AL-KO Caravan Chassis Handbook User Manual
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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 rod as above (Figs 11, 13a\b). 13. OVER ADJUSTMENT of either the wheel brakes or linkages, will result in difficult reversing causing the wheels to ‘lock-up’. 14. When parking, the handbrake lever MUST ALWAYS be engaged into the fully upright position (90°). If difficulty is experienced in this operation, try easing the caravan backwards with one hand while engaging the handbrake fully with the other. This manoeuvre should not be attempted on a rearwards facing slope. In this case wheel chocks should be used combined with the handbrake. 15. Finally, if the road wheels have been removed, re-tighten all M12 wheel bolts using a calibrated Torque Wrench to 110Nm for Alloy Wheels and 88Nm for steel wheels. The wheel bolts should be tightened in sequence, ie. North, South, East, West NOT clock or anti-clockwise (refers to steel wheels only). Remember to over-tighten is just as dangerous as to under- tighten, as this can distort the wheel rims. Avoid the use of power wrenches. IMPORTANT The torque settings should be rechecked after 50 km. Wheel bolts should NEVER be lubricated. AL-KO BRAKING SYSTEM ADJUSTMENT
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 exceeded, components will be overloaded and the operation of the assembly adversely affected! Fig 14 Maximum Articulation Of Coupling Head 25°25° 25° 25°
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. e1*94/20*0930*00.
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 stabiliser handle must be at least 330 mm (B) + the stroke movement (D) (85mm- 100mm), which equates to 440 mm when used in conjunction with an AL-KO overrun. Max. 50 mm (C) clearance between the centre of the towball and top of the overrun assembly or fairing, to ensure both coupling handle and stabiliser handle do not foul on operation. Maintain the same clearances for other manufacturers’ overrun assemblies. 2. Not suitable for use with overrun devices which can revolve above 25 (Fig 16) or BPW overruns fitted with gas strut handbrakes from 2001 model year onwards. (If in any doubt about usage consult your manufacturer). 3. Swan Neck towbars (fixed or detachable) are suitable for use with the AKS 3004 providing they comply to EC Directive 94/20 and have the required minimum 60 mm clearance, measured from the centre of the towball (Fig 16). Fig 20 Clearances for Stabiliser Handle Fig 15 Necessary Clearances ABD CMIN. 60mm MIN. 67mm
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 grease, paint and other residue, otherwise the stabilising effect is greatly reduced. 6. If friction pads become contaminated with grease, they should be replaced. 7. The AKS 3004 should only be operated by one person, when opening or closing the handle, to reduce injury risks. Fig 17 A 50-1 Couplings Fig 16 Max suitable rotation of overrun device is 25° Fig 18 Bolted In Coupling 25° Min. 60mm OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER
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 the clean towball. The handle must now make an audible click and return to the flat position. WARNING The coupling is correctly engaged when the green edge of the safety indicator button is visible (Fig 22/Item 2). STABILISER UNIT To operate the stabiliser (once coupled to the towball), simply press the stabiliser handle down as far as it will go (Fig 22/Item 3). To ensure the stabiliser is correctly coupled, check the arrowhead lines up with the black line marked 2 (Fig 22 /Item 4 and Fig 24/C). UNCOUPLING Pull the stabiliser handle up as far as it will go, open the coupling handle and lift the AKS 3004 from the towball. With larger nose loads, coupling and uncoupling can be made easier by using the jockey wheel to assist lifting. NOTE The friction pads (Fig 23/Items 1,2&3) are pressed against the towball and hence generate a stabilising/damping force. These pads are therefore subject to wear over time, however they will have a long service life (circa.30,000 Miles), provided they are well maintained and kept free of grease/dirt.
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 are still as new (Fig 24/A). 4. If the arrowhead lines up with the two red lines then the friction pads are worn and should be replaced immediately (Fig 24/B). NOTE When the stabiliser handle is correctly applied, the arrowhead should line up with the black line marked 2 (Fig 24/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 24 Checking Left/Right Friction Pads OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER 1 2 1 1 A 2 1 1 B 2 1 1 C