INFORMATION/SERVICE MANUAL & PARTS LIST
Contents
1. 11 16 TYP 111 1mm 4 3 8 DL1802A 27 0mm 1 1 16 12 7mm 1 2 SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com iS TRAILERS Description Base DL1402A E Ring Drive Shaft K Rope Clamp Rope Clamp Kit Carriage Bolt Reel 7 8 Hub AJ Reel 1 7 8 Hub Opt Bolt Ratchet Kit Ratchet Lever Ratchet Kit Ratchet Sleeve f DL1602A Spring Ratchet Kit a ie OO L1402A 1400 Ibs 635 kg DL1602A 1600 lbs 726 kg DL1802A 1800 Ibs 817 kg CABLE DL1402A Va x 40 ft 6 mm x 14 2 m DL1602A VA x 58 ft 6 mm x 20 m Y N aol y DLIAD2A 4 421 DL1802A 2 x 58 ft 7 mm x 17 9 m X je DL1602A 5 4 1 m gt DL1802A 5 4 1 Some winch spares may need to be ordered in specially Please call for details SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com SBS TRAILERS E Ring 2 Drive Shaft DL1800A 2000A 2500A Drive Shaft DL3200A Dr Shaft w Hole DL1800A thru 2500A H Drive Shaft DL1800A Drive Shaft DL2000A H Drive Shaft DL2500A Dr Shaft w Hole DL3200A Drive Shaft DL3200A H Drive Shaft DL2500A Spec Opt Base DL2500A Brake Pin Optional M Brake Band Optional N E Ring Optional 4 6 3 1800Ib 2 speed winch amp 2500Ib 2 speed winch M2. 17 SBS TRAILERS 4 6 Winches 4 6 1 900Ib winch e 42 9mm _ 1 11 16 2 7mmO 7 64 23 8mm0 15 16 TYP 6 4mm0 1 4 TYP 85 7mmO 3 3 8 DL600A DL900A DL600A 600 Ibs 272 kg Base DL600A DL900A 900 Ibs 408 kg Base DL900A DL1100A 1100 Ihs 499 kg B n 3 DLI300A 1300 Ihs 590 kg E Ring Drive Shaft DL600A S TO Sure A 7 32 X Ol Tt 4 mm x 19 2 m Drive Shaft DL600A DL900A 3 16 x 40 ft 5 mm x 10 9 m Threaded Both Ends Opt re DL1100A 16 x 79 ft 5 mm x 22 2 m Debs 7 Drive Shaft DL900A D19008 3 21 DL1300A 7 32 x 56 ft 6 mm x 14 2 m Handle 7 w Nut DL1100A 3 7 1 Handle 6 w Nut DL1300A 4 4 1 C Handle 5 N Some winch spares may need to be ordered in specially Please call for details C Ratchet Kit SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 18 SBS TRAILERS 4 6 2 1400Ib winch amp 1800Ib single speed winch 27 0mm 1 1 16 TYP 1 4 TYP 92 1mm 3 5 8 DL1402A 46 0mm 3 4mm 1 13 16 9 64 31 8mm 127 8mm 5 1 32 68 7mm AK AL 6 4mm DL1602A j 1 ayaq 27 0mm 1 4 TYP AH 2 1 1 16 gt ee f 92 1mm 3 5 8 7 Nu DL1602A f l 55 6mm P AG 2 aji 6 DL1802A 31 8mm 1 1 4 79 4mm 3 1 8 139 7mm 5 1 2 4 8mm 12 7mm 3 16 1 2 TYP 27 0mm
3. 6 8mm on tandem axles Measured on the Bowden inner cable where attached to abutment bracket on axle tube on tandem axles the abutment is always on the forward axle SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 23 Only ever set or adjust the wheel brake by means of the adjuster screw 1 Adjust in the direction of the arrow and release against the direction of the arrow Fig 13 Reconnect the brake linkage to the balance bar and apply the handbrake hard several times to allow the braking system to settle Apply preload by tightening the ball nuts i e the inner Bowden cables are easily pulled out 1 2mm Use a locknut to locate the ball nuts to the hexagon nuts Lubricate the contact surfaces of the ball nuts Fig 11 e On the spring cylinder version 2 adjust the locking nuts M10 1 to the spring cylinder until there is approximately 1mm free play between the tension bar 3 and the self locking hexagon nuts M10 Fig 14 N B on some chassis the locking nuts 1 are replaced with a single Nylock self locking nut Check the setting e Apply the handbrake lever up to the first or second tooth and when the wheels are turned in the direction of travel check whether there is equal braking resistance On the gas strut version hold the handbrake lever on the first tooth manually t 0845 230 5670 When adju
4. Maintenance I r r4i r4r4r rsfofLL U u u 6 2 4 Function iid wut Operation of the overrun brake system 4 lLLuUUUUUUI a 9 42 Service brake 000 9 ee eee Oe 4221 ReVversi g a L lll ur III as T 4 2 2 Parking brake r J ll s ee lO 48 Wheel pearing 0 11 AAO hubs tt 12 ee 4 4 1 AL KO 2051 euro hub lll U 4 4 2 AL KO 2361 euro hub eae lS 4 8 Coupling heads el LUUUUU IU 14 nn 4 5 1 AL KO 161S to suit Omm box 14 aan ss ss 4 5 2 AL KO 2515 to suit 80mm box _ Ll 19 a 4 5 3 AL KO 2519 delta u 16 P 4 5 4 Info for all AL KO Couplings k Af 4 5 4 Bradley coupling head 17 SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailerscom e sales sbstrailers com SEBS TRAILERS u 46 Winches_ nnn 18_ ssp 4 6 1 900Ib winch 18 ln 4 6 2 1400lb winch amp 1800 b single speed winch 19 eee 4 6 3 1800Ib 2 speed winch amp 2500ID 2 speed winch 21 r eer ee 4 6 4 Information for all winches ee _9 Servicing and Repair nn 23_ 2l BRAK CS iid 9 1 1 Adjusting the wheel brakes nn 23 nd 1 2 Servicing the wheel brakes 25_ DTS Visual checks Oaa 26_ ceed TA Function tests 00000 26_ an 0 2 Replacing the brake shoes OCO aaa 2 ceed 1 Expanding cluich 0000 20 0 92 2 Return SPFINGS r ll J Um1s1vxSs r _ Ua 28 cen 2 3 Transmission lever rr el ll LLL mil1iSs s U 28 092 4 Adjuster assembly 00 28 92 09 Leaf springs adjuster housing x eeeLJ 28 ee 9 3 Changing worn or damaged brake cable
