Page 1
Wood-Mizer ® Safety, Operation, Maintenance & Parts Manual AL-KO Kober Trailer Safety is our #1 concern! Read and understand all safety information and instructions before operating, setting up or maintaining this machine. Form #623...
Page 2
Table of Contents Section-Page SECTION 1 SAFETY & GENERAL INFORMATION Safety measures ......................1-1 Fitting and adjustment ....................1-2 SECTION 2 MAINTENANCE SECTION 3 ADJUSTING THE BRAKING SYSTEM Adjusting the braking force of the left and right wheel..........3-1 Adjusting the brake rod and Bowden cables ............. 3-3 SECTION 4 TROUBLESHOOTING GUIDE Overrun Device And Axle Problems.................
Table of Contents Section-Page SECTION 5 PARTS LISTS How To Use The Parts List ..................5-1 Sample Assembly ...................... 5-1 Trailer Brake 3081 Assembly .................. 5-2 Euro-Brake 2051 Assembly ..................5-4 Euro-Brake 2361 Assembly ..................5-6 Trailer Hitch Assembly 161S ..................5-8 251S Trailer Hitch Assembly ..................
Page 4
Safety & General Information Safety measures SECTION 1 SAFETY & GENERAL INFORMATION This manual is provided as a supplement to the equipment manufacturer’s manuals. This symbol calls your attention to instructions concerning your personal safety. Be sure to observe and follow these instructions. This symbol accompanies a signal word. The word DANGER indicates an imminently hazardous situation which, if not avoided, will...
Page 5
Safety & General Information Fitting and adjustment Fitting and Adjustment DANGER! Do not remove the spring hook of the breakaway cable (safety for transport) until the overrun device is mounted and the brake rod attached to the transmission lever. Non-observance will mean handbrake does not work.
Page 6
Maintenance SECTION 2 MAINTENANCE Replacing Dampers in 161 S / 251 S Overruns Please ensure that a genuine AL-KO damper is fittied, which will automatically return the drawbar after the braking process. See Figure 2-1. The main components of the overrun device are shown below. FIG.
Page 7
Maintenance DISMANTLING 1. Slacken off and remove screw (1). 2. Remove bellows (8) from the ball coupling (9). 3. Slacken off and remove screws (3). 4. Remove the defective shock absorber from the rear. MOUNTING 1. Push the new shock absorber into the draw tube from the rear. Damper lug must be parallel to drawbarholes in drawshaft.
Page 8
Adjusting the braking system Adjusting the braking force of the left and right wheel SECTION 3 Adjusting the Braking System Adjusting the braking force of the left and right wheel Friction linings of the left and right wheel drums must be adjusted in such a way that the braking force of the left and right wheel (or left and right wheels in case of two-axle trailers) is the same.
Page 9
Adjusting the braking system Adjusting the braking force of the left and right wheel 3. Set the wheel in rotation as when travelling forward and use e.g. a screwdriver to move the teeth in the adjustment hole in the direction indicated by the arrow until the wheel is blocked.
Page 10
Adjusting the braking system Adjusting the brake rod and Bowden cables Adjusting the Brake Rod and Bowden Cables See Photo 3-3 1. If it is necessary to replace the brake rod, first pass the new rod through the handles mounted on the frame. Handle PHOTO 3-3 See Photo 3-4...
Page 11
Adjusting the braking system Adjusting the brake rod and Bowden cables PHOTO 3-4 TUVdoc053121 Adjusting the braking system...
Page 12
Adjusting the braking system Adjusting the brake rod and Bowden cables Braking system, 1.8 t axle See Photo 3-5 and See Photo 3-6 Install the following elements on the brake rod (1) from the side of the axles: the yoke (2), the sleeve (7), the nut (6) - used to adjust the brake rod tension, the jam nut (5) - used to prevent the nut (6) from loosening after the brake rod tension has been adjusted.
Page 13
Adjusting the braking system Adjusting the brake rod and Bowden cables PHOTO 3-6 TUVdoc053121 Adjusting the braking system...
