AL-KO AKS 2700 Handbook User Manual

							ASSEMBL
Y AND OPERA TING
INSTRUCTIONS FOR AL-KO  AKS 2700 ST ABILISER
PLEASE ENSURE  YOU READ THESE INSTRUCTIONS CAREFULL Y,
BEFORE COMMENCING T O OPERATE THIS PRODUCT .REGULATIONS:
1)  The  AKS 2700 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 t andem axle) trailers, with a minimum weight of 200 Kg and a maximum permissible weight
of  2700 Kg.3) EC design approval has been given to the  AL-KO AKS 2700 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 ef fect from 01.12.95.
RESTRICTIONS OF USE:S pare wheels fitted to rear door of vehicle, or vehicle with plat forms etc:
1) the  AKS 2700 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 special att achments, 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 separate towball sheet.
W ARNINGS:
1) In accordance with EC Directive 94/20, couplings type  A 50-1 cannot be used (see Fig. 2).
2)  A bolted-in type ball coupling (Fig. 1) is only permissible if the thread is locked.
3)  The   AKS 2700 cannot be used with a laterally att ached reversing lever, on the left side, when
facing direction of traf fic.
 Fig. 1  Fig. 2 This type of coupling must be locked to ensure it cannot revolve.
1
5.  GENERAL  INFORMATION
The surface of the ball must be free from grooves, rust and siezing marks.   Any
Dacromet coating (dull silver corrosionprotection coat) must be removed, otherwisethere will be increasing wear and a reduction inthe st abilsiing ef fect.
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
overloading component p arts.
Manoeuvring with towing vehicle:Pull the st abilising handle to the top
position(manoeuvre position) to make themanoeuvring easier (on camp sites etc). S toring:
T o reduce the cont amination of component
p art s of the  AKS 2700, the st abilising handle
should be closed if stored over a longer period. Protect the towball of the vehicle from rusting. 1)
Foreign bodies or dirt between thefriction 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 grease all of the exposeddrive shaf t (see Fig. 27).
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.
During winter use, spray the visual indicatorbutton with de-icer .
8AL-KO Kober Lt
d
South W arwickshire Business Park
Kineton RoadSouthamW arwickshire, CV47 0AL
01926 818500   01926 818562www .al-ko.co.uk
Part No. 1385107  Iss. 2 -  11/03
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:
S
pare Part s/Attachment Part s:
W arning:
1) Only original  AL-KO spare parts may
be used.
2) All attachment s and accessories must
be approved by  AL-KO.
F AILURE  TO COMPL Y WITH  THIS DEMAND
WILL  RELEASE  THE MANUF ACTURER OF
AKS 2700 FROM  ALL GUARANTEE
OBLIGA TIONS.     
						

							1. PLEASE CHECK THE CONDITIONS FOR ATT ACHMENT BY  FOLLOWING THE STEPS
LISTED BELOW .
T owing vehicle with towball att achment:
The equipment may only be used for connect-ing to towballs to Directive 94/20 EC  A50,
where the clearance below the ball, is at least60 mm (Fig. 3).  According to British S tandards
the prescribed rot ation of ±25
0 will thus be
achieved.  Not suit able for use with revolving
shaf ts above 25
0.
Handbrake lever on right:The  AKS 2700 can be used only on overrun
devices where the handbrake is mounted onthe right, viewed by someone facing thedirection in which the vehicle is moving.  Forhandbrake levers on the lef t, please order the
special handles, Part No. 581 158 & 581158. Fig. 3
Press worn friction linings (Fig. 22/Item 2) inwards and remove (use punch and hammer- replace one at a time). Insert the new friction linings from below with the pin in the sleeve (Fig. 22/Item 3) and pressin as far as possible (pin engages, no toolsnecessary).  Also reinsert adjusting washers, if
present on original friction p ads.
Check wear on ball: If the wear indicator (Fig. 23/Zu) is no longer visible, it is probable that the ball is worn andhas developed play within the couplinghousing.  Proceed as follows:- Connect ball DIN 74058 (ISO 50)
- Handle is automatically tightened
- No pushing by hand
- Check the position of the wear indicator
W arning:   The  AKS 2700 can disengage and
the caravan could uncouple from the towingvehicle.  Check  AKS and towball immediately!
W arning:   Exchange the worn out p art
immediately .  The diameter of the towball
should be ascert ained first of all, so that
conclusions may be drawn as to the wear ofthe coupling mechanism (min dia. 49.61 mm).
  Fig. 247 Fig. 23Checking the towball coupling:Have the towball re-checked with st andardised
test ball at the  AL-KO service st ation.  The
towball coupling/trailer ball is not worn at handle (Fig. 23/A) (T ightening only via spring
force, without pushing by hand).
 
