AL-KO Caravan Chassis Handbook User Manual

21
OPERATING INSTRUCTIONS 
FOR AKS 3004 STABILISER
MANOEUVRING
For easier manoeuvring (on campsites etc), pull the stabiliser  
lever to the ‘up’ position.
Please do not use the stabiliser lever as a manoeuvring 
handle. Please use the handles on the Caravan or fit the AL-KO 
manoeuvring handle to your jockey wheel (available separately).
1. During opening or closing, the AKS must only be 
operated by one person.
2. Press stabiliser lever down by hand force only DO NOT 
use your foot or an extension bar,...

22
NOISES WHILST DRIVING
As a rule, the friction pads of the AKS 3004 do not make a noise 
during driving. Any clicking, creaking or squeaking noises that 
do arise may be due to the following:
a. Foreign bodies, dirt or exhaust particle build up between the 
friction pad and towball.
b. Dry operation of the drawshaft inside the overrun device.
c. A detachable towball which has too much play in the 
locking mechanism.
REMEDIAL ACTION
a.  Clean the towball and friction pads before each journey by 
lightly...

23
OPERATING INSTRUCTIONS 
FOR AKS 3004 STABILISER
SERVICING AND CLEANING
Friction Pad Replacement
(Replace one at a time)
1. Uncouple AKS 3004.
2. Remove protective caps (Fig 27/Item 1) with the aid of a 
small screwdriver.
3. Press worn out pad inwards and remove (use punch and 
hammer) (Fig 27/Item 2).
4. Insert new friction pad from below (after first re-inserting 
shim washers if they were present) and press in as far as it 
will go (Fig 27/Item 3 & Fig 27a).
Fig 27 Remove Worn Pads
Fig 27a Insert...

24
CHECKING THE EFFICIENCY OF THE 
FRONT/REAR FRICTION PADS
1. Couple the AKS 3004 to the towball but do not activate 
the stabiliser.
 2. If a green indicator is visible (on the handle), then the 
AKS 3004 is in a new condition or the pads and towball 
are within the permissible limits (Fig 28/Item 2).
3. If only a red indicator is visible (Fig 29/Item 3), then this 
may have the following causes:
a. AKS 3004 is okay but the towball has reached the 
lowest limit of 49.61 mm.
b. AKS 3004 shows signs of...

25
OPERATING INSTRUCTIONS 
FOR AKS 3004 STABILISER
Fig 30a Remove Cheese-Head Screws
Fig 30 Friction Pad Replacement
Fig 33
Fig 31 Remove Head Cap Screw
Fig 28 Wear indicator - good condition
Fig 29 Wear indicator - poor condition
2
1
2
5
3
46
3
3  

26
IMPORTANT MAINTENANCE & CLEANING ADVICE
1. The towball should be cleaned regularly to remove grease 
or other residue, the use of Thinners, White Spirit or 
Brake Cleaner is recommended - otherwise the stabilising 
effect will be severely reduced.
2. If friction pads are contaminated, they should not be 
cleaned but replaced. 
3. The surface of the towball must be free of grooves, rust 
or seizing marks.
4. Towballs coated (with paint or similar) must have this  
surface completely removed (use 100 or...

27
COUPLING TYPES AK160 & AK300
OPERATING INSTRUCTIONS
COUPLING UP
Open coupling handle. To do this pull the coupling handle up 
(Fig 33) in the direction of the arrow.
The coupling mechanism has a fixed open position, ie. 
as long as the coupling head is not placed on the ball the 
coupling will remain open.
Put the open coupling onto the towball. The coupling 
handle automatically and audibly clicks into position. 
In the interests of safety, press the handle down by 
hand (Fig 33).
The coupling head...

28
WEAR INDICATOR
A wear indicator on the coupling head (Fig 34) shows 
whether the wear limit of the towing vehicle’s towball or the 
trailer coupling has been reached. For this purpose, hitch up 
the trailer to the towball and drive the unit for approx. 500 m. 
This will set the coupling head adjustment. Following this, 
check the wear indicator as follows:
If the green indicator is visible on the coupling (with the 
coupling engaged Fig 34), the coupling head is in good 
condition or the wear on the...

29
This type of coupling is normally fitted to 
trailers or older model caravans.
OPERATING INSTRUCTIONS
COUPLING UP
Push the safety lever (Fig 35/Item 1) up with the index finger 
and lift the handle up and forwards. Put the opened coupling 
onto the towball with the handle pulled up and in addition 
press down by hand. The coupling will close by applying a 
light pressure. Press the handle down by hand until the catch 
snaps out (Fig 35/Item 3).
The coupling head is correctly engaged when the green...

30
WEAR INDICATOR
If the handle reaches the back of the cutaway portion of 
the housing, when the coupling head is engaged (Fig 36) 
there will be play between the towball and coupling head. 
Automatic re-adjustment is no longer possible and the 
assembly will need inspecting.
CAUTION
Under these circumstances, the coupling head can become 
detached from the towball and the caravan/ trailer can 
breakaway from the tow vehicle. The coupling head and 
towball must therefore be checked IMMEDIATELY before...