ASSEMBLY AND OPERATING INSTRUCTIONS FOR AL
Contents
1. only be used for connect ing to towballs to Directive 94 20 EC A50 where the clearance below the ball is at least 60 mm Fig 3 According to British Standards the prescribed rotation of 25 will thus be achieved Not suitable for use with revolving shafts above 25 Handbrake lever on right The AKS 2700 can be used only on overrun devices where the handbrake is mounted on the right viewed by someone facing the direction in which the vehicle is moving For handbrake levers on the left please order the special handles Part No 581158 amp 581158 Clearances for AKS 2700 Fig 4 a The area above the towing ball of the vehicle must be free from vehicle components eg spare wheels Clearing for stabiliser handle 340 B stroke D 85 100 mm 440 mm with AL KO overrun devices Max 50 mm C clearance for coupling handle at initial operation Min 45 mm clearance E to towing vehicle Nose Weight Kg Distance Between Holes rear of Weight Kg Length D Fig 5 177 177 177 Use a screwdriver to remove plastic protec tive caps fig 22 Item 1 Checking the towball coupling Have the towball re checked with standardised test ball at the AL KO service station The towball coupling trailer ball is not worn at handle Fig 23 A Tightening only via spring force without pushing by hand Press worn friction linings Fig 22 Item 2 inwards and remove use punch and2. push out hexagon bolt Fig 6 Item 1 Knock through hexagon bolt Fig 7 Item 2 with retaining pin Fig 7 Item 1 and leave in retaining pin to secure shock absorber damper in the drawbar The AKS 2700 is designed for drawshaft tubes up to 50 mm dia For small diameters spacer brackets are enclosed Fig 8 Assembly of the AKS 2700 Stabiliser Place AKS and spacers if required Fig 9 Item 3 onto the drawshaft aligning mounting holes 1 amp 2 and spacer sleeve Fig 9 Item 4 Insert hexagon bolt M12x80 75 Fig 9 ltem 1 and take up spacer sleeve if used 50 mm no spacer required 40 mm Spacer a required 35 mm Spacer b 5 5 mm 1x5 0 mm amp 1x2 5 mm 45 mm Spacer c 2 5 mm Warnings Always insert horizontal bolts from stabiliser lever side as this allows correct clearances and theft prevention if used with AL KO barrel lock not included Always insert vertical bolt from top to bottom and re use original shim used on the overrun Fig 10 Item 1 Knock through retaining pin with hexagon bolt M12x80 75 Fig 9 Item 2 Shock absorber damper will remain in place For your own safety please check To ensure shock absorber damper is retained in place push drawshaft in and out If resistance is felt when pulling the drawshaft out then the shock absorber damper is in place Place the lock nut use the new nuts enclosed onto the bolt and torque to 100 Nm Warning Self loc
3. thin film of grease Fig 21 Item 1 C Type of lubricant Multi purpose grease to DIN 51825 KTA 3K or equivalent Warning When lubricating no oil or grease should get onto the friction area or on the ball holding areal ee ay ASTIN f Ww Replacing Friction Linings The marking on the pressure plate Fig 19 Item 4 has reached or passed the replace marking on the housing Fig 19 ltem 3 Uncouple the AKS 2700 All EC Countries The installation 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 papers GB Installation only possible with special tow ball attached to towing vehicle Towball label will appear as follows ee oe A50 S 150kg e11 94 20 1203 00 see regulations and restrictions of use on page 1 2 ASSEMBLY INSTRUCTIONS Removal of existing coupling head Before you begin dismantling the coupling head please note the following The shock absorber damper on most overrun equipment is suspended on the rear fixing bolt Fig 6 Attention The shock absorber moves out independently and for this reason you will find a retaining pin in the box to facilitate coupling head removal Remove gaiter from coupling head Loosen and remove hexagon nuts Fig 6 Item 1 amp 2 Pull or
4. ILPRIL L AG NE h FAMILIES How to check the efficiency of the AKS 2700 1 Couple the AKS 2700 2 Pull stabilising handle into off position Fig 19 ltem 1 3 Close stabilising handle until resistance is felt friction linings are in contact with the towball but not under pressure 4 The mark on the pressure plate is between the two marks Fig 19 ltem 4 on the housing Fig 19 ltems 2 amp 3 5 The friction linings are beyond permissible wear range and require adjustment when the marking on the pressure plate coincides or passes the marking on the housing Fig 19 ltem 3 Friction Friction linings Wear new range linings worn Lubrication Coupling Mechanism In order to maintain the easy action of the coupling mechanism and to achieve a longer life for the AKS 2700 the coupling mechanism must be lubricated at regular intervals at least once a year Type of lubricant General purpose grease to DIN 51825 KTA 3K or local equivalent Fig 24 Warning When lubricating no oil or grease should get on the friction area or the ball holding area If friction pads are contaminated with grease they should not be cleaned as this will have a reduced stabilising effect Therefore friction pads should be replaced Stabilising Unit Should lubrication of the stabiliser unit parts become necessary then the following must be observed a Clean all parts thoroughly b Areas may only be covered with a
