Road Wheels: Jacks: Jockey Wheel:

CARE & MAINTENANCE INSTRUCTIONS FOR

In most instances the road wheels The Corner Steadies Should Lubricate screw thread and wheel
and tyres are supplied by the Caravan never be used to jack up the spindle periodically. YOUR AL-KO CHASSIS AND COMPONENTS
Manufacturer. The condition of caravan. When jacking becomes
wheels and tyres should be checked necessary use the AL-KO Side Lift
regularly, particularly for distortion of Jack or 2-Tonne Jack system.
flanges and the wheel dish. Wheels NOTE: It is essential that the car General Information:
that are damaged or distorted, or & caravan are hitched together The AL-KO lightweight chassis has It is recommended that the chassis/ Loadings on Coupling Heads,
have wheel bolt seatings cracked or before commencing jacking. All been perfected by many years of components are washed off, using a Overrun Assemblies and
deformed must not be repaired or AL-KO chassis from 1992 onwards research and development, supported pressure washer on an annual basis Axles:
used in service - these must be have 2 holes punched in the chassis by an exhaustive test programme. (especially after winter usage), to
replaced. members, each side (rear of the avoid undesirable build up of salt and
Spare Wheel Carriers: The permitted ‘nose’ weights of the
axle); to accept the brackets for the Manufactured from high quality steel, dirt deposits.
Important - Standard AL-KO coupling head/stabiliser, overrun
Jack(s). (See Accessory Price List). the chassis has extra deep sections
caravan chassis use M12 wheel Each caravan has a set of punched assembly and drawbars, must never
Corner Steadies may be used for to provide strength at points of The galvanised chassis should not be
bolts. These must always only be holes in the chassis member to exceed the lowest value stamped on
stability ONLY, when the caravan is maximum stress. Large elongated painted or subjected to any other
tightened to the correct torque setting facilitate the fitting of a spare wheel the assemblies.
in the jacked position. holes are punched in the longitudinal protective treatment.
of 88 Nm (65 lbs/ft), in sequence, carrier. The assembly is of a strong,
lightweight construction and zinc chassis members, to reduce weight The maximum axle loading is that
(i.e. North, South, East, West); The caravan should never be lifted
plated for all-weather protection. to a minimum. Each hole incorporates Should the galvanising become stamped on the oval (Fig. 1), (or
NEVER clock or anti-clockwise. by jacking up under the chassis
a return flange to maintain the required superficially damaged exposing the square, if German production (Fig.
ALWAYS use a calibrated torque member.
There are 3 variants to suit most strength and provide rigidity in the steel core, this should be cleaned and 2)), plate located in the centre of the
wrench, do not use a corner steady extra deep sections. treated with a Cold Galvanising
brace, power or electric wrench. It is Side Lift AL-KO chassis (record your tyre size axle, facing rearwards. The third line
Spray obtainable from vehicle down marked “Capacity” (on German
as dangerous to overtighten wheel Jack on this booklet for future reference).
The carriers can be fitted for left or The chassis frame is of a bolted accessory outlets. plates “Achlast”) is the maximum
bolts as it is to not tighten them construction which allows
sufficiently. Important - The torque right hand operation and are easy to permitted axle loading and must
fit. replacement of individual parts should not be exceeded.
settings should be re-checked after the need arise. Damage to chassis members through
50 Km. The telescopic frame tubes should
impact etc, MUST NOT be Where the Caravan
g or Welding Manufacturer
of Parts or
2-Tonne be lubricated periodically.
The chassis is Hot Dipped straightened or welded. Damaged states a maximum loading weight,
If other wheel bolts are used please Jack Galvanised. This is regarded as one chassis members MUST be replaced. then this is the maximum
ensure the torque settings are as of the best forms of corrosion permitted load. This figure must
follows: protection. It does however require
If working under the caravan in an Drilling or Welding of Parts not exceed the maximum axle
minimal maintenance in certain load.
M10 - 49 Nm (36 ft. lb) elevated position, axle stands must or Accessories:
circumstances.
M14 - 135 Nm (99.5 ft. lb) be used for safety. Wheel chocks
M16 - 210 Nm (155 ft. lb) for the opposite wheel(s) are also The chassis is designed and built to
When new, the chassis is of a bright
advisable. precise tolerances and must not be
and shiny appearance. As the Enter your Axle details for future
Special Note - RECORD YOUR SPARE WHEEL CARRIER INFORMATION HERE: galvanising cures during the initial 2/ drilled or welded (except in
reference:
Aluminium Wheels 3 month period, this will gradually accordance with certain AL-KO
change to a medium/dark grey colour. Accessory Operating Instructions).
