AL-KO AKS 3004 Stabiliser Handbook User Manual
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11 OPERATING INSTRUCTIONS Fig 8 Pull Coupling Handle Up Fig 7 Raise Stabiliser LeverFig 9 Correct Engagement With Towball Fig 6 AKS 3004 StabiliserFig 10 AKS 3004 Friction Pads 1 1 2 3 2 3 1 4 AL-KO AL-KO 2
12 OPERATING INSTRUCTIONS 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, this will damage the components (Fig 11). 3. When opening or closing the stabiliser lever, please ensure your hand does not touch the coupling handle - you may accidentally trap your fingers (Fig 11). Fig 11 How NOT to operate the stabiliser lever
13 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 rubbing the surfaces with a light emery paper (100- 120 grit) or use brake cleaning fluid to remove the build up. b. Lubricate the drawshaft sleeve via the grease nipples. In addition, push the gaiter forward and grease (DIN 51 825 KTA 3K) the exposed part of the shaft (Fig 12). c. Visit a specialist workshop to have the ball holding area checked for damage and the locking mechanism for function. If necessary, change the towball.Fig 12 Remedial Action OPERATING INSTRUCTIONS
14 CHECKING THE EFFICIENCY OF THE SIDE 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 lever (Fig 13/Item 1) down until resistance is felt (i.e. The friction pads are in contact with the ball but not yet under pressure). 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 are still as new (Fig 13/A). 4. If the arrowhead lines up with the two red lines then the friction pads are worn and should be replaced immediately (Fig 13/B). NOTE When the stabiliser lever is correctly applied, the arrowhead should line up with the black line marked 2 (Fig 13/C). NOTE The friction pads do not require any form of lubrication and should be cleaned with a fine emery paper prior to every journey. It is not necessary to adjust the friction pads. Fig 13 Checking Left/Right Friction Pads SERVICING AND CLEANING 1 2 1 1 A 2 1 1 B 2 1 1 C
15 SERVICING AND CLEANING FRICTION PAD REPLACEMENT (SIDE) (Replace one at a time) 1. Uncouple the AKS 3004 stabiliser. 2. Remove protective caps (Fig 14/Item 1) with the aid of a small screwdriver. 3. Press worn out pad inwards and remove (use punch and hammer) (Fig 14/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 14/Item 3 & Fig 15). Fig 14 Remove Worn Pads Fig 15 Insert New Pads 1 2 3
16 CHECKING THE EFFICIENCY OF THE FRONT/REAR FRICTION PADS 1. Couple the AKS 3004 stabiliser 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 16/Item 2). 3. If only a red indicator is visible (Fig 17/Item 3), then this may have the following causes: a. AKS 3004 is okay but the towball has reached the lowest limit of 49.61mm. b. AKS 3004 stabiliser shows signs of wear. c. Towball is in a new condition (50mm) but the front/ rear friction pads show a high degree of wear. Establish the diameter of the towball so that conclusions may be drawn as to the wear of the friction pads (ball diameter must not be less than 49.61mm). FRICTION PAD REPLACEMENT (FRONT/REAR) 1. Uncouple the AKS 3004 stabiliser. 2. Remove the soft dock (pull up & off), (Fig 20/Item 1). 3. Press the safety indicator outwards and secure with SW14 hex. spanner (not included), (Fig 20/ Item 2). 4. Remove cheese-head screw (Fig 20/Item 3 & Fig 18), using special torx tool. 5. Press friction lining recess (Fig 20/Item 4) inwards and pull down and out. 6. Open coupling handle (Fig 20/Item 5). 7. Remove countersunk head cap screw using special torx tool (Fig 20/Item 6 & Fig 19). 8. Press friction pad inwards with a screwdriver and remove. 9. Fit new friction pads in reverse. Tighten screws to 5Nm (Fig 20/ Items 3&6) 10. Replace rubber soft dock, insert top section then bottom. SERVICING AND CLEANING
17 SERVICING AND CLEANING Fig 18 Cheese-head screw revealedFig 20 Friction Pad Replacement Fig 33 Fig 19 Remove Head Cap Screw Fig 16 Wear indicator - good condition Fig 17 Wear indicator - poor condition 2 125 3 46 3
