AL-KO AKS 1300 Triple Pack User Manual

							ASSEMBL
Y AND OPERA TING INSTRUCTIONS FOR  AL-KO AKS 1300
ST ABILISER &  AL-KO SECURITY  DEVICE
PLEASE ENSURE  YOU READ THESE INSTRUCTIONS CAREFULL Y,
BEFORE COMMENCING T O OPERATE THIS PRODUCT .
REGULA TIONS:
1)  The  AKS 1300 must be used in conjunction with 50 mm dia. towballs which conform to EC Directive 94/20 (DIN
74058 or local equivalent). 2) Suit able for att achment to drawbars or approved overrun braking equipment for single axle (and some  t andem
axle) trailers, with a minimum weight of 180 Kg and a maximum permissible weight of  1360 Kg.3) EC design approval has been given to the  AL-KO AKS 1300 coupling under permit No. e1*94/20*0030*00.
4)  This design approval has been recognised by all EC member st ates and must be implemented with effect from
01.12.95.5)  The  AL-KO Security Device (Hitch Lock)  Anti-Theft Device is ef fective against the following unauthorized
operations:a) Uncoupling from the towing vehicleb) Coupling onto another towing vehiclec)  Thef t of the S tabiliser from the trailer/caravan.
RESTRICTIONS OF USE:S pare wheels fitted to rear door of vehicle, or vehicle with plat forms etc:
1) the  AKS 1300 S tabiliser is based on the latest regulations.   This means the new DIN 74070 (dimensions of
couplings) are  also adhered to.2)  The trailer coupling may only be connected to towing vehicles where the clearance for the st abiliser can be
observed, in accordance with Directive 94/20 EC (DIN 74058).  If these clearances are infringed by specialatt achment s, then the use must be checked sep arately.
3) Not suit able for use with overrun devices which revolve above 25
o.
4) For Swan Neck towbars (fixed or det achable), refer to clearances on page 4.
5)  This product is not suit able for use where the overrun has a reverse lock fitted, on the side (Fig. 1).
6) For GB Use, please use the extended neck towball included with this kit (A50-X).7)  AL-KO recommends the use of the  AL-KO Safety Ball to complement the  AL-KO Security Device.  The Safety
ball is inserted into the coupling area of the S tabiliser , before the  AL-KO Safety is locked into position (Fig. 2).   This
prevent s your caravan from being coupled to any other tow hook or smaller towball and being towed away .
APPROV AL:
1)  The  AL-KO Security Device holds full  TUV approval and is also Sold Secure  Approved.
W ARRANTY :
1) Product warranty is given in accordance with S10, Clause 1-7 of the General  Terms of Business and is usually
12 months from date of purchase. W ARNINGS:
1) In accordance with EC Directive 94/20, couplings type  A 50-1 cannot be used (see Fig. 4).
2)  A bolted-in type ball coupling (Fig. 3) is only permissible if the thread is locked.
 Fig. 1
1
  Fig. 2
8
Part No. 1385181  Iss. 2 -  01/04
1)
Foreign bodies or dirt between the friction p ad and towball.
Remedial action:Clean the towball and cleanfriction p ads by lightly rubbing over the
p ad with sand paper (100-200 grain).
2) Dry operation of the towball shaf t in
 the sleeve of the overrun equipment.Remedial action:Lubrication of the sleeves through thegrease nipples (use multi-purposegrease DIN 51825 KT A 3K),
additionally pull the gaiter of f the
overrun, towards  the front and greaseall of the exposed drive shaf t
(see Fig. 24).
3) The towball on the towing vehicle hastoo much play in the lockingmechanism (if det achable).
Remedial action:Go to specialist workshop.  Have thetowball checked for damage.If necessary change towball or ifpermissible re-lubricate lockingmechanism.
AL-KO Kober Lt d
South W arwickshire Business Park
Kineton RoadSouthamW arwickshire, CV47 0AL
01926 818500   01926 818562www .al-ko.co.uk Fig. 24
GENERAL  INFORMA TION
Manoeuvring by hand: S tabilising lever may  not be used as a
manoeuvring handle.  Please use the handleson your caravan or the  AL-KO manoeuvring
handle which can be purchased sep arately to
att ach to your jockey wheel.
