AL-KO OFF-ROAD PIN COUPLING · AL-KO OFF-ROAD PIN COUPLING USERS MANUAL Save This Manual. Keep this manual for the assembly, operation, maintenance and cleaning procedures. Keep this

AL-KO OFF-ROAD PIN COUPLING USERS MANUALSave This Manual. Keep this manual for the assembly, operation, maintenance and cleaning procedures. Keep this manual and the receipt or proof of purchase in a safe place for future reference.

619400 - Includes Coupling & Pin

WARNINGRead this manual before using this product. Use only AL-KO XPC-1 tow pin with AL-KO XPC-1 tow pin coupling. RETAIN THIS MANUAL.

www.alko.com.au

1. Mounting AL-KO XPC-1 Tow Pin on Tow HitchFit tow pin to tow hitch with supplied spring washer and 7/8” UNF nut and torque to 240Nm (177lb-ft).

Off Road Tow Coupling

Author: Bryan Kennedy Version: 0.1 Date: November 2017

1. Mounting AL-KO Tow Pin on Tow Hitch

Fit tow pin to tow hitch with supplied spring washer and 7/8” UNF nut and torque to 480Nm (355lb-ft).

2. Mounting Tow Coupling onto Drawbar

Use four M12 Class 8.8 or ½ inch Grade 5 Bolts to attach the coupling to the drawbar.

Bolts should be fastened with either nyloc nuts or plain nuts with spring washers.

Bolts should be of an appropriate length to ensure 100% thread engagement of the nut. At least one full thread must protrude past the nut. Please consult your bolt supplier to determine the recommended tightening torque of bolts.

* Ensure that the tow coupling is only used with an AL-KO tow pin. No other pin or tow ball is suitable for use with the ALKO Off Road Pin Coupling. *

Check that the there is enough clearance on the tow hitch – refer to diagram below. Some tow hitch designs are not compatible with the off-road coupling. A nose load of at least 50kg but not exceeding 350kg is recommended.

80mm MINIMUM

TOW PIN COVER (619411)

RED LID BUTTON

AL-KO TOW PIN (619410)

4 X MOUNTING HOLES

Page 1

USE CAUTION NOT TO DAMAGE SEAL WHEN TIGHTENING .!


RED LID BUTTON


4 X MOUNTING HOLES



1. Mounting AL-KO Tow Pin on Tow Hitch

Fit tow pin to tow hitch with supplied spring washer and 7/8” UNF nut and torque to 480Nm (355lb-ft).

2. Mounting Tow Coupling onto Drawbar

Use four M12 Class 8.8 or ½ inch Grade 5 Bolts to attach the coupling to the drawbar.


Bolts should be of an appropriate length to ensure 100% thread engagement of the nut. At least one full thread must protrude past the nut. Please consult your bolt supplier to determine the recommended tightening torque of bolts.

* Ensure that the tow coupling is only used with an AL-KO tow pin. No other pin or tow ball is suitable for use with the ALKO Off Road Pin Coupling. *

Check that the there is enough clearance on the tow hitch – refer to diagram below. Some tow hitch designs are not compatible with the off-road coupling. A nose load of at least 50kg but not exceeding 350kg is recommended.

80mm MINIMUM


RED LID BUTTON


4 X MOUNTING HOLES

2. Mounting AL-KO XPC-1 Tow Coupling onto Drawbar

Use four M12 Class 8.8 or ½ inch Grade 5 Bolts to attach the tow coupling to the drawbar.


Bolts should be of an appropriate length to ensure 100% thread engagement of the nut.

At least one full thread must protrude past the nut.

Please consult your bolt supplier to determine the recommended tightening torque of bolts.

* Ensure that the AL-KO XPC-1 tow coupling is only used with an AL-KO XPC-1 tow pin. No other pin or tow ball is suitable for use with the AL-KO XPC-1 Off Road tow pin coupling. *

Check that the there is enough clearance on the tow hitch – refer to diagram below. Some tow hitch designs are not compatible with the off-road coupling.

A nose load of at least 50kg but not exceeding 350kg is required.

Page 2

80mm MINIMUM

www.alko.com.au



3. How to Hitch

1) Ensure the Pin Cover has been removed from the tow pin. 2) Raise the coupling by using the jockey wheel so it is higher than the tow pin. 3) Align the tow coupling opening over the pin by moving trailer and/or vehicle.

