AL-KO Overrun Braking System Handbook User Manual
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The o ve rru n d evic e c a n b e d escrib ed a s th e c o ntr o l d evic e o f th e o ve rru n b ra ke s ys te m . A d ra w -b ar f o rc e is p ro duce d a t th e
c o uplin g p oin t b y r e ducin g th e s p eed o f th e to w in g v e hic le . A fte r th e th re sh old le ve l h as b een p asse d, th e d ra w s h aft is
p ush ed in , th us a ctu atin g th e o ve rru n le ve r, th e w heel b ra ke s ( 1 & 2 ) a re th en a pplie d v ia th e e xp andin g c lu tc h ( 3 ) ( F ig 2 )
O pera tio n o f t h e o ve rru n b ra kin g s ys te m .
R eve rs in g.
W hen r e ve rs in g, th e to w in g v e hic le p ush es in th e d ra w
s h aft o f th e o ve rru n d evic e . T he b ra ke s h oes ( 1 ,2 ) a re
p re sse d a gain st th e b ra ke d ru m v ia b ra ke lin ka ge,
B ow den c a ble a nd e xp ander c lu tc h ( 3 ). T he b ra ke
d ru m tu rn s b ack w ard s, ta kin g th e tr a ilin g s h o e ( 1 ) w it h
i t . T he tr a nsm is sio n le ve r ( 4 ) s w in gs b ack a n d a llo w s
t h e d ra w s h aft to c o m ple te it ’s f u ll tr a ve l. T he b ra kin g
e ffe ct is v ir tu ally c a nce lle d o ut a nd th e w hee ls c a n
r e vo lv e f r e ely in r e ve rs e (F ig 3 ).
P ark in g.
O n th e s p rin g c ylin der v e rs io n, e ngage th e h andbra ke le ve r r ig ht u p to th e la st to oth ( 9 0°). O n th e g as s tr u t h andbra ke
v e rs io n, p ull th e h andbra ke le ve r o ve r c e ntr e . T he b ra ke s h oes ( 1 a nd 2 ) a re p re sse d a gain st th e b ra ke d ru m b y th e b ra ke
l in ka ge e tc . a nd th is a pplie s th e tr a ile r b ra ke s.
W hen th e c a ra va n/tr a ile r h as b een r e ve rs e d, th e b ra ke d ru m w ill a ls o r o ta te b ack w ard s. T he tr a ilin g b ra ke s h oe ( 1 ) is ta ke n
w it h it a nd m ove s th e tr a nsm is sio n le ve r ( 4 ) b ack . T his le ve r th en p ush es th e a dju ste r a sse m bly ( 5 ) w hic h in tu rn p ush es
th e le adin g b ra ke s h oe ( 2 ) a gain st th e s to p ( 6 ). T he c a ra va n/tr a ile r is th en b ra ke d.
F ig 1
F ig 2
F ig 3 F ig 4
Wheel B earin g
A dju stin g t h e w heel b ra kes.
It m ust b e n ote d t h at w hen t h e h an dbra ke is
ap plie d , t h e v eh ic le m ay r o ll a p pro xim ate ly
2 5 c m ( 1 0 in ch es) b ackw ard s b efo re t h e
p ark in g b ra ke f o rc e is u sed t o it ’s f u lle st
e xte n t.
F ig 5
F ig 6
T he w heel b earin g is a d ouble -ro w in clin ed b a ll
b earin g. It h as th e f o llo w in g a dva nta ges o ve r
n orm al b earin gs.
· No a dju stm ents n ece ssa ry .
· Easy to m ain ta in ( lu bric a te d f o r lif e a n d
s e ale d)
· Pro te cte d a gain st d ir t in gre ss ( s e ale d u nit )
· Less s e nsit iv e to s ie zu re th an a ta per r o lle r
b earin g.
The b earin g m ust n ot b e p re sse d
out o f t h e d ru m a s t h is m ay d am ag e
t h e b earin g a n d b ra ke d ru m .