Failure to comply result s in danger of over-
loading component p arts.
Noises when driving As a rule the friction linings DO NOT  MAKE A
NOISE when driving!   Any clicking, creaking,
or squeaking noise arising, could have the following causes:
  Fig. 22Replacing Friction Pads:Loosen ret aining ring (Fig. 23/Item 1) with
pointed object.  Push out friction p ad (Fig. 23/
Item 2) from outwards to inwards.  Please only replace one p ad at a time.  Fit new p ad,
replace ball race and secure with a newret aining ring.  Proceed in the same way on
the other side.  Remember , if any washers
come away with the p ad, please replace on
the new p ad. Fig. 23        
						

							 Fig. 3 This type of coupling must be locked to ensure it cannot revolve. Fig. 4
7
Removal of existing fixing bolt s:
Before you st art to remove the existing fixing
bolt s, please note the following:  On most over-
run assemblies, the shock absorber is secured by the fixing bolt (Fig. 5/Item 2). W
arning:
The shock absorber (damper) extendsindependently .  Enclosed with this box is a
ret aining pin (Fig. 6) to aid assembly .
a) Remove gaiter
b) Loosen self-locking nut from hexagoncap bolt (Fig. 5, Items 1/2)
c) Push or knock out hex. cap bolt(Fig. 5/Item 1)
d) Knock through ret aining pin (Fig. 6/2)
with (Fig. 6/Item 1) and leave the pinin the shaf t for centring the shock
absorber (damper).
e) Any spacers originally fitted must be
re-used. Fig. 5
  Fig. 6 Fitting of 
AL-KO Security Device:
Horizont al Bolt Fitting: (for  AL-KO Overruns)
Part s configuration as Fig. 7
Item 1 Locking plates lef t/right
2 Allen Bolt M12 8.8 with flat headto DIN 7984
3 Self locking nut M12
Cross-type Bolt Fitting: (for other overruns)Part s configuration as Fig. 8
Item1 Locking plates lef t/right
2 Allen Bolt M12 8.8 with flat headto DIN 7984
3 Dome Head Bolt M12 8.8
4 Half moon shaped fixing lugs
5 Section washer (not included in this kit)- please use original washer fromcoupling head you are removing
6 Self locking nut M12 During winter use, sp
ay a tiny amount of de-
icer onto the indicator button.  Ensure that thisfluid does not come into cont act with the friction
p ads.
S tabilising Unit
Should lubrication of the st abiliser unit parts
become necessary then the following must beobserved:1) Clean all p arts thoroughly .
2) Areas may only be covered with a thinfilm of grease (see Figs. 21/22).
3) Use multi-purpose grease to DIN51825KTA 3 K (or local equivalent)
W arning:   When lubricating - no oil or grease
Important Operating Factors:
The towball should be completely free of grease and other residue.  Clean thoroughly withThinners, White S pirit or Brake Cleaning fluid.
Hint s:   The surface of the towball must be free
of grooving, rust and scratch marks,Otherwise increased wear and tear will occur .
If p ads are cont aminated by p aint or if they are
glazed, they can be cleaned with 100-200 grainsand paper ,
Painted towballs or similar coatings: In theevent of the ball being coated, this must bethoroughly removed (with 100-200 grainsand paper).  Otherwise reduced st abilising
ef fect, increased wear and damage to  AKS
1300 component s may occur. should be allowed to come into cont
act with the
friction p ads or onto the ball holding area.
If friction p ads are cont aminated with grease,
they should not be cleaned as this will have areduced st abilising ef fect.  Therefore friction
p ads should be replaced.
When opening or closing the st
abilising lever,
care should be t aken not to trap fingers between
the lever and the coupling handle (Fig. 20).  Seegrip areas (Fig. 20).  When applying thest abiliser lever some resist ance should be
experienced.  Should this not be the case, thenthe handwheel may possible be jammed. IF NO ST ABILISING EFFECT IS FEL T
Cause: The handwheel has been turned forcibly against the end top onopening.