Caravan Make (eg Bailey):
The standard M12 x 1.5 60o Conical This grey finish is the ideal, giving the Failure to comply will invalidate all
Caravan Model (eg Pageant):
Wheel bolts are NOT SUITABLE for Year of Manufacture: correct protective coating. During this warranties.
aluminium wheel rims. Special wheel Tyre Size (eg 195R 13):
curing period the surface should be
Dimension ‘X’ in mm:
bolts should be used. protected to avoid possible wet Independent Suspension:
(taken from following diagram)
storage stain, in the form of a soft,
light coloured, porous, oxidation layer. The AL-KO rubber suspension is
Tyres: If the chassis members are in contact designed and developed to suit all
with any salt deposits from roads this types of road conditions and is
The legal requirements for tread should immediately be washed off with maintenance free. Three rubber
depth on motor vehicles, also applies a high pressure washer. Salt attracts elements are contained within a
Fig.1
to caravan and trailers. moisture allowing the surfaces to hexagonal axle tube. These provide
remain wet, this prevents curing and suspension and have inherent
also allows formation of wet storage damping characteristics. (Only the
AL-KO Kober Limited, South Warwickshire Business Park, Kineton Road, Southam, Warwickshire, CV47 0AL
Tel: 01926 818500 Fax: 01926 818562 www.al-ko.co.uk stain. hubs and wheel brakes require
Part No. 1386853 Iss. 1 06/03 attention - see axle section).
16 1
 Load Over Axle Fig 5. and compensates for the entire travel. Trouble Shooting & Fault Finding:
Optimum road holding together with
maximum braking effect. Hand Brake: Table 3 Overrun Devices:
Exceptionally heavy loads should be With the gas strut version, pull the Fault Cause Remedy
packed directly over the axle. handbrake lever until upright. With
the spring cylinder version, pull the
Attention should be paid to the handbrake lever right up to the last Poor Braking Overrun shaft tight. Lubricate overrun shaf.t
legal regulations regarding the tooth. The caravan is then braked. Overrun shaft corroded. and replace any damaged
permitted pressure exerted by the See page 12/13 for further details on Body housing damaged. parts.
towbar on the towed unit. different handbrake types.
Brakes Overheating During Handbrake not fully released. Release handbrake.
AXLE TYPES: Towing Braking system incorrectly set. Reset brakes as page (4).
IMPORTANT NOTE: Incorrect attachment of breakaway Ensure correct attachment as listed
Fig. 2
Safety Precautions: Please note that with the handbrake cable. on page (12) or refer to Braked Trailers
Loading: fully applied, the caravan/trailer is Use of Breakaway Cables sheet.
No welding is permitted on AL-KO able to move backwards by 25 cms
Loads to be carried in the caravan Axles until the spring cylinder/gas spring Handbrake Force Low Defective gas strut. Replace gas strut.
should be placed directly over, or as It is important that the wheel and hub/ takes effect. Incorrect setting of spring cylinder. Reset spring cylinder as page (4).
close as possible to the axles, brake drum are compatible. This mean
otherwise the handling will be that the PCD, wheelbolts and inset Maintenance and Cleaning: Brakes Apply During Overrun damper is defective. Replace the overrun damper.
impaired. must all be compatible with both the Maintenance of Euro-Plus/Euro- Deceleration or
hub/brake drum and the wheel rim. Compact and Euro-Delta. Downhill Travel
Maximum gross weight, as advised Particular attention must be paid to the The above semi-trailing axles come
by the caravan manufacturer, must recommended torque figures for the fitted with maintenance free wheel
not be exceeded without approval wheelbolts (see pg 16). bearings (greased and sealed for life)
from AL-KO. The axle type details shown on axle and no adjustment is necessary. Accessories: Stabilisers: ball, to ensure maximum theft
type plates must not be obscured or NOTE: The hub bearing is not Deterrent (please see our accessory
Maximum loading is defined as the made illegible by application of any protected against water ingress. Corner Steadies: AL-KO overruns can be fitted with a price list for further details). All ‘Red’
difference between ex-works weight additional surface finish. Check wheel brake linings for wear range of AL-KO Stabiliser devices (if coloured AL-KO Security Devices
and the permitted total weight. every 10,000 kilometers or every 12 not already fitted as standard), have full TUV and Sold Secure
months via the inspection hole (Fig. Corner Steadies are as stated, for the
Operating Instructions: purpose of steadying the caravan dependent on the maximum gross Approvals and are available from
6/Item 1). weight of the caravan. AL-KO most good caravan dealers or direct
corners. They are NOT JACKS AND
Function: SHOULD NEVER BE USED AS stabilisers operate on a friction type from AL-KO Mail Order on 0800 074
Fig. 3 Service Brake: SUCH. The screw and pivot pins basis, whereby friction pads grip onto 4334.
When the towing vehicle is braking or should be lubricated periodically to a Dry, Grease Free Towball. It is
Load Too Far Forward Fig 3. travelling down hill, the overrun device important to note that the AKS range
ensure their satisfactory operation. AKS 1300 &
Steering and braking ability reduced. shaft is pushed in (dependent on the of stabilisers are suitable for use with
(See also Jack Operation). Security
Increased loading on the rear axle magnitude of the thrust on the shaft) swan neck, fixed or detachable type
and chassis of the tow vehicle. Device
and presses on the overrun lever. This towbars or the special AL-KO
acts on the bowden cables and Extended Neck Bolt-On Towball. We
Shock Absorbers:
expander mechanism, which in turn do not approve the use of any other
expands the brake shoes applying the Fig. 6 bolt-on type towball, other than the
All AL-KO chassis have pre punched AKS 2700 &
wheel brakes. AL-KO Towball. Failure to use the
Fig. 4
Adjust if necessary. Where holes to accommodate Shock Security
correct towball may result in product
Load Too Far Back Fig. 4. continuous travel in hilly regions or Absorbers, in front of the axle. On Device
Reversing: failure and will invalid your warranty.