Page 14
Adjusting the braking system Adjusting the brake rod and Bowden cables Braking system, 2.2 t axle See Photo 3-7 Mount the brake rod (1) and Bowden cables (4) on the yoke (2). Install the nuts (6) and jam nuts (5) on the Bowden cables (4). ...
Page 15
Adjusting the braking system Adjusting the brake rod and Bowden cables Secure the nut (11) of the rod using the jam nut (12). PHOTO 3-8 When adjusting the nuts (6), be sure the yoke (2) remains perpendicular to the line ...
Page 16
Adjusting the braking system Adjusting the brake rod and Bowden cables Pull the lever upwards PHOTO 3-9 See Photo 3-10 6. The pawl of the brake lever (9) should be locked on the first or second tooth (10). Adjusting the braking system TUVdoc053121...
Page 17
8. If the braking system is properly adjusted, the machine should be stably immobilized when the brake lever is engaged. When the brake lever is disengaged, the wheels should be fully unblocked. CAUTION! If the braking system is malfunctioning, immediately contact AL-KO or Wood-Mizer Customer Service. 3-10 TUVdoc053121 Adjusting the braking system...
Page 18
Troubleshooting Guide Overrun Device And Axle Problems SECTION 4 TROUBLESHOOTING GUIDE Overrun Device and Axle Problems PROBLEM CAUSE SOLUTION Braking effect too weak Drawshaft pushing right in Adjust Linings not bedded in Will correct after brake has been applied a few times Linings damaged Replace shoes Friction losses too great...
Page 19
Troubleshooting Guide Overrun Device And Axle Problems Internal parts of coupling dirty Clean and grease coupling. or not moving freely. Take care Replace if necessary if snow or ice present Trailer can not be uncoupled Towball not round Align trailer and car in same direction and uncouple Too much play between Coupling worn...
Headquarters and Manufacturing Facility at +48-63-2626000 or +48-3912-1319. Have your customer number, vehicle identification number, and part numbers ready when you call. From other international locations, contact the Wood-Mizer distributor in your area for parts. PARTS LISTS doc053121...
PARTS LISTS Trailer Brake 3081 Assembly Trailer Brake 3081 Assembly REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) PART # W-M PART # BOWDEN CABLE 366.165 CABLE SEAT NOSE 278.196.00.14 BRAKE SHOES 384.414 084056 RETURN SPRING RIGHT 355.833 RETURN SPRING LEFT 258.925.00.04 BRAKE EXPANDER MECHANISM 354.433...
PARTS LISTS Trailer Assembly for M Super/LT70M Super Frame 5.15 Trailer Assembly for M Super/LT70M Super Frame REF. DESCRIPTION ( Indicates Parts Available in Assemblies Only) PART# TRAILER, M FRAME - COMPLETE 500741 AXLE, AL-KO DMC-2200 A-1370 C-1830 TRAILER 097864 WHEEL, ALKO-KOBER TRAILER - COMPLETE 087768 TIRE, 205/65 R17.5...
PARTS LISTS Trailer Assembly, 3.0T, S and M Frames REF. DESCRIPTION ( Indicates Parts Available in Assemblies Only) PART # BOLT, M10X30-8.8 CARRIAGE ZINC F81003-101 PIN, 3/8X2 1/4 SNAP 014151 LANYARD, 3/64X6 016030 SCREW, ISO 7045-M4X8-4.8-H-A2 PAN HEAD F81011-45 5.17 Trailer Assembly, 3.0T, S and M Frames REF.
Page 48
PARTS LISTS Trailer Assembly, 3.0T, S and M Frames REF. DESCRIPTION (* Indicates Parts Available In Assemblies Only) PART # FRAME, TRAILER AXLE (GENERAL-PURPOSE) 086918-1 BOLT, M16X50-8.8 HEX HEAD FULL THREAD ZINC F81006-7 WASHER, 17 SPLIT LOCK ZINC F81058-1 NUT, M16-8 HEX NYLON ZINC LOCK F81036-2 ROD, LONG BRAKE (M FRAME) 524669-1...