5. Number Capacity Z l W Fu A AXLE REF EE l lB and Gross Vehicle Weight ff m MAXIMUM RATED SPEED 60MPH 100KMH GVW Please ensure the ID ium Plate is kept in a legible condition It is often the only means of identification and will make ordering spares accessories or replacement parts easier Also ensure that you have filled in the relevant information on the cover of this manual and refer to it when contacting us about your trailer SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 1 3 Axle plates e AL KO axles are identified by the oval plate fitted on the rear of each axle On UK production this is green in colour Fig 2 The data on this plate Is vital should information about the system be AL KO required TYPE EL SL e The top line indicates the type of axles the CAPACITY K9 customer using the NCC code the year and 25kn h month of manufacture e The middle line pre fixed LE is the Works Order number this is most important On the other side of the securing pop rivet are the individual axle number and the quantity i e 6 of 36 e The third line is the maximum capacity of the axle and MUST NOT BE EXCEEDED The E after this weight indicator stands for Euro Axle e The fourth line confirms that the axle was designed for speeds in excess of 25km h A FA German
6. Turn the lever over and reassemble Do not over tighten bolt Check opera on to the underside of the reel To do this carefully examine ratchetassembly and remove it from winch WINCH MAINTENANCE This winch has been fully lubricated at the factory but for continued smooth performance and increased life occasional greasing of gears and resl shaft and an occasi tion to insure the ratchet lever rotates binding rap of oil on drive shaft bearings are recommend winch in good working order Damaged sayaraly worn parts create unnecessary dang Bali result in samc injury or prope ty damage SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com sales sbstrailers com 22 35 TRAILERS 5 Servicing and Repair 5 1 Brakes 5 1 1 Adjusting the wheel brakes A Before adjusting the wheel brakes always rotate the wheel s in the forward direction Hexagon nut M10 e Lift the caravan trailer using a lifting Bowden cable platform e Ensure the coupling head and overrun draw shaft are fully extended e Release the handbrake completely e Completely release the brake linkage on the balance bar ball nut and hexagon nut Fig 11 e Check the free play in the wheel brake A 5 8 5 8 u The free play should be as uniform as i possible for 2 and 4 wheel brakes respectively Nominal 4 6mm on single axle
7. can be described as the control device if the overrun brake system A drawbar force is produced at the coupling point by reducing the speed of the towing vehicle After the threshold level has been passed the draw shaft is pushed in thus actuating the overrun lever the wheel brakes 1 2 are then applied via the expanding clutch 3 Fig 6 SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 4 2 1 Reversing When reversing the towing vehicle pushes in the draw shaft of the overrun device The brake shoes 1 2 are pressed against the brake drum via the transmission lever 4 brake linkage Bowden cable and expander clutch 3 The brake drum turns backwards taking the trailing shoe 1 with it The transmission lever 4 swings back and offsets the whole pedal travel The braking effect is virtually cancelled out and the bottom plate travels backwards figs 6 and 7 4 2 2 Parking brake On the spring cylinder version engage the hand brake lever right up to the last tooth 90 On the gas strut handbrake version pull the handbrake over dead centre The braking shoes 1 2 are pressed against the brake drum by the brake linkage Bowden cables and expander clutch 3 and this applies the trailer brakes Fig 8 When the caravan trailer has been reversed the brake drum will also rotate backwards The trailing brake sho
8. lubricate the pivot bolt e Replace seized up transmission levers together with pivot bolts e lf the transmission lever does not abut on the adjusting housing stop the extension spring must be replaced Fig 18 5 2 4 Adjusting assembly e Lubricate stiff adjusting nuts using Molybdenum Disulphide grease e Unscrew the adjusting screw and lubricate the thread e Replace seized up adjusting screw together with adjusting nuts 5 2 5 Leaf springs adjuster housing e Replace relaxed leaf springs N B The adjuster screw nut and leaf springs are only supplies as a complete assembly The part numbers for these are as follows System 1637 38 77 06 System 2051 387323 System 2361 387323 All friction points must be lubricated with Molybdenum Disulphide grease AL KO Part No 800098 5 3 Changing worn or damaged brake cables Remove the control mechanism at the centre of the axle Slacken and drop cable end from the centre axle bracket and detach cables To refit reverse the procedure SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 28 6 Troubleshooting Braking effect too weak Towing shaft pushes in fully Adjust Linings not bedded in Will wear off after the vehicle has braked several times Linings damaged Replace the shoe set Friction losses too great Ensure that the transmission Corrosion of the tow s
