Great Wall - Wingle 5 - Workshop Manual - 2011 - 2011

Towbar Fitting Instructions To Suit GREAT WALL V240 STEP & NON STEP AND CAB CHASSIS 2009-on GREAT WALL V200 4x4 4x2 UTE 08 / 2011 On Part Number QTGW001L Rating (V240) 2250 - 225 kg Rating (V200) 2000 - 200 kg WARNING: Do not, drill, cut, weld or otherwise modify the tow bar. 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. 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 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 you check your tow ball to ensure that it complies with 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 FOR TOWING PURPOSES ONLY For towing capacity details please refer to vehicle owner’s manual or to the manufacturer. Overloading can void your warranties. Place load rating sticker inside driver’s door here Tow bar Maintenance and Care. RECOMMENDED ASSEMBLY TORQUE LISTING Diameter Grade 8.8 Bolt M6 M8 M10 M12 M14 M16 9.5 Nm 21.7 Nm 43.4 Nm 77.3Nm 146 Nm 189.8 Nm 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 recommend to remove Tow Ball Mounts (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. Page 1 of 2 Issue Date 28-11-11 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9898 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Towbar Fitting Instructions To Suit GREAT WALL V240 STEP & NON STEP AND CAB CHASSIS 2009-on GREAT WALL V200 4x4 4x2 UTE 08 / 2011 On Part Number QTGW001L Rating (V240) 2250 - 225 kg Rating (V200) 2000 - 200 kg M12 SPACER PLATE M12 BOLT WITH WIRE M12 FLAT WASHER M12 SPRING WASHER M12 NUT TOW BAR COLLAR COVER TBM M10x25 BOLT M10 NUT PULL PIN & CLIP M10x40 SET SCREW M10 LOOSE PLATE M10 FLAT WASHER M10 SPRING WASHER M10 NUT 1. Insert M12 bolt with wire in to forward vertical hole from inside chassis rail on both sides. 2. Remove cable tie from chassis rail on both side. 3. Fit towbar to chassis with M12 nut, spring washer and flat washer to M12 bolt with wire. 4. Insert M12 bolt with wire inside chassis on to horizontal hole. Secure with M12 nut, spring washer and flat washer on both sides. Note: you must insert spacer plate to horizontal hole on tow hook side. 5. Secure rear most holes using M10 bolt, loose plate from inside chassis rail to M10 nut, spring washer & flat washer. 6. Torque all fasteners, starting from horizontal holes first. Page 2 of 2 Issue Date 28-11-11 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9898 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit GWM V240 Ute & Cab Chassis GWM V200 4X2 & 4X4 Part Number 100193-WL Wiring Loom Installation Instructions GWM V240 Ute & Cab Chassis GWM V200 4X2 & 4X4 Part No: 100193-WL Ute -Tail Harness Length Required: 1800mm Cab Chassis – Tail Harness Length Required: 1200mm ECU (Optional) Part No: 04826 Power Harness (Optional) Part No: 04825 RPA Override Switch Part No: 04848 (If Fitted) Ute – Page 3 - 4 Cab Chassis – Page 3 Wiring Loom Installation Time: Approx 40 Mins Page 1 of 4 Issue Date 29-11-11 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit GWM V240 Ute & Cab Chassis GWM V200 4X2 & 4X4 Part Number 100193-WL Important Maximum trailer Electrical Load The Great Wall GWMV240 vehicle – like many other vehicles – has a limited amount of current available for powering trailer lighting circuits. If the vehicle circuits are overloaded by the trailer lighting circuits, vehicle fuses can fail and potential damage to wiring can occur. While most trailers have a small number of lamps on them, some larger trailers (especially 2 axle trailers and caravans) have a large number of lighting circuits. The optional power harness and ECU for the Great Wall GWMV240 allows any large trailer to be towed without concern about drawing too much power from the vehicle circuits. Refer to the tables below to see the maximum lighting loads with and without the ECU and power harness option. Recommended Maximum trailer Electrical Load without ECU Light Signal Name Load (Watts) total Left Turn Right Turn Tail Lamps Reverse Lamps Stop Lamps 52W 52W 96W 52W 52W Recommended Maximum trailer Electrical Load with ECU Light Signal Name Load (Watts) total Left Turn Right Turn Tail Lamps Reverse Lamps Stop Lamps 96W 96W 132W 96W 96W Current Load (Amps) total (at 12V) 4.3A 4.3A 8A 4.3A 4.3A Load (Amps) total (at 12V) 8A 8A 11 A 8A 8A UTE Page 2 of 4 Issue Date 29-11-11 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit GWM V240 Ute & Cab Chassis GWM V200 4X2 & 4X4 Part Number 100193-WL 1. Remove the RHS tail light fasteners and then remove the tail light. Repeat for the LHS side. 2. From underneath the RHS rear quarter, route the trailer patch harness (P/No: 100193WL) up the tail light cavity and connect the trailer Patch harness to the vehicle tail light connector. 