Trailboss QTHY264L User manual

Towbar Fitting Instructions
To Suit HYUNDAI TUCSON TL & TLe SERIES
Part Number QTHY264L
Rating 1600/140kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
:etaDeussI1egaPA:veR 21-04-2016
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
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 destroyany 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
RECOMMENDED ASSEMBLY TORQUE LISTING
Diameter
mN5.96M
mN7.128M
mN4.3401M
mN3.7721M
mN64141M
mN8.98161M

Towbar Fitting Instructions
To Suit HYUNDAI TUCSON TL & TLe SERIES
Part Number QTHY264L
Rating 1600/140 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Rev: A Page 2 Issue Date: 21-04-2016
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
Post: PO Box 4050, Dandenong South VIC 3175
QTY. DESCRIPTION ITEM NO.
1 WELDE D CENTRE ASSEMBLY 1
1 LHS SIDEARM ASSY 2
1 RHS SIDEARM ASSY 3
1 TR AILER BALL MOUNT 21148 4
2 BUM PER TAB BRACKET 5
2 SMART KEY ANTENNA BRACKET 6
1 PLUG BRACKET 7
8 SET SCREW M10-1.25x30 GR 8.8 Z/P 8
8 WASHER FT M10x25.4x3 9
8 SET SCREW M12x45x1.25P G10.9 10
12 WASHER FLAT M12 11
4 HEX NUT M12x1.25 PC8 12
4 TEK SCREW 14-20 HEX HD 22mm 13
2 SET SCREW HEX HD M5x20x0.8P 14
4 WASHER FLAT M6x12.5x1.2 15
2 NUT HYLOC M5-0.8 Z/P 16
2 NUT NYLOC M4-0.7 Z/P 17
1 SILENT HITCH PIN-SILVER 18
1 50 mm TOWBALL 19
2 10mm “D” SHACKLE 20
1 HITCH BOX COLLAR COVER 21
2 ACR YLIC COMPLIANCE LABEL 22
1 WIRING LOOM 23
1
2
22
4
21
20
3
23
717
89
89
14 15 15 16
10 11 11 12
5
6
13
18
19

Towbar Fitting Instructions
To Suit HYUNDAI TUCSON TL & TLe SERIES
Part Number QTHY264L
Rating 1600/140 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Rev: A Page 3 Issue Date: 21-04-2016
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
Post: PO Box 4050, Dandenong South VIC 3175
INSTRUCTION:
1. Remove plastic trim cover adjacent to tail light assembly.
Repeat for opposite side of vehicle.
2. Remove 2x Screws securing taillights to vehicle. Remove tail light assembly.
Repeat for opposite side of vehicle.
3. Remove 2x push rivets from taillight cavity.
Repeat for opposite side of vehicle.
4. Remove 4x Screws within rear wheel arch.
Repeat for opposite side of vehicle.
5. Remove 2x Screws adjacent to chassis rail, securing rear impact beam to rear the panel.
Repeat for opposite side of vehicle.
6. Remove 3x push rivets under vehicle behind rear wheel arch and 1x push rivet from within rear wheel arch.
Repeat for opposite side of vehicle.
7. Remove plastic undertray from behind rear wheel arch.
Repeat for opposite side of vehicle.
8. Carefully unclip and remove rear bumper; disconnecting any applicable wiring looms.
9. Remove 3x push rivets securing impact beam bumper tabs to bumper.
10. Remove 2x clips securing top of impact beam to bumper.
11. Where applicable, release smart key antenna from impact beam.
12. Detach wiring from impact beam and remove and discard impact beam from rear bumper.
13. Loosely secure sidearm to side face of chassis rail using 2x M10 Screws, complete with 1x Flat washer per Screw.
Repeat for opposite side of vehicle.
14. Loosely secure sidearm to underside of chassis rail using 2x M10 Screws, complete with 1x Flat washer per Screw.
Repeat for opposite side of vehicle.
15. Loosely secure welded assembly to sidearms using 4x M12 Screws per side arm, complete with 2x Flat washer and
1x M12 Nut per 2 of the Screws, and 1x Flat washer per the remaining 2 Screws.