9. the best protection against corrosion available U bolts brake back plates fastenings winches and other fitments are electro plated which does not offer the extended protection of galvanised parts Therefore special care of additional protective coatings should be applied to these components e The Alko Euro hubs as described in this manual are fitted with the waterproof bearings However this does not mean they are impervious to the vagaries of saltwater immersion Regular service inspections are still necessary to ascertain the condition of the bearings The simplest way to do this is with the wheels off the ground Place the hands on the top of the free wheel and rock back and forth to check for bearing play A small amount of play should be present If the wheel rocks excessively more than 2mm the bearings are either worn or the flange nut needs to be checked that it is done up to the correct torque e Also at the same time the wheel can be spun It should spin freely If a rumbling or grinding noise can be heard it is likely that the bearing is worn and should be replaced First check that any noise is not due to brakes binding Once it is determined that the bearing is failing then the hub must be removed see 5 1 2 If the hub found to be severely corroded then we recommend replacing the complete hub Order from the hub reference no stamped on the hub e The principle cause of bearing failure in our opinion is due to poorly maintain
10. winch with the strap fully extended Always leave at least three turns of strap on the reel e Only operate the winch manually The winch should not be operated by a motor of any kind If the winch cannot be cranked easily with one hand then it is probably overloaded e Never park your loaded trailer for any length of time with the handbrake on as the brakes will bind to the drums Always chock the wheels do not rely on the handbrake to hold the trailer on an incline 2 2 Towing your trailer 2 2 1 Attaching the trailer to your towing vehicle Become methodical about hitching up so you do not forget anything Use the following instructions to safely attach your trailer to your vehicle e Slowly reverse your vehicle to within a few feet of the coupling You may need a helper to stand with their hands showing you where the hitch is e Raise the front of the trailer by means of the jockey wheel assembly to the required height and roll the trailer up to the rear of the towing vehicle Do not use the winch handle jockey wheel or any other moving part for pulling or manoeuvring the trailer SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com If the trailer has tandem axles then raising the jockey wheel sufficiently to raise the front wheels off the ground will aid manoeuvrability Lower the trailer by means of the jockey wheel assembly onto t
11. 230 5671 e mail sales sbstrailers com You can also contact us at the usual address SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com
12. 30 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 12 SBS TRAILERS 4 4 1 AL KO 2051 Euro Hub 44 811003 ETI No Backplate Welded LH Backplate Welded RH Detachable Bowden Cable Outer Cable Length Cable Eye Cast Version Pressed Version Reverse Lever Spring Reverse Lever LH Reverse Lever RH Brake Shoe Pair Pull off Spring Expanding Clutch Brake Drum Complete 350mm 530mm 770mm 890mm 1020mm 1130mm 1320mm 1430mm 1620mm 1790mm 112 x 5 M12 x 1 5 139 7 x 4 M12 x 1 5 140 x 5 M14 x 1 5 165 1 x 5 M16 studs 972372 572373 247281 247282 247283 247284 247285 247286 247287 247288 247289 247290 371388 604262 2187370003 571386 571387 ECS BRCMP06 2082000007 571510 573194 610529 578834 578835 SBS Trailers AL KO KOBER Ltd 2004 Flange Nut Dust Cap Wheel bolt 582506 582505 Conical M12 x 1 5 2081670018 R12 Spherical M12 x 1 5 2081670020 R14 Spherical M14 x 1 5 2081670002 Wheel Nut Spherical M16 x 2 F14631002 Conical M16 x 2 602439 Bearing Bolt Split Pin 4 x 20 DIN 94 Shoe Retaining Spring Adjuster Assembly Complete Plastic Plug Cover Plate Bowden Cable Shell Stub Axle Locking Nut Cover Included with ECS BRCMP06 item 6 Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com 368651 700192 2088800003 387706 373245 2382610002 371387 5825
13. 41 703112 582542 e sales sbstrailers com 13 SBS TRAILERS 4 5 Coupling heads 4 5 1 AL KO 161S to suit 70mm box oO OO OO BW ND ks O Coupling Head 50 mm Damper Hexagon Nut M12 DIN 985 10 A3C Gaiter Bump Rubber Hexagon Nut M12 DIN 985 10 A3C Front Bearing Bush Not Reamed Spacer Hexagon Bolt M12 x 70 DIN 931 Housing Complete with Bearings Overrun Shaft Rear Bearing Bush Not Reamed Hexagon Nut M12 DIN 985 10 A3C Grease Nipple AM 8 x 1 Overrun Lever Lever Stamped 27 Lever Stamped 25 Grease Nipple AM6 Included in Item 15 Quote Model Details 370556 702750 366356 371372 702750 353943 370559 700061 Quote PartNo amp ETI No 571873 353942 702750 2171710001 380265 380692 700203 SBS Trailers Burst Ring Handbrake Pivot Bolt Handbrake Assy Includes Burst Ring Item 17 amp Breakaway Cable Item 20 Breakaway Cable NOTE For Overruns Produced from Jan 94 Onwards Order Assembly Part No Includes Items 17 amp 20 Hexagon Bolt M12 x 90 DIN 931 Reinforcement Plate Washer 19 2 x 34 x 3 DIN 125 Jockey Wheel Clamp Kit Complete Pressed Steel Clamp Illustrated Cast Clamp Not Illustrated Part No Details 811033 ETI No Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com 2045470102 581145 220096 209157 380843 700312 581699 370693 293020 285750 e sales sbstrai
