SPARE WHEEL CARRIER

CARE AND MAINTENANCE FOR

YOUR AL-KO SPARE WHEEL CARRIER
 Fig. 5

Fig. 1 Fig. 2

Fig. 6

Fig. 3 Fig. 4
CONTENTS

DIAGRAMS 1
CONTENTS 2
INSTRUCTIONS 3
ENGLISH 3
GERMAN 5
COMPLEMENTARY PRODUCTS 7
ACCESSORIES RANGE 10

2
 OPERATING INSTRUCTIONS

CONTENTS ASSEMBLY
- Maintenance and cleaning - Introduction Assembly of the tubular carrier frame
- Spare parts - Safety instructions The two telescopic tubes (fig. 1/1) are held in place by the connection
bracket (fig. 1/5) and the end plate (fig. 2/4). Secure the connection bracket
- Troubleshooting plan
in place with 2 clamp brackets (fig. 1/6), 4 hexagon head screws M6x12 (fig.
1/22) and 4 hexagon nuts (fig. 1/23). The space from the end plate should
INTRODUCTION be approx 400mm (pay attention to the size of the tyre).
Dear Customer, Screw the end plate (fig. 2/4) to the telescopic tubes with hexagon head
screws M6x30 (fig. 2/21) and 4 hexagon nuts (fig. 2/23). Insert the locking
The instructions contained in this manual are there to help you install and screw (fig. 2/9) from the inside out through the borehole (dia 13mm).
operate the Spare Wheel Carrier easily. Please take time to read through all Tighten it with the hexagon nuts (fig. 2/15).
the instructions carefully before installing the carrier and comply with the
technical information. It is advisable to keep the operating instructions with Once the carrier frame is assembled, slide the extraction handles (hooked
the other vehicle manuals supplied with the caravan ends of the assembly) onto the chassis frame (on the left hand side for use
in the UK, and the right hand side for Europe). Screw on the star grip (fig.
2/8) and hang on the securing chain (fig. 2/10).
SAFETY INSTRUCTIONS
- Install the spare wheel carrier so that the spare wheel can be taken off Assembly of the telescopic tubes to chassis members
from the pavement side of the road (nearside). Insert the rubber grommets (fig. 3/12) into the pre-punched holes on the
- After fitting, check that the carrier is securely fixed and working properly. opposite chassis member. Thread a washer (fig. 3/17) onto each telescopic
- Before setting off on a journey, ensure that the star handle is secured in tube and insert the tubes through the rubber grommets. Insert another
place with the securing hook. washer (fig. 3/17) and the lug type bushing onto the ends of the tubes.
Secure the telescopic tubes on to the chassis by fixing them either side with
- Fitting the spare wheel carrier adds approximately 7kg to the unladen 2 x 4x36 split pins (fig. 3/20).
weight of the caravan and 8.8kg if the holding plates (pt no 294284) are
fitted. Therefore the payload weight of the caravan will be affected by this
weight addition. Securing the Spare Wheel in place
A hexagon head screw M12 (fig. 6/14) is secured in place in the middle
- The operation of other equipment should not be impaired by the fitting of pre-punched hole on the connection bracket with two washers (fig. 6/16) and a
the spare wheel carrier. hexagon nut (fig. 6/18). Depending on the diameter of the hole in the wheel, a
hexagon head screw M12 (fig. 6/14) is secured in place in the elongated hole of
the connection bracket with two washers (fig. 6/16) and a hexagon nut (fig. 6/18).
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 MAINTENANCE
The space between the wheel rim and the connection bracket (fig. 6/5) is In order to ensure that the spare wheel carrier is working properly, the
also set with a self-locking nut (fig. 6/19). The spare wheel is tightened once telescopic tubes must be cleaned at regular intervals to ensure that any dirt
in the middle with the tapered clamping sleeve (fig. 6/7) and on the hole and debris that can accumulate during usage and journeys does not cause
circle with the tapered nut (fig. 6/13). the tubes to stick. The tubes should not be greased.
N.B. Only tighten the tapered clamp and the tapered nut to the point
where the spare wheel sits securely on the spare wheel holder. Excessive SPARE PARTS
tightening can lead to damage to the wheel (pressure points). The two
Spare parts are safety parts. If parts other than original AL-KO spares
self-locking nuts (fig. 6/19), which are set in accordance with the height of
are used, this will invalidate the warranty and product liability, i.e. we,
the wheel rim, serve as a limit stop for the tapered clamping sleeve (fig. 6/7)
as manufacturers, will no longer assume liability for any faults and
and tapered nut (fig. 6/13).
consequences which occur. Do not underestimate the consequential
damages which can occur in traffic, including injuries to people!
Assembly of the add-on kit, part no. 294284 If repairs are required, we operate a Europe-wide network of AL-KO Service
The space between the holding plates and the axle should be approx. 700 Centres. If you require a directory of service centres, please visit our ‘Service
mm. Drill two holes (Ø 12.5 mm), 275 mm apart, in the two parts of the Centres’ page on our website - www.al-ko.co.uk.
frame. The holes must be drilled in the middle of the stay (neutral zone).
N.B. Repairs and setting work may only be carried out by AL-KO Approved
Secure the two holding plates (fig. 4/24) with two hexagon head screws
Service Centres. In order to clearly identify spare parts, Service Centres
M12x25 (fig. 4/25) and self locking hexagon nuts M12 (fig. 4/26). Insert the
require the spare parts identification number (ETI). This is imprinted on the
locking screw (fig. 4/9) from the inside out through the pre punched hole (Ø
end plate. Consequently, have both codes to hand before calling us.
13) in the right holding plate. Tighten the hexagon nuts M12 (fig. 4/18).

