Westfalia Tow Bar Installation and Operating Instructions for Ford Mondeo

Important Safety Warnings and General Information

General Regulations:

• Always observe national guidelines concerning official approval and installation checks.
• Any alteration or conversion of the tow bar is prohibited and will result in the cancellation of the type approval.
• Remove insulating compound and/or underseal from the vehicle's mating surfaces.
• The tow bar is designed for towing trailers with ball couplings and for load-bearing implements approved for attachment to the tow bar. Any other use is prohibited.

Parking Assistance Systems:

• Vehicles equipped with Parking Distance Control (PDC) or parking assistance systems may experience malfunctions after tow bar installation. This can occur if parts of the tow bar (e.g., ball bar, ball coupling) are within the sensors' detection area.
• In such cases, the detection area should be adjusted, or the parking assistance system deactivated.
• Malfunctions are not expected when using detachable or pivoted ball bars if the ball bar is removed from its operating position.

General Operation:

• The ball bar can be easily installed and removed with normal hand force.
• Never use aids or tools, as this may damage the mechanism.
• Never unlock the tow bar when a trailer or load-bearing implement is attached.
• Always remove the ball bar and insert the plug into the receiver for journeys without a trailer or load-bearing implement. This is crucial if the ball obstructs the view of the vehicle's registration plate or lights.

Maintenance:

• Keep the ball bar and receiver clean to ensure proper operation.
• Regular servicing of mechanical parts is essential. Treat the lock only with graphite.
• Lubricate bearing points, friction surfaces, and balls regularly with resin-free grease or oil for corrosion protection.
• When cleaning the vehicle with a steam jet cleaner, remove the ball bar and insert the plug. Do not clean the ball bar with a steam cleaner.

Important Notes:

• The detachable ball bar comes with 2 keys. Note and keep the key number (????) for future orders.

Technical Specifications and Approval

Approval Number: e13*94/20*00*2155

Type: 307 311

Coupling Class: A 50-X

D-Value: 11.6 kN

Vertical Load (S): 80/90 kg (from 01/08)

Towing Capacity: Refer to vehicle's registration document.

Clearance Requirements: Adherence to Directive 94/20/EC, Appendix VII, Diagram 30 is mandatory.

Vehicle Weight Ratings:

• * At permissible gross vehicle weight.

Declaration of Correct Installation: The undersigned company declares that the tow bar has been installed correctly according to manufacturer's specifications.

Parts List and Diagram Description

The detachable ball bar system includes the following main components:

• 1. Receiver/Mounting Tube: The part that attaches to the vehicle chassis.
• 2. Ball Bar: The removable part that holds the tow ball.
• 3. Locking Balls: Mechanisms that secure the ball bar in the receiver.
• 4. Release Lever: Used to disengage the locking mechanism.
• 5. Handwheel: Operates the locking mechanism.
• 6. Cover/Cap: Protects the lock mechanism.
• 7. Key: Used to operate the lock.
• 8. Red Marking (Handwheel): Indicator on the handwheel.
• 9. Green Marking (Handwheel): Indicator on the handwheel.
• 10. Green Marking (Ball Bar): Indicator on the ball bar.
• 11. Symbol (Release): Indicates the release function.
• 12. Plug/Stopper: Used to cover the receiver when the ball bar is removed.
• 13. Stop Pin/Insertion Bolt: Part of the ball bar assembly.
• 14. No Gap: Indicates correct locking (between parts 2 and 5).
• 15. Gap of approx. 5 mm: Indicates unlocked state (between parts 2 and 5).

Diagram shows the detachable ball bar assembly with numbered parts.

Installation Procedure

Note: The following steps are a summary based on the diagrams and text. Refer to the original document for full details and safety precautions.

1. Preparation: Remove the plug from the receiver. Ensure the ball bar is in the unlocked state (visible gap, red marking on handwheel aligned with green marking on ball bar). If the locking mechanism is engaged, pre-tension it by inserting the key, opening the lock, pulling out and turning the handwheel (arrow 'a' then 'b'). Release lever engages, mechanism stays tensioned.
2. Mounting the Ball Bar: Insert the ball bar (2) with its insertion bolt into the receiver (1) from below and push upwards. The locking mechanism will engage automatically. Keep hands away from the handwheel as it rotates during locking.
3. Securing: Close the lock and always remove the key. Press the cover onto the lock.

Removal of the Ball Bar:

1. Remove the cover from the lock and place it on the key handle. Open the lock with the key.
2. Hold the ball bar firmly. Extract the handwheel in the direction of arrow 'a' and turn it to the stop in direction 'b' to unlock it in the extracted position.
3. Remove the ball bar from the receiver. The handwheel will then release and automatically engage in the unlocked position.
4. Store the ball bar safely in the vehicle's boot, protected from dirt.
5. Insert the plug into the receiver.

Vehicle Modifications (Bumper):

Diagrams show specific modifications required for the Ford Mondeo bumper, including cutting or removing sections, depending on the vehicle's production date (e.g., 07/2010, 08/2010). These steps involve removing the bumper, potentially cutting specific areas for clearance, and then refitting the bumper.

Main Tow Bar Assembly Installation:

The main tow bar structure is mounted to the vehicle's chassis using bolts (e.g., M8x25, M10x45). Specific torque settings are provided (e.g., 30 Nm for M8x25, 62±3 Nm for M10x45). The exhaust system and other components may need to be temporarily removed or adjusted.

Operation Checks Before Driving

Before each journey, verify the following:

• Green Markings: The green marking on the handwheel must align with the green marking on the ball bar.
• Handwheel Position: The handwheel must rest snugly against the ball bar with no gap.
• Lock Status: The lock must be closed, and the key withdrawn. The handwheel should not be pullable.
• Ball Bar Security: The ball bar must be fully inserted and securely fitted into the receiver. Check by shaking it gently.

If any of these checks fail, do not use the tow bar and contact the manufacturer.

Maintenance and Care

Regular cleaning and maintenance are essential for proper function. Ensure the ball bar and receiver are always clean. Lubricate moving parts and the lock mechanism as described. Avoid using high-pressure water jets for cleaning.

Technical Diagrams

The document includes diagrams illustrating:

• Clearance requirements according to European Directive 94/20/EC.
• Vehicle weight ratings and specifications.
• Detailed views of the detachable ball bar mechanism in locked and unlocked states.
• Installation steps showing component placement and tightening torques.
• Bumper modification guidelines based on vehicle production dates.