14. 5671 w www sbstrailers com e sales sbstrailers com 2 Loading Towing and Unloadin 2 1 Loading your trailer e Recover the craft onto the trailer by using the trailer winch e Check the winch and ratchet are undamaged then extend and attach the winch strap to the external bow eye on the hull of the craft e Never use any other fitting on the boat to attach the winch strap To unwind or reel out the strap securely grip the winch handle and apply force in a clockwise direction so that the ratchet lever can be disengaged Carefully turn the handle in a counter clockwise direction Do not lose control Never use the winch to pull the trailer up a slip or to let it down a slip On A many winches the handle cannot be disengaged If the ratchet lever fails then the handle will also spin violently Also never exceed rated capacity excess load may cause premature failure and could result in serious personal injury e Never drive the boat onto the trailer as this can result in serious damage to the hull if you misjudge it e Be aware of people in the water trying to help and make sure they stay away from the propeller e Wind the winch strap onto the winch reel by turning the winch handle in a clockwise direction with the ratchet lever in up position The ratchet should produce a loud clicking noise Make sure that the ratchet lever is in up position and holding the load before releasing the handle e Never apply load on the
15. 6406 Up to 750 kg 140 x5 M14 x 1 5 578825 Backplate Welded RH up to 650kg 571377 112 x 5 M12 x 1 5 586450 Backplate Welded LH up to 750kg 586407 Flange Nut 581200 Detachable Bowden Cable Dust Cap 581197 Outer Cable Length Wheel bolt Conical M12 x 1 5 2081670018 350mm 299707 Spherical M12 x 1 5 2081670020 530mm 299708 Spherical M14 x 1 5 2081670002 770mm 299709 890mm 299710 Bearing Bolt 368651 1020mm 299711 Split Pin 4 x 20 DIN 94 700192 1130mm 299712 Shoe Retaining Spring 2088800003 1320mm 299713 1430mm 299714 1620mm 299715 1790mm 299716 Adjuster Assembly Complete 387706 373188 604262 Cable Eye Pressed Version 373245 2382610002 Plastic Plug Cover Plate Reverse Lever Spring 2187370003 Bowden Cable Shell 371387 Reverse Lever LH 571386 Reverse Lever RH 571387 Stub Axle Brake Shoe ECS BRCMP02 Stabilform up to 900kg 583563 Pull off Spring 2182000007 Stabilform 900kg 1300kg 581043 Expanding Clutch 571510 Forged S A 900kg 1500kg 583664 Brake Drum Complete 98 x4 M12 x 1 5 573191 100 x 4 M12 x 1 5 Up to 650kg 573192 101 6 x 4 M12 x 1 5 610949 112 x 5 M12 x 1 5 573193 702881 581196 Locking Nut Cover Included with ECS BRCMP02 item 6 SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 2
16. O FW D Damper Hexagon Nut M12 DIN 985 10 A3C Gaiter Bump Rubber Hexagon Nut M12 DIN 985 10 A3C Front Bearing Bush Not Reamed Spacer Hexagon Bolt M12 x 80 DIN 931 Housing Complete with Bearings Overrun Shaft Rear Bearing Bush Not Reamed Hexagon Nut M12 DIN 985 10 ASC Grease Nipple AM 8 x 1 Details 370589 702750 366356 371372 702750 353943 357242 700945 Quote Part No amp ETI No 571874 353942 702750 2171710001 SBS Trailers Lever Stamped 27 Lever Stamped 30 Grease Nipple AM 6 Included in Item 15 Burst Ring Handbrake Pivot Bolt Handbrake Assy Includes Burst Ring Item 17 amp Breakaway Cable Item 20 Breakaway Cable NOTE For Overruns Produced from Jan 94 Onwards Order Assembly Part No Includes Items 17 amp 20 Hexagon Bolt M12 x 90 DIN 931 Reinforcement Plate Washer 19 2 x 34 x 3 DIN 125 Jockey Wheel Clamp Kit Complete Pressed Steel Clamp Illustrated Cast Clamp Not Illustrated Part No Details 4 811025 ETI No Lever Ratio Stamp Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com 380265 380285 700203 2045470102 581145 220099 209157 380843 700312 581699 370693 293020 285750 e sales sbstrailers com 16 SBS FRAILERS 4 5 4 Info for all AL KO couplings The coupling head is designed to engage automatically with the international 50mm towing ball recommended by B
17. OUNTING Description Sleeve Ratchet Spring Ratchet Kit Spacer Locknut Bolt Reel Shaft DL1800A 2000A Reel Shaft DL2500A Reel Shaft DL3200A opacer Reel Reel 1 1 8 Hub DL1g00A 2000A Reel 2 1 2 Hub DL1800A 2000A Opt Reel 1 1 8 Hub DL2500A Reel 2 1 2 Hub DL2500A Opt Reel 1 1 8 Hub DL3200A Reel 2 1 2 Hub DL3200A Opt Carriage Bolt Rope Clamp Nut J Gear Cover DL1800A 2000A Opt Gear Cover DL2500A Opt screw Optional 2 Rope Clamp Kit Some winch spares may need to be ordered in specially Please call for details SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 21 SBS TRAILERS 4 6 4 Information for all winches a IMPORTANT SAFETY INFORMATION This winch is built for poke cove hauling as os operations It is not recommended for lifting appli cations For lifting use a self lo ocking inch D nches are not to be used as hoists for lifting supporting people could be present Respect this winch High fo force i inch i should be operated and mai i cas 8 wal nce with instructions Never allow children or on pe is not familiar with the operation of the rt dance it Maintain a firm grip on the winch handle at all times never r release the handle when dran ever is n oan cked position with a load on the winch Otherwise could cause ise handle will spin vi
18. Version 1 1 Updated 05 08 SBS TRAILERS INFORMATION SERVICE MANUAL amp PARTS LIST SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com SBS TRAILERS SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com SBS TRAILERS TO BE COMPLETED BY DEALER ee OC Date Of Manufacture SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com SBS TRAILERS SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com SBS TRAILERS CONTENTS General Information i 1 1 1 You and your towing vehicle ll Es 1 2 Yourtrailer_ r M Zen 1 2 1 Specification and loading nial Zen 1 2 2 Identification lt Bann 1 3 Axle Plates 2 S 1 4 Capacties _ n a 1 5 Torque settings xr l l Lll lu s a 1 6 Tyre pressure information re v r 2 Loading Towing and Unloading kaka 4 un 2 1 Loading yourtraler LLL 2 2 TOWING Your Trailer c Lu L 2 2 1 Attaching your trailer to your vehicle UU aaa 1 2 2 2 Checks before eachjourney a S N x lLLlJUUU uuuu Y 6 IU 2 2 3 1 General 00 0 6 POE E E E 2 2 3 2 Reversing a O _ u 2 3 Unloading your trailer _ 0 AA O _ 9 General