Towbar Fitting Instructions
To Suit HYUNDAI TUCSON TL & TLe SERIES
Part Number QTHY264L
Rating 1600/140 kg
PLACE THESE INSTRUCTIONS IN THE VEHICLE’S GLOVEBOX AFTER INSTALLATION IS COMPLETED
Rev: A Page 4 Issue Date: 21-04-2016
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [e-mail]
Post: PO Box 4050, Dandenong South VIC 3175
16. Tighten all screws to torque listed on page 1 of this document.
17. Where required, secure smart key antenna brackets to holes in top of towbar using Tek screws.
18. Secure bumper tab brackets in holes on rear face of towbar using Tek screws.
19. Identify centre of bumper and create bumper cut as per diagram below.
20. 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.
21. Refit rear bumper by following steps 1 to 4 and 6 to 8 in reverse order.
22. Where applicable, secure smart key antenna to smart key antenna brackets.
23. Secure loose wiring to towbar using cable ties.
DRWING NOT TO SCALE

Wiring Loom Fitting Instructions
To Suit Hyundai Tucson TL
Part Number 201365-WL
Page 3 of 3 Issue Date 10-09-15
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected].au
Post
: PO Box 4050, Dandenong South VIC 3175
Wiring Loom Installation Instructions
Hyundai Tucson TL
Part No: 201365-WL
Tail Harness Length Required: 1200mm
RPA Over ride Switch Part No: 04848 (if fitted)
Wiring Loom Installation Time: Approx 50 Mins

Wiring Loom Fitting Instructions
To Suit Hyundai Tucson TL
Part Number 201365-WL
Page 3 of 3 Issue Date 10-09-15
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected].au
Post
: PO Box 4050, Dandenong South VIC 3175
1. Fold down the rear passenger seats.
2. Remove the luggage compartment floor, tools jack and jack bracket.
3. Remove the rear trim and remove the two fasteners.
4. Remove the four fasteners from each side of the luggage compartment trims and then
dislodge the luggage compartment trims.
5. Remove rear passenger RHS kick trim.
6. Remove the driver’s door sill trim.
7. Remove the bonnet handle and then remove the driver’s kick panel trim.
8. On the RHS of the luggage compartment, locate the RHS rear quarter existing
grommet hole (1) and drill out to Ø30mm. Apply rust inhibitor after drilling (not
supplied). If the grommet hole is occupied, pick a nearby location on the vehicle sheet
metal to drill through.
9. From the vehicle interior, retrieve the vehicle RHS tail light connector.
10. Route the trailer patch (P/No:201365-WL) connectors to the retrieved RHS tail light
connector and connect to the mating trailer patch connector.
11. Route the remaining trailer patch connector through the vehicle grommet hole until the
trailer patch grommet is seated correctly.
12. Route the trailer patch LHS branch towards the LHS vehicle tail light area and then
connect the trailer patch connector to the mating vehicle harness tail light connector.
13. Pierce a small hole into the vehicle grommet and route the trailer patch reverse terminal
into the vehicle.

Wiring Loom Fitting Instructions
To Suit Hyundai Tucson TL
Part Number 201365-WL
Page 3 of 3 Issue Date 10-09-15
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected].au
Post
: PO Box 4050, Dandenong South VIC 3175
14. Following the table below, connect the ezy-tap to the corresponding vehicle wire, then
connect the trailer patch terminal to the ezy-tap.
BLACK / WHITE RED
Trailer Patch Vehicle Connector
REVERSE
Function
15. At the rear exterior of the vehicle, mount the tail harness socket to the towbar mounting
bracket using M4 fasteners (not supplied).
16. Route the tail harness (tail length: 1200mm) across the RHS and up into the drilled out
hole. Adjust the trailer patch harness grommet so that it is seated correctly and cable tie
(not supplied) in place.
17. Connect the tail harness 8-way connector to the Trailer Patch 8-way mating connector.
18. At the RHS rear quarter interior, secure the trailer patch ground ring terminal (1) to the
vehicle stud (2) (nut not supplied).
19. Route the trailer patch 1-way connector (3) along the vehicle harness, all the way
towards the driver’s fuse panel area.

Wiring Loom Fitting Instructions
To Suit Hyundai Tucson TL
Part Number 201365-WL
Page 3 of 3 Issue Date 10-09-15
Cequent Customer Service
Ph: 1800 812 017 Fax: [phone]
Email: [email protected].au
Post
: PO Box 4050, Dandenong South VIC 3175
20. Remove the indicated vehicle 30A fuse (1). Insert the vehicle fuse 30A fuse (1) and the
supplied 20A fuse (2) to the add-a-fuse harness (3). Connect the trailer patch 1-way
connector (4) to the add-a-fuse harness (3). Insert the add-a-fuse harness (5) to the
previously removed fuse location (6). Ensure the add-a-fuse harness is orientated
as shown.
21. For RPA over ride function, locate the 13-way connector (1) at the LHS lower rear
exterior of the vehicle.
22. Locate the ORANGE wire (2) on the connector and cut the ORANGE wire.
23. Patch RPA Over ride (P/No: 04848) in between the cut ORANGE wire.
24. Seal and waterproof the connection appropriately after patching.
25. Refit the tail lights.
26. Test the Trailer Harness function using a light board or multi-meter.
27. Secure all harnesses using cable ties (not supplied).
28. Re-fit removed parts and secure all fasteners, ensuring there are no squeaks or
rattles.
29. Place the instructions in the glove box after fitment.

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