PARTS LISTS Trailer Assembly, 3.0T, M Super Frame 5.18 Trailer Assembly, 3.0T, M Super Frame REF. DESCRIPTION (* Indicates Parts Available In Assemblies Only) PART # TRAILER, 3T M-SUPER FRAME - COMPLETE 523574 AXLE, AL-KO DMC-3000 A-1370 C-1830 523217 WHEEL, 205/65 R17.5 COMPLETE 095348 RIM, 17.5"...
Page 50
PARTS LISTS Trailer Assembly, 3.0T, M Super Frame REF. DESCRIPTION (* Indicates Parts Available In Assemblies Only) PART # WASHER, 10.5 FLAT ZINC F81055-1 BOLT, M10X25 8.8 HEX HEAD FULL THREAD ZINC F81003-11 NUT, M10-8-B HEX NYLON ZINC LOCK F81033-1 ROD, BRAKE - LONG 524669-1 GUARD, COMPLETE CE...
PARTS LISTS Tandem Trailer Assembly, 3.0T 5.19 Tandem Trailer Assembly, 3.0T REF. DESCRIPTION ( Indicate Parts Available in Assemblies Only) PART# TRAILER, 3T TANDEM - COMPLETE 090099 AXLE, B 1500 A1420 112X5 C T FRONT 090011 PLATE WELDMENT, MOUNT - WIDE 089780-1 PLATE WELDMENT, MOUNT - NARROW 089781-1...
Page 52
PARTS LISTS Tandem Trailer Assembly, 3.0T REF. DESCRIPTION ( Indicate Parts Available in Assemblies Only) PART# BRACKET, 3.5T TANDEM TRAILER BRAKE CABLE 088890 BUSHING, 14/20-40 ZINC-PLATED 506412-1 NUT, M12-8-B HEX ZINC F81034-1 PIN, 3/8X2 1/4 SNAP 014151 LANYARD, 3/64X6 016030 SCREW, ISO 7045-M4X8-4.8-H-A2 PAN HEAD F81011-45 PARTS LISTS...
PARTS LISTS Trailer Assembly, 2.6T 5.23 Trailer Assembly, 2.6T REF. DESCRIPTION (* indicates parts available in assemblies only) PART # TRAILER, 2.6T - COMPLETE 550484 BRACKET WELDMENT, TRAILER HITCH CONNECTION 085803-1 OVERRUN DEVICE, ALKO MODEL 2500 085591 PLATE, DATA 522268 RIVET, 3.2 X 7.4 ALUMINUM F81021-1 GLAND, DW11/H CABLE...
Page 60
PARTS LISTS Trailer Assembly, 2.6T REF. DESCRIPTION (* indicates parts available in assemblies only) PART # BOLT, M10X25 8.8 HEX HEAD FULL THREAD ZINC F81003-11 NUT, M10-8-B HEX NYLON ZINC LOCK F81033-1 TIE WRAP, TK 50/8 F81082-3 GUARD, CE COMPLETE 099851 PLATE, CE GUARD MAIN 095818-1...
PARTS LISTS Lighting Kit for 9 m Frame 5.24 Lighting Kit for 9 m Frame REF. DESCRIPTION ( Indicates Parts Available in Assemblies Only) PART # LIGHTING KIT, 9M FRAME 087934 BAR, LIGHT - COMPLETE (L FRAME) 510772-L BAR, ALUMINUM LIGHT 510774 LAMP, LT-120 LICENCE PLATE 088597...
Page 62
PARTS LISTS Lighting Kit for 9 m Frame REF. DESCRIPTION ( Indicates Parts Available in Assemblies Only) PART # NUT, M5 8 HEX ZINC F81030-1 BRACKET, LIGHT BAR MOUNT - COMPLETE 090422 SPRING, .715X1.53X.068DIA SS COMP. P04282 RING, Z 10 OUTSIDE RETAINING F81090-13 WASHER, 6.4 FLAT ZINC F81053-1...
Page 63
PARTS LISTS Lighting Kit for 9 m Frame REF. DESCRIPTION ( Indicates Parts Available in Assemblies Only) PART # ELEMENT, EE63 MOUNTING F81080-4 GLAND, DW11/H CABLE 085388 5-44 doc053121 PARTS LISTS...