High skid risk together with poor When the towing vehicle is reversing, high mileage is experienced, earlier the Euro-Axle System, axle swing
arms have a removable rectangular
braking effect. the overrun device shaft is pushing in, inspection and adjustment may be The AKS range is available in three
plastic cap exposing a slot to
applying the brakes via the overrun necessary. different models: The AKS 1300 is
accommodate retro-fit brackets for
lever, brake rod system, bowden suitable for caravans up to a
the Octagon Shock Absorbers. (See AKS 2004 &
cables and the expander mechanism. maximum gross weight of 1360 Kg,
Accessory Price List). Delta Axles Security
The backwards rotation of the brake the AKS 2700 up to 2700 Kg and the
have Shock Absorbers fitted as Device
Fig. 5 drum causes the secondary brake new AKS 2004 up to 2000 Kg. Each
standard which MUST NOT BE
shoe to collapse cancelling out the Stabiliser can also be retro-fitted with
REMOVED.illin
braking effect, allowing the trailer to an AL-KO Security Device and Safety
move backwards. At the same time
the transmission lever swings back
2 15
Trouble Shooting & Fault Finding: Note: The flanged hub-nut, located months through inspection hole (Fig. The AL-KO rubber suspension axle
under the dust cap, used to keep the 6) and adjust if necessary. Where has been designed & developed to
Table 1 Axles: brake drum in situ, is a ONE-SHOT continuous travel in hilly regions or suit all types of road conditions and
NUT (ie. must only be used once). If high mileage is experienced, earlier is maintenance free.
Fault Cause Remedy removed it must be replaced with a inspection and adjustment may be
NEW flanged nut - torqued to 290 ± necessary. Three rubber elements are contained
Poor Braking Linings worn or damaged. Replace Brake Linings. 10 Nm (214 ± 7.5 lbs/ft). A small within an hexagonal axle tube.
Brake Linings not bedded in. Will pass after braking a few times. amount of special mineral grease, SPARE PARTS: These provide suspension and have
Brake set up incorrect. Reset Brakes as page (4) & ensure available from AL-KO must be applied inherent damping characteristics.
system is lubricated. to stub axle thread prior to fitting the Spare parts are safety critical parts!
new flanged nut. After fitting excess For this reason when fittting spare
Difficulty in Reversing Braking system set too tightly. Reset Brakes as page (4). grease must be removed with white parts in our products we recommend
Auto-Reverse lever too stiff. Lubricate and free off Reverse Lever. sprit. the use of original AL-KO parts or
those parts that we have explicitly
The rear hexagon cap head bolt approved. The reliability, safety and
Brakes Overheating Incorrect setting. Reset Brakes as page (4). located under the black plastic cap suitability of parts designed
Braking system not fully released. Check Handbrake has been released MUST NOT BE DISTURBED under especially for our products, has been
& the system is running freely. any circumstance. Interference with determined using a special test
Overrun lever stuck. Lubricate and free off Reverse Lever. this nut will result in immediate tyre procedure. In spite of constantly Fig. 8
Damage or Corrosion to braking system Check system as page (4) and wear and damage to the braking monitoring the market we are unable
repair or renew parts as necessary. system and WILL INVALIDATE ALL to assess or vouch for other Figs. 8, 9 & 10 show the deformation
WARRANTIES. Should the rear nut products. of the rubber elements at the
Handbrake Force Low Incorrect setting of the brakes. Reset brakes as page (4) and accidentally be disturbed then the If repair work or servicing is required, extremes of suspension movement.
lubricate as necessary. complete axle must be returned to AL-KO have a large network of
Linings not bedded in. Will pass after braking a few times. AL-KO for resetting of the toe-in and AL-KO service stations throughout The axle is designed to ride with the
camber. Europe. suspension drop arm at, or slightly
Uncomfortable ride or Loose braking adjustment. Reset brakes as page (4). below, the horizontal position.
Uneven Braking Damper defective. Check and replace damper if No attempt should be made to remove To establish the correct spare parts
necessary. the bearing. In the event of damage required for your axle you should
Axle shock absorbers defective. Replace shock absorber. to the bearing or drum, only the drum always quote the axle type (axle
complete with bearing and circlip will identification plate Figs. 1/2) and
be available as a spare. No grease is Spare Part Identification no. (ETI
used in the hub other than the mineral No.), which will be stamped onto the
grease on the stub axle. No grease wheel brake or on the identification
should be placed in the DUST cap. plate (Fig. 7). Please establish these
Table 2 Coupling Heads: This is not a grease cap as used in all numbers before contacting AL-KO
previous hubs or a Service Agent.
