Westfalia Tow Bar Installation and Operating Manual

General Information

This document provides installation and operating instructions for the Westfalia detachable tow bar, part number 346 019 600 001.

The tow bar is designed for towing trailers and carrying loads. Any other use is prohibited.

Important Safety Notes:

• National regulations regarding type approval must be observed.
• Any modifications or alterations to the tow bar are forbidden and will void the operating license.
• Remove any insulating compound or underbody protection from the vehicle in the area of the tow bar contact surfaces.
• Vehicles with parking assistance systems may experience malfunctions after installation if parts of the tow bar are within the sensor range. Adjustments to the sensing range or deactivation of the parking assistance system may be necessary.
• The tow bar is a safety-critical component and must only be installed by qualified companies. Improper installation can lead to serious accidents.
• The German text of this manual is binding.

Product Identification and Components

Tow Bar Type: 346 019

Approval Number: e 13

D-Value: 10.9 kN

Vertical Load (S): 90 kg

Coupling Class: A 50-X

Part Number: 346 019

Vehicle Compatibility: Hyundai Tucson 2004 onwards, Kia Sportage / KM 2004-2010.

Components (as depicted in diagrams):

• Diagram 1 (Page 1): Shows the complete tow bar assembly, indicating key components and specifications.
• Diagram 2 (Page 2): Illustrates the various hardware included: 6x M10x1.25x40 (8.8) bolts, 8x 10.5x25x3 bolts, 8x 10.5x20x2 bolts, and 2x M10x1.25 bolts.
• Diagrams (Pages 7-9): Illustrate the step-by-step installation process on the vehicle's rear chassis, showing the attachment of mounting brackets and the main tow bar assembly using bolts and nuts. Specific torque values are indicated for bolt tightening (e.g., M10 = 50Nm, M10 = 40Nm).
• Diagram (Page 10): Depicts required clearance specifications (angles and dimensions) and a table relating to vehicle weight.
• Diagrams (Pages 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40): Show the detachable ball bar mechanism. These diagrams detail the components of the detachable ball bar, including the receiver tube, ball bar, locking balls, release lever, handwheel, key, and various markings (red and green). They illustrate the locked position (ready for use) and the unlocked position (removed from the vehicle).

Installation Instructions

General Preparation:

• Ensure the vehicle is on a level surface.
• Refer to the vehicle's manual for any specific instructions related to bumper removal or access to mounting points.

Step-by-Step Installation (referencing diagrams on pages 7-9):

1. Vehicle Preparation: The rear of the vehicle is shown.
2. Exhaust System: The diagram shows the exhaust system in relation to the tow bar mounting points, suggesting potential modification or removal of a section of the exhaust.
3. Mounting Brackets: Diagrams illustrate attaching mounting brackets to the vehicle's chassis using bolts.
4. Main Tow Bar Assembly: The main tow bar assembly is shown being attached to the chassis using bolts and nuts.
5. Securing the Tow Bar: Further diagrams show the tow bar being secured to the vehicle frame with bolts.
6. Final Assembly: A view of the installed tow bar on the rear of the vehicle.
7. Torque Tightening: Specific torque values are indicated for tightening bolts, such as M10 = 50Nm and M10 = 40Nm, ensuring secure attachment.

Detachable Ball Bar Operation:

The detachable ball bar mechanism requires specific checks before each journey to ensure it is correctly locked:

• The green marking on the handwheel must align with the green marking on the ball bar.
• The handwheel must sit flush against the ball bar with no gap.
• The lock must be closed, and the key withdrawn. The handwheel should not be pullable.
• The ball bar must be fully inserted and securely fixed in the receiver tube; check by shaking it.

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

Mounting and Dismounting the Detachable Ball Bar:

• The ball bar can be mounted and removed using normal hand strength. Do not use tools as this may damage the mechanism.
• Never unlock the mechanism when a trailer or load carrier is attached.
• When driving without a trailer or load carrier, the ball bar must be removed, and the plug inserted into the receiver tube. This is crucial if the ball obstructs the view of the license plate or lights.
• Mounting Process: Remove the plug from the receiver. The ball bar is typically in an unlocked state when removed from the vehicle (indicated by a gap and specific markings). If the locking mechanism is engaged, it must be pre-tensioned by inserting the key, unlocking, pulling out the handwheel, and turning it to the stop. The ball bar is then inserted into the receiver and pushed up; the locking mechanism engages automatically. Keep hands away from the handwheel as it rotates during locking. Close the lock and remove the key.
• Dismounting Process: Remove the cover from the lock and place it on the key handle. Unlock the mechanism with the key. Hold the ball bar, pull out the handwheel, and turn it to release the lock. Remove the ball bar from the receiver. The handwheel will then automatically lock in the unlocked position. Store the ball bar safely and protected from dirt. Insert the plug into the receiver tube.

Maintenance and Care

• Repairs and disassembly of the detachable ball bar should only be performed by the manufacturer.
• Affix the provided information plate to a visible location on the vehicle, near the receiver or inside the boot.
• Keep the ball bar and receiver tube clean for proper function.
• Regularly maintain the mechanical parts. Treat the lock only with graphite.
• Lubricate bearing points, sliding surfaces, and balls with resin-free grease or oil for smooth operation and corrosion protection.
• When cleaning the vehicle with a high-pressure washer, remove the ball bar and insert the plug. Do not clean the ball bar with a steam cleaner.

Important: The detachable ball bar comes with 2 keys. Note the key number ???? for future orders.