Fig. 22
Use a screwdriver to remove plastic protec-tive cap
s (fig. 22/Item 1).
 Min Tot al Nose Weight
 Mass Permissble Weight Kg
 Kg Weight Kg Kg
 200 2700 100 5
 Hole Shaft Distance Length
  T ype Dia. (mm)
Between Holes
D
A (Fig. 5) BC        (Fig. 5)
 Horiz 50 5012177
35&40 5412177
 Cross 46&51 4018177
 T able 1 Fig. 4Clearances for 
AKS 2700 (Fig. 4):
a) The area above the towing ball of the vehicle must be free from vehiclecomponent s (eg. spare wheels).
b) Clearing for st abiliser handle = 340 (B)
+ stroke (D) (85-100 mm) = 440 mmwith  AL-KO overrun devices.
c) Max. 50 mm (C) clearance for couplinghandle (at initial operation).
d) Min. 45 mm clearance (E) to rear oftowing vehicle.
2      
						

							Remove gaiter from coupling head. Loosen and remove hexagon nuts
(Fig. 6/Item 1&2).Pull or push out hexagon bolt(Fig. 6/Item 1).Knock through hexagon bolt(Fig. 7/Item 2) with ret aining pin (Fig. 7/Item 1)
and leave in ret aining pin to secure shock
absorber (damper) in the drawbar .
The  AKS 2700 is designed for drawshaf t tubes
up to 50 mm dia.  For small diameters, sp acer
bracket s are enclosed (Fig. 8).
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
2700 component s may occur.
T echnical Information:  The friction linings are
pressed against the towing ball and generate ast abilising/damping force.   The friction pads are
therefore subjected to wear .  The linings have
reserves of wear and thus have a long servicelife (Fig. 18). How to check the ef ficiency of the AKS 2700:
1) Couple the  AKS 2700.
2) Pull stabilising handle into of f position
(Fig. 19/Item 1).
3) Close st abilising handle until resist ance
is felt (friction linings are in cont act with
the towball - but not under pressure).
4) The mark on the pressure plate is between the two marks (Fig. 19/Item 4)on the housing (Fig. 19/Items 2&3),
5) The friction linings are beyondpermissible wear range and requireadjustment, when the marking on thepressure plate coincides or p asses the
marking on the housing (Fig. 19/Item 3). S
tabilising Unit:
Should lubrication of the st abiliser unit parts
become necessary then the following must beobserved:a) Clean all p arts thoroughly .
b) Areas may only be covered with a thinfilm of grease (Fig. 21/Item 1).
c) Type of lubricant: Multi-purpose grease
to DIN 51825 KT A 3K (or equivalent)
W arning:   When lubricating, no oil or grease
should get onto the friction area or on the ballholding area!. Replacing Friction Linings: The marking on the pressure plate (Fig. 19/ Item 4) has reached or p assed the “replace”
marking on the housing (Fig. 19/Item 3). Uncouple the  AKS 2700.3Assembly of the  AKS 2700 Stabiliser:
Place  AKS (and sp acers - if required) (Fig. 9/
Item 3) onto the drawshaf t, aligning mounting
holes 1&2 and sp acer sleeve
(Fig. 9/Item 4). Insert hexagon bolt M12x80/75 (Fig. 9/Item 1)and t ake up sp acer sleeve (if used).
2.  ASSEMBL Y INSTRUCTIONS
Removal of existing coupling head:Before you begin dismantling the couplinghead, please note the following:The shock absorber (damper) on most overrunequipment is suspended on the rear fixing bolt(Fig. 6).
  Fig. 8
50 mm = no sp acer required
40 mm = S pacer (a) required
35 mm = S pacer (b) 5.5 mm
(1x5.0 mm & 1x2.5 mm) 45 mm = S pacer (c) 2.5 mm
 Fig. 6
  Fig. 7
 Fig. 21Lubrication:Coupling Mechanism: In order to maint ain the easy action of the
coupling mechanism and to achieve a longerlife for the  AKS 2700, the coupling mechanism
must be lubricated at regular intervals (at leastonce a year).   Type of lubricant: General
purpose grease to DIN 51825 KT A 3K (or local
equivalent). (Fig. 24). W arning:  When lubricating, no oil or grease
should get on the friction area or the ball holding area. If friction p ads are cont aminated with grease
they should not be cleaned as this will have a reduced st abilising ef fect.  Therefore friction
p ads should be replaced.
 Fig. 19
 Fig. 20
6
 Fig. 18 Attention: The shock absorber moves out independentlyand for this reason, you will find a ret
aining
pin  in the box, to facilit ate coupling head
removal.
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 label
will  appear as follows:  (see regulations and restrictions of use on p age 1).
 Fig. 5          
						