Important note:
If this is added with two additional holding plates, the owner of the vehicle
must (re)submit the vehicle for an MOT inspection, submitting a certificate
confirming that the vehicle meets regulations (in accordance with § 19 of
the Motor Vehicle Safety Ordinance (StVZO).

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 BEDIENUNGSANLEITUNG

INHALTSVERZEICHNIS MONTAGE
- Wartung und Reinigung - Einleitung Montage des Schiebeteiles
- Ersatzteile - Sicherheitshinweise Die beiden Teleskoprohre (Bild 1/1) werden durch das Verbindungsblech
(Bild1/5) und die Befestigungsplatte (Bild2/4) verbunden. Das
- Fehlersuchplan
Verbindungsblech mit 2 Klemmschellen (Bild1/6), 4 Skt.- Schrauben M
6x12 (Bild1/22) sowie 4 Skt.-Muttern (Bild1/23) befestigen. Der Abstand zur
EINLEITUNG Befestigungsplatte soll ca. 400 mm betragen (Reifengröße beachten). Die
Sehr verehrter Kunde, Befestigungsplatte(Bild2/4) mit 4 Skt.- Schrauben M 6x30 (Bild2/21) sowie
Um eine zuverlässige Montage und Bedienung des AL-KO Ersatzradhalters 4 Skt.- Muttern M 6 (Bild2/23) an den Teleskoprohren verschrauben.
zu ermöglichen, haben wir diese Anleitung geschaffen. Wir bitten Sie, vor Am rechten Rahmenteil die Arretierschraube (Bild2/9) von innen nach außen
der Montage die Anleitung einmal ganz durchzulesen und die technischen durch die Bohrung Ø13 stecken. Skt.-Mutter M12 (Bild 2/15) festschrauben.
Daten zu beachten. Das Schiebeteil nach der Montage der Teleskoprohre am Rahmen
Die Bedienungsanleitung ist mit den Fahrzeugpapieren aufzubewahren. einhängen. Sterngriff (Bild 2/8) aufdrehen und Sicherungskette (Bild 2/10)
einhängen.
SICHERHEITSHINWEISE
Montage der Teleskoprohre
- Ersatzradhalter vorzugsweise so einbauen, daß das Ersatzrad an der
In die vorhandenen Bohrungen im linken Rahmenteil (in Fahrtrichtung)
abgewandten Seite der Straße entnommen werden kann.
Gummitüllen (Bild 3/12) einschieben. Auf jedes Teleskoprohr eine Scheibe
- Nach der Montage den ordnungsgemäßen Anbau sowie die Funktion 21 (Bild 3/17) fädeln und Rohre durch die Gummitüllen stecken. Auf die
überprüfen. Rohrenden eine weitere Scheibe 21 (Bild 3/17) sowie eine Ansatzbuchse
- Vor dem Fahren vergewissern, daß der Sterngriff mit Sicherungshaken (Bild 3/11) aufstecken. Durch beidseitiges Befestigen mit je 2 Splinten 5x30
gesichert ist. (Bild 3/20) die Teleskoprohre im Rahmen sichern.
- Das Leergewicht erhöht sich durch den Anbau des Ersatzradhalters um
ca. 6 kg und mit Halteplatten um ca. 7,8 kg zuzüglich dem Gewicht des Befestigung des Ersatzrades
Ersatzrades. Die Nutzlast verringert sich entsprechend. Auf dem Verbindungsblech (Bild 6/5) wird in der mittigen Bohrung eine
- Durch den Einbau dürfen keine anderen Einrichtungen beeinträchtigt Sechskantschraube M12 (Bild 6/14) mit zwei Scheiben (Bild6/16) und einer
werden. Sechskantmutter (Bild6/18) befestigt. Im Langloch wird entsprechend dem
Lochkreisdurchmesser des Rades ebenfalls eine Sechs-kantschraube M12
(Bild 6/14) mit zwei Scheiben (Bild 6/16) und einer Sechskantmutter (Bild