19. bstrailers com 26 5 2 Replacing the brake shoes 2 TRAILERS e lf the individual parts are to be removed from the wheel brake the Bowden cable on the balance bar must be loosened and unhooked from the expander clutch e Replace brake shoes where linings have a residual thickness of less than 2mm Use genuine AL KO replacement parts e Also replace the shoe pressure springs and cover plate if required On type 1637 the left and right brake shoes are different The embossed markings see arrows must be followed when fitting brake shoes Fig 19 On types 2051 and 2361 the left and right shoes are identical Replace the brake shoe pressure springs if any signs of weakness 5 2 1 Expanding clutch Lubricate stiff expander lever pivots Replace expanders that have seized up pivots Note the correct position for fitting Expander lever pivot arm 2 to transmission lever pivot bolt 1 Fig 20 The two pivot points must always be on the same side of the overall assembly If the above instructions are not A followed the brake application stroke will be altered and the braking effect impaired SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com SBS TRAILERS 5 2 2 Return springs e Replace relaxed or damaged return pull off springs 5 2 3 Transmission lever e Remove stiff transmission levers and
20. ctly distributed i e not too much or too little nose weight Is the load within the trailers official payload Is the gross weight being towed within the towing vehicle manufacturers recommended maximum limit whether braked or unbraked Is the load correctly secured Are all of the electrical components undamaged and working correctly Is the correct number plate fitted both registration and style Is the breakaway cable or secondary coupling undamaged and correctly connected to a suitable point on the tow bar or towing vehicle and the trailer correctly coupled to the tow ball Are the tyre pressures correct with all tyres free from cuts and bulges and do they have adequate tread including the spare Tyres must have a continuous tread depth of at least 1 6mm on cars light vans and trailers across the centre three quarters of the width of the tyre 1mm for other vehicles Are the wheel nuts bolts tightened to the correct torque Are the mudguards in satisfactory condition and secure Is the coupling height correct i e not excessively nose down or nose up Make sure that the trailer is level wnen coupled to the towing vehicle Unless the trailer is very light or unloaded is the nose weight between 50 and 100kg Are the jockey wheel and any corner steadies or prop stands fully wound up and secure SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbst
21. e 1 is taken with it and moves the transmission lever 4 back This lever then pushes the leading brake shoe 2 against the stop 6 The caravan trailer is then braked t 0845 230 5670 It must be noted that when the handbrake is applied the vehicle may roll approximately 25cm 10 backwards before the parking brake force is used to its fullest extent SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD f 0845 230 5671 w www sbstrailerscom e sales sbstrailers com 10 SBS TRAILERS t 0845 230 5670 4 3 Wheel bearing The wheel bearing is a double row inclined ball bearing It has the following advantages over normal bearings e No adjustment necessary e Easy to maintain lubricated for life and sealed e Protected against dirt ingress sealed unit e Less sensitive to seizure than a taper roller bearing e All trailers from 2007 onwards are fitted with waterproof bearings of the drum as this may damage the bearing and brake drum The bearing must not be pressed out SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 11 SBS TRAILERS 4 4 AL KO hubs 4 4 1 AL KO 2361 euro hub AL KO KOBER Ltd 2004 Description AL KO Item Description AL KO Item No No Backplate Welded LH up to 650kg 571376 139 7 x 4 M12 x 1 5 578826 Backplate Welded RH up to 750kg 58
22. ed or incorrectly adjusted brake cables Due to their exposed position on the trailer they suffer from contamination from road salt and dirt and spray before they have even got near a launch site These cables must be regularly checked to ensure that they allow the brake shoes to release fully If not they can cause the shoes to bind on the hub causing excessive heat build up which literally boils the grease out of the bearing leading to inevitable failure e Trailers from 2007 onwards are fitted with stainless steel cables These are now available as retrofit for older trailers e The winch webbing strap must also be regularly checked for damage or wear Replace when worn As far as possible ensure that during recovery the strap lies flat against itself This will help prolong its life and avoid snarl ups Following these simple and largely common sense guides together with the service details outlined in this manual should ensure years of trouble free trailing If you require clarification of any points or have any comments with regards to the quality and design of your SBS trailer we would be pleased to hear from you Contact details are as below SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com SBS TRAILERS 4 Function 4 1 Operation of the overrun brake system Draw shaft transverse force AAN 4 2 Service brake The overrun device
