Drawbar Box Installation Guide with U-Bolts

Instructions for assembling an aluminum drawbar box

Package contents:

Aluminum drawbar box
2x U-bolts
2x counter plate (in the box)
4x safety nuts
Pad for vibration reduction between drawbar and box

Required tools or aids:

Cordless drill (with M10 attachment)
(Deburring tool)
Wrench (size 10?)
Flex

Warning notices:

The assembly must be carried out exactly according to the manufacturer's instructions – otherwise, incorrect assembly could lead to a safety risk.
Use the product only for its intended purpose.
Read these instructions carefully before you begin assembly.
Always wear appropriate protective equipment, including gloves and safety glasses.
Ensure that no people, especially children, are near the assembly area.
Work only in a well-lit, clean, and safe work area.
The maximum payload of the drawbar box of XY kg must not be exceeded.
Note the maximum vertical load of the trailer or trailer hitch.
The lid of the box must be closed and locked during driving; remove the key.
Check the fastening screws after 50 km and once a year, and tighten them if necessary.
Make sure that the chassis number is not covered during installation.
Do not drill any holes in the existing chassis.

Cleaning and care instructions:

Clean with a soft, damp cloth (water and mild dish soap or soap solution).

Step-by-step instructions:

Step 1: Positioning the drawbar box

Position the drawbar box where you intend to mount it. Ensure the box is correctly aligned and securely rests on the drawbar. Make sure the lid opens freely and is not obstructed by any other objects or structures. Important: The vehicle identification number (VIN) must not be covered by the box.

Step 2: Marking the holes

The next step is to mark the locations where the holes for the U-bolts will be drilled in the drawbar box. Mark these points carefully to ensure even placement of the U-bolts.

Although not strictly necessary, it is recommended to position the holes towards the edge of the box. This ensures that the counter plate and locking nuts are not located in the center of the box, thus making optimal use of the available storage space. Furthermore, it is advisable to position the holes so that the existing dividers remain fully functional.

These considerations will allow you to use the space in your drawbar box efficiently and store your belongings undisturbed. Carefully plan the positioning of the holes to maximize the benefits of your drawbar box.

Step 3: Drilling the holes

Drill holes at the previously marked locations. Use a drill bit large enough to accommodate the U-bolts and ensure the holes are clean and free of burrs.

Always remember: The drawbar itself must not be drilled!

Step 4: Attaching the U-bolts

Insert the U-bolts from below through the drilled holes in the drawbar box, so that the ends of the bolts protrude from the drawbar box and the underside of the U-bolts grips the drawbar box. Ensure that the U-bolts are evenly aligned.

Step 5: Measuring and marking the U-bolts

To ensure that the U-bolts do not protrude unnecessarily far into the box, you should measure and mark the correct length before removing any excess material.

To do this, push the U-bolt as far upwards as possible into the drawbar box and measure the height that the nut and the counter plate will occupy. Mark this position on the U-bolt. This will be the point where the U-bolt should be cut.

By performing this step, you ensure that the U-bolts are exactly the right length to work safely and efficiently inside the drawbar box without protruding unnecessarily into the interior.

Step 6: Mounting the counter plate and lock nuts

Begin by guiding the counter plate over the ends of the U-bolts protruding from the drawbar box. Ensure the counter plate is correctly positioned and lies flat against the inside of the drawbar box. Proper positioning of the counter plate is crucial for the stability and longevity of the assembly.

Next, attach the safety nuts to the ends of the U-bolts. Tighten the nuts evenly to ensure an even load distribution. Even tightening of the nuts ensures that the drawbar box is subjected to a uniform load and helps prevent premature wear.

Use a suitable wrench or ratchet to tighten the nuts. Ensure the nuts are tightened securely, but not excessively, as this could damage the U-bolts.

This step completes the assembly of your drawbar box. Ensure that all components are securely fastened before using the drawbar box.

Step 7: Final exam

Check that all components are securely attached and the drawbar box is stable. Make sure the nuts are tightened securely.