18 IMPORTANT MAINTENANCE & CLEANING ADVICE 1. The towball should be cleaned regularly to remove grease or other residue, to maintain the efficiency of the friction pads. The use of thinners, white spirit or brake cleaner is recommended for cleaning the towball and friction pads. 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 120 grain emery paper). If this is not done, increased towball wear will occur and may cause damage to the AKS 3004 stabiliser components. 5. In winter, you should carefully spray only the visual indicator with de-icer. Fig 21 Lubrication points LUBRICATION Should lubrication of the stabiliser parts become necessary, then the following must be observed. a. Clean all parts thoroughly. b. Areas may only be covered with a thin film of grease (Fig 21). c. Use multipurpose grease DIN 51825 KTA 3K. WARNING When lubricating, ensure none gets into the friction pad or towball holding area. SERVICING AND CLEANING
19 FAQS STABILISER CAN THE RED AND/OR GREEN INDICATOR BUTTONS BE REPLACED IF BROKEN/MISSING? This is usually caused by catching the button with the hitch lock when fitting the hitch lock. The green section can in some circumstances be replaced. Please contact AL-KO for further advice. The red part cannot be replaced. THE STABILISER ARMS KEEP LIFTING UP WHEN I TRAVEL. The most likely cause is the handbrake handle catching on the stabiliser lever when braking. Gently tease the handle away from the contact point - 5mm should be sufficient. Whilst doing this, make sure you support the base of the handbrake with a block of wood to stop it coming off the ratchet plate. FRICTION PADS WHEN SHOULD I CHANGE MY FRICTION PADS? The friction pad life expectancy is around 30,000 miles and can be prolonged by regular cleaning with fine grade emery paper. Simply remove them according to the instructions on pages 15-17, clean them and replace. However, they will wear out and this can be monitored via wear indicators on your stabiliser. See pages 14-17 for wear indicator information, and instructions on changing them. MY FRICTION PADS LOOK ‘GLASSY’ WITH BITS FLAKING OFF. Contamination has built up on the pads. This could be due to grease on the towball, spray from the road, diesel fumes or failure to remove all of the coating on the towball. You need to remove the friction pads according to the instructions on pages 15-17, and rub them lightly with a fine grade emery paper. AL-KO recommend cleaning the pads in this way after every journey to prevent build up and prolong friction pad life.
20 FAQS WHEN TOWING I CAN HEAR LOUD CREAKING OR GROANING. 2 possible causes: 1 The incorrect towball could be fitted. Check your towball is compatible with your stabiliser, and if it isn’t replace it immediately. Failure to do so could result in your caravan becoming unhitched during towing. The necessary clearances are outlined on page 4, and AL-KO recommends the AL-KO extended neck towball which complies to all the necessary specifications. 2 Contamination may have built up on the friction pads. This could be due to grease on the towball, spray from the road, diesel fumes or failure to remove all of the coating on the towball. You need to remove the friction pads according to the instructions on pages 15-17 and rub them lightly with a fine grade emery paper. AL-KO recommend cleaning the pads in this way after every journey to prevent build up and prolong friction pad life. THE END HAS SNAPPED OFF OF MY FRICTION PAD. This usually happens when the pads have not been fully disengaged before dropping the stabiliser onto the towball. You will need to replace the friction pad with a new one. To avoid this in future always place, rather than drop, the stabiliser onto the towball and ensure the stabiliser lever has been lifted fully. CAN I TOW MY CARAVAN WITHOUT ACTIVATING THE FRICTION PADS? Yes, but AL-KO do not recommend it. It is the hitch handle that attaches the stabiliser to the towball. If you do not activate your friction pads then you will have no damping benefits. TOWBALL MY TOWBALL HAS GREASE ON IT. CAN I USE IT WITH AN AKS STABILISER? Under no circumstances can a greased towball be used with an AKS stabiliser. Ensure you remove all grease before hitching up. Use a cloth to remove the excess grease, and use brake cleaner to remove any residue. We do not recommend methylated spirit as this can leave a greasy residue.