23. haft linage including the brake control rod is moving smoothly Reversal is sluggish or Only occurs if the braking Re adjust the braking impossible system has been set too system tightly Brake overheats during Set incorrectly Re adjust the braking forward travel system Braking system is not Release the handbrake released properly during forward travel Check the transmission linkage and transmission lever of the overrun device check that they are moving smoothly buckled broken Rust beginning to form in Replace the brake drum the brake drum see page 9 and also the brake shoes if necessary Handbrake effect too weak Linings not bedded in Will wear off after the vehicle has braked several times Friction losses too great Ensure that the transmission linage including the brake control rod is moving smoothly system Jerky braking Defective shock absorber on Replace the shock absorber the overrun device braking system system SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 29 SBS TRAILERS SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 30 SBS TRAILERS You can order your spare parts or request this booklet in large print full colour or soft copy by phone fax or e mail Tel 0845 230 5670 Fax 0845
24. he tow ball of the vehicle Some coupling heads have a locking handle which stays up and automatically locks onto the ball others have to be held up and may have an indicator to show the ball is in place Once the coupling head appears to be locked on lower the jockey wheel a few turns to lift the back of the vehicle to prove that the coupling head is on properly then fully raise the wheel before unclamping it and finally locking it fully raised Check that the wheel is not interfering with the operation of the overrun mechanism this could cause damage to your trailer or your vehicle Attach the safety breakaway cable to the rear of the vehicle This cable will apply the handbrake if for any reason the trailer becomes detached whilst towing Clip the breakaway cable to the special rings that some tow bars have or loop it around the bar making sure not to foul the coupling head Do not loop it around the tow ball neck unless you can find no alternative Check that the breakaway cable and lighting cables have enough slack for cornering but will not touch the ground Plug in the lighting plug and check all lights and indicators The electrical plug only fits one way so line up its cutout with the lug on the bottom edge of the socket Some cars have two sockets use the one with the black cover flap The white flap is for caravan supplementary electrical systems 2 2 2 Checks before each journey If the trailer is laden is the load corre
25. lers com 14 OON O O O PD oO SBS TRAILERS 4 5 2 AL KO 251S to suit 80mm box Coupling Head 50mm Damper Hexagon Nut M12 DIN 985 10 ASC Gaiter Bump Rubber Hexagon Nut M12 DIN 985 10 ASC Front Bearing Bush Not Reamed Spacer Hexagon Bolt M12 x 75 DIN 931 Housing Complete with Bearings Overrun Shaft Rear Bearing Bush Not Reamed Hexagon Nut M12 DIN 985 10 A3C Grease Nipple AM 9x 1 Overrun Lever Lever Stamped 27 Lever Stamped 30 Lever Stamped 33 5 Quote Model Details 370589 702750 366356 371372 702750 353943 357242 701249 Quote Part No amp ETI No 571874 353942 702750 375900 380265 380285 380527 Grease Nipple AM 6 Included in Item 15 Burst Ring Handbrake Pivot Bolt Handbrake Assy Includes Burst Ring Item 17 amp Breakaway Cable Item 20 Breakaway Cable NOTE For Overruns Produced from Jan 94 Onwards Order Assembly Part No Includes Items 17 amp 20 Hexagon Bolt M12 x 105 DIN 931 Reinforcement Plate Washer 17 2 x 30 x 3 DIN 125 Washer 17 x 27 x 2 700203 2045470102 2077710503 219010 209157 380843 700313 581699 700625 700273 Part No Details 4 811019 ETI No Lever Ratio Stamp SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com SBS TRAILERS 4 5 3 AL KO 251S delta Coupling Head 50mm Quote Model Overrun Lever O ON D
26. manufactured axles use a prefix A and Achslast TA Achslast capacity on rectangular plates Fig 3 Mod 1 4 Capacities A The vehicle weight must not exceed the maximum permissible weight On tandem axle sets the correct capacity is NOT double that indicated on the axle i e 2x750kgs 1500kgs Because of weight transference as axle transverse uneven ground the capacity of each axle is reduced by 100kgs to allow for the excess that may be loaded on one axle at a time Therefore a tandem set of 2x750kg has a MAXIMUM CAPACITY of 1300kg NOT 1500kg THIS RULE MUST BE OBSERVED A Never remove the axle identification plate from the axle tube SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com S TRAILERS 1 5 Torque settings meadi 9 f f 280 300 290 10 214 7 5 lbs ft 600 to 650 700 to 750 DO NOT TOUCH if disturbed return to AL KO Shock absorber attachment Nm 86 Nm 63 5 Ibs ft Axle attachment Nm 86 Nm 63 5 Ibs ft 1 6 Tyre pressure information net max load to be used as ati 400x 8 165 x 13 520 x 10 165 x 13 500 x 10 175 x 13 Tightening Torque Nm Tightening torque Nm 500 x 10 175x 13 500 x 10 185 70R13 145 x 10 195 50R13 145 x 10 175 x 14 155 x 13 185 x 14 SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230