5
6/18) verschraubt. Mit jeweils einer selbstsichernden Mutter (Bild 6/19) WARTUNG
wird der Abstand zwischen der Felge und dem Verbindungsblech (Bild 6/5) Um die Funktion des Ersatzradhalters sicherzustellen, sind die Teleskoprohre
eingestellt. Das Ersatzrad wird einmal mittig mit dem Spannkegel (Bild 6/7), in ausgezogenem Zustand zu reinigen und einzufetten.
sowie am Lochkreis mit der Kegelmutter (Bild 6/13) festgespannt.
ERSATZTEILE
Bitte beachten: Den Spannkegel und die Kegelmutter nur so fest Ersatzteile sind Sicherheitsteile. Werden andere als AL-KO Originalersatzteile
anziehen, daß das Ersatzrad spielfrei auf dem Ersatzradhalter befestigt eingesetzt erlischt die Gewährleistung und Produkthaftung d. h. wir als
ist. Übermäßiges Festspannen kann zu Beschädigungen des Rades Hersteller sind für eventuell auftretende Fehler und Folgen nicht mehr aftbar.
(Eindruckstellen) führen. Die beiden, entsprechend der Felgenhöhe Folgeschäden bis hin zu Personenschäden sind im Straßenverkehr nicht zu
eingestellten, selbstsichernden Muttern (Bild 6/19) dienen als Anschlag für unterschätzen, bitte bedenken Sie dies bei Ersatzteilen!
Spannkegel (Bild 6/7) und Kegelmutter (Bild 6/13).
Im Reparaturfall verfügen wir über ein flächendeckendes Netz von AL-KO
Servicestationen in Europa. Das Servicestellenverzeichnis kann bei Bedarf
Montage Nachrüstsatz part.-Nr. 294284 direkt bei uns angefordert werden. Bitte beachten Sie, daß Reparaturen und
Der Abstand der Halteplatten bis zur Achse soll ca. 700mm betragen. In die Einstellarbeiten nur von kompetenten Fachbetrieben durchgeführt werden
beiden Rahmenteile werden zwei Bohrungen Ø12,5 mm im Abstand 275 mm dürfen. Für eine eindeutige Identifizierung der Ersatzteile benötigen die
gebohrt. Die Bohrungen müssen in der Stegmitte (neutrale Zone) angebracht Servicestationen die ETI = Ersatzteilidentifizierungsnummer. Diese ist auf der
werden. Die beiden Halteplatten (Bild 4/24) mit 2 Skt.-Schrauben M12x25 Befestigungsplatte eingeprägt. Bitte deshalb beide Daten, vor dem Griff zum
(Bild 4/25) und selbstsichernde Skt.-Muttern M12 (Bild 4/26) befestigt. Telefon, am Objekt feststellen.
Die Arretierungsschraube (Bild 4/9) von innen nach außen durch die
Bohrung Ø13 in der rechten Halteplatte stecken. Skt.-Mutter M12 (Bild 4/18)
festdrehen.

