Westfalia Tow Bar Installation and Operating Manual

General Information

Westfalia products are manufactured with the utmost care. If you encounter any issues, please contact your contract partner directly. Ensure you provide the charge number found on the type plate for your complaint to be processed.

Parts List

• 1: Receiver / Mounting tube
• 2: Ball bar / Tow ball
• 3: Locking balls
• 4.1: Release ball / Disengagement ball
• 4.2: Release lever / Disengagement lever
• 5: Handwheel
• 6: Cover / Cap
• 7: Key
• 8: Red marking (handwheel)
• 9: Green marking (handwheel)
• 10: Green marking (ball bar)
• 11: Symbol (release activation)
• 12: Plug / Stopper
• 13: Stop pin / Insert pin
• 14: No gap between 2 and 5
• 15: Gap of approx. 5 mm

Safety and General Instructions

National guidelines concerning the installation and approval of towing devices must be observed.

Any alteration or modification of the tow bar is prohibited and voids the operating license.

Remove any insulating compound or underbody protection from the vehicle's contact surfaces where the tow bar will be mounted.

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

Vehicles equipped with parking assistance systems may experience malfunctions after tow bar installation if parts (e.g., ball bar, coupling ball) are within the sensor's range. In such cases, adjust the sensing range or deactivate the parking assistance system. For tow bars with removable or pivoting ball tow bars, malfunctions are unlikely if the ball tow bar is not in the operating position.

The tow bar is a safety-critical component and must only be fitted by qualified companies. Improper assembly may result in a serious accident hazard. The German text of this instruction is binding.

Subject to change.

Pre-Drive Checks

Before each journey, ensure the detachable ball bar is correctly locked by checking the following:

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• The lock is closed and the key is withdrawn.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

If any of these checks are not satisfactory, repeat the installation procedure. If any requirement is still not met, do not use the tow bar, as there is a risk of accidents. Contact the manufacturer.

Installation of the Ball Bar

Step 1: Remove the plug from the receiver. The ball bar is usually in the unlocked position when removed from the vehicle's storage compartment. This is indicated by a visible gap of approximately 5 mm between the handwheel and the ball bar, and the red marking on the handwheel aligning with the green marking on the ball bar. Note: The ball bar can only be inserted in this state!

If the locking mechanism has been accidentally released before installation and is in the locked position, it must be pre-tensioned. The locked position is identified by the green marking on the handwheel aligning with the green marking on the ball bar, and the handwheel resting against the ball bar without a gap. To pre-tension the locking mechanism: Insert the key, open the lock, pull the handwheel out in direction of arrow 'a', and turn it to the stop in direction of arrow 'b' to pre-tension. The release ball is pre-tensioned, and the locking mechanism remains pre-tensioned after releasing the handwheel. The release lever engages, and the locking mechanism remains pre-tensioned after releasing the handwheel.

Step 2: To mount the ball bar, insert it from below into the receiver with the stop pin and push it upwards. The locking process is then performed automatically. Keep hands away from the handwheel as it rotates during locking.

Step 3: Close the lock and always remove the key. The key cannot be withdrawn if the lock is open. Press the cover onto the lock.

Removal of the Ball Bar

Step 1: Pull the cover off the lock and press it onto the key's handle. Open the lock with the key.

Step 2: Hold the ball bar firmly, pull the handwheel out in direction of arrow 'a', and turn it to the stop in direction of arrow 'b' to unlock it in the extracted position. Remove the ball bar from the receiver. The handwheel can now be released; it automatically engages in the unlocked position.

Step 3: Stow the ball bar safely in the boot of the vehicle, protected against dirt.

Step 4: Insert the plug into the receiver.

Diagrammatic Information

Vehicle Compatibility and Towing Limits:

The tow bar is designed for towing trailers and carrying loads. Ensure correct usage.

Weight Limits:

• Bike rack load: maximum 60 kg
• Single bike load: maximum 30 kg
• Vertical load (S): maximum ?? kg (refer to vehicle manual for exact value)

Break-in Period:

• Check after 0 km.
• Service check after 1000 km.

Clearance Requirements (Directive 94/20/EG):

Ensure adequate clearance as specified in Appendix VII, diagram 30 of Directive 94/20/EG. This includes specific angle and distance requirements for the tow bar and vehicle components, particularly concerning parking assistance sensors.

Vehicle Weight Definitions:

* At gross vehicle weight rating (GVWR)

Torque Specifications:

• 'a' bolts: M10x1.25x30 → 10 Nm
• 'b' bolts: M10x1.5x35 → 55 Nm
• 'c' bolts: M10x1.5x35 → 55 Nm
• 'a' bolts (Step 7): M10x1.25x30 → 40 Nm

Notes and Warnings

Repairs and dismantling of the detachable ball bar should only be carried out by the manufacturer.

Attach the enclosed warning label to the vehicle in a clearly visible location near the receiver or inside the boot.

For proper operation, the ball bar and receiver must always be clean. Regular maintenance of the 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 high-pressure steam cleaner, the ball bar must be removed and the plug inserted into the receiver. The ball bar must not be cleaned with a steam cleaner.

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