Bosal Oris Towbar Instruction Manual

1. Introduction

This manual provides comprehensive instructions for the installation, operation, and maintenance of your Bosal Oris Towbar, Model BOS050133. This towbar is specifically designed for the Audi A6 Sedan, manufactured between May 2004 and February 2011. Please read this manual thoroughly before attempting any installation or use to ensure safe and correct operation.

2. Safety Information

Always prioritize safety during installation and use. Failure to follow these instructions may result in serious injury or damage to property.

• Installation should only be performed by a qualified technician or an individual with appropriate mechanical experience.
• Ensure the vehicle is securely supported on a level surface before beginning installation.
• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Do not exceed the maximum towing capacity or vertical load specified for your vehicle or the towbar. Refer to your vehicle's owner's manual for specific limits.
• Regularly inspect the towbar for signs of wear, damage, or corrosion. Do not use if damaged.
• Ensure all bolts and fasteners are tightened to the specified torque settings.
• Disconnect the vehicle's battery before performing any electrical connections.

3. Package Contents

Verify that all components are present and undamaged before proceeding with installation.

• Towbar main frame
• Detachable towball neck (RDSOV type)
• Mounting hardware (bolts, nuts, washers)
• Key for detachable towball
• Protective cap for towball housing
• Instruction manual (this document)
• Electrical kit (sold separately or included depending on package)

Figure 3.1: Main components of the Bosal Oris detachable towbar, showing the main frame and the detachable towball neck.

4. Setup and Installation

This section outlines the general steps for installing the towbar. Specific vehicle-dependent instructions may be found in supplementary documents or the vehicle's service manual.

4.1 Pre-Installation Steps

1. Park the vehicle on a level, firm surface and engage the parking brake.
2. Disconnect the negative terminal of the vehicle's battery.
3. Remove any existing bumper or trim panels as required to access the vehicle's chassis mounting points. Refer to your vehicle's service manual for precise removal instructions.
4. Clean any dirt or debris from the mounting areas.

4.2 Towbar Frame Installation

1. Position the towbar main frame against the designated mounting points on the vehicle's chassis.
2. Insert the provided bolts and washers through the towbar frame and into the vehicle's mounting holes.
3. Hand-tighten all fasteners to ensure proper alignment.
4. Using a torque wrench, tighten all bolts to the torque specifications provided in the towbar's specific fitting instructions (typically found on a separate sheet or diagram). Ensure even tightening across all fasteners.

Figure 4.1: Exploded view of the towbar frame installation, illustrating the placement of bolts and washers for secure attachment to the vehicle chassis.

4.3 Detachable Towball Assembly

1. Ensure the towball mechanism is clean and free of debris.
2. Insert the key into the lock and turn it to the unlocked position (usually indicated by a green marker).
3. Push the towball neck firmly into the receiver housing on the towbar frame until it clicks securely into place. The lock should automatically engage, and the indicator should show green.
4. Remove the key and store it safely. Always test the security of the towball by pulling on it before connecting a trailer.
5. To remove, re-insert the key, turn to the unlocked position, and pull the towball out.

4.4 Electrical Connection (If applicable)

If an electrical kit is being installed, follow the specific instructions provided with the kit. This typically involves connecting to the vehicle's wiring harness for trailer lights and other functions. Professional installation is highly recommended for electrical systems.

4.5 Post-Installation Checks

• Reconnect the vehicle's battery.
• Test all vehicle lights and trailer lights (if electrical kit installed) to ensure proper function.
• Reinstall any removed bumper or trim panels.
• Perform a final check of all fasteners to ensure they are tight.

5. Operating Instructions

5.1 Attaching a Trailer

1. Ensure the detachable towball is securely locked into the towbar housing (green indicator visible).
2. Position the trailer coupling over the towball.
3. Lower the trailer coupling onto the towball until it engages securely. Listen for a click or visual confirmation of engagement.
4. Attach the safety chain or breakaway cable to the designated attachment point on the towbar or vehicle.
5. Connect the trailer's electrical plug to the vehicle's socket.
6. Test all trailer lights (brake, turn signals, running lights) before driving.

5.2 Detaching a Trailer

1. Park the vehicle and trailer on a level surface and engage the parking brake on both.
2. Disconnect the trailer's electrical plug.
3. Remove the safety chain or breakaway cable.
4. Raise the trailer coupling off the towball.

5.3 Driving with a Trailer

• Adjust your driving style to account for the added weight and length of the trailer.
• Increase braking distances and allow more time for acceleration.
• Be mindful of increased vehicle length when turning and maneuvering.
• Check tire pressures on both the vehicle and trailer before each journey.
• Ensure the trailer load is distributed evenly and securely.

6. Maintenance

Regular maintenance ensures the longevity and safe operation of your towbar.

• Regular Inspection: Before each use, visually inspect the towbar for any signs of damage, cracks, corrosion, or loose fasteners.
• Cleaning: Keep the towbar and especially the detachable mechanism clean and free of dirt, sand, and road salt. Use mild soap and water, then dry thoroughly.
• Lubrication: Periodically apply a light grease or lubricant to the moving parts of the detachable mechanism (e.g., locking pins, ball bearings) to ensure smooth operation. Do not lubricate the towball itself, as this can reduce friction with the trailer coupling.
• Storage: When the detachable towball is not in use, remove it and store it in a clean, dry place. Use the provided protective cap for the receiver housing on the vehicle.
• Torque Check: Annually, or after significant off-road use, re-check the torque of all mounting bolts to ensure they remain tightened to specifications.

7. Troubleshooting

8. Specifications

• Model: BOS050133
• Brand: Bosal Oris
• Compatibility: Audi A6 Sedan (Type 4F), Model Years 05/2004 - 02/2011
• Towball Type: Detachable (RDSOV - Removable Diagonal System Oris Vertical)
• Maximum Towing Capacity: Refer to vehicle manufacturer's specifications. Do not exceed the lowest rating of the vehicle or towbar.
• Maximum Vertical Load (Nose Weight): Refer to vehicle manufacturer's specifications.
• Material: High-strength steel
• Finish: Corrosion-resistant coating

9. Warranty and Support

Bosal Oris products are manufactured to high quality standards and come with a manufacturer's warranty against defects in materials and workmanship. The specific terms and duration of the warranty may vary by region and product. Please retain your proof of purchase for warranty claims.

For technical support, spare parts, or warranty inquiries, please contact your authorized Bosal Oris dealer or the point of purchase. You may also visit the official Bosal website for further information and contact details.

Note: Unauthorized modifications or improper installation will void the product warranty.