1. Introduction
This manual provides essential instructions for the safe and proper installation, operation, and maintenance of your AL-KO AK 161-50 mm Ball Coupling. This coupling is designed for braked trailers with a permissible total weight of up to 1600 kg.
The AL-KO AK 161 features integrated safety and wear indicators to ensure secure coupling and timely maintenance. Please read this manual thoroughly before use to ensure optimal performance and safety.
Figure 1: AL-KO AK 161-50 mm Ball Coupling. This image shows the complete ball coupling unit with its black and red handle and galvanized steel body.
2. Setup and Installation
Installation of the AL-KO AK 161 ball coupling is designed to be straightforward. It replaces existing couplings using a two-screw attachment method.
2.1 Installation Steps
- Ensure the trailer is securely supported and cannot move during installation.
- Carefully remove the old coupling by unscrewing its two attachment bolts.
- Position the new AL-KO AK 161 coupling onto the trailer drawbar, aligning the bolt holes.
- Insert two new bolts (mounting material is not included with the coupling) and tighten them to the specified torque of 86 Nm.
- Verify that the coupling is securely fastened and all bolts are tightened to the correct specification.
Important: Mounting material (bolts) is not included and must be sourced separately. Always use appropriate high-strength bolts for trailer components.
2.2 Dimensions
Refer to the diagram below for detailed dimensions of the AL-KO AK 161-50 mm Ball Coupling to ensure compatibility with your trailer drawbar.
Figure 2: Dimensional drawing of the AL-KO AK 161-50 mm Ball Coupling, showing key measurements in millimeters for installation planning.
3. Operation
The AL-KO AK 161 ball coupling is designed with user-friendly features to ensure safe and reliable trailer connection.
3.1 Coupling to the Towing Vehicle
- Ensure the towing vehicle's hitch ball is clean and free from grease or debris.
- Lift the coupling handle fully to open the coupling mechanism.
- Lower the trailer coupling onto the towing vehicle's hitch ball.
- Press the coupling handle down firmly until it locks into place.
3.2 Safety Indicator
The AL-KO AK 161 features a visible safety indicator. Once the coupling is properly placed on the towing vehicle's hitch ball and the handle is secured, a green cylinder will be visible. If the green cylinder is not visible, the coupling is not correctly engaged, and you must re-check the connection before towing.
3.3 Wear Indicator
An additional indicator on the coupling handle provides information about wear. This indicator shows whether the wear limit of the towing vehicle's hitch ball or the trailer's coupling mechanism has been reached. Regularly check this indicator to ensure safe operation and to determine if replacement parts or a new coupling are necessary.
3.4 Flat Handle Design
The coupling features a flat handle design, complying with current regulations. This design allows for easier opening of tailgates on towing vehicles, even those with a low loading sill, without obstruction from the coupling handle.
Figure 3: Detailed view of the AL-KO AK 161-50 mm Ball Coupling, highlighting the safety (green cylinder) and wear indicators for proper connection and maintenance assessment.
4. Maintenance
Regular inspection and maintenance are crucial for the longevity and safe operation of your AL-KO AK 161 ball coupling.
- Visual Inspection: Before each use, visually inspect the coupling for any signs of damage, cracks, deformation, or excessive wear.
- Wear Indicator Check: Regularly check the wear indicator on the handle. If the indicator suggests that the wear limit has been reached for either the hitch ball or the coupling, replace the affected component immediately.
- Lubrication: Keep moving parts of the coupling clean and lightly lubricated as per general trailer maintenance guidelines. Avoid over-lubricating the hitch ball itself, as this can interfere with braking systems.
- Fastener Check: Periodically check the tightness of the mounting bolts. Re-tighten to 86 Nm if necessary.
- Cleaning: Clean the coupling regularly to prevent dirt and debris buildup, which can affect its operation.
Warning: Never use a damaged or excessively worn coupling. Doing so can lead to trailer detachment and serious accidents.
5. Troubleshooting
This section addresses common issues you might encounter with your AL-KO AK 161 ball coupling.
- Coupling not engaging properly (Green cylinder not visible):
- Ensure the hitch ball is correctly positioned within the coupling.
- Check for any obstructions preventing the handle from fully closing.
- Verify that the hitch ball diameter matches the coupling (50 mm).
- Inspect the hitch ball and coupling for excessive wear or damage.
- Handle is stiff or difficult to operate:
- Clean the moving parts of the handle and coupling mechanism.
- Apply a light lubricant to the pivot points of the handle.
- Check for any physical damage or bending of the handle or mechanism.
- Excessive play or rattling when coupled:
- Check the wear indicator. If it shows excessive wear, replacement of the hitch ball or coupling may be necessary.
- Ensure the mounting bolts are tightened to the correct torque (86 Nm).
If you encounter persistent issues or are unsure about the safety of your coupling, consult a qualified trailer technician or contact AL-KO customer support.
6. Technical Specifications
| Feature | Specification |
|---|---|
| Model Number | AK 161 (Manufacturer Part Number: 219) |
| Permissible Total Weight (Trailer) | Up to 1600 kg (3527.39 lbs) |
| Bearing Load | 120 kg |
| Material | Alloy Steel |
| Finish Type | Galvanised |
| Hole Configuration | Horizontal + Cross |
| EC Mark | E1 55R-01 2669 |
| Tightening Torque | 86 Nm |
| Item Weight | 1.7 kg |
| Vehicle Service Type | Trailer |
| Automotive Fit Type | Universal Fit |
7. Warranty Information
Specific warranty details for the AL-KO AK 161-50 mm Ball Coupling are typically provided at the point of purchase or can be found on the official AL-KO website. Please retain your proof of purchase for any warranty claims. The warranty generally covers manufacturing defects under normal use conditions.
For detailed warranty terms and conditions, please refer to the documentation provided with your product or visit the AL-KO official website.
8. Customer Support
If you have any questions regarding the installation, operation, or maintenance of your AL-KO AK 161-50 mm Ball Coupling, or if you require technical assistance, please contact AL-KO customer service or your authorized AL-KO dealer.
You can typically find contact information on the AL-KO official website or through your product retailer.