4) Lower the tow coupling onto the tow pin using the jockey wheel. 5) Once the tow coupling is fully seated on the pin, the coupling automatically double locks. Ensure the green indicator on the button showing.

6) When the green indicator is showing and the base of the tow coupling head sits over the tow pin, the coupling is locked on to the tow pin.



3. How to Hitch




3. How to Hitch 1) Ensure the Pin Cover has been removed

from the tow pin. 2) Raise the coupling by using the jockey

wheel so it is higher than the tow pin. Ensure the red lid is pressed down and the button is in (No green showing on the indicator button).

3) Align the tow coupling opening over the pin by moving trailer and/or vehicle.

4) Lower the tow coupling onto the tow pin using the jockey wheel.

5) Once the tow coupling is fully seated on the pin, the coupling automatically double locks. Ensure the green indicator on the button is showing.

6) When the green indicator is showing and the base of the tow coupling head sits over the tow pin, the tow coupling is locked on to the tow pin.

Page 3

Off R

oad Tow Coupling

Author: Bryan Kennedy Version: 0.1

Date: November 2017

4. How to Unhitch

1) Push and hold dow

n red lid. 2) W

hile holding down red lid, push in red button until it rem

ains depressed.

3) Raise the tow

coupling by using the jockey wheel until clear of tow

pin. 4) Re-cover the tow

pin with the supplied pin cover.

5. Maintenance

Regularly flush tow coupling head w

ith water to rem

ove any dirt ingress which m

ight impact function.

Grease the shaft by pumping m

ulti purpose grease into the grease nipples at the front and rear of the body until a sm

all amount if grease appears from

each end of the shaft - see diagram below

.

6. Weight Distribution Hitches (W

DH)

On-road use: The tow

coupling can be used with w

eight distributions hitches for on-road use, providing the coupling’s m

ovement is not restricted by the W

DH. O

ff-road use: Prior to using the tow coupling in an off-road scenario, load levelling devices m

ust be rem

oved, as the off-road coupling is designed for applications which require a large am

ount of articulation and m

ay interfere with load levelling devices.

Grease nipples

1 2 LOCKED

UNLOCKED

Small am

ount of grease visible



3. How to Hitch






3. How to Hitch




Off R

oad Tow Coupling

Author: Bryan Kennedy Version: 0.1

Date: November 2017

4. How to Unhitch

1) Push and hold dow

n red lid. 2) W

hile holding down red lid, push in red button until it rem

ains depressed.

3) Raise the tow

coupling by using the jockey wheel until clear of tow

pin. 4) Re-cover the tow

pin with the supplied pin cover.

5. Maintenance

Regularly flush tow coupling head w

ith water to rem

ove any dirt ingress which m

ight impact function.

Grease the shaft by pumping m

ulti purpose grease into the grease nipples at the front and rear of the body until a sm

all amount if grease appears from

each end of the shaft - see diagram below

.

6. Weight Distribution Hitches (W

DH)

On-road use: The tow

coupling can be used with w

eight distributions hitches for on-road use, providing the coupling’s m

ovement is not restricted by the W

DH. O

ff-road use: Prior to using the tow coupling in an off-road scenario, load levelling devices m

ust be rem

oved, as the off-road coupling is designed for applications which require a large am

ount of articulation and m

ay interfere with load levelling devices.

Grease nipples

1 2 LOCKED

UNLOCKED

Small am

ount of grease visible



3. How to Hitch




ENSURE COUPLING IS ORIENTATED IN THE CORRECT DIRECTION AS PER THE IMAGE ABOVE IN STEP 5 WITH INDICATOR BUTTON FACING TRAILER / CARAVAN.!



4. How to Unhitch

1) Push and hold down red lid. 2) While holding down red lid, push in red button until it remains depressed.

3) Raise the tow coupling by using the jockey wheel until clear of tow pin. 4) Re-cover the tow pin with the supplied pin cover.

5. Maintenance Regularly flush tow coupling head with water to remove any dirt ingress which might impact function. Grease the shaft by pumping multi purpose grease into the grease nipples at the front and rear of the body until a small amount if grease appears from each end of the shaft - see diagram below.

6. Weight Distribution Hitches (WDH)

On-road use: The tow coupling can be used with weight distributions hitches for on-road use, providing the coupling’s movement is not restricted by the WDH. Off-road use: Prior to using the tow coupling in an off-road scenario, load levelling devices must be removed, as the off-road coupling is designed for applications which require a large amount of articulation and may interfere with load levelling devices.