B efo re a d ju stin g t h e w heel b ra kes alw ays
ro ta te t h e w heel( s ) in t h e f o rw ard d ir e ctio n
· Lif t th e c a ra va n/tr a ile r u sin g a s u it a ble ja ck .
· Ensu re th e c o uplin g h ead a nd o ve rru n s h aft a re f u lly
e xte nded.
· Rele ase th e h andbra ke c o m ple te ly .
· Rele ase th e b ra ke lin ka ge f r o m th e b a la nce b ar(F ig 7 )
· On n ew er m odels th e M 8 n uts a re q uic k f it n ip ple s.
· Check th e f r e e p la y in th e w heel b ra ke .
The f r e e p la y s h ould b e a s u nif o rm a s p ossib le f o r 2
o r 4 w heel b ra ke s r e sp ectiv e ly .
Nom in al : 4 - 6 m m o n s in gle a xle s.
6 – 8 m m o n ta ndem a xle s.
M easu re d o n th e in ner c a ble w here a tta ch ed to th e
a xle a butm ent b ra ck e t .
M 8 n uts F ig 7
F ig 8
S erv ic in g t h e w heel b ra kes.
· Only e ve r s e t o r a dju st th e w heel b ra ke b y m ean s o f th e
a dju ste r s cre w ( 1 )(F ig 9 ). A dju st in th e d ir e ctio n o f th e
a rro w , a nd r e le ase a gain st th e d ir e ctio n o f th e a rro w .
· Reco nnect th e b ra ke lin ka ge to th e b ala nce b ar, a nd
a pply th e h andbra ke h ard s e ve ra l tim es, to a llo w th e
b ra kin g a dju stm ent to s e ttle .
F ig 9
F ig 1 0
· On th e s p rin g c ylin der ty p e ( 2 ), a dju st th e lo ck in g n uts
M 10 ( 1 )(F ig 1 0) to a llo w 1 m m o f f r e e p la y b etw een th e
n ut a nd th e s p rin g c ylin der. T he c ylin der s h ould b e a ble
t o r o ta te f r e ely b ut n ot s lid e o n th e b ra ke ro d.
N .B On s o m e c h assis th e lo ck in g n u ts a re r e pla ce d
w it h a s in gle N ylo c n ut.
C heck t h e s ettin g
· Apply th e h andbra ke le ve r u p to th e f ir s t o r s e co nd
t o oth , a nd c h eck th at th ere is e qual b ra kin g r e sis ta nce
o n e ach w heel.
· On th e g as s tr u t v e rs io n th e h andbra ke le ve r h as to b e
h eld o n th e f ir s t to oth m anually .
W hen a d ju stin g t h e w heel b ra ke, o nly
tu rn t h e w heels in a f o rw ard d ir e ctio n s o
th at r e v ers e m ode is n ot a ctu ate d .
F ig 1 1
D is m an tlin g t h e b ra ke d ru m .
· Rem ove th e w heel a nd ty re .
· Mark th e p osit io n o f th e p la stic c a p o n t h e s w in g a rm w it h
a f e lt tip p en s o th at a ny m ove m ent o n t h e s tu b a xle c a n
b e d ete cte d ( F ig 1 1)
I f t h e s tu b a xle o r b ack n ut a re m oved t h is w ill
a lt e r t h e t o e-in a n d c am ber . S hou ld s u ch
m ovem en t t a ke p la ce t h e a xle s h o uld b e r
e m oved
an d r e tu rn ed t o A L-K O t o b e r e alig ned .
· Rem ove d ust c a p w it h F orm er T ool ( 6 03 751).
· Unscre w th e f la nge n ut. A lw ays u se a n ew n ut w hen
r e fit tin g.
· Befo re f it tin g n ew n ut a pply a s m all a m ount o f m in era l
g re ase ( 8 00052) to th e s tu b a xle th re ad.
· Rele ase th e h andbra ke a nd r e m ove th e d ru m .
· R epla ce w orn o r c o rro ded b ra ke d ru m s.
