AL-KO Caravan Chassis Handbook User Manual

11
AL-KO BRAKING SYSTEM ADJUSTMENT
Fig 11 Brake Linkage
Fig 12 Adjusting the Starwheel
1
Rubber sprung axle
Brake shoe 
inspection bung
‘Starwheel’ 
adjustment access
Balance
barAbutmentBowden cable
Rotation direction forwardsAxle side 
plate
Brake rod
Handbrake lever
Stabiliser
Overrun lever
Breakaway cable  

12
12. Remove the slack in the brake rod by adjusting the long 
ball nut, rear of the balance bar, ensuring the overrun 
lever makes contact with the end of the towing shaft. 
Note! Over adjustment to the long ball nut (Fig 13/Item 
2) could induce movement of the inner brake cable, 
reducing the effective clearance of the brake shoes. If the 
overrun lever will not make contact, it is possible the two 
lock nuts, forward of the spring cylinder, are incorrectly 
adjusted. Loosen the nuts and adjust brake...

13
Bowden Cable Abutment
(welded to axle tube)
AL-KO BRAKING SYSTEM ADJUSTMENT
Fig 13a Standard Brake Linkage
Fig 13b Brake Linkage with ATC Fitted
Balance bar
238576002
34
4
21
1- Brake rod
2- M10 Ball nut 2088890006
3- M10 Locknut 700109
4- Bowden Cables
Bowden Cable Abutment
(welded to axle tube)
Balance bar
238576002
21
1- Brake rod
2- M10 Ball nut 2088890006
3- ATC Push Rod
4- Bowden Cables
Axle
Axle
ATC Mounting Bracket
AT C 
Guide Tube
3  

14
STABILISER AND COUPLING DEVICES
Your caravan will be fitted with either an AKS 3004 stabiliser 
or an AK160/300 coupling head.
SAFETY PRECAUTIONS
Always ensure that the coupling head is properly connected 
to the tow vehicle’s towball every time you couple up. If this 
procedure is not carried out correctly, the caravan/ trailer 
may become detached from the towing vehicle! Maximum 
possible articulation of the coupling head must not exceed 
±25° vertically and ±20° horizontally - see Fig 14. 
If...

15
OPERATING INSTRUCTIONS 
FOR AKS 3004 STABILISER
REGULATIONS
1. The AKS 3004 must be used in conjunction with 50 mm 
dia. towballs which conform to EC Directive 94/20 (DIN 
74058 or local equivalent).
2.  Suitable for attachment to drawbars or approved 
overrun braking equipment for single (and tandem axle) 
caravan/trailers, with a minimum weight of 200 Kg and a 
maximum permissible weight of 3000 Kg.
3.  EC design approval has been given to the AL-KO AKS 
3004 coupling under permit No....

16
OPERATING INSTRUCTIONS 
FOR AKS 3004 STABILISER
RESTRICTIONS OF USE
1. The trailer coupling may only be connected to towing 
vehicles where the clearances for the stabiliser can be 
observed, in accordance with EC Directive 94/20 (DIN 
74058). If these clearances are infringed by special 
attachments, then the use must be checked separately.
 
 The area above the towball of the vehicle must be free 
from vehicle components or attachments (A) (eg spare 
wheels, platforms etc.) 
 The clearance for the...

17
SAFETY WARNINGS
1. In accordance with EC Directive 94/20, couplings of type 
A 50-1 cannot be used (see Fig 17), your warranty will be 
invalid if this type of towball is used.
2. For UK use, use the extended neck towball (type A50-X).
3. A bolted-in type ball coupling (Fig 18) is only permissible 
if the thread is locked or welded.
4. The AKS 3004 cannot be used with a laterally attached 
reversing lever, on the left side, when facing the 
direction of traffic.
5. The towball must be free from...

18
OPERATING INSTRUCTIONS 
FOR AKS 3004 STABILISER
AKS 3004 DELIVERY INSTRUCTIONS
Coupling Handle (Fig 20/Item 1) 
Stabiliser Lever (Fig 20/Item 2)
PREPARATION FOR COUPLING/UNCOUPLING
The Stabiliser lever (Fig 20/Item 2) must be in the 
uppermost position (open).
COUPLING UP
Pull the coupling handle (Fig 21/Item 1) up in the direction 
of arrow. The coupling mechanism has an open position ie. 
as long as the AKS 3004 is not placed on the ball, the handle 
will remain open. Put the opened coupling onto...

19
OPERATING INSTRUCTIONS 
FOR AKS 3004 STABILISER
Fig 21 Pull Coupling Handle Up
Fig 20 Raise Stabiliser LeverFig 22 Correct Engagement With Towball
Fig 19 Coupling Handle & Stabiliser Lever
Fig 23 AKS 3004 Friction Pads
1
1
1
2
2
3
23
1
4
AL-KO

AL-KO

2  

20
CHECKING THE EFFICIENCY OF THE 
LEFT/RIGHT FRICTION PADS
1. Check that the stabiliser is correctly coupled by ensuring 
the coupling handle is fully down and the red indicator 
button is in the raised position. 
2.  Push the stabiliser handle down until resistance is felt 
(ie. the friction pads are in contact with the ball but not yet 
under pressure) (Fig 24/Item 1).
3. Check the position of the arrowhead on the arm of the 
stabiliser.  If it lines up with the two green lines then the 
friction pads...