27. ng behind you because of the large blind spot Ideally have someone see you back especially in crowded places Reversing a trailer is skill that can be mastered with a little perseverance by anyone who has learned the basic theory Find somewhere with plenty of space and practice reversing It helps to have someone who knows how to do it to tell you if and where you are going wrong 2 3 Unloading your trailer The first step to safely launching your craft is to check the ground over which the trailer and vehicle will be running Ensure that it is relatively level and not too soft Avoid launching on surfaces that are too soft and loose as it may cause difficulties when removing your trailer and vehicle from the launch area Ensure that there is enough depth of water for your boat to clear any objects in the water or on the sea river bed Once you are satisfied with the launch area please follow these instructions to help you launch easily e Ensure that all security straps are removed from over the boat and that the light set has been removed from the back of the trailer SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com SBS TRAILERS e Reverse slowly down to the waters edge with the assistance of somebody in the boat and continue reversing until the boat begins to float e f using a bunk style trailer you will need to submerge the trailer
28. olently w hub increases ed on the winch Bil hapa Sr app load on winch with cable or rope fully extended Keep at least thr on the reel Secure load properly When winching operation is complete do not depend on winch to support load Operate with hand power only This winch should not be si beet with a motor of any kind If the winch cannot be cranked easily with one hand it is probably lo Leeks Insert bol ch d sole in both real sidopla kiss so that nut is on gear side Tightan only untl snug with bolt in bottom of slot next to reel hub Select a winch line with breaking strength at least 1 1 2 times the winch rating and a hook 1 1 2 times stronger than the line If steel cable is OPERATING INSTRUCTIONS Attach winch handle securely to primary drive shaft upper peed shaft Make sure that handle clip engages with groove in drive shaft Wind line on inch ree by turning I handle counteroook j afore gt Wa peel ng is sed To unwind or reel c out lina securaly grip winch handle and apply force in counterclockwise direction so that ratchet lever can ea sily be moved to up position Carefully turn handle in clockwise direction Do not lose control If handle is attached to rmediate lower or high speed shaft operate as described above reversing clockwise and counter clockwise The winch can be converted to wind line tion and holdin ver To Unwind ot lose small parts
29. on an average slope slipway to roughly halfway up to the wheel With a roller trailer you should be able to launch as soon as your boat has around 300mm clearance of water under the keel once floating e Once you have reached this depth push the boat off the trailer slowly Never use the winch to pull the trailer up a slip or to let it down a slip On many winches the handle cannot be disengaged If the ratchet lever fails then the handle will also spin violently e Be aware of any tidal or stream effects in the water otherwise you may end up with your boat floating in the wrong direction e Once your boat has been launched thoroughly rinse the trailer with fresh water this will greatly increase the life of your trailer and its parts In the case of braked trailers once this has been done drive your trailer for a few hundred metres and apply the brakes a few times This will heat up the brake drums and dry up any excess fresh water on the brake pads and drums SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 3 General Maintenance Due to the harsh environment many trailers operate in the following points should be noted e Whilst all components carry manufacturers warranty of 12months against defective parts immersion in saltwater invalidates some warranties e The frame and axle beam together are galvanised and hence offer
30. railers com a i 2 2 3 Driving 2 2 3 1 General Always keep to the legal limit for the road that you are using In the UK e 30mph limit applies on all roads with street lighting unless signs show otherwise e 50mph applies on singles carriageways unless signs show otherwise e 60mph applies on dual carriageways motorways and all other National Speed Limit roads e You must nol travel in the right hand lane of a motorway with three lanes or more if you are towing a trailer e Always drive at a speed that is well within your capabilities and is suitable for the road and weather conditions that prevail at the time e f your trailer begins to snake or swerve ease of the accelerator and reduce speed GENTLY This can happen if you are driving too fast or if load on the trailer is wrongly positioned e Do NOT brake sharply on a bend this could cause a possible jack knife situation Reduce speed before bends and use the appropriate gear for the speed that you are travelling then gently accelerate out of the bend e When turning with your trailer the overall length of your towing vehicle and trailer effectively lengthens the wheelbase Consequently it is necessary to compensate by slightly widening your turning circle to avoid curbing Remember that your trailer does not follow the same line around a corner as the towing vehicle it will cut the corner 2 2 3 2 Reversing Never reverse a trailer without checki