							IMPORTANT:
In any operating condition, there must always be free room of approx. 25 mm between theAKS controls and the operating p arts of the
overrun device, so that a hand can be inserted.(Figs. 1 1/11a)
This should be checked as follows:a) AKS 2700- stabiliser handle closed
- st abiliser handle open 3. OPERA
TING INSTRUCTIONS
AKS 2700 Delivery S pecifications:
Fig. 12/Item 1: S tabilising Lever
Fig. 12/Item 2: Coupling Handle Coupling/Uncoupling:Please Note: When coupling or uncoupling, the st abiliser lever must be in the top position
(open). Pull st abiliser handle fully up right to stop
(open) (see Fig. 14/Item1). Coupling Up:Coupling Head:Open the ball coupling - to do this, pull coupling handle fully upwards in direction of arrow (Fig.14/Item 2). Put the opened coupling on the towball of the towing vehicle and release the coupling handle.It should now slide back into the initial positionon it
s own.  However , press down with the
hand as well.  Closure and fastening areautomatic. Safety W arning:  If the st abiliser is correctly
coupled to the towball, then the green edge of the safety indicator is visible.   The coupling
mechanism is correctly positioned when thehand lever can no longer be pressed downeven by hand (Fig. 15/Item 3). If the  AKS 2700 is not correctly coupled to
the towball, then the trailer/caravan can become disconnected from the towingvehicle! Press the st abilising handle down until it is over
centre and against the end stop.
Uncoupling:Lower the jockey wheel. Det ach breakaway cable and electrical plugs.
Pull st abilising lever up, right to stop (Fig. 13/
Item 1).Pull coupling handle  hard up in direction ofarrow (Fig. 14/Item 2).Lif t coupling head from towball of towing
vehicle.   This process can be carried more
easily if the towbar is set high with the jockeywheel, when the coupling handle is opened. Safety T
ips:
During coupling and uncoupling, the  AKS 2700
must only be operated by one person. W arning;   Never operate with foot or extension
bar!   The component s will be overloaded and
damaged.  (Fig. 16).Only press st abilising handle down or pull it up
with one-hand only .
W arning:   The st abilising lever must not be
used as an aid for manoeuvring. Caution:   When opening or closing st abilising
handle, do not leave hands on the coupling handle (Fig. 17). Import ant Operating Factors :
The towball should be completely free of grease and other residue.  Clean thoroughlywith  Thinners, 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 pads are
cont aminated by p aint or if they are glazed,
they can be cleaned with 100-200 grainsand paper .
4
5 Fig. 17 Fig. 15
 Fig. 16
  Fig. 12  Fig. 14  Fig. 13 Fig. 1 1  Fig. 1 1ab)
Overrun device - drawshaf t telescoped out
- drawshaf t telescoped in
- handbrake lever on- handbrake lever released
The free room is required to guarantee correctfunctioning and ease of operation.
Knock through ret aining pin with hexagon bolt
M12x80/75 (Fig. 9/Item 2).  Shock absorber(damper) will remain in place. For your own safety please check: T o ensure shock absorber (damper) is ret ained
in place, push drawshaf t in and out.
If resist ance is felt when pulling the drawshaf t
out, then the shock absorber (damper) is inplace. Place the lock-nut (use the new nut s enclosed)
onto the bolt and torque to 100 Nm. W arning : Self-locking nut s may only be used
once. Depending on design of gaiter may either be: - put over coupling- linked into sp ace bracket
- fixed over ret aining ring.
 
Fig. 9  
Fig. 10
Warnings:
Always insert horizont al bolts from st abiliser
lever side, as this allows correct clearances and thef t prevention if used with  AL-KO barrel
lock (not included).Always insert vertical bolt from top to bottomand re-use original shim used on the overrun.(Fig. 10/Item 1).