Westfalia Detachable Tow Bar Installation and Operating Manual

Introduction and General Information

This manual provides instructions for the installation and operation of the Westfalia detachable tow bar system. The manual is available in multiple languages, including German (DE), Czech (CS), Danish (DK), Spanish (ES), French (FR), Finnish (FI), English (EN), Greek (EL), Hungarian (HU), Italian (IT), Norwegian (NO), Dutch (NL), Polish (PL), Russian (RU), and Swedish (SV).

Manufacturer: WESTFALIA-Automotive GmbH, Am Sandberg 45, D-33378 Rheda-Wiedenbrück.

Product Details:
Part Number: 306 400 600 001
Type: 306 398
Approval Number: E13 55R-01 3497
Class: A 50-X
D-VALUE: 7.5 kN
MAX. VERT. LOAD: 90 kg

Safety Precautions

Before each journey, ensure the detachable ball bar is correctly locked. Verify the following:

• The green marking on the handwheel aligns with the green marking on the ball bar.
• The handwheel is flush against the ball bar (no gap).
• The lock is closed and the key is withdrawn. The handwheel cannot be pulled out.
• The ball bar is fully and securely inserted into the receiver tube. Check by shaking it.

If any of these checks are unsatisfactory, repeat the installation. If any condition remains unmet, do not use the tow bar due to the risk of accidents. Contact the manufacturer.

Important Safety Notes:

• Use only normal hand strength for mounting and dismounting; do not use tools or aids, as this may damage the mechanism.
• Never unlock the system when a trailer or load carrier is attached.
• When driving without a trailer or load carrier, always remove the ball bar and insert the plug into the receiver tube. This is crucial if the ball obstructs the view of the license plate or lights.
• 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 proper function and corrosion protection.
• Remove the ball bar and insert the plug before cleaning the vehicle with a steam cleaner. Do not clean the ball bar with a steam jet.

Parts List

The detachable ball bar system includes the following components:

1. Receiver tube
2. Ball bar
3. Locking balls
4. Release ball
5. Release lever
6. Handwheel
7. Cover
8. Key
9. Red marking (handwheel)
10. Green marking (handwheel)
11. Green marking (ball bar)
12. Symbol (release activation)
13. Plug
14. Stop pin
15. No gap between 2 and 5
16. Gap of approx. 5 mm

Installation Instructions

General Installation Steps:

1. Remove the plug from the receiver tube.
2. Ensure the ball bar is in the unlocked position. This is indicated by the green marking on the handwheel aligning with the green marking on the ball bar, and a visible gap of approximately 5 mm between the handwheel and the ball bar.
3. Insert the ball bar from below into the receiver tube, ensuring the stop pin aligns correctly, and push it upwards until it locks automatically.
4. Keep hands clear of the handwheel as it rotates during the locking process.
5. Close the lock and always remove the key. The key cannot be removed if the lock is open. Press the cover onto the lock.

Vehicle-Specific Notes: The diagrams illustrate specific mounting points for the FIAT 500L, FIAT 500L Living, and FIAT 500L Trekking models. Ensure correct alignment and use of specified hardware (e.g., M10x35 bolts, M8 bolts) with correct torque settings (e.g., 40 Nm, 25 Nm) as indicated in the diagrams.

Operation: Mounting and Dismounting the Ball Bar

Mounting the Ball Bar:

1. Ensure the ball bar is in the unlocked position (green markings aligned, no gap between handwheel and ball bar).
2. Insert the ball bar into the receiver tube from below and push upwards until it locks automatically.
3. Close the lock and remove the key.

Dismounting the Ball Bar:

1. Hold the ball bar firmly.
2. Pull the handwheel in direction 'a' and turn it in direction 'b' to the stop to unlock it.
3. Remove the ball bar from the receiver tube. The handwheel will then automatically lock in the unlocked position.
4. Store the ball bar safely in the vehicle's luggage compartment, protected from dirt.
5. Insert the plug into the receiver tube.

Maintenance and Care

• Keep the ball bar and receiver tube clean at all times for proper operation.
• Perform regular maintenance on the mechanical components.
• Use only graphite for lubricating the lock.
• Lubricate bearing points, sliding surfaces, and balls with resin-free grease or oil regularly. This also provides additional corrosion protection.
• Before cleaning the vehicle with a high-pressure washer or steam cleaner, remove the ball bar and insert the plug into the receiver tube. Do not expose the ball bar to steam jets.

Technical Specifications and Approvals

Clearance Requirements (ECE-R 55): Ensure adequate clearance as per Appendix 7, Figures 25a and 25b of the ECE-R 55 directive.

Key Information: The detachable ball bar comes with two keys. Note down the key number ???? for future reference and safekeeping.