ASSEMBLY AND OPERATING INSTRUCTIONS FOR AL
Contents
1. Fitting of AL KO Security Device Horizontal Bolt Fitting for AL KO Overruns Parts configuration as Fig 4 Item 1 Locking plates left right 2 Inner Hex Bolt M12 8 8 with flat head to DIN 7984 3 Self locking nut M12 Cross type Bolt Fitting for other overruns Parts configuration as Fig 5 Item Locking plates left right Inner Hex Bolt M12 8 8 with flat head to DIN 7984 Dome Head Bolt M12 8 8 Half moon shaped fixing lugs Section washer not included in this please use original washer from coupling head you are removing Self locking nut M12 Procedure Push Gaiter onto the drawshaft followed by the AK160 300 coupling or AKS 1300 stabiliser with spacers Fig 6 if necessary so that the fixing holes line up If present position the spacer sleeve in the draw shaft Fit parts as shown on figs 4 or 5 If a spacer sleeve is in the draw shaft thread this on as well Push retaining pin Fig 3 Item 1 through with the bolt behind horizontal or vertical Shock absorber damper is threaded on For your own safety please check To make sure the shock absorber damper is threaded on push the draw shaft in and out If you can feel resistance then it is correctly positioned Always insert horizontal bolts as shown in Figs 4 5 ie from right to left when facing caravan as this allows correct clearances Always insert vertical bolt from top to bottom and re use original shim used on the overrun W2. Secure gaiter with tie wrap Put security device on and lock If the cover is difficult to put on or lock unlock then you need to reposition the locking plates Loosen front bolt and the plates can now move laterally Re tighten bolts to correct torque and check if safety cover now fits 2 OPERATING INSTRUCTIONS Insert left and right lugs of safety cover into cutaway portion of the attached locking plates Fig 7 Item 2 Push security device firmly forward until it can go no further Fig 8 Item 1 Hold security device in place turn key to the right and press the lock cylinder in until it clicks into place Fig 9 Turn the key to the left into the locked position The strain bolt then moves out and locks Swing the dust cap over the lock cylinder to protect from dirt Fig 9 Removing Security Cover reverse order to fitting cover Open dust cap Insert key and turn to the right as far as it will go about 60 As a result the lock cylinder will slide up automatically If necessary press the safety cover forward and pull out the lock cylinder with the key turned about 60 Pull security device back Remove security device and stow in vehicle or caravan So that the dust cap is not damaged during transit remove key inserting lock and swing dust cap over the lock cylinder Important Information Never attempt to fix or remove the security device with the aid of a hammer this may result in dam
3. age to the cover 3 MAINTENANCE Clean strain bolt locking bolts and the cutaway portion in the locking plates if they become dirty A little grease may be applied but remove excess with a cloth so that only a thin film remains Operate the locking cylinder periodically if the cover has not been used for a while If the lock only operates with difficulty spray the cylinder with WD 40 or similar ALKO QUALITY FOR LIFE AL KO Kober Ltd South Warwickshire Business Park Kineton Road Southam Warwickshire CV47 OAL 01926 818500 01926 818562 www al ko co uk Part No 1385108 Iss 02 2011 ASSEMBLY AND OPERATING INSTRUCTIONS FOR AL KO SECURITY DEVICE FOR AK160 300 COUPLINGS amp AKS 1300 STABILISER ALEKO QUALITY FOR LIFE PLEASE ENSURE YOU READ THESE INSTRUCTIONS CAREFULLY BEFORE COMMENCING TO OPERATE THIS PRODUCT GENERAL 1 The AL KO Security Hitch Lock Device is effective against the following unauthorized operations a Uncoupling from the towing vehicle b Coupling onto another towing vehicle c Theft of the Coupling Stabiliser from the trailer caravan 2 AL KO recommends the use of the AL KO Safety Ball to complement the AL KO Security The Safety ball is inserted into the coupling area of the Stabiliser before the AL KO Safety is locked into position Fig 1 This prevents your caravan from being coupled to any other tow hook or smaller towball and being towed away The AL KO Safety Ball i
4. ith cross type bolt fixing do not forget to insert half moon shaped plates Fig 5 Item 4 and section washer Fig 5 Item 5 For horizontal bolts tighten with Allen Key size 8 as the nuts are fixed and cannot be moved For vertical bolt tighten nut and torque as follows Overrun Torque Type Setting AL KO 30S AL KO 60S 60S 2 AL KO 90S 90S 3 Other overruns with M12 8 8 Bolts
5. s available from most Caravan Shops or if this Safety Device was purchased via AL KO S direct Mail Order Service the Safety Ball is provided with the kit APPROVAL 1 This product holds full TUV approval and is also Sold Secure Approved WARRANTY 1 Product warranty is given in accordance with S10 Clause 1 7 of the General Terms of Business and is usually 12 months from date of purchase Please note the Safety Ball is only included with kits purchased direct from AL KO s main factory if this item is purchased from a caravan dealer then the Safety Ball is an additional item Please Note All diagrams shown in this booklet represent AK160 300 couplings but assembly procedure for AKS 1300 Stabiliser is identical 1 ASSEMBLY INSTRUCTIONS Removal of existing fixing bolts Before you start to remove the existing fixing bolts please note the following On most overrun assemblies the shock absorber is secured by the fixing bolt Fig 2 Item 2 Warning The shock absorber damper extends independently Enclosed with this box is a retaining pin Fig 3 Item 1 to aid assembly Remove gaiter Loosen self locking nut from hexagon cap bolt Figs 2 3 Items 1 2 Push or knock out hex cap bolt Fig 2 Item 1 Knock through retaining pin Fig 3 2 with Fig 3 ltem 1 and leave the pin in the shaft for centring the shock absorber damper Any spacers originally fitted must be re used
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