Grease nipples

1

2

Small amount of grease visible



3. How to Hitch




3) Raise the tow coupling by using the jockey wheel until clear of tow pin.

4) Re-cover the tow pin with the supplied pin cover.

4. How to Unhitch 1) Push and hold down red lid. 2) While holding down red lid, push in red

button until it remains depressed.

Page 4

Off

Roa

d To

w C

oupl

ing

Auth

or: B

ryan

Ken

nedy

Ve

rsio

n: 0

.1

Date

: Nov

embe

r 201

7

4. H

ow to

Unh

itch

1)

Pus

h an

d ho

ld d

own

red

lid.

2) W

hile

hol

ding

dow

n re

d lid

, pus

h in

red

butto

n un

til it

rem

ains

dep

ress

ed.

3)

Rai

se th

e to

w co

uplin

g by

usin

g th

e jo

ckey

whe

el u

ntil

clear

of t

ow p

in.

4) R

e-co

ver t

he to

w p

in w

ith th

e su

pplie

d pi

n co

ver.

5. M

aint

enan

ce

Regu

larly

flus

h to

w co

uplin

g he

ad w

ith w

ater

to re

mov

e an

y di

rt in

gres

s whi

ch m

ight

impa

ct fu

nctio

n.

Grea

se th

e sh

aft b

y pum

ping

mul

ti pu

rpos

e gr

ease

into

the

grea

se n

ippl

es a

t the

fron

t and

rear

of t

he b

ody

until

a sm

all a

mou

nt if

gre

ase

appe

ars f

rom

eac

h en

d of

the

shaf

t - se

e di

agra

m b

elow

.

6. W

eigh

t Dist

ribut

ion

Hitc

hes (

WDH

)

On-

road

use

: The

tow

coup

ling

can

be u

sed

with

wei

ght d

istrib

utio

ns h

itche

s for

on-

road

use

, pro

vidi

ng

the

coup

ling’

s mov

emen

t is n

ot re

stric

ted

by th

e W

DH.

Off-

road

use

: Prio

r to

usin

g th

e to

w co

uplin

g in

an

off-r

oad

scen

ario

, loa

d le

velli

ng d

evice

s mus

t be

rem

oved

, as t

he o

ff-ro

ad co

uplin

g is

desig

ned

for a

pplic

atio

ns w

hich

requ

ire a

larg

e am

ount

of

artic

ulat

ion

and

may

inte

rfere

with

load

leve

lling

dev

ices.

Grea

se n

ippl

es

1

2 LO

CKED

UN

LOCK

ED

Smal

l am

ount

of g

reas

e vi

sible

Off

Roa

d To

w C

oupl

ing

Auth

or: B

ryan

Ken

nedy

Ve

rsio

n: 0

.1

Date

: Nov

embe

r 201

7

4. H

ow to

Unh

itch

1)

Pus

h an

d ho

ld d

own

red

lid.

2) W

hile

hol

ding

dow

n re

d lid

, pus

h in

red

butto

n un

til it

rem

ains

dep

ress

ed.

3)

Rai

se th

e to

w co

uplin

g by

usin

g th

e jo

ckey

whe

el u

ntil

clear

of t

ow p

in.

4) R

e-co

ver t

he to

w p

in w

ith th

e su

pplie

d pi

n co

ver.

5. M

aint

enan

ce

Regu

larly

flus

h to

w co

uplin

g he

ad w

ith w

ater

to re

mov

e an

y di

rt in

gres

s whi

ch m

ight

impa

ct fu

nctio

n.

Grea

se th

e sh

aft b

y pum

ping

mul

ti pu

rpos

e gr

ease

into

the

grea

se n

ippl

es a

t the

fron

t and

rear

of t

he b

ody

until

a sm

all a

mou

nt if

gre

ase

appe

ars f

rom

eac

h en

d of

the

shaf

t - se

e di

agra

m b

elow

.

6. W

eigh

t Dist

ribut

ion

Hitc

hes (

WDH

)

On-

road

use

: The

tow

coup

ling

can

be u

sed

with

wei

ght d

istrib

utio

ns h

itche

s for

on-

road

use

, pro

vidi

ng

the

coup

ling’

s mov

emen

t is n

ot re

stric

ted

by th

e W

DH.