PARTS LISTS Outrigger Assembly (Front), Optional 5.25 Outrigger Assembly (Front), Optional REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) PART # FINE ADJUST OUTRIGGER ASSEMBLY, FRONT 094587 Leg, Fine Adjust Outrigger See Section 5.40 093589 Guide, Outrigger Leg 506116-1 Pin, Outrigger Locking Zinc-plated 087012-1 Spring, SR.21x38x2 Zinc...
PARTS LISTS Outrigger Assembly (Middle and Rear), Optional 5.26 Outrigger Assembly (Middle and Rear), Optional SMTUV08D REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) PART # FINE ADJUST OUTRIGGER ASSEMBLY, MIDDLE AND REAR 094584 Leg, Fine Adjust Outrigger See Section 5.40 093589 Guide, Outrigger Leg 506114-1...
PARTS LISTS Outrigger Assembly (Side), Optional 5.27 Outrigger Assembly (Side), Optional SMTUV09D REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) PART # FINE ADJUST OUTRIGGER ASSEMBLY, SIDE 094583 Leg, Fine Adjust Outrigger See Section 5.40 093589 Guide, Outrigger Leg 504243-1 Pin, Outrigger Detent 090197...
PARTS LISTS Outrigger Assembly (S & M Frame), Optional 5.28 Outrigger Assembly (S & M Frame), Optional REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) PART # FINE ADJUST OUTRIGGER ASSEMBLY, S & M FRAME 094586 Leg, Fine Adjust Outrigger See Section 5.40 093589 Guide, Outrigger Leg...
PARTS LISTS Outrigger Assembly (L Frame), Optional 5.29 Outrigger Assembly (L Frame), Optional SMTUV19B REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) PART # FINE ADJUST OUTRIGGER ASSEMBLY, L FRAME 094585 Leg, Fine Adjust Outrigger See Section 5.40 093589 Guide, Outrigger Leg 506114-1 Pin, Outrigger Detent...
PARTS LISTS Fence Assembly, S Frame 5.30 Fence Assembly, S Frame REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) W-M PART FENCE ASSEMBLY, S-TYPE FRAME 100691 Fence Assembly, Front 100496 Beam, Front Trailer 100497-1 Clamp, Front Trailer Fence 521882-1 Nut, M16 Wing Zinc-plated F81036-3 Lanyard, 3/64 x 6...
Page 70
PARTS LISTS Fence Assembly, S Frame Lamp, 40134003 White Marker E85131 Lamp, 40129001 Yellow Marker E85217 Screw, C-ST 4.2 x 13 Cross Recessed Pan Head Tapping Zinc F81010-1 Lanyard, 3/64 x 6 016030 Pin, Retainer P05059 Socket, 2-Pole (FENCE LIGHTING) E85126 Grommet, GH6 Rubber 085338...
PARTS LISTS Fence Assembly, M Frame 5.31 Fence Assembly, M Frame REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) W-M PART # FENCE ASSEMBLY, M-TYPE FRAME 100505 Fence Assembly, Front 100496 Beam, Front Trailer 100497-1 Clamp, Front Trailer Fence 521882-1 Nut, M16 Wing Zinc-plated F81036-3...
Page 72
PARTS LISTS Fence Assembly, M Frame Lamp, 40129001 Yellow Marker E85217 Screw, C-ST 4.2 x 13 Cross Recessed Pan Head Tapping Zinc F81010-1 Lanyard, 3/64 x 6 016030 Pin, Retainer P05059 Socket, 2-Pole (FENCE LIGHTING) E85126 Grommet, GH6 Rubber 085338 Cable, 0.75mm sq.x 2 OMPY Stranded Grey R80582-2 6.5m...
PARTS LISTS Fence Assembly, LT70M Super 5.35 Fence Assembly, LT70M Super smtuv28b 22 23 24 REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) W-M PART FENCE ASSEMBLY, LT70M SUPER COMPLETE 100376 Fence Assembly, Front, “M” Super Bed Frames 100379 Beam, Front Trailer 100377-1 Clamp, Front Trailer Fence...
