woodmizer AL-KO Kober Guide

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
!

Table of Contents Section-Page
2 TUVdoc053121 Table of Contents
SECTION 1 SAFETY & GENERAL INFORMATION 1-1
1.1 Safety measures ......................................................................................................... 1-1
1.2 Fitting and adjustment ............................................................................................... 1-2
SECTION 2 MAINTENANCE 2-1
SECTION 3 ADJUSTING THE BRAKING SYSTEM 3-1
3.1 Adjusting the braking force of the left and right wheel............................................. 3-1
3.2 Adjusting the brake rod and Bowden cables ............................................................. 3-3
SECTION 4 TROUBLESHOOTING GUIDE 4-1
4.1 Overrun Device And Axle Problems......................................................................... 4-1

Table of Contents Section-Page
Table of Contents TUVdoc053121 3
SECTION 5 PARTS LISTS 5-1
5.1 How To Use The Parts List ....................................................................................... 5-1
5.2 Sample Assembly ...................................................................................................... 5-1
5.3 Trailer Brake 3081 Assembly .................................................................................. 5-2
5.4 Euro-Brake 2051 Assembly ...................................................................................... 5-4
5.5 Euro-Brake 2361 Assembly ...................................................................................... 5-6
5.6 Trailer Hitch Assembly 161S .................................................................................... 5-8
5.7 251S Trailer Hitch Assembly .................................................................................. 5-10
5.8 Trailer Hitch Assembly, 2.8 VB.............................................................................. 5-12
5.9 Eye-Hook Hitch (Italian Market Only) ................................................................... 5-14
5.10 Trailer Assembly, 1.6T ........................................................................................... 5-15
5.11 Trailer Assembly, LT40S 1.8T ............................................................................... 5-17
5.12 Trailer Assembly, LT40M 1.8T ............................................................................. 5-19
5.13 Trailer Assembly, 2.2T ........................................................................................... 5-21
5.14 Trailer Assembly, 2.6T ........................................................................................... 5-23
5.15 Trailer Assembly for M Super/LT70M Super Frame ........................................... 5-25
5.16 Trailer Assembly for M Super/LT70M Super 2.6 Frames...................................... 5-26
5.17 Trailer Assembly, 3.0T, S and M Frames ........................................................... 5-28
5.18 Trailer Assembly, 3.0T, M Super Frame .............................................................. 5-30
5.19 Tandem Trailer Assembly, 3.0T ............................................................................ 5-32
5.20 Trailer Assembly, 2.2 ............................................................................................. 5-34
5.21 Complete Fence, ”M” Frame ................................................................................ 5-36
5.22 Complete Light Beam, ”M” Frame ....................................................................... 5-38
5.23 Trailer Assembly, 2.6T .......................................................................................... 5-40
5.24 Lighting Kit for 9 m Frame .................................................................................. 5-42
5.25 Outrigger Assembly (Front), Optional ................................................................. 5-45
5.26 Outrigger Assembly (Middle and Rear), Optional ................................................. 5-46
5.27 Outrigger Assembly (Side), Optional ..................................................................... 5-47
5.28 Outrigger Assembly (S & M Frame), Optional .............................................. 5-48
5.29 Outrigger Assembly (L Frame), Optional ............................................................. 5-49
5.30 Fence Assembly, S Frame ....................................................................................... 5-50
5.31 Fence Assembly, M Frame...................................................................................... 5-52
5.32 Fence Assembly, LT40 Wide ”M” Frame ............................................................ 5-54
5.33 Fender Assembly ..................................................................................................... 5-56
5.34 Fender Assembly, Trailer without Fence ............................................................... 5-57
5.35 Fence Assembly, LT70M Super.............................................................................. 5-58
5.36 Light Bar Assembly, S Frame ................................................................................. 5-60
5.37 Light Bar Assembly, M Frame................................................................................ 5-62
5.38 Light Bar Assembly, M Frame................................................................................ 5-64
5.39 Light Bar Assembly, L & M Super Frame.............................................................. 5-66
5.40 Fine Adjust Outrigger Leg .................................................................................... 5-68
SECTION 6 ELECTRICAL INFORMATION 6-1
6.1 Electrical Symbol Diagram ....................................................................................... 6-1
6.2 Electrical Components............................................................................................... 6-3

Safety & General Information
Safety measures
Safety & General Information TRdoc053121 1-1
1
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
result in death or serious injury. WARNING suggests a potentially hazardous situation
which, if not avoided, could result in death or serious injury. CAUTION refers to potentially
hazardous situations which, if not avoided, may result in minor or moderate injury to
persons or equipment. Read all safety instructions before operating this equipment and
observe all safety warnings!
1.1 Safety Measures
The overruns are specially design for the new AL-KO wheel generation according to the
toxic substance regulation and EC directive.
When parking a towing vehicle with the trailer hooked on, one must apply the handbrake
of the trailer. If the trailer is disconnected from the vehicle, additional safety is given when
using two wheel chocks.
DANGER! The braking system may not function if used
with different wheel brakes.

