Wiring Loom Fitting Instructions
To Suit Holden Commodore ZB Wagon
Part Number 101996-WL
Page 1 of 3 Issue Date 17-09-18
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: inf[email protected]
Post: PO Box 4050, Dandenong South VIC 3175
Wiring Loom Installation Instructions
Holden Commodore ZB Wagon
Part No: 101996-WL
ECU: 04839
Tail Harness Part No: WLT-019
RPA Disable: Near Transmission Lever
Electric Brake Input Location: Near Blue Connector
Wiring Loom Installation Time: Approx 15 Mins

Wiring Loom Fitting Instructions
To Suit Holden Commodore ZB Wagon
Part Number 101996-WL
Page 2 of 3 Issue Date 17-09-18
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: inf[email protected]
Post: PO Box 4050, Dandenong South VIC 3175
1. In the boot, remove the LHS cover.
2. For V6 AWD variants: In the boot, disconnect the negative battery terminal.
3. For V6 AWD variants: In the LHS rear quarter panel in front of the battery towards
the tail light, locate the vehicle grey pre-wire connector.
4. For V6 AWD variants: Connect the trailer patch (101996-WL) 13-way grey connector
to the vehicle pre-wire connector.
5. For I4 FWD variant: In the engine bay, disconnect the negative battery terminal.
6. For I4 FWD variant: In the LHS rear quarter panel towards the tail light, locate the
vehicle grey pre-wire connector.
7. For I4 FWD variant: Connect the trailer patch (101996-WL) 13-way grey connector to
the vehicle pre-wire connector.
8. Using an alcohol wipe, clean a suitable area of the LHS inner sheet metal and the
underside of the ECU (04839).
9. Connect the trailer patch 22-way connector to the ECU.
10. Apply double sided tape to the ECU and secure it to the vehicle sheet metal.
Note: Mount the ECU, ensuring the connector is orientated downwards.
11. With the rear bumper removed, secure tail harness (Part No: WLT-019) to towbar.
12. Connect the tail harness 8-way connector to the trailer patch mating 8-way connector.
13. Cut-off, crimp and tail harness GREY and GREY/BLACK wires to the trailer patch
matching WHITE and GREY/BLACK wires.
14. Apply silicone grease (not supplied) to waterproof connector.
15. Under the vehicle LHS, locate the vehicle trailer harness pre-wire connector.
16. Remove the blanking plug sealing the connector and connect the black and purple
connector on the patch harness to the vehicle pre-wire connector.
17. Test the trailer patch function using a light board or multi-meter.
18. Secure all harness using supplied Cable Ties.
19. Re-fit all removed parts and secure all fasteners, ensuring there are no squeaks or
rattles.

Wiring Loom Fitting Instructions
To Suit Holden Commodore ZB Wagon
Part Number 101996-WL
Page 3 of 3 Issue Date 17-09-18
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: inf[email protected]
Post: PO Box 4050, Dandenong South VIC 3175
20. The RPA function can be disabled via a switch next to the transmission lever.
21. Place the fitting instructions in the glove box after fitment.
Note: Keep harness routing clear of all sharp edges, moving parts and places
of extreme heat.

FITTING INSTRUCTIONS
Silent Anti-Rattle Hitch Pin (PRO001)
Pro Series
PO BOX 4050, Dandenong South, VIC 3164
[email protected] I 1800 812 017
www.pro-series.com.au
• These fitting instructions are supplied to ensure
understanding of how the HITCH PIN should be fitted and
used correctly.
•Once installed, we recommend ALL instructions are kept and
placed in the vehicle glove box.
NOTE: Routine maintenance and inspection of the towbar &
HITCH PIN is required. Regularly inspect for wear and check
the tightness of the Hitch Pin. Follow instructions below to
retighten the nut when necessary.
*Do not tow with your vehicle if the R CLIP or the HITCH PIN is
loose or missing. Replacement parts are available from your
Pro Series Distributor.
Hitch Pin Nut
R-Clip
Hitch Pin
Fig 1. Silent Anti-Rattle Hitch Pin assembly
Fig 2. Installation of Trailer Ball Mount Fig 3. Silent Anti-Rattle Hitch Pin orientation
Insert Trailer Ball Mount (TBM) into towbar HITCHBOX, aligning hole in TBM SHANK with hole in HITCHBOX
(Fig 2).
Insert HITCH PIN through hole in HITCHBOX and hole in TBM SHANK; ensure
the LOCATORS are inserted into the NOTCHES in the HITCHBOX (Fig. 3).
STEP 1
STEP 2
Screw HITCH PIN NUT onto HITCH PIN ; tighten HITCH PIN NUT until finger
STEPSTEP 3 3 tight, ensuring TBM is restrained from movement.
Tighten HITCH PIN NUT by turning nut a further 1/8th of a turn in the
clockwise direction using a 24mm spanner (Fig. 4).
STEP 4
Install HITCH PIN R CLIP through the hole on the HITCH PIN (Fig. 1).
STEP 5
Step 4
Fig 4. Tightening of Silent
Anti-Rattle Hitch Pin Nut
Notches
Locators
STEP 3