Introduction
This document provides comprehensive installation and operating instructions for the Westfalia detachable tow bar, specifically designed for the Kia Sportage (2010 model year). It details safety warnings, technical specifications, a parts list, and step-by-step guidance for mounting and using the detachable ball mechanism, ensuring correct and safe operation of the towing equipment.
Technical Specifications
- Type Approval: e4*94/20*4297*00
- Class: A50-X
- D-Value: 10.65 kN
- Max. Vertical Load (S): 80 kg
- Max. Towing Capacity: Refer to vehicle registration document
- Part Number: 44.4251-345079600001
Parts List
- FBA 6177
- FFJ 10101H
- FFJ 10101V
- 317034601009
- 313115630101
- 313183630121
- M12x40 (8.8)
- M10x1.25x35 (8.8)
- M12 lock nut (8)
- 13x24x2
- 10.5x22x2
- 10.2
Safety and Legal Warnings
General: National guidelines regarding installation approval must be observed. Any modification or conversion of the tow bar is prohibited and will void the type approval. The tow bar is a safety-critical component and must only be installed by qualified technicians. Incorrect installation can lead to serious accidents. ⚠️
Intended Use: The tow bar is designed for towing trailers and for use with load carriers. Any other use is prohibited.
Vehicle Compatibility: When installed on vehicles with parking assistance systems, malfunctions may occur if the tow ball or coupling is within the sensor range. Adjust the sensing range or disable the parking assistance system if necessary. For detachable or pivoting tow balls, malfunctions are less likely when the ball is removed from its operating position.
Installation: Remove any insulating compound or underbody protection from the vehicle's contact surfaces for the tow bar.
Maintenance: Regular maintenance of the mechanical parts is essential. Treat the lock only with graphite. Lubricate bearing points, sliding surfaces, and balls regularly with resin-free grease or oil. This also provides additional corrosion protection. Clean the ball bar and receiver regularly. Do not clean the ball bar with a steam jet cleaner.
Key Information: The detachable ball bar comes with two keys. Note the key number for future orders. ?
Installation Instructions
The installation involves attaching the main tow bar structure to the vehicle's chassis. Specific mounting points and hardware (bolts, nuts) are detailed in the diagrams. Key steps include:
- Securing the main frame to the vehicle's designated mounting points using the provided hardware.
- Attaching any specific brackets or components as shown in the diagrams.
- Ensuring all connections are tightened to the specified torque values (e.g., M10 bolts to 48 Nm, M12 bolts to 83 Nm).
Clearance Requirements: Ensure clearance according to directive 94/20/EG (Appendix VII, Fig. 30) is maintained. This includes specific minimum and maximum angles and distances for various vehicle components relative to the tow bar.
Operating Instructions for Detachable Ball Bar
Before Each Journey: Check the correct locking of the detachable ball bar. ✔️
- Verify that the green marking on the handwheel aligns with the green marking on the ball bar.
- Ensure the handwheel is flush against the ball bar with no gap.
- Confirm the lock is closed and the key is withdrawn.
- Check that the ball bar is securely inserted into the receiver by shaking it.
Mounting the Ball Bar:
- Remove the plug from the receiver.
- The ball bar is typically in an unlocked state when removed from storage. If it is in a locked state, pre-tension the mechanism by inserting the key, unlocking, pulling out the handwheel, and turning it to the stop.
- Insert the ball bar into the receiver from below and push upwards until it locks automatically. Keep hands away from the handwheel as it rotates during locking. ?
- Close the lock and remove the key. Attach the protective cap to the lock.
Dismounting the Ball Bar:
- Remove the protective cap from the lock and place it on the key handle.
- Open the lock with the key. ?
- Hold the ball bar, pull out the handwheel, and turn it to the stop to unlock.
- Remove the ball bar from the receiver. The handwheel will automatically return to the unlocked position.
- Store the ball bar safely and protected from dirt.
- Insert the plug into the receiver.
Important Notes:
- Repairs or dismantling of the detachable ball bar must only be performed by the manufacturer.
- Attach the provided information plate visibly on the vehicle.
- The ball bar and receiver must always be clean for proper function.
- Never unlock the mechanism when a trailer or load carrier is attached.
- When not in use, the ball bar must be removed and the plug inserted into the receiver, especially if the ball obstructs the license plate or lights.