N ote t h e t o rq ue s ettin g ( 2 90N m + /- 1 0N m ).
B ra ke d ru m s m ust n ot b e r e skim m ed .
F ig 1 2
Vis u al c h ecks.
C heck t h e c o ndit io n o f t h e b ra ke s h oes.
T he w ear o n th e s h oes is g re ate st w here th e in sp ectio n h ole is lo ca te d o n th e b ack p la te . T he le adin g s h oe u su ally w ears
f a ste r th an th e tr a ilin g s h oe.
Alw ays r e p la ce b ra ke s h oes a s a p air .
· Check th at th e e xp ander c lu tc h ,a dju ste r n ut a nd tr a nsm is sio n le ve r a re lu bric a te d a nd r u nnin g s m ooth ly ( u se
M oly b denum D is u lp hid e g re ase ).
· Check th e te nsio n o n th e le af s p rin g a nd th at th e a dju stin g n ut is e ngaged o nto th e b ra ke sh oe.
· Check th e p re ssu re o f th e b ra ke sh oe r e ta in in g s p rin gs.
· Tra nsm is sio n le ve r ( 1 ) m ust a but th e a dju ste r h ousin g
s to p ( 2 ).
F ig 1 3
F ig 1 4
· If a ny p arts a re to b e r e m ove d f r o m th e w heel b ra ke th e B ow den c a ble m ust b e u nhooke d f r o m th e e xp ander c lu tc h .
· Repla ce b ra ke sh oes w here lin in gs a re le ss th an 2 m m th ic k n ess.
· If r e pla cin g p re ssu re s p rin gs a ls o r e pla ce c o ve r p la te s.
· On ty p e 1 637, th e le ft a nd r ig ht s h oes a re d if fe re nt. T he e m bosse d m ark in gs ( s e e a rro w s F ig 1 5) m ust b e f o llo w ed.
If t h e s h oes a re f it te d t o t h e w ro ng s id e t h e b ra ke w ill n ot f u nctio n.
· 2051 a nd 2 361 b ra ke s h oes a re N O T h anded.
F ig 1 5 F ig 1 6
E xp an din g c lu tc h .
· Lubric a te e xp ander p iv o t p oin ts .
· Repla ce c o rro ded e xp anders .
· N.B N ote th e c o rre ct p osit io n f o r f it tin g:
E xp ander le ve r p iv o t a rm ( 2 ) to tr a nsm is sio n le ve r p iv o t b olt ( 1 ). T hese p oin ts m ust a lw ays
b e o n th e s a m e s id e ( F ig 1 6).
Retu rn s p rin gs.
· Repla ce r e la xe d o r d am aged r e tu rn ( p ull o ff) s p rin gs.
T ra n sm is sio n le ve r.
· Lubric a te p iv o t p oin ts .
· Repla ce c o rro ded o r d am aged le ve rs a nd p iv o t b olt s .
· If th e le ve r d oes n ot a but th e a dju ste r h ousin g s to p , r e pla ce e xte nsio n s p rin g ( F ig 1 4).
A dju stin g a ssem bly .
· Lubric a te a dju stin g n uts .
· Unscre w th e a dju ste r s cre w a nd lu bric a te th e th re ad.
· Repla ce c o rro ded o r d am aged s cre w s o r n uts .
L eaf s p rin gs ( a d ju ste r h ousin g).
· Repla ce c o rro ded o r r e la xe d le af s p rin gs.
N .B T he a d ju ste r s cre w ,n ut a n d le af s p rin g a re o nly s u pplie d a s a c o m ple te a ssem bly .
P art N o.s a re a s f o llo w s:
1 637 B ra kes - 3 87706
2 051 B ra kes - 3 87323
2 361 B ra kes - 3 87323
All f r ic tio n p oin ts o n t h e w heel b ra ke m ust b e lu bric ate d w it h
Moly b den um D is u lp hid e G re ase ( A L-K O P art N o. 8 00098 )