Fault Cause Remedy
Fig. 9

Coupling does not engage Ball diameter too large. Change ball to correct size. “Standard Axle” Maintenance
onto ball Ball could be damaged or deformed. Fit new ball. (taper roller bearings)
Coupling head dirty or defective. Clean & Lubricate coupling and After 1500 km or 6 months:
replace if necessary. Have the axial play of the hub bearing
checked and adjusted if necessary.
Difficulty in Uncoupling Ball damaged or deformed. Fit new ball. After 10,000 km or 12 months:
Coupling damaged or deformed. Replace if necessary. Check quantity and quality of grease,
Coupling head under pressure Pull foward a few inches to renew if necessary.
from damper. to relieve pressure With boat trailers which are driven
into fresh/salt water, the hub bearing Fig. 7 Fig. 10
Too much play in the Coupling damaged or deformed. Replace if necessary. should be regreased shortly after
coupling Ball too small. Fit new ball. contact with the water (with the
exception of waterproof hubs).
Check the wear of the wheel brake
linings every 10,000 Km or every 12 For Trouble Shooting & Fault Finding
- please see Table 1 on page 14.

14 3
AL-KO BRAKING 8. Repeat for other wheel or wheels. strut handbrake then no spring Coupling Up (Euro-Overrun
Caution:
cylinder is fitted - therefore ignore this If the handbrake is not fully applied
SYSTEM ADJUSTMENT Devices):
9. On tandem axles the brake cables paragraph). as detailed above, there is danger
Fully retract Jockey Wheel inner tube
from the rear axle should pass over that the trailer could roll backwards!
so that it locks against Jockey Wheel
1. Ensure the towing shaft with this axle and cross over each other, 14. CORRECT ADJUSTMENT of outer tube.
coupling head is pulled FULLY before being connected to the the linkage is checked by operating Automatic Handbrake Lever (Fig.
Slacken Jockey Wheel Clamp handle
FORWARD. (Fig. 11). 43):
abutment (bracket) on the front axle. the handbrake lever so that when the and raise complete assembly through
Ensure handbrake is fully applied (as
second or third tooth is engaged, a cutout in body to its highest position
2. Release the handbrake to the highlighted). This will ensure that the
10. Ensure the balance bar slight braking force is felt on the road (ensure it doesn’t come into contact
FULLY OFF position. If the gas strut or spring cylinder will
(compensator) is being pulled wheels. with the brake rod assy), fully tighten
automatically re-apply the wheel brakes
handbrake will not go down the whole evenly (Figs.11 & 13). Excessive Jockey Wheel Clamp handle to ensure
if the trailer starts to roll backwards.
way because of the fairing or any movement to this bar (double on 15. OVER ADJUSTMENT of either the Jockey Wheel is firmly held in
other obstruction; then the fairing tandem axles) would indicate the wheel brakes or linkages, will position (Fig. 44).
Caution:
must be cut away and/or the possible incorrect adjustment (if result in difficult reversing causing If the handbrake is not fully applied
obstruction removed to achieve this Uncoupling (All Types):
appropriate, repeat step No. 7 - Fig. the wheels to “lock-up”. as detailed above, there is danger Fig. 46
desired position. It will not be 13). that that the trailer could roll
Secure caravan/trailer by chocking both Recommended lubricant. General
possible to set up the braking system 16. When parking, the handbrake backwards!
wheels. Apply handbrake fully. There purpose grease to DIN 51825 KTA
properly when the handbrake is not 11. Check the brake rod support lever MUST ALWAYS be engaged are 4 different handbrake systems (See 3KA.
in the FULLY OFF position. (Fig. 11). bracket, (fixed to the floor) IS into the fully upright position (90°). To Release: Servicing and care of hot dip galvanized
Figs 41-45). With all four systems
supporting the brake rod evenly. This is to compress the spring within Firmly push the handbrake lever back parts:
please observe the following:
The brake rod MUST ALWAYS run the spring cylinder and thereby create into the off position (Handbrake The formation of white rust is only a
3. Jack up one side of the caravan, horizontal).
straight, NEVER bent or curved an energy store which will Handbrake Lever With Gas Strut (Fig. surface coating and has no adverse
using the AL-KO Side Lift Jack
under any fittings. On tandem automatically engage the brakes 41): effect on the anti-corrosion properties
System. (see Jack Operating Handbrake Lever With Spring
axles, using the double balance bar, further should the caravan move. If Ensure handbrake is fully applied (as of galvanising. In order to minimise the
Instructions). Cylinder and Gas Strut (Fig. 45), potential for the formation of white rust
a brake rod support tube (Part No. difficulty is experienced in this highlighted). This will ensure that the
normally fitted to commercial units: the following precautions should be
operation, try easing the caravan gas strut will automatically re-apply the
4. Remove the inner plastic bung 228827) MUST ALWAYS be fitted Ensure handbrake is fully applied (as taken:
backwards with one hand while wheel brakes if the trailer starts to roll
from the backplate to expose the on the end of the brake rod, passing backwards.
described). This will ensure that the Ensure there is adequate air circulation
“starwheel” adjuster access. (Figs. 11 through the centre aperture on the engaging the handbrake fully with the gas strut or spring cylinder will when storing hot dip-galvanized parts.