Wichtiger Hinweis: Bei nachträglichem Anbau mit zwei zusätzlichen

Halteplatten hat der Fahrzeughalter unter Vorlage des Gutachtens über den
vorschriftsmäßigen Zustand des Fahrzeugs eine erneute Betriebserlaubnis
für das Fahrzeug bei der Zulassungsstelle zu beantragen (gem. § 19, Abs. 2
StVZO).

6
 COMPLEMENTARY PRODUCTS

AL-KO AMS MAMMUT AL-KO SIDE LIFT JACK

AMS Mammut is the only caravan The AL-KO side lift jack is the perfect solution
mover designed to fully integrate with for lifting a caravan to change a wheel, or to
the AL-KO Chassis. With the power fit the AL-KO Secure Wheel Lock. The simple
and strength to improve the to use, smooth winding operation of the jack
manoeuvrability over uneven terrain allows the caravan to be lifted easily with the
and inclines, plus the agility to handle minimum of effort.
tight spaces AMS Mammut is the next,
natural product choice for your caravan. FEATURES & BENEFITS
Fitting AMS Mammut to your caravan gives you maximum ground • Fitting underneath - it is deployed under
clearance and protects your investment against collision damage from the caravan (leave the towing vehicle
hitting kerbs, speed bumps and potholes. coupled in position).
• Insert system - Positive engagement via
FEATURES & BENEFITS
the insert pocket of the mounting bracket
• Simple operation - Simple, one handed operation via the joystick allowing prevents sliding. The specially designed
smooth and sensitive speed control and continuous 360° manoeuvring. brackets reinforce the chassis frame
and stiffen the caravan floor, providing
• Precise manoeuvring - The remote control directs the movement of the
significant local support for jacking.
caravan to the desired position using variable speed and close control.
The variable speed control also simplifies the coupling process of the • Two versions are available - One for
caravan to the towing vehicle. vehicles up to 1600 kg and one for
1601 kg - 2000 kg weight ranges.
• Powerful, reliable technology - AL-KO AMS Mammut can overcome
obstacles and kerbs up to 4cm high inclines up to a maximum of 28%. • The kit includes a set of support brackets
The lightweight design means the complete system weighs only 29 kg and all fixings and operating instructions.
(excl. battery) and the durable outer cover completely seals the unit from
water ingress, and guarantees functionality even in wet conditions.

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AL-KO AKS 3004 AL-KO ATC
The AKS 3004 Stabiliser efficiently and AL-KO Automatic Trailer Control
effectively suppresses the initial signs of is the award winning electronic
vehicle instability and snaking movements braking system for caravans.
of the caravan or trailer. ATC monitors and applies the
caravan brakes should the
Made from low-wear material, four
vehicle experience unexpected
specially engineered friction pads
instability due to high winds,
surround the towball and continue
overtaking HGVs or during
to ensure optimum friction damping.
evasive manoeuvres.
Fitment of the AKS 3004 stabiliser
ATC can be retro-fitted to any caravan running on an
significantly improves the smoothness
AL-KO chassis and runs off either the 12 volt 7-pin
of a journey and provides the driver with the confidence and control
supplementary socket or alternatively off 13-pin electrics.
required to handle critical driving situations such as high cross winds
and overtaking HGVs more effectively. The AL-KO ATC trailer control system provides the
assurance to drivers that, even in the most difficult of
FEATURES & BENEFITS driving scenarios, the stability of their caravan and car
is monitored, providing an unparalleled level of safety
• Improves towing stability by 30% during the journey.
• Easy to use - simple lever action
• Safe towing - safety fitment indicator shows correct coupling FEATURES & BENEFITS

• Safety indicators to monitor wear on the towball, front/rear Insurance discounts - ATC is proven to be so stable, that most insurance
and side friction pads companies offer a discount for caravans with ATC fitted.

