Westfalia Tow Bar Installation and Operating Instructions

General Information and Safety

This document provides installation and operating instructions for the Westfalia tow bar system. It is crucial to adhere to all national guidelines and regulations concerning the installation and approval of towing hitches.

Important Safety Notes:

• Any alterations or modifications to the tow bar system are strictly prohibited and will void the operating license.
• The tow bar is a safety-critical component and must only be fitted by qualified companies or technicians. Improper assembly can lead to serious accident hazards.
• The German text of these instructions is binding.
• Ensure the area around the contact surface of the trailer hitch is free of insulating compound and underbody coating.

ECE-R 55 Regulations:

Clearance must be provided according to Appendix 7, Figures 25a and 25b of the ECE-R 55 directive. This includes ensuring adequate vertical and horizontal clearance around the tow ball and hitch mechanism.

Vehicle Weight Considerations:

• When towing, consider the vehicle's gross vehicle weight rating (GVWR).
• Maximum towing capacity for bicycles: max. 60kg (two bicycles), max. 30kg (one bicycle).
• Ensure the towing vehicle's permissible total weight is not exceeded.

Installation Steps

The installation process involves several steps, including:

1. Preparation: Accessing the rear of the vehicle, potentially removing bumper components.
2. Mounting the Tow Bar Frame: Securing the main tow bar structure to the vehicle's chassis using provided hardware (bolts, nuts, washers). Specific bolt types and quantities are indicated in the diagrams (e.g., M14x2x90, M14x2x40, 15x28x2.5, 14.5x24x1).
3. Attaching the Tow Ball and Hitch Mechanism: Assembling the detachable tow ball and its locking mechanism.
4. Electrical Connection: Connecting the trailer's electrical system to the vehicle's socket.
5. Final Checks: Ensuring all components are securely fastened and the system is correctly engaged.

Detailed Visual Descriptions of Installation Steps:

Step 1: Vehicle Preparation

The rear of the Range Rover Velar is shown with the tailgate open. Arrows indicate access to the rear bumper area. A diagram shows the removal of bumper components, labeled "b".

Step 2: Bumper Removal

The rear of the vehicle is shown with bumper components removed, revealing the chassis. Labels "c" and "d" indicate specific points or areas.

Step 3: Chassis Preparation

The underside of the vehicle's rear chassis is depicted. Arrows show the placement of mounting brackets, labeled "a" and "d". Four "a" bolts and four "d" bolts are indicated for each side.

Step 4: Mounting Brackets

The mounting brackets are shown being attached to the chassis. Four "a" bolts are used for each bracket. Warning symbols indicate the importance of correct placement.

Step 5: Tow Bar Main Beam Installation

The main tow bar beam (labeled "1") is shown being positioned between the chassis mounting points. Hardware includes four 15x28x2.5 washers, four 14.5x24x1 washers, and four M14x2x90 bolts for each side.

Step 6: Securing the Tow Bar Beam

The tow bar beam is shown being secured. Two M14 bolts and two M14x2x40 bolts are used on each side. Arrows indicate the direction of tightening. Warning symbols highlight the use of M14x2x40 bolts.

Step 7: Attaching Hitch Arms

The tow bar hitch arms (labeled "2" and "3") are shown being attached to the main beam. M14x2x90 bolts with a torque of 150 Nm are specified.

Step 8: Final Tightening of Tow Bar

The complete tow bar assembly is shown mounted to the vehicle. M14x2x40 bolts are used with a torque of 150 Nm. Arrows indicate the tightening points.

Step 9: Final Assembly Check

The rear of the vehicle with the tow bar fully installed is shown. Label "b" indicates the tow ball assembly.

Step 10: Tow Ball Dimensions

Diagrams show the tow ball and its dimensions, including a height of 110mm and a width of 175mm. A label "b" refers to the tow ball.

Step 11: Tow Ball Mechanism Assembly

The tow ball mechanism components are shown disassembled and then assembled. Hardware includes 2x M12 bolts and 2x 13x24x2.5 washers. The M12x1.75x100 bolt is tightened to 120 Nm.

Step 12: Tow Ball Engagement

The rear of the vehicle is shown with the tow bar attached. Arrows indicate the insertion of the tow ball assembly.

Step 13: Tow Bar Operation and Safety

Diagrams illustrate the correct and incorrect methods for attaching and detaching the tow ball. A green checkmark indicates correct operation, while a red cross indicates incorrect operation. Specific actions like inserting the ball and locking it are shown.

Step 14: Tow Ball Locking Mechanism

Detailed views of the tow ball locking mechanism are provided. Step 1.1 shows a correct insertion with approximately 5mm clearance. Step 1.2 shows an incorrect insertion with 0mm clearance, leading to an error (red cross). Step 1.3 shows the correct locking procedure.

Step 15: Tow Ball Engagement and Locking

Step 2.1 demonstrates the correct engagement of the tow ball with a green checkmark, while an incorrect engagement is shown with a red cross. Step 2.2 shows the final locking mechanism being engaged.

Step 16: Tow Ball Detachment and Locking

Step 3.1 illustrates the correct procedure for engaging and locking the tow ball, with green checkmarks indicating success. The right side shows incorrect procedures with red crosses, including a "click" sound indicating proper locking.

Step 17: Tow Ball Removal and Storage

Step 4.1 shows the process of removing the tow ball and its components. Step 4.2 illustrates the correct way to handle and store the tow ball.

Step 18: Tow Ball Storage

Step 5.1 shows the tow ball being placed into its storage bag and then stored in the vehicle's trunk.

Maintenance and Usage

Regular checks of the tow bar system are recommended to ensure continued safety and functionality. Refer to the vehicle's manual for specific towing guidelines and weight limits.

Maintenance:

• Keep the tow ball and hitch mechanism clean and free from debris.
• Periodically check all bolts and connections for tightness.
• Lubricate moving parts as recommended.

Usage:

• Always ensure the tow ball is correctly and securely locked before towing.
• Observe the maximum towing capacities specified for the vehicle and the tow bar system.
• When not in use, the tow ball should be removed and stored safely.

Declaration of Correct Installation

A declaration section is provided for the installer to confirm that the tow bar system has been installed correctly according to the manufacturer's instructions and vehicle specifications. This includes details such as the tow bar type, vehicle registration, and installer's stamp and signature.