Westfalia Tow Bar Installation and Operating Instructions

Introduction

This document provides installation and operating instructions for the Westfalia detachable tow bar designed for the Audi A6 Allroad. It includes important safety information, technical specifications, and detailed steps for mounting and using the tow bar system.

General Safety and Important Notes

Safety First: Always ensure the tow bar is correctly locked before each journey. Failure to do so can lead to serious accidents. Installation should only be performed by qualified personnel. Unauthorized modifications are prohibited and will void the operating license.

Pre-Operation Checks: Before driving, verify the following for the detachable ball bar:

• The green marking on the handwheel aligns with the green marking on the ball bar.
• The handwheel rests snugly against the ball bar with no gap.
• The lock is closed and the key is withdrawn.
• The ball bar is fully inserted and securely fixed in the receiver tube; check by shaking it.

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

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

Parking Assistance Systems: Be aware that parking assistance systems may experience malfunctions after tow bar installation if components obstruct sensors. Adjust the sensing range or deactivate the system as necessary. This is less likely with removable or pivoting ball bars when not in the operational position.

Maintenance: Keep the ball bar and receiver tube clean at all times. Regularly service the mechanical parts. Treat the lock only with graphite. Lubricate bearing points, friction surfaces, and balls with resin-free grease or oil for corrosion protection. Remove the ball bar and insert the plug before cleaning the vehicle with a steam jet cleaner; the ball bar itself must not be cleaned with steam.

Storage: When not in use, remove the ball bar and always insert the plug into the receiver tube. Store the ball bar safely in the vehicle's boot, protected from dirt.

Technical Specifications

• Tow Bar Type: 305 407
• Vehicle: Audi A6 Allroad (4G, AU????)
• Attachment Class and Type: A50-X
• Homologation: E13 55R-01 3585
• D-Value: 12.6 kN
• Max. Vertical Load (S): 100 kg
• Towing Capacity: Refer to vehicle's registration document.
• ECE-R 55 Compliance: Ensures clearance requirements as per Appendix 7, Figures 25a and 25b.

Installation Procedure

Note: Installation requires removing parts of the vehicle's rear bumper and accessing mounting points on the chassis.

1. Preparation: Remove the plug from the receiver tube. Ensure the ball bar is in the unlocked position (indicated by a gap and specific markings).
2. Pre-tensioning (if necessary): If the locking mechanism is already engaged, pre-tension it by inserting the key, opening the lock, pulling out the handwheel (arrow a), and turning it until it stops (arrow b).
3. Mounting the Tow Bar: Insert the ball bar assembly from below into the receiver tube using the insertion pin and push upwards. The locking mechanism engages automatically. Keep hands clear of the handwheel during this process.
4. Securing: Close the lock and always remove the key.
5. Bumper Modification/Removal: Diagrams indicate that the rear bumper may need to be removed or modified to accommodate the tow bar.
6. Attachment Points: The tow bar attaches to specific points on the vehicle's chassis. Bolts are shown with specified torque values (e.g., 20Nm for bolt 'a', 55Nm for M10x35 bolts).
7. Electrical Connection: While not detailed in the diagrams, electrical connections for trailer lights are implied.
8. Final Checks: Ensure all bolts are tightened to the specified torque and that the ball bar is securely locked.

Diagram Descriptions (General):

• Diagrams on pages 8-10 illustrate the step-by-step process: removing the bumper, identifying mounting points, attaching the main tow bar structure using specified bolts and torques (e.g., 20Nm, 55Nm), and connecting components.
• Diagrams on page 7 and 11 show clearance requirements (e.g., minimum distances, angles) related to ECE-R 55 regulations and vehicle weight limits.

Detachable Ball Bar Operation

The detachable ball bar mechanism allows for easy removal and attachment.

Locking Procedure:

1. Ensure the ball bar is fully inserted into the receiver.
2. Check the green markings on the handwheel and ball bar align.
3. Verify there is no gap between the handwheel and the ball bar.
4. Confirm the lock is closed and the key is withdrawn.
5. Shake the ball bar to ensure it is securely locked.

Unlocking and Removal:

1. Insert the key and open the lock.
2. Hold the ball bar firmly. Pull the handwheel outwards (arrow a) and turn it to the released position (arrow b) to unlock.
3. Remove the ball bar from the receiver. The handwheel will automatically return to the unlocked position.
4. Store the ball bar safely and insert the plug into the receiver.

Key Information: The detachable ball bar comes with 2 keys. Note the key number ???? for future reference or reordering.