AL-KO Caravan Chassis Handbook User Manual

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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, this will damage the 
components (Fig 25). 
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 25).
Fig 25 How NOT to operate the stabiliser handle
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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 26).
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 26 Remedial Action
OPERATING INSTRUCTIONS 
FOR AKS 3004 STABILISER  
						

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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 New Pads
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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 wear.
c. Towball is in a new condition (50 mm) 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 
49.61 mm).
FRICTION PAD REPLACEMENT (FRONT/REAR)
1. Uncouple the AKS 3004.
2. Remove the soft dock (pull up & off), (Fig 30/Item 1 & Fig 30a.).
3. Press the safety indicator outwards and secure with SW14 hex. 
spanner (not included), (Fig 30/ Item 2). 
4. Remove cheese-head screws (Fig 30/Item 3 & Fig 30a), using 
special torx tool. 
5. Press friction lining recess (Fig 30/Item 4) inwards and pull 
down and out. 
6. Open coupling handle (Fig 30/ Item 5). 
7. Remove countersunk head cap screw using special torx tool 
(Fig 30/ Item 6 & Fig 31).
8. Press friction pad inwards with a screwdriver and remove from 
ball cup. 
9. Fit new linings in reverse. Tighten screws 3 & 5 to 5 Nm.
10. Replace rubber soft dock, insert top section then bottom.
OPERATING INSTRUCTIONS 
FOR AKS 3004 STABILISER  
						

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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
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2
5
3
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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 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 32 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 32).
c. Use multipurpose grease DIN 51825 KTA 3K.
WARNING
When lubricating, 
ensure none gets into 
the friction pad or 
towball holding area.
OPERATING INSTRUCTIONS 
FOR AKS 3004 STABILISER  
						

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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 is correctly connected when the green 
cylinder part of the safety indicator is visible (when viewed 
from the side - Fig 33/ Item 2).
The coupling mechanism is correctly engaged when the 
coupling handle can no longer be pressed down any further 
(by hand).
Fig 33 Coupling Up
CAUTION
If the coupling head is not correctly hitched onto the towball, 
then the caravan/trailer can become disconnected from the 
towing vehicle.
UNCOUPLING
Open the coupling handle and lift the coupling head from 
the towball. When there are higher nose loads, coupling and 
uncoupling can be made easier by using the jockey wheel.
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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 towball is within permissible limits.
When the green indicator on the coupling handle is 
completely covered over and only the red portion is visible 
(Fig 34), this could be caused by the following:
- Towball has reached the lowest wear limit of 49.61mm dia.
- Both coupling head and towball are showing signs of wear.
- Towball is in good condition with 50mm dia, but the 
coupling head is showing an excessive level of wear.
CAUTION
Under these circumstances, the coupling head can become 
detached from the towball and the caravan/trailer can break 
away from the tow vehicle. The coupling head and towball must 
therefore be checked IMMEDIATELY before future use. Any faulty 
parts must be changed IMMEDIATELY.
All maintenance work should be carried out by AL-KO 
Approved Workshops.
Fig 34 Wear indicator
COUPLING TYPES AK160 & AK300  
						

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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 
cylinder part of the safety indicator is visible (Fig 35/Item 2).
CAUTION
It is most important to check that the coupling head is 
properly engaged on the towball each time.
Fig 35 Coupling Up
UNCOUPLING
Lift coupling handle fully and remove the coupling head from 
the towball. Where there are higher nose loads, coupling and 
uncoupling can be made easier by using the jockey wheel. 
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COUPLING TYPES AK7, AK10/2 OR AK252  
						

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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 
future use. Any faulty parts must be changed IMMEDIATELY. 
All maintenance work should be carried out by AL-KO 
Approved Workshops.
Fig 36 Wear indicator
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COUPLING TYPES AK7, AK10/2 OR AK252