Trailboss QTHY263L User manual

Towbar Fitting Instructions
To Suit HYUNDAI SANTA FE –DM SERIES
Part Number QTHY263L
Rating 2500/150 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Rev: A Page 1 Issue Date: 21-01-2016
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected]m.au
Post: PO Box 4050, Dandenong South VIC 3175
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
12. Pull Pin must be fit in down position.
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

Towbar Fitting Instructions
To Suit HYUNDAI SANTA FE –DM SERIES
Part Number QTHY263L
Rating 2500/150 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Rev: A Page 2 Issue Date: 21-01-2016
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected]m.au
Post: PO Box 4050, Dandenong South VIC 3175
QTY.
DESCRIPTION
ITEM NO.
1
TOWBAR WELDED ASSY
1
1
CLASS 4 TBM ASSY
2
1
BUMPER ADAPTER PASSENGER SIDE
3
1
BUMER ADAPTER DRIVERS SIDE
4
4
WASHER FT M10x25.4x3
5
4
BOLT HEX HD M12x120x1.25P G10.9
6
4
HEX NUT M12x1.25 PC8
7
8
WASHER FLAT 1/2"x1 1/8”x1/8”
8
4
SET SCREW HEX HD M10x35x1.25P
9
12
WASHER FLAT M6x12.5x1.2
10
6
SET SCREW HEX HD M5x20x0.8P
11
6
NUT NYLOC M5-0.8 Z/P
12
1
BUMPER TRIM PINCH WELD 350mm
13
1
ACRYLIC COMPLIANCE LABEL
14
1
WIRING LOOM
15
1
HITCH BOX COLLAR COVER
16
1
SILENT HITCH PIN-SILVER
17
2
10mm “D” SHACKLE
18
1
50mm TOWBALL
19

Towbar Fitting Instructions
To Suit HYUNDAI SANTA FE –DM SERIES
Part Number QTHY263L
Rating 2500/150 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Rev: A Page 3 Issue Date: 21-01-2016
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected]m.au
Post: PO Box 4050, Dandenong South VIC 3175
INSTRUCTION:
1. Open boot and remove 2x Screws from the LHS Tail Light. Repeat for RHS.
2. Remove LHS Tail Light and disconnect the Connector. Repeat for RHS.
3. Remove 1x Scrivet from inside the LHS Tail Light Cavity. Repeat for RHS.
4. Remove 4x Screws from inside the LHS Wheel Arch. Repeat for RHS.
5. Remove 4x Screws from underneath of Bumper on the LHS. Repeat for the RHS.
6. Remove 3x Bolts from underneath vehicle on LHS Back Panel. Repeat for RHS.
7. Disconnect the Wiring Connector near the LHS Chassis Rail at the Rear of the vehicle. If fitted, remove reverse
Sensor and Rear view Camera Connectors.
Carefully remove Bumper and place in a safe area.
8. Remove Rubber Grommet from underneath of both Chassis Rails. Offer towbar to vehicle. The Towbar will sit on the
outer face of the LHS Chassis Rail, and the inner face of the RHS Chassis Rail. Loosely secure the Towbar using the
fastener sequence as seen below.
Tighten to the following torque specifications:
M12 x 120 x 1.25P GR10.9 = 125Nm
M10 x 35 x 1.25P = 49Nm
9. Remove Impact Beam from Bumper by dislodging 5x Scrivets and Wiring Plugs. Retain 2x Scrivets.
10. Attach Bumper Tab Brackets onto Towbar by using 2x M5 Bolts, 4x M5 Washers, and 2x M5 Nyloc Nuts per side.
11. Identify the centreline of the bumper; perform a bumper cut by measuring the outside of the bumper as per the image
shown. Use bumper trim supplied.
12. Re-attach Bumper using steps in 1-7 reverse order. Use two retained Scrivets to attach Bumper to Towbar.
Bottom Edge of Bumper

Wiring Loom Fitting Instructions
To Suit Hyundai Santa Fe DM / DM2 / DM3
Part Number 100863-WL
Page 1 of 6 Issue Date 21-12-15
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected]
Post: PO Box 4050, Dandenong South VIC 3175
Wiring Loom Installation Instructions
Hyundai Santa Fe DM / DM2 / DM3
Part No: 100863-WL
Tail Harness Length Required: 1200mm (DM / DM2),
1800mm (DM3)
Wiring Loom Installation Time: Approx 45 Mins