3. Route the tail harness (tail length 1800mm) up through the RHS tail light cavity. 4. Apply electrical grease or silicon on to the back of the connectors to make them waterproof. 5. Connect the tail harness male 8-way connector to the trailer Patch harness female 8-way connector. 6. Connect the trailer Patch harness ECU connector to the ECU. Secure the ECU inside the RHS tail light cavity using cable ties or double sided adhesive tape (not supplied). Note: If the fitment does not require the ECU, connect the supplied ECU blanking connector into the trailer harness ECU connector. 7. From underneath the vehicle RHS, drill into the indicated point and secure the trailer Patch harness ground ring terminal using a tech screw. 8. Route the trailer Patch harness across to the LHS tail light cavity and connect the body wiring to the trailer patch harness. Proceed with step 9 only if ECU has been fitted. 9. Connect the power harness (P/No: 04825) 1-way connector to the trailer Patch harness 1-way connector. Note: If an ECU is required, continue with Steps 10, 11 and 12. Otherwise, go to Step 13. 10.Route the power harness ORANGE wire ring terminal along the LHS chassis and to the brake lines. 11.Continue to route the power harness ring terminal along the brake lines, towards the engine bay. 12.Retrieve the power harness ring terminal and secure the terminal to the engine bay battery terminal. 13.Connect the trailer Patch harness to the tail light assembly connector. 14.Refit both tail light assemblies. 15.Using M4 fasteners (not supplied) mount the tail harness socket onto the towbar mounting plate. 16.Test the trailer harness function using a light board or multi meter. Page 3 of 4 Issue Date 29-11-11 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit GWM V240 Ute & Cab Chassis GWM V200 4X2 & 4X4 Part Number 100193-WL 17. Secure the all harnesses using cables ties (not supplied). 18.Refit all removed parts and secure all fasteners ensuring there are no squeaks or rattles. 19.Please place the fitting instructions in the glove box after installation. CAB CHASSIS 1. Disconnect the RHS tail light connector. 2. Connect the RHS tail light connector to the trailer harness (P/No: 100193-WL) mating connector. 3. Connect the trailer harness connector to the RHS tail light assembly mating connector. 4. Route the trailer harness along the rear of the vehicle tray towards the LHS tail light assembly. 5. Connect the LHS tail light connector to the trailer harness mating connector. 6. Connect the trailer harness connector to the LHS tail light assembly mating connector. 7. Secure the trailer harness to the vehicle tray using cable ties (not supplied). 8. Connect the tail harness (tail length 1200mm) 8-way connector to the trailer harness mating 8-way connector. 9. Using electrical grease or silicone, water proof the back of the tail harness connector, trailer harness connector and 12-way ECU connector. 10.Route the tail harness towards the towbar. 11.Secure the trailer socket to the towbar mounting bracket using M4 fasteners (not supplied). 12.Secure the tail harness to the vehicle towbar using cable ties (not supplied). 13.Test the trailer harness function using a light board or multi meter. 14.Secure all harnesses to the vehicle using cable ties (not supplied). 15.Refit all removed parts and secure all fasteners ensuring there are no squeaks or rattles. 16.Please place the fitting instructions in the glove box after installation. Page 4 of 4 Issue Date 29-11-11 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175