& 12). abutment. other. This manoeuvre should not be automatically re-apply the wheel brakes
To Release: After winter journeys it is recommended
attempted on a rearwards facing if trailer starts to roll backwards. that surfaces are washed with clean
Press the handbrake push button fully
5. ALWAYS rotating the road wheel 12. Remove the slack in the brake slope. In this case wheel chocks home and firmly press the handbrake water.
rod by adjusting the long ball nut, should be used combined with the Caution:
in the forward direction - NEVER lever back into the off position
handbrake. See page 12/13 for all If the handbrake is not fully applied Spare Parts:
backwards; adjust the starwheel with rear of the balance bar, ensuring the (handbrake horizontal).
handbrake operations. as detailed above, there is danger Spare parts are safety critical parts! For
a suitable screwdriver, in the direction overrun lever makes contact with the
that the trailer could roll backwards! this reason when fittting spare parts in
of the arrow embossed on the end of the towing shaft. Note! Over Caution:
backplate until there is resistance in adjustment to the long ball nut (Fig. If the handbrake is not fully applied our products we recommend the use
To Release: of original AL-KO parts or those parts
the wheel rotation. (Fig. 12). 13/Item 2) could induce movement as detailed above, there is danger
17. Finally, if the road wheels have Press the handbrake push button fully that we have explicitly approved. The
of the inner brake cable, reducing that the trailer could roll backwards!
been removed, re-tighten using a home and firmly press the handbrake reliability, safety and suitability of parts
6. Slacken off the starwheel adjuster the effective clearance of the brake lever back into the off position
calibrated Torque Wrench to 88 Nm designed especially for our products,
until the road wheel turns freely in the shoes. If the overrun lever will not (handbrake horizontal).
(65 lbs/ft) - on all M12 wheel bolts - Caution: has been determined using a special
FORWARD direction. (Fig. 12). make contact, it is possible the two test procedure. In spite of constantly
in sequence, i.e. North, South, East, The brake rod must not be under
lock nuts, forward of the spring tension/bowed when the handbrake
Servicing: monitoring the market we are unable
West NOT clock or anti-clockwise Every 10,000 - 15,000 Km or every 12
7. Check the adjustment at the end cylinder, are incorrectly adjusted. is disengaged, otherwise the to assess or vouch for other products.
(refers to steel rims only). Remember months:
of the brake cable where it is secured Loosen the nuts and adjust brake breakaway mechanism will not If repair work or servicing is required,
to over-tighten is just as dangerous Lubricate/grease all sliding and moving
to the abutment (bracket), welded to rod as above (Figs. 11 & 13). function. AL-KO have a large network of
as to under-tighten, as this can distort parts of the overrun device as show in
the centre of the axle. When the inner Handbrake Lever With Spring AL-KO service stations throughout
the wheel rims. Avoid the use of Fig. 46.
cable is pulled out it should extend 13. Adjust the two locking nuts, Cylinder (Fig. 42): Europe. To establish the correct spare
power wrenches. parts required you should always quote
between 5 and 8 mm. (Fig. 13). (On forward of the spring cylinder (Fig. Apply handbrake fully ensuring that
tandem axles a double abutment 11), (on some chassis a single handbrake is in the vertical position. the model and type of overrun device
IMPORTANT - The torque settings This will ensure that the spring cylinder in question along with the ETI No.
(bracket) is fitted to the front axle Nyloc nut is used) to give 1 mm of
should be rechecked after 50 Km. energy store is fully loaded and will which is stamped into the overrun
ONLY). clearance on the spring cylinder.
Wheel bolts should NEVER be automatically re-apply the wheel brakes device housing. The ETI number for the
This cylinder (the energy store for
lubricated. if the trailer starts to roll backwards. Euro Overrun can be found on the
the handbrake operation) must be
handbrake lever (See Fig. 44).
able to rotate ONLY, not slide on
For Troubleshooting and Fault Finding,
the brake rod. (Fig. 13). (If the
please see Table 3 on Page 15.
overrun assembly is fitted with a gas
4 13
Overrun Devices:
Overrun device fitted with Eye End:
Lock the eye end into the eye end jaw
In the importance of Safety, please
assembly and see operating
familiarize yourself with the operation
instructions for vehicles fitted with eye
of this overrun device BEFORE using
end jaw assembly.
your caravan/trailer.
Overrun Device Fitted with 50 mm
Safety Precautions: Fig. 39
Coupling Head:
When parking your tow vehicle and
Connect trailer electric plug controlling
caravan/trailer on site, you must apply
lights and indicators etc. into towing
the caravan handbrake. If the unit is

Brake Linkages: It is recommended that all brake linkage threads are lightly greased for protection.
vehicle socket.
parked but disconnected from the tow
Wind the jockey wheel up fully and
vehicle, it is strongly recommended that
clamp securely in position, ensuring

Fig. 12
each wheel is chocked using AL-KO
that it does not foul the brake rod or
or suitable wheel chocks.
Fig. 40 breakaway cable.