Wiring Loom Fitting Instructions
To Suit Hyundai Santa Fe DM / DM2 / DM3
Part Number 100863-WL
Page 2 of 6 Issue Date 21-12-15
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected]
Post: PO Box 4050, Dandenong South VIC 3175
1. In the luggage compartment, remove the sun shade and the tool compartment cover.
2. Remove the luggage compartment foam tool tray.
3. Remove the plastic tool tray by removing the three screws.
4. Remove the four bolts on the third row passenger seats and the four bolts in front of the
third row of the passenger seats.
5. Remove the third row passenger seats from the vehicle.
6. On the LHS of the luggage compartment trim, remove the two screws and one seat belt
bolt.
7. Dislodge the LHS luggage compartment trim.
Repeat steps 6 & 7 for the RHS.
Note: On the RHS luggage compartment, 12v power and light connector may need
to be disconnected before dislodging.
8. Dislodge the RHS second row passenger seats to gain access to the RHS side panel
trim.
9. Remove the RHS rear door sill trim.
10.On the driver’s side, remove the door sill trim.
11.Dislodge the RHS ‘B’ pillar trim.
12.Underneath the driver’s side dash, remove the RHS kick panel trim by first remove the
screw on the bonnet lever.
13.On the outside of the vehicle, remove the RHS tail light by first removing the two screws.

Wiring Loom Fitting Instructions
To Suit Hyundai Santa Fe DM / DM2 / DM3
Part Number 100863-WL
Page 3 of 6 Issue Date 21-12-15
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected]
Post: PO Box 4050, Dandenong South VIC 3175
14.For Santa Fe DM1 and DM2 models only:
On the RHS rear quarter of the vehicle, drill a Ø30mm hole (1). File any rough or sharp
edges and spray with rust inhibitor.
15.For Santa Fe DM3 models:
Locate the existing vehicle grommet hole and remove the grommet (1). Drill out the
grommet hole to Ø30mm. File any rough or sharp edges and spray with rust inhibitor.
1
16.File any rough or sharp edges and spray with rust inhibitor.

Wiring Loom Fitting Instructions
To Suit Hyundai Santa Fe DM / DM2 / DM3
Part Number 100863-WL
Page 4 of 6 Issue Date 21-12-15
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected]
Post: PO Box 4050, Dandenong South VIC 3175
17.On the LHS of the luggage compartment, connect the ezy-tap (1) to the corresponding
vehicle wires (2), then connect the trailer patch terminal (3) to the ezy-tap (1).
YELLOW YELLOW / BLACK
Trailer Patch Vehicle Connector
L.IND
Function
BLACK REDREVERSE
Santa Fe DM / DM2 models:
YELLOW GREY
Trailer Patch Vehicle Connector
L.IND
Function
Santa Fe DM3 models:
18.Route the trailer harness towards the RHS of the vehicle tail light.
19.On the RHS of the vehicle, from the outside feed the existing vehicle grommet and tail
light connector through the grommet hole and into the vehicle.
20.Inside the luggage compartment, feed the trailer harness connector through the
grommet hole and connect to the tail light assembly connector.
21.Connect the 2nd trailer harness connector to the mating vehicle connector.

Wiring Loom Fitting Instructions
To Suit Hyundai Santa Fe DM / DM2 / DM3
Part Number 100863-WL
Page 5 of 6 Issue Date 21-12-15
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected]
Post: PO Box 4050, Dandenong South VIC 3175
22.Using a tek screw, secure the ground ring terminal (1) to the sheet metal as shown.
DM / DM2 models:
DM3 models:
23.Route the ‘ORANGE’ power wire towards the front of the vehicle along the RHS existing
vehicle harness.
24.Continue routing the ‘ORANGE’ power wire, past the ‘B’ pillar trim and the driver’s side
door sill towards the front of the vehicle.
25.Continue routing the ‘ORANGE’ power wire up through the kick panel area towards the
fuse panel.
26.Inside the fuse panel, locate the 20-amp (1) fuse as shown and discard.
27.Insert the supplied 20-amp fuse (2) into the lower slot of the add-a-fuse (3) and insert
the supplied 30-amp fuse (3) into the upper slot of the add-a-fuse (4).
28.Plug the add-a-fuse (4) into the previously removed 20-amp fuse slot.

Wiring Loom Fitting Instructions
To Suit Hyundai Santa Fe DM / DM2 / DM3
Part Number 100863-WL
Page 6 of 6 Issue Date 21-12-15
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected]
Post: PO Box 4050, Dandenong South VIC 3175
29.Connect the power patch 1-way connector (5) into the add-a-fuse harness mating
connector (6).
30.Mount the tail harness (DM / DM2: 1200mm, DM3: 1800mm) trailer socket to the tow
bar mounting bracket using M4 fasteners (not supplied).
31.Route the tail harness across the tow bar towards the LHS of the vehicle and up through
the previously drilled out hole.
32.Ensure the tail harness grommet is seated correctly and secure in place using a cable
tie (not supplied).
33.Connect the tail harness (tail length 1200mm) 8-way connector to the trailer patch
mating 8-way connector.
34.Test the trailer patch function using a light board or multi meter.
35.Secure all harnesses using cable ties (not supplied).
36.Re-fit all removed parts and secure all fasteners, ensuring there are no squeaks or
rattles.
37.Place the fitting instructions in the glove box after fitment.
38. The RPA function can be disabled via the switch on the dash panel.

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