• Light and compact design, built for long life - galvanised and 3 Easy fitment options - Choose from nationwide AL-KO approved Service
corrosion resistant Centres, mobile fitting services or AL-KO’s Head Office in Southam.

• Integrated brackets for AL-KO Security Device (available separately)

• High weight load - max. cap. 3000 kg
• Universal model - fits most chassis
• Friction pads are available as spares

8
 AL-KO SECURE PREMIUM JOCKEY WHEEL
The AL-KO Secure Wheel Lock is the most AL-KO Jockey Wheels are designed for
secure anti-theft device available for any stability, durability, ease of operation
caravan with an AL-KO chassis with alloy and long service life. They are available
wheels. The Sold Secure Diamond Standard in a variety of models, with a range of
wheel lock provides the highest level of innovative features to suit your personal
protection to ensure that the caravan remains caravanning needs.
safe and secure on site, at home or in storage.
The Premium Jockey Wheel (shown) is
With over 33,000 security combinations, a 9 pin designed for use with motorised caravan
anti-pick radial lock mechanism and a registered movers and features extra wide, grooved
key management system, AL-KO Secure is the most rubber tyres, swing arm suspension and
effective anti-theft deterrent available for caravans. an integrated load indicator to gauge the
nose weight of the caravan. This saves time
Leading insurance companies offer significant discounts where
and effort preparing for your journey.
AL-KO Secure is fitted and when combined with other AL-KO
Security Devices even greater reductions can be achieved.
FEATURES & BENEFITS
FEATURES & BENEFITS • Integrated Wheel Nose Load Display
• Sold Secure SS110 Diamond Approved • Broad, grooved rubber wheel
• Registered key management system • Integrated swing arm suspension
• Drill resistant lock with anti-pick tumbler system • Detachable wheel
• Wheel specific insert protects wheel nuts • Removable, ergonomic crank handle
• Precision engineering contoured to your alloy • Thrust bearing and low friction crank ensures
which prevents leverage smooth and easy operation
• Positioning of wheel receiver protects stub axle • High-quality corrosion protection
bolt/nut and receiver fixings

CALL US NOW ON 01926 818500 EMAIL US MAIL@AL-KO.CO.UK OR VISIT WWW.AL-KO.CO.UK TO PLACE YOUR ORDER.

9
FOR THE FULL RANGE OF AL-KO SHOCK ABSORBERS MUDFLAPS CORNER STEADIES
ACCESSORIES, AND ADVICE ON ATC ANTI SNAKE BRAKING SYSTEM PLASTIC MOULDED WINCHES, Electric, Universal and Swivel Foot
HOW TO FIT AND USE THEM, CABLES & STRAPS Corner Steadies
VISIT WWW.AL-KO.CO.UK COUPLING HEADS
Unbraked or Braked Load Reverse Braked Winches, CORNER STEADY COMFORT KIT
Compact Winches, Unbraked Winches A-FRAME CHASSIS
OVERRUN DEVICES
WHEELS AND TYRES Delta or Square JACKS
JOCKEY WHEELS Side Lift Jacks
Prop stands/Clamps and Fixing Kits LIGHTING/ELECTRICAL EQUIPMENT
Reflectors, Lights and Fog Lamps AL-KO BIKE RACK
Heavy duty, Standard and Special
MUDGUARDS SPARE WHEEL CARRIER
STABILISERS AND
SECURITY DEVICES Plastic or Galvanised Steel WHEEL CHOCKS AND CARRIERS
Various sizes, Single or Tandem Plastic or Galvanised Steel

10
 QUALITY FOR LIFE
AL-KO Kober Ltd, South Warwickshire Business Park, Kineton Road, Southam, Warwickshire, CV47 OAL
E-Mail: mail@al-ko.co.uk www.al-ko.co.uk T el: 01926 818500
Due to a policy of continuous product improvement, AL-KO reserves the right to change technical specifications.
Part No. 1555865 01/16.