If a ‘detachable’ type drawbar is fitted
Ensure handbrake is fully off by pushing
(as with catering trailers), the drawbar Caution:
must not be removed from the trailer The breakaway cable operates the it fully down (Figs. 41-45).
with the hand-brake applied. handbrake (emergency brake), in the Remove wheel chocks if fitted and stow
event of the caravan/trailer becoming safely.
Caution: detached from the towing vehicle
Please note when parking the during towing. For this emergency Caution:
caravan/trailer, the wheelbrake auto- brake to work correctly, it is absolutely Failure to comply with this could result
reverse mechanism will allow the essential that the following points are in the brakes overheating.
caravan/trailer to travel backwards observed:
for approximately 25 cm (please
allow sufficient clearance when 1) The breakaway cable MUST run
parking). through the breakaway cable guide.
2) The breakaway cable MUST NOT
Operation: be wrapped around the jockey wheel,
AL-KO overrun devices are a as this disables the emergency brake
mechanical type, using a hydraulic (Fig. 40).
damper. 3) The cable MUST run as straight as Fig. 42
possible and not be restricted.
Coupling Up: 4) Ensure the cable is long enough to
Manoeuvre towing vehicle or trailer to allow for cornerning and will not
coupling point. become taut or snag during use, as this
Overrun devices fitted with 50 mm could result in the handbrake operating
coupling head: whislt towing.
Fully open coupling head handle and Please refer to ‘Braked Trailers Use of
secure hitch onto the towball. See Breakaway Cables’ Information sheet,
pages 6/7 (coupling up). supplied with your caravan/trailer. Fig. 43
Thread the breakaway cable through
the breakaway cable guide provided
(Fig. 39) and connect it to attachment
point provided on towing bracket (Fig.
38). Please refer to ‘Braked Trailers Use
of Breakaway Cables’ for further detail.
Fig. 44

Fig. 13
Fig. 11
Fig. 38 Fig. 41 Fig. 45
12 5
Coupling Heads/Combined Operation: 10) Replace rubber soft dock, insert 4) Towballs coated (with paint or
Stabiliser Devices: For Coupling types AK160, AK300 top section first then bottom. similar) must have this surface
& AK350. completely removed (use 100 or 120
Your Caravan will be fitted with Important Maintenance and grain emery paper). If this is not done,
either a standard coupling head Coupling Up: Cleaning Advice: increased towball wear will occur and
or a combined stabiliser/coupling Open coupling handle. To do this pull may cause damage to the AKS 2004
unit. If your caravan is fitted with the coupling handle up (Fig. 15) in the 1) The towball should be cleaned components.
red green red
an AKS 1300 Stabiliser, please direction of the arrow. regularly to remove grease or other 5) In Winter, carefully spray only the
request Part No. 1385106 for full Fig. 32a residue, the use of Thinners, White visual indicator with de-icer.
The coupling mechanism has a fixed
operating instructions. If fitted Spirit or Brake Cleaner is
open position, ie. as long as the
with AKS 2700, request Part No. recommended - otherwise the Lubrication:
coupling head is not placed on the ball
1385107. green stabilising effect will be severely
the coupling will remain open.
Fig. 16 red reduced. Should lubrication of the stabiliser
Safety Precautions: 2) If friction pads are contaminated, parts become necessary, then the
Put the open coupling onto the towball.
If the green indicator is visible on the they should not be cleaned but following must be observed.
The coupling handle automatically and
Always ensure that the coupling head coupling (with the coupling engaged replaced. a) Clean all parts thoroughly.
audibly clicks into position. In the
is properly connected to the tow Fig. 16), the coupling head is in good 3) The surface of the towball must b) Areas may only be covered with a
interests of safety, press the handle
vehicle’s towball every time you condition or the wear on the towball be free of grooves, rust or seizing thin film of grease (Fig. 37).
down by hand (Fig. 15). Fig. 33
couple up. If this procedure is not is within permissible limits. marks. c) Use multipurpose grease DIN
carried out correctly, the caravan/ When the green indicator on the 51825 KTA 3K.
The coupling head is correctly
trailer may become detached from the coupling handle is completely
connected when the green cylinder
towing vehicle! covered over and only the red portion Warning: When lubricating, ensure
part of the safety indicator is visible red
Maximum possible articulation of the is visible (Fig. 16), this could be none gets into the friction pad or
(when viewed from the side - Fig. 15/
coupling head must not exceed ±25o caused by the following: towball holding area.
Item 2).
vertically and ±20o horizontally - see The towball has reached the lowest
Fig 14. wear limit of 49.61 mm dia.
The coupling mechanism is correctly
engaged when the coupling handle Both coupling head and towball are Fig. 34
If exceeded, components will be showing signs of wear.
can no longer be presssed down any
overloaded and the operation of the Towball is in good condition with 50
further (by hand). Friction Pad Replacement
assembly adversely affected! mm dia, but the coupling head is (Front/Rear only):
Caution: showing an excessive level of wear.