Off-

road

use

: Prio

r to

usin

g th

e to

w co

uplin

g in

an

off-r

oad

scen

ario

, loa

d le

velli

ng d

evice

s mus

t be

rem

oved

, as t

he o

ff-ro

ad co

uplin

g is

desig

ned

for a

pplic

atio

ns w

hich

requ

ire a

larg

e am

ount

of

artic

ulat

ion

and

may

inte

rfere

with

load

leve

lling

dev

ices.

Grea

se n

ippl

es

1

2 LO

CKED

UN

LOCK

ED

Smal

l am

ount

of g

reas

e vi

sible

LOCKED UNLOCKED

www.alko.com.au



4. How to Unhitch

1) Push and hold down red lid. 2) While holding down red lid, push in red button until it remains depressed.

3) Raise the tow coupling by using the jockey wheel until clear of tow pin. 4) Re-cover the tow pin with the supplied pin cover.

5. Maintenance Regularly flush tow coupling head with water to remove any dirt ingress which might impact function. Grease the shaft by pumping multi purpose grease into the grease nipples at the front and rear of the body until a small amount if grease appears from each end of the shaft - see diagram below.


On-road use: The tow coupling can be used with weight distributions hitches for on-road use, providing the coupling’s movement is not restricted by the WDH. Off-road use: Prior to using the tow coupling in an off-road scenario, load levelling devices must be removed, as the off-road coupling is designed for applications which require a large amount of articulation and may interfere with load levelling devices.

Grease nipples

1

2 LOCKED UNLOCKED

Small amount of grease visible

5. MaintenanceRegularly flush the tow coupling head with water to remove any dirt ingress which might impact function.

Grease the shaft by pumping multi purpose grease into the grease

nipples at the front and rear of the body until a small amount if grease appears from each end of the shaft - see diagram below.


On-road use: The tow coupling can be used with weight distributions hitches for on-road use, providing the coupling’s movement is not restricted by the WDH.

Off-road use: Prior to using the tow coupling in an off-road scenario, any WDH or other load levelling devices must be removed, as the off-road coupling is designed for applications which require a large amount of articulation and may interfere with the WDH or other load levelling device.

Page 5

7. Coupling Dimensions

8. RatingsBoth tow coupling and tow pin are rated to a maximum ATM of 3500 kg and nose load of 350 kg.

Tow XPC-1 tow coupling is ADR 62/01 and 62/02 compliant.

Page 6

54mm

184mm

150m

m

423mm

151mm 83mm

54mm

184mm

150m

m

423mm

151mm 83mm

www.alko.com.au




8. Ratings

Both tow coupling and tow pin are rated to a maximum ATM of 3500 kg and nose load of 350 kg.

Tow coupling is ADR 62/01 and 62/02 compliant.

9. Spare Parts

Replacement Part Description Part Number

PIN FOR O/ROAD TOW COUPLING SUITABLE FOR 619400 619410

COVER FOR TOW PIN 619410 SUITABLE FOR 619400 619411

9. Parts

Part Number: 619410

PIN FOR O/ROAD XPC-1 TOW COUPLING SUITABLE FOR 619435

Part Number: 614053

MECHANICAL PARK BRAKE MECHANISM LOW PROFILE.

Part Number: 619150 & 618926

MECHANICAL PARK BRAKE MECHANISM 280mm WITH CABLE PULLEY & FRONT SPACER PLATE.




8. Ratings

Both tow coupling and tow pin are rated to a maximum ATM of 3500 kg and nose load of 350 kg.

Tow coupling is ADR 62/01 and 62/02 compliant.

9. Spare Parts

Replacement Part Description Part Number

PIN FOR O/ROAD TOW COUPLING SUITABLE FOR 619400 619410

COVER FOR TOW PIN 619410 SUITABLE FOR 619400 619411

Part Number: 619411

COVER FOR XPC-1 TOW PIN 619410

Part Number: 619100

MECHANICAL PARK BRAKE MECHANISM 400mm.

Page 7

See www.alko.com.au for fitting instructions.

Part Number: 614055

MECHANICAL PARK BRAKE MECHANISM LOW PROFILE, NARROW BODY.