Safety & General Information
Fitting and adjustment
1
1-2 TRdoc053121 Safety & General Information
1.2 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 the
handbrake does not work.
DANGER! The breakaway cable enables the trailer to
brake, should it become detached from the towing vehicle.
Loop the breakaway cable through the neck of the towball
and fasten with safety hook on the cable. Do not attach the
safety hook directly onto the hook.
DANGER! The breakaway cable automatically operates
the handbrake lever in the event that the trailer should
become detached from the towing vehicle. The driver is
therefore required to ensure that the cable is correctly
attached before every journey.
DANGER! Chock the trailer wheels to prevent movement
before unhitching it from the towing vehicle. Failure to do so
may result in serious injury or death.
DANGER! Be sure that the hitch and safety chains are
secure before towing the sawmill. Check all lights and
signals for correct operation. Check to see tires are
properly inflated and surge brakes are working before
towing the sawmill.
WARNING! Always check trailer tires for proper inflation
before towing sawmill.
CAUTION! Always keep away from tailer axle to avoid
being caught between the axle and moving saw carriage.

Maintenance
Maintenance TRdoc053121 2-1
2
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. 2-1

Maintenance
2
2-2 TRdoc053121 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.
2. Push screw (3) through the damper lug and lock check operating of coupling.
3. Push damper (6) in from rear and secure using screw and plate.
4. Locate bellows (8) on the screw(3). Torque: 86 Nm

Adjusting the braking system
Adjusting the braking force of the left and right wheel
Adjusting the braking system TUVdoc053121 3-1
3
SECTION 3 Adjusting the Braking System
3.1 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.
1. To adjust the braking force of the brake drum, the wheel to be adjusted should be lifted
using a jack so that it can be freely rotated.
2. When the wheel is already lifted, remove the green cap located on the inside of the wheel
to expose the adjustment hole.
See Photo 3-1
PHOTO 3-1

Adjusting the braking system
Adjusting the braking force of the left and right wheel
3
3-2 TUVdoc053121 Adjusting the braking system
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.
See Photo 3-2
4. Then loosen the shoes by moving approx. 10 teeth in the adjustment hole in the opposite
direction until the wheel rotates freely.
5. Secure the adjustment hole using the cap removed earlier.
6. Repeat the steps described above for the second wheel (or remaining wheels in case of a
two-axle trailer).
PHOTO 3-2

Adjusting the braking system
Adjusting the brake rod and Bowden cables
Adjusting the braking system TUVdoc053121 3-3
3
3.2 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.
See Photo 3-4
2. Install the jam nut (3) on the brake rod (1) from the side of the overrun assembly.
3. Then screw the brake rod (1) in the sleeve of the fork head (2) all the way and secure with
the jam nut (3).
PHOTO 3-3
1
U
Rod
Handle

Adjusting the braking system
Adjusting the brake rod and Bowden cables
3
3-4 TUVdoc053121 Adjusting the braking system
PHOTO 3-4
1
U
132

Adjusting the braking system
Adjusting the brake rod and Bowden cables
Adjusting the braking system TUVdoc053121 3-5
3
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.
Install the Bowden cables of the road wheels (4) to the yoke (2).
Adjust the brake rod tension using the nut (6). To increase the tension of the brake
rod (1), turn the nut (6) clockwise. To decrease the brake rod tension, turn the nut
(6) counterclockwise.
After the braking system adjustment has been finished, secure the adjustment nut
(6) using the jam nut (5).
PHOTO 3-5
1
U
1
7
2

Adjusting the braking system
Adjusting the brake rod and Bowden cables
3
3-6 TUVdoc053121 Adjusting the braking system
PHOTO 3-6
1
U
1
4
6
2
4
5

Adjusting the braking system
Adjusting the brake rod and Bowden cables
Adjusting the braking system TUVdoc053121 3-7
3
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).
See Photo 3-8
Mount the adjustment nut (11) and lock nut (12) on the brake rod (1).
Mount the nuts on the rod and on the cable so that the yoke has some clearance
(3-4 mm in the horizontal plane) allowing adjustment.
PHOTO 3-7
1
U
1
6
2
5
6
5
4