Remedy: Contact AL-KO Service S tation.
2  Fig. 7
 Fig. 20
  Fig. 19
Coupling Mechanism In order to maintain the easy action of the
coupling mechanism and to achieve a longerlife for the  AKS 1300, the coupling mechanism
must be lubricated at regular intervals (at leastonce a year).  See Fig. 22.
 Fig. 21            
						

							6
Procedure: Push gaiter and AKS 1300 onto the draw shaf t,
with sp acers (Fig. 9) if necessary , so that the
fixing holes line up.  If present, position the sp acer sleeve in the draw shaf t.
Fit p arts as shown on Figs. 7/8.   If a sp acer
sleeve is in the draw shaf t, thread this on as
well.  Push ret aining pin (Fig. 6/Item 1) through
(with the bolt behind - horizont al or vertical).
Shock absorber (damper), is threaded on. For your own safety , please check:
T o make sure the shock absorber (damper) is
threaded on, push the draw shaf t in and out.
If you can feel resist ance, then it is correctly
positioned. Always insert horizont al bolts from right hand
side (when facing st abiliser), as this allows
correct clearances. Always insert vertical bolt from top to bottom (Fig 8/Item 3) and re-use original shim usedon the overrun (not supplied- Fig. 8/Item 5). Secure gaiter with tie wrap (or ret
aining ring).
Put security device on and lock.  If the cover isdif ficult to put on or lock/unlock then you need
to reposition the locking plates.  Loosen frontbolt s and the plates can now move laterally .
Re-tighten bolt s to correct torque and check if
safety cover now fit s.
OPERA TING INSTRUCTIONS (AL-KO
SECURTY DEVICE): Insert lef t and right lugs of security device into
cut away portion of the att ached locking plates
(Fig. 10/Item 2).Push device firmly forward until it can go no further (Fig. 1 1/Item 1).
Hold security device in place, turn key to theright and press the lock cylinder in, until it clicksinto place (Fig. 12).   Turn the key to the lef t
into the locked position.   The strain bolt then
moves out and locks. Swing the dust cap over the lock cylinder to protect from dirt (Fig. 12).3
Coupling UpOpen coupling handle  - to do this, pull thecoupling handle (Fig. 17/Item 3) in the directionof arrow
.  The coupling mechanism has an open
position, i.e. as long as the  AKS 1300 is not
placed on the ball, the coupling handle willremain open.  Place the open coupling onto thetowball.   The coupling handle should audibly
click back into st arting position.
Safety W arning:  If the st abiliser is correctly
coupled to the towball, then the green edge ofthe safety indicator is visible.   The coupling
mechanism is correctly positioned when thehand lever can no longer be pressed down evenby hand. If the  AKS 1300 is not correctly coupled to
the towball, then the trailer/caravan can become disconnected from the towingvehicle! .
  Fig. 16 Fig. 17
Uncoupling: Uncoupling of the trailer from the towing vehicle takes place in reverse order .  Pull the stabiliser
lever up, until the marking on the st abiliser lever
(Fig. 18/Item 6) matches the marking on thest abiliser cover (top end position of the
st abilising lever).   Turn the hand wheel in an
anti-clockwise direction (lef t) until it will not go
any further .  Open coupling handle and lif t AKS
1300 from the towball of the towing vehicle. Coupling and uncoupling can be made easier by use of the jockey wheel. Fig. 18 For vertical bolt: tighten nut and torque as follows:  Overrun
Torque
  T ype Setting
   AL-KO 30S 60 Nm
   AL-KO 60S-60S/2 60 Nm
   AL-KO 90S-90S/3 70 Nm
  Other overruns 86 Nm
  with M12 (8.8) Bolt s
With cross-type bolt fixing, do not forget to insert half moon shaped plates (Fig. 8/Item 4) andshim (not included - Fig. 8/Item 5). For horizontal bolts, tighten with  Allen Key (size
8), as the nut s are fixed and cannot be moved.