31. ritish Standards Institution National Caravan Council Society of Motor Manufacturers and Traders and ISO AL KO coupling heads incorporate a correct attachment indicator Coupling heads should never be drilled AL KO produce several types of coupling head each having provision for an anti theft device as an optional extra which consists of a key operated brass insert The anti theft device comes complete with two keys Securing the coupling head inhibits movement of the locking catch making it possible to lock the coupling whether or not the towing ball is connected 4 5 4 Bradley coupling head HEAD HANDLE ae TRIGGER 3 se asa F ALLOWANCE FOR BALL WEAR 3mm A ONCE COUPLED TOGETHER IF THE SQUARE LUG 1 AT THE REAR OF THE HEAD HANDLE 2 IS RESTING ON THE BOTTOM OF THE SLOT IN THE TRIGGER 3 EITHER THE COUPLING HEAD OR THE TOW BALL 50mm DIA BALL OR BOTH ARE WORN B IF SO CHECK FURTHER BY USING A NEW 50mm BALL IF THE LUG REMAINS AT THE BOTTOM OF THE SLOT THE COUPLING HEAD IS EXCESSIVELY WORN AND SHOULD BE REPLACED HOWEVER IF THE LUG IS NOW RIDING NOTICEABLY HIGHER UP THE SLOT YOUR ORIGINAL 50mm BALL SHOULD BE REPLACED N B IFYOU NEED TO REPLACE YOUR COUPLING HEAD REMEMBER TO CARRY OUT THE FIRST CHECK ONCE MORE AS YOUR 50mm BALL MAY NEED REPLACING AS WELL SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com
32. s 8 6 Troubleshooting 29 SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com SBS TRAILERS 1 General Information 1 1 You and your towing vehicle You are legally obliged to ensure the following e That the towing limit recommended by your vehicle manufacturer is greater than the Gross Vehicle Weight GVW of your trailer Your vehicles towing limit can be found in the vehicles handbook or on the VIN plate on the chassis e That the tow bar fitted to your vehicle is appropriately rated e That your driving licence permits you to tow the specified combined weight of your vehicle and trailer Failure to do so is breaking the law 1 2 Your trailer 1 2 1 Specification and loading Your trailer has been specified from information supplied to us about the craft you wish to tow including weight length and hull type Do not attempt to carry any load other than that for which it has been specified Consult your dealer or SBS Trailers if in doubt 1 2 2 Identification The unique serial number of 3 SBS Lid MACROME ROAD WOLVERHAMPTON your trailer can be found on the d A TELEPHONE 01902 755133 FAX 01902 755363 ID Plate at the front nearside of ay L www sbstrailers co uk m SERIAL No SSE g UNLADEN WEIGHT I Eli KGS the A Frame Fig 1 The ID Plate displays the trailer be s max cross LOAD EEE cs model Serial
33. skimmed e Completely release the handbrake Loosen the linkages if necessary SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 5 1 3 Visual checks Fig 17 gt Sp I _ Spring carrier Adjuster housing 7 HE Transmission lever eee Hi _ Adjusting nut RL ection hole Tairgs Shoe mn free Wa oy reverse Check the condition of the brake shoes The wear on the shoes is greatest where the inspection hole opening is located on the brake back plate In the case of the simplex brake the leading shoe overrun shoe in the direction in which the drum turns is pressed against the brake drum The secondary shoe trailing shoe is pressed away from the drum against the direction in which the drum turns This is why the two brake shoes have different degrees of wear e The transmission lever 1 must be abut on the adjusting housing 2 stop 5 1 4 Function tests Check that the expander pivot adjusting nut and transmission lever are moving smoothly Check the adjuster housing and adjuster assembly are lubricated use Molybdenum Disulphide grease Check the tension on the leaf spring and check that the adjusting nut is properly engaged Check the pressure on the brake shoe pressure springs SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD t 0845 230 5670 f 0845 230 5671 w www sbstrailers com e sales s
34. sting the wheel brake only turn the wheels in the forward direction so that reverse mode is not actuated SBS Trailers Macrome Road Tettenhall Wolverhampton WV6 9HD f 0845 230 5671 w www sbstrailers com e sales sbstrailers com 24 iS TRAILERS 5 1 2 Servicing the wheel brakes e Remove the wheel rim and tyre e Mark the position of the plastic cap on the rocker arm with a felt tip pen so that any movement can be detected Fig 15 A If the stub axle or back nut are moved in any way this will alter the toe in and camber resulting in excessive and unequal tyre wear Should such movement take place the axle will have to be removed and returned to AL KO to be re aligned and or repaired e Knock cap 1 with a hammer and a blunt chisel from below When reinstalling use a new cap 1 and locate using a former 2 Fig 16 e Unscrew the flanged nut When refitting use a new self locking flanged nut e Before fitting a new flanged nut a small amount of the special mineral grease AL KO Part No 800052 must be applied to the stub axle thread A Note the tightening torque The wheel bearing free play is adjustable via the tightening torque of the flanged nut Section 1 6 Torque Settings e Replace worn brake drums showing e Turn the brake drum slightly by hand grooves or significant corrosion and remove If necessary hit the cooling fins with a rubber mallet A Brake drums must not be re
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