Adjusting the braking system
Adjusting the brake rod and Bowden cables
3
3-8 TUVdoc053121 Adjusting the braking system
Secure the nut (11) of the rod using the jam nut (12).
When adjusting the nuts (6), be sure the yoke (2) remains perpendicular to the line
of the brake rod. To increase the tension of the brake rod (1), turn the nuts (6)
clockwise. To decrease the brake rod tension, turn the nuts (6) counterclockwise.
After the braking system adjustment has been finished, secure the adjustment nuts
(6) using the jam nuts (5).
See Photo 3-9
4. Step I - press the button (8) on the brake lever and engage the brake several times to
remove the slack of cables.
5. Step II - when the brake is in the released position, pull the brake lever without pressing
the button (8) - the lever should automatically jump upwards (simulation of emergency
engagement of the brake).
PHOTO 3-8
1
U
1
4
2
12
4
11
65
65

Adjusting the braking system
Adjusting the brake rod and Bowden cables
Adjusting the braking system TUVdoc053121 3-9
3
See Photo 3-10
6. The pawl of the brake lever (9) should be locked on the first or second tooth (10).
PHOTO 3-9
1
U
1
4
6
2
4
5
8
Pull the lever upwardsII.

Adjusting the braking system
Adjusting the brake rod and Bowden cables
3
3-10 TUVdoc053121 Adjusting the braking system
7. If the brake lever moves past too many teeth, tighten the brake rod (See Photos 3-6 and
3-8). If the brake lever cannot move past at least one tooth, loosen the brake rod (See
Photos 3-6 and 3-8).
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.
PHOTO 3-10
1
U
1
4
6
2
4
5
9
10

Troubleshooting Guide
Overrun Device And Axle Problems
Troubleshooting Guide TUVdoc053121 4-1
4
SECTION 4 TROUBLESHOOTING GUIDE
4.1 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
Corrosion on connecting rod
Ensure free movement of
linkage including cables
Reversing difficult Occurs only if brake system is
set too tight
Adjust
Brakes overheating
(service braking)
Wrong setting Adjust as per instructions
Brakes not fully released
during forward motion
Slacken handbrake
Check linkage (ease of
movement)
Check transfer lever in
overruns (ease of movement)
Wheel brake dirty Clean
Cable or Bowden cable kinked Replace Bowden cable
Return springs sluggish or
broken
Replace springs
Slight rust deposit in brake
drum
Replace brake drum and if
necessary shoes as well
Hand brake too weak Linings not run in Will correct after brief
running-in period for linings
Friction losses too great Ensure ease of movement of
linkages including Bowden
cable (oil)
Faulty setting Set as per instructions
Uneven or jerky braking Faulty damper Replace damper
Too much play in system Re-set
Premature braking on overrun Faulty damper Replace damper
Coupling does not engage
with towball
Towball diameter larger than
500mm
Replace towball

Troubleshooting Guide
Overrun Device And Axle Problems
4
4-2 TUVdoc053121 Troubleshooting Guide
Internal parts of coupling dirty
or not moving freely. Take care
if snow or ice present
Clean and grease coupling.
Replace if necessary
Trailer can not be uncoupled Towball not round Align trailer and car in same
direction and uncouple
Too much play between
coupling and towball, danger
of uncoupling
Coupling worn Replace coupling
Towball worn
Bucking angle exceeded
Rivet buckled
Replace towball
General instruction Stronger types of overruns and drawbars should be fitted to trailers being
towed by lorries, omnibuses or towing vehicles with rigid suspension. Please consult
manufacturers.

PARTS LISTS
How To Use The Parts List
PARTS LISTS doc053121 5-1
5
SECTION 5 PARTS LISTS
5.1 How To Use The Parts List
Use the table of contents or the index to locate the assembly that contains the part you need.
Go to the appropriate section and locate the part in the illustration.
Use the number pointing to the part to locate the correct part number and description in the
table.
Parts shown indented under another part are included with that part.
Parts marked with a diamond () are only available in the assembly listed above the part.
See the sample table below. Sample Part #A01111 includes part F02222-2 and subassembly
A03333. Subassembly A03333 includes part S04444-4 and subassembly K05555. The diamond ()
indicates that S04444-4 is not available except in subassembly A03333. Subassembly K05555
includes parts M06666 and F07777-77. The diamond () indicates M06666 is not available except in
subassembly K05555.
To Order Parts:
From the continental U.S., call 1-800-448-7881 to order parts. From Europe call our European
Headquarters and Manufacturing Facility at [phone] or [phone]. 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.
5.2 Sample Assembly
REF. DESCRIPTION ( Indicates Parts Available In Assemblies Only) PART # QTY
SAMPLE ASSEMBLY, COMPLETE (INCLUDES ALL INDENTED PARTS BELOW) A01111 1
1Sample Part F02222-22 1
Sample Subassembly (Includes All Indented Parts Below) A03333 1
2Sample Part ( Indicates Part Is Only Available With A03333) S04444-4 1 
Sample Subassembly (Includes All Indented Parts Below) K05555 1
3Sample Part ( Indicates Part Is Only Available With K05555) M06666 2 
4Sample Part F07777-77 1