PARTS LISTS Light Bar Assembly, S Frame 5.36 Light Bar Assembly, S Frame SMTUV29_D 510772_MANUAL 11 12 REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) W-M PART # BAR ASSEMBLY, LIGHT (S FRAME) 100700 BEAM, REAR (GP FENCE) 086961-1 BRACKET, S FRAME REAR FENCE 100698-1 SCREW, M10X25 8.8 HEX SOCKET HEAD CAP ZINC...
Page 80
PARTS LISTS Light Bar Assembly, S Frame GROMMET, GH6 RUBBER 085338 BULB, 5W 12V SMALL 085390 LIGHT, LT120 LICENCE PLATE 088597 GROMMET, HV12 WHITE R80670-1 BULB, 21W 12V 088847 LAMP, LT-50P MULTIFUNCTION 510773 R80582-2 WIRE, OMYp 2 x 0.75 mm BAR, ALUMINUM LIGHT 510774 LIGHT, LO 361 MARKER...
PARTS LISTS Light Bar Assembly, M Frame 5.37 Light Bar Assembly, M Frame REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) W-M Part No. BAR ASSEMBLY, LIGHT (M FRAME) 550472 BEAM, REAR (GP FENCE) 086961-1 WASHER, 5.3 FLAT ZINC F81052-1 BAR, S/M FRAME LIGHT - COMPLETE 550470...
Page 82
PARTS LISTS Light Bar Assembly, M Frame REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) W-M Part No. SCREW, C-ST 4.2 X 13 CROSS RECESSED PAN HEAD TAPPING ZINC F81010-1 ROD, PLUG W85163-1 WASHER, 10.5 FLAT ZINC F81055-1 SCREW, M10X25 8.8 HEX SOCKET HEAD CAP ZINC F81003-32 BOLT, M5X65 8.8 HEX HEAD ZINC F81000-62...
PARTS LISTS Light Bar Assembly, M Frame 5.38 Light Bar Assembly, M Frame SMTUV20_F 510772_MANUAL 11 12 REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) W-M PART # BAR ASSEMBLY, REAR LIGHT (M FRAME) 094711 BEAM, REAR (GP FENCE) 086961-1 BRACKET, REAR FENCE 094710-1...
Page 84
PARTS LISTS Light Bar Assembly, M Frame GROMMET, GH6 RUBBER 085338 BULB, 5W 12V SMALL 085390 LIGHT, LT120 LICENCE PLATE 088597 GROMMET, HV12 WHITE R80670-1 BULB, 21W 12V 088847 LAMP, LT-50P MULTIFUNCTION 510773 R80582-2 WIRE, OMYp 2 x 0.75 mm BAR, ALUMINUM LIGHT 510774 LIGHT, LO 361 MARKER...
PARTS LISTS Light Bar Assembly, L & M Super Frame 5.39 Light Bar Assembly, L & M Super Frame SMTUV31_B 11 12 098203_MANUAL SCALE 0.1 SMTUV31_B 510772-L_MANUAL REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) W-M PART # BAR, COMPLETE LIGHT (M SUPER FRAME) 098203 FENCE, “M”...
Page 86
PARTS LISTS Light Bar Assembly, L & M Super Frame BULB, 21W 12V 088847 R80582-2 CABLE, OMYp 2 x 0.75 mm LAMP, LT-50P MULTIFUNCTION 510773 BAR, ALUMINUM LIGHT 510774 LAMP, LO 363 MARKER 502653 BRACKET, ”M-SUPER” FRAME MARKER LAMP 502594-1 PLUG, 12V 13-PIN E85117 CONNECTOR, 2-POLE...
PARTS LISTS Fine Adjust Outrigger Leg 5.40 Fine Adjust Outrigger Leg REF. DESCRIPTION (* Indicates Parts Available in Assemblies Only) PART # LEG, MAIN TUBE FINE ADJUST OUTRIGGER 093589 BASE WELDMENT, OUTRIGGER LEG 093596-1 BOLT, OUTRIGGER LEG 093590-1 GUIDE, OUTRIGGER LEG 093593-1 WASHER, 10.5/30-5 505156-1...
Need help?
Do you have a question about the AL-KO Kober and is the answer not in the manual?
Questions and answers