If the coupling head is not correctly 1) Uncouple the AKS 2004
hitched onto the towball, then the Caution: 2) Remove the rubber soft dock (pull Fig. 35

caravan/trailer can become up and off) Fig. 35/Item 1 & Fig 35a.
disconnected from the towing vehicle. Under these circumstances, the 3) Press the safety indicator
coupling head can become detached outwards and secure with SW14
Uncoupling: from the towball and the caravan/ hex. spanner (not included), (Fig. 35/
Open the coupling handle and lift the trailer can breakaway from the tow Item 2).
coupling head from the towball. When vehicle. The coupling head and 4) Remove cheese-head screws
there are higher nose loads, coupling towball must therefore be checked (Fig. 35/item 3 & Fig 35a), using
Fig. 14 and uncoupling can be made easier IMMEDIATELY before future use. special torx tool.
Any faulty parts must be changed Fig. 37
by using the jockey wheel. 5) Press friction lining recess (Fig.
IMMEDIATELY. 35/Item 4) inwards and pull down Fig. 35a
Wear Indicator: and out.
A wear indicator on the coupling head All maintenance work should be 6) Open coupling handle (Fig. 35/
(Fig. 16) shows whether the wear limit carried out by AL-KO Approved Item 8).
of the towing vehicle’s towball or the Workshops. 7) Remove countersunk head cap
trailer coupling has been reached. screw using special torx tool (Fig. 35/
Item 5 & Fig. 36).
For this purpose, hitch up the trailer 8) Press friction pad inwards with a
green to the towball and drive the unit for screwdriver and remove from ball
approx. 500 m. This will set the cup.
coupling head adjustment. Following 9) Fitment of new linings takes place
this, check the wear indicator as in reverse. Tighten screws 3 & 5 to Fig. 36

Fig. 15 follow. 5 Nm.

6 11
 .

Remedial Action: Checking the efficiency of the Operation: Wear Indicator: Servicing & Cleaning:
front/rear friction pads: If the handle reaches the back of the Lubrication Points (Fig. 19)
a) Clean the tow ball and friction pads For coupling types AK7, AK 10/2 cutaway portion of the housing, when
by lightly rubbing the surface (100- 1) Couple the AKS 2004 to the towball or AK252. (This type of coupling the coupling head is engaged (Fig. Clean Towball.
120 grit emery paper). but do not activate the stabiliser. is normally fitted to trailers or 18) there will be play between the Lightly grease, or oil ball socket, joints
b) Lubricate the drawshaft sleeve via 2) If a green indicator is visible (on older model caravans). towball and coupling head. Automatic and bearing points as appropriate.
the grease nipples. In addition, push the handle), then the AKS 2004 is in re-adjustment is no longer possible General purpose grease to DIN
the gaiter forward and grease (DIN 51 a new condition or the pads and Coupling Up: and the assembly will need 6=51825 KTA 3K.
825 KTA 3K) the exposed part of the towball are within the permissible Push the safety lever (Fig. 17/Item inspecting.
shaft (Fig. 31). limits (Fig. 33/Item 2). 1) up with the index finger and lift the
c) Visit a specialist workshop to have 3) If only a red indicator is visible (Fig. handle up and forwards. Put the
the ball holding area checked for 34/Item 3), then this may have the opened coupling onto the towball with
damage and the locking mechanism following causes: the handle pulled up and in addition
for function. If necessary, change the a) AKS 2004 is okay but the towball press down by hand. The coupling
towball. has reached the lowest limit of 49.61 will close by applying a light pressure.
mm Press the handle down by hand until
b) AKS 2004 shows signs of wear the catch snaps out (Fig. 17/Item 3).
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 Fig. 18

so that conclusions may be drawn as
to the wear of the friction pads (ball
Fig. 19
diameter must not be less than 49.61
mm) Caution:
Under these circumstances, the
coupling head can become detached
from the towball and the caravan/ For Toubleshooting and Fault Finding
Fig. 30 green trailer can breakaway from the tow - please see Table 2 on Page 14.
vehicle. The coupling head and
Fig. 31
Noises whilst driving: towball must therefore be checked
IMMEDIATELY before future use.
As a rule, the friction pads of the AKS Servicing and Cleaning: Any faulty parts must be changed
2004 do not make a noise during IMMEDIATELY.
driving. Any clicking, creaking or Friction Pad Replacement (please Fig. 17 All maintenance work should be
squeaking noises that do arise may replace one at a time): carried out by AL-KO Approved
be due to the following: Fig. 32
Workshops.
1) Uncouple AKS 2004. The coupling head is correctly
a) Foreign bodies or dirt between the 2) Remove protective caps (Fig. 32/ engaged when the green cylinder part
friction pad and tow ball. Item 1) with the aid of a small of the safety indicator is visible (Fig. .
b) Dry operation of the drawshaft screwdriver. 17/Item 2).
inside the overrun device. 3) Press worn out pad inwards and
c) A detachable towball which has too remove (use punch and hammer) Caution:
much play in the locking mechanism. (Fig. 32/2) It is most important to check that the
4) Insert new friction pad from below coupling head is properly engaged on
(after first re-inserting shim washers the towball each time.
if they were present) and press in as
far as it will go (Fig. 32/Item 4 & Fig. Uncoupling:
32a). 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.