 Fig. 9 Fig. 8
S tarting Position:   The AKS 1300 is connected
to the towball.   Turn the handwheel to the right
(clockwise) (Fig. 18/Item 2), until the torque limit can be heard and felt to ratchet.  Press thest abilising lever (Fig. 18/Item 1) down .   The
AKS 1300 is now functional
S
tabiliser Unit:
Safety T ips:
The  AKS 1300 should only be operated by one
person when coupling or uncoupling. W arning:   Never operate with foot or extension
bar!   The component s will be overloaded and
damaged.  (Fig. 19).      
						

							45
Removing Security Device (reverse order to fitting cover): Open dust cap.Insert key and turn to the right, as far as it will go (about 60
0).  As a result the lock cylinder will
slide up automatically .  If necessary, press the
cover forward and pull out the lock cylinder withthe key (turned about 60
0).
Pull safety cover back. Remove security device  and stow in vehicle or caravan.  So that the dust cap is not damagedduring transit, remove key (inserting lock) andswing dust cap over the lock cylinder .. Operate the locking cylinder periodically
, if the
cover has not been used for a while.  If the lock only operates with dif ficulty, spray the cylinder
with WD 40 (or similar)
PLEASE CHECK THE CONDITIONS FORA TT ACHMENT BY  FOLLOWING THE STEPS
LISTED BELOW .
T owing vehicle with towball att achment:
The equipment may only be used for connectingto towballs to (DIN 74058 or local equivalent),where the clearance below the ball, measuredfrom the centre of the coupling point, is at least60 mm (Fig. 13).  According to British S tandards
the prescribed rot ation of ±25
o will thus be
achieved.
  Fig. 13
  Fig.1 1
  Fig. 12
  Fig. 14Coupling to 
T railer Measurement s (attachment
hole dimensions B horizont al or cross)
Please check dimensions of  your coupling (Fig. 15) on your overrun equipment and also referto t able 1 for dimensional information. All EC Countries: The inst
allation is to be examined in conformity
to the stipulations in  Appendix 1, No.5.10,
according to the demands of  Appendix VII of
Directive EC 94/20.   These installation and
operating instructions are to be included with the caravan/trailer p apers.
GB  - Inst allation only possible with special tow
ball att ached to towing vehicle.   Towball type
A50-X (included with this kit).(see regulations and restrictions of use onp age 1).
OPERA TING INSTRUCTIONS(AL-KO  AKS
1300) AKS 1300 Delivery S pecifications
Fig. 16/Item 1: S tabilising Lever
Fig. 16/Item 2: Handwheel Fig. 17/Item 3: Coupling Handle Coupling/Uncoupling Please Note: When coupling or uncoupling, thest abiliser lever must be in the up position (open)
and the handwheel (2) must be as far open aspossible (Fig 16). Attention:  Do not turn the handwheel against the stop by force.
  Fig. 15  Min
 T ot al Nose Weight
  Mass  Permissble Weight Kg
  Kg  Weight Kg Kg
 180  1360 100 3.5
  Hole  Shaft Distance Length
   Type  Dia. (mm)
Between Holes
D
  A BC
  Horiz  35, 40,50      50-54 12168
  Cross 45&50 4018168
 T able 1
S
tabiliser Lever Clearances (Fig. 14)
No component p arts are allowed in the sp ace
marked X.   The measurement of X  should
correspond at least to the travel of the overrun equipment (as a rule 80 - 100 mm accordingto type).  Measurement is t aken with a fully
extended drawbar .  AL-KO overrun equipment
fulfils this requirement.
Import
ant Information:
Never attempt to fix or remove the securitydevice  with the aid of a hammer - this mayresult in damage to the cover .
MAINTENANCE Clean strain bolt, locking bolt s and the cutaway
portion in the locking plates if they become dirty .
A little grease may be applied but remove excess with a cloth so that only a thin film remains
 Fig. 10