Page 8

For technical questions or to replace damaged or lost labels, please call (03) 9767 3700

PLEASE READ THE FOLLOWING CAREFULLYTHE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY APPROPRIATE TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

Page 9

AL-KO INTERNATIONAL PTY LTDWARRANTY

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.AL-KO International Pty Ltd (ABN 96 003 066 813) (“AL-KO”) provides the following warranty in relation to its Tow Pin Coupling (“Product”).The benefits of this warranty are in addition to any rights and remedies imposed by Australian State and Federal legislation that cannot be excluded. Nothing in this warranty is to be interpreted as excluding, restricting or modifying any State or Federal legislation applicable to the supply of goods and services which cannot be excluded, restricted or modified.WARRANTYAL-KO warrants that, subject to the exclusions and limitations below, the Product will be free from defects in materials and workmanship for a period of 36 months from date of purchase.This warranty is not transferable to a subsequent person if the Product is sold by the original purchaser during the warranty period.If a defect appears in the Product before the end of the warranty period and AL-KO finds the Product to be defective in materials or workmanship, AL-KO will, in its sole discretion, either:(a) replace or repair the Product or the defective part of the Product free of charge; or(b) cause the Product or the defective part of the Product to be replaced or repaired by a qualified repairer free of charge.AL-KO reserves the right to replace defective parts of the Product with parts and components of similar quality, grade and composition where an identical part or component is not available.Goods presented for repair may be replaced by refurbished goods of the same type rather than being repaired. Refurbished parts may be used to repair the goods.

WARRANTY CLAIMS1. If a fault covered by warranty occurs, the customer must within 7 days contact the dealer from which the Product was purchased, or AL-KO at the contact address listed below.2. Any warranty claim must be accompanied by:(a) proof of purchase;(b) full details of the alleged defect; and(c) any relevant documentation (such as maintenance records).3. The customer must make the Product available to AL-KO or its authorised repair agent for inspection and testing within 14 days of contacting AL-KO or the dealer in accordance with this warranty claims procedure. If inspection and testing finds no defect in the Product, the customer must pay AL-KO’s costs of service work and testing.4. The cost of transportation to or from AL-KO or the authorised repair agent is to be paid by the customer.EXCLUSIONSThe warranty will not apply where:(a) the Product has been repaired, altered or modified by someone other than AL-KO or an authorised repair agent;(b) the Product was improperly installed;(c) AL-KO cannot establish any fault in the Product after testing and inspection;(d) the Product has been used other than for the purpose for which it was designed;(e) the defect in the Product has arisen due to the customer’s failure to properly use and maintain the Product in accordance with AL-KO’s instructions, recommendations and specifications (including maintenance);(f) the Product has been subject to abnormal conditions, including environment, temperature, water, fire, humidity, pressure, stress or similar;(g) the defect has arisen due to abuse, misuse, neglect or accident;(h) the defect has arisen due to a power surge or of the fault in the supply of electricity; or(i) unauthorised parts or accessories have been used on or in relation to the Product.(j) the defect is a deterioration of the appearance of the Product(k) the defect is a result of wear & tear.LIMITATIONSAL-KO makes no express warranties or representations other than set out in this warranty.The repair or replacement of the Product or part of the Product is the absolute limit of AL-KO’s liability under this express warranty.CONTACTAL-KO International Pty Ltd 67 Nathan Road, Dandenong South, Victoria, 3175 Phone: (03) 9767 3700

NO pART Of ThIS DOCUMENT MAY bE REpRODUCED WIThOUT AL-KO’S pERMISSION. ALL pART NUMbERS, DIMENSIONS AND SpECIfICATIONS IN ThIS DOCUMENT ARE SUbjECT

TO ChANgE WIThOUT NOTICE.

Visitwww.alko.com.au

VIC: 67 Nathan Road, Dandenong South, 3175 Phone: (03) 9767 3700 Fax: (03) 9792 0877NSW: 26 Hallstrom Place, Wetherill Park, 2164 Phone: (02) 8784 9400 Fax: (02) 9725 4557QLD: 13 Union Circuit, Yatala, 4207 Phone: (07) 3386 6300 Fax: (07) 3386 6399NZ: 1 Airpark Drive, Airport Oaks, Mangere, Auckland Phone: (09) 255 5611 Fax: (09) 255 5612

When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken, please call (03) 9767 3700 as soon as possible.

Documents

AL-KO OFF-ROAD PIN COUPLING · AL-KO OFF-ROAD PIN COUPLING USERS MANUAL Save This Manual. Keep this manual for the assembly, operation, maintenance and cleaning procedures. Keep this