10 7
Operating Instructions for AKS Max. 50 mm (C) clearance between SAFETY WARNINGS: Stabiliser Unit: Manoeuvring:
2004 (if applicable) the centre of the towball and top of 1) In accordance with EC Directive
REGULATIONS: the overrun assembly or fairing, to 94/20, couplings of type A 50-1 To operate the Stabiliser (once For easier manoeuvring (on
1) The AKS 2004 must be used in ensure both coupling handle and cannot be used (see Fig. 22), your coupled to the towball), simply press campsites etc), pull the stabiliser lever
conjunction with 50 mm dia. towballs stabiliser handle do not foul on warranty will be invalid if this type of the stabiliser lever down as far as it to the ‘up’ position.
which conform to EC Directive 94/20 operation. towball is used. will go (Fig. 27/Item 2).
(DIN 74058 or local equivalent). 2) For UK use, please use the
2) Suitable for attachment to drawbars Maintain the same clearances for extended neck towball (type A50-X). Uncoupling:
or approved overrun braking other manufacturers’ overrun 3) A bolted-in type ball coupling (Fig.
equipment for single (and tandem assemblies. 23) is only permissible if the thread Pull the stabiliser lever handle up as
axle) caravan/trailers, with a minimum is locked or welded. far as it will go, open the coupling
weight of 200 Kg and a maximum 2) Not suitable for use with overrun 4) The AKS 2004 cannot be used handle and lift the AKS2004 from the
permissible weight of 2000 Kg. devices which can revolve above 25o with a laterally attached reversing towball. With larger nose loads,
3) EC design approval has been given (Fig. 21). lever, on the left side, when facing coupling and uncoupling can be
to the AL-KO AKS 2004 coupling 3) Swan Neck towbars (fixed or direction of traffic. made easier by using the jockey
under permit No. e1*94/20*0930*00. detachable) are suitable for use with 5) The towball must be free from wheel to assist lifting.
the AKS 2004 providing they comply grease, paint and other residue,
RESTRICTIONS OF USE: to EC Directive 94/20 and have the otherwise the stabilising effect will be Please Note: The friction pads (Fig. Fig. 28
required minimum 60 mm clearance, greatly reduced. 28/Items 1,2&3) are pressed against Fig. 24
1) The trailer coupling may only be measured from the centre of the 6) If friction pads become the towball and hence generate a
connected to towing vehicles where towball (Fig. 21). contaminated with grease, they stabilising/damping force. These
the clearances for the stabiliser can should be replaced. pads are therefore subject to wear
be observed, in accordance with EC 7) The AKS 2004 should only be over time, however they will have a
Directive 94/20 (DIN 74058). If these operated by one person, when long service life (circa.30,000 Miles),
clearances are infringed by special opening or closing the handle, to provided they are well maintained and
attachments, then the use must be reduce injury risks. kept free of grease/dirt.
checked separately.
AKS 2004 Delivery Checking the efficiency of the left/
Clearances for Stabiliser Handle Specifications: right friction pads:
(Fig. 20):
Coupling handle (Fig. 24/Item 1), 1) Couple up AKS 2004.
Fig. 25
Stabiliser Lever (Fig. 24/Item 2) 2) Open Stabiliser lever (Fig. 29/
Fig. 21 Item1).
Preparation for coupling/ 3) Close Stabiliser lever until
uncoupling: resistance is felt (ie friction pads are
The Stabiliser lever (Fig. 25/Item 2) in contact with the ball but not yet Fig. 29
must be in the uppermost position under pressure).
(open). 4) If the arrow on the arm (Fig. 29/ Please do not use the stabiliser lever
Item 4) is before or on the marked as an manoeuvring handle. Please
Coupling: area (Fig. 29/Item 2) the friction pads use the handles on the Caravan or fit
are still as new (See A) the AL-KO manoeuvring handle to
Pull the coupling handle (Fig. 26/Item 5) The arrow on the arm should lie your jockey wheel (available
Fig. 20
Min. 67 mm
Fig. 22 1) up in the direction of arrow. The between the marked area on the soft separately).
Fig. 26
coupling mechanism has an open dock (See B)
The area above the towball of the position ie. as long as the AKS2004 6) If the arrow on the plate reaches 1) During opening or closing, the AKS
vehicle must be free from vehicle is not placed on the ball, the handle or passes the marked area on the soft must only be operated by one person.
components or attachments (A) (eg will remain open. Put the opened dock then the friction pads need 2) Press stabiliser lever down by hand
spare wheels, platforms etc.) coupling onto the clean towball. The replacing (See C). force only DO NOT use your foot or
handle must now make an audible Please Note: It is not necessary to an extension bar, this will damage the
The clearance for the stabiliser handle click and return to the flat position. adjust the friction pads components (Fig. 30).
must be at least 330 mm (B) + the 3) When opening or closing the
stroke movement (D) (85mm- Warning: The coupling is correctly stabiliser lever, please ensure your
Fig. 27
100mm), which equates to 440 mm engaged when the green edge of the hand does not touch the coupling
when used in conjunction with an safety indicator button is visible handle - you may accidentally trap
AL-KO overrun. (Fig. 27/Item 3). your fingers! (Fig. 30).
Fig. 23
8 9