5. Spare Parts Attachment Parts Warning 1 Only original AL KO spare parts may be used 2 All attachments and accessories must be approved by AL KO FAILURE TO COMPLY WITH THIS DEMAND WILL RELEASE THE MANUFACTURER OF AKS 2700 FROM ALL GUARANTEE OBLIGATIONS 5 GENERAL INFORMATION The surface of the ball must be free from grooves rust and siezing marks Any Dacromet coating dull silver corrosion protection coat must be removed otherwise there will be increasing wear and a reduction in the stabilsiing effect Manoeuvring by hand Stabilising lever may not be used as a manoeuvring handle Please use the handles on your caravan or the AL KO manoeuvring handle which can be purchased separately to attach to your jockey wheel Failure to comply results in danger of overloading component parts Manoeuvring with towing vehicle Pull the stabilising handle to the top position manoeuvre position to make the manoeuvring easier on camp sites etc Storing To reduce the contamination of component parts of the AKS 2700 the stabilising handle should be closed if stored over a longer period Protect the towball of the vehicle from rusting 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 1 Foreign bodies or dirt between the friction pad and towball Remedial action Clean the towball and cl
6. d Hints The surface of the towball must be free of grooving rust and scratch marks otherwise increased wear and tear will occur If pads are contaminated by paint or if they are glazed they can be cleaned with 100 200 grain sandpaper
7. ean friction pads by lightly rubbing over the pad with sandpaper 100 200 grain 2 Dry operation of the towball shaft in the sleeve of the overrun equipment Remedial action Lubrication of the sleeves through the grease nipples use multi purpose grease DIN 51825 KTA 3k additionally pull the gaiter off the overrun towards the front and grease all of the exposed drive shaft see Fig 27 3 The towball on the towing vehicle has too much play in the locking mechanism if detachable Remedial action Go to specialist workshop Have the towball checked for damage If necessary change towball or if permissible re lubricate locking mechanism During winter use spray the visual indicator button with de icer Vehicle Technology AL KO Kober Ltd South Warwickshire Business Park Kineton Road Southam Warwickshire CV47 OAL 01926 818500 01926 818562 www al ko co uk Part No 1385107 Iss 2 11 03 ASSEMBLY AND OPERATING INSTRUCTIONS FOR AL KO AKS 2700 STABILISER NK Vehicle Technology PLEASE ENSURE YOU READ THESE INSTRUCTIONS CAREFULLY BEFORE COMMENCING TO 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 Suitable for attachment to drawbars or approved overrun braking equipment for single axle and tandem axle trailers with a minimum weight of 200 Kg and a maximum permissible we
8. hammer replace one at a time Insert the new friction linings from below with the pin in the sleeve Fig 22 Item 3 and press in as far as possible pin engages no tools necessary Also reinsert adjusting washers if present on original friction pads Check wear on ball If the wear indicator Fig 23 Zu is no longer visible it is probable that the ball is worn and has developed play within the coupling housing Proceed as follows Connect ball DIN 74058 ISO 50 Handle is automatically tightened No pushing by hand Check the position of the wear indicator Warning The AKS 2700 can disengage and the caravan could uncouple from the towing vehicle Check AKS and towball immediately Warning Exchange the worn out part immediately The diameter of the towball should be ascertained first of all so that conclusions may be drawn as to the wear of the coupling mechanism min dia 49 61 mm Painted towballs or similar coatings In the event of the ball being coated this must be thoroughly removed with 100 200 grain sandpaper Otherwise reduced stabilising effect increased wear and damage to AKS 2 00 components may occur Technical Information The friction linings are pressed against the towing ball and generate a Stabilising damping force The friction pads are therefore subjected to wear The linings have reserves of wear and thus have a long service life Fig 18 N f SNS ZS WN R N a L BS I
9. ight 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 states and must be implemented with effect from 01 12 95 RESTRICTIONS OF USE Spare wheels fitted to rear door of vehicle or vehicle with platforms etc 1 the AKS 2700 Stabiliser 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 stabiliser can be observed in accordance with Directive 94 20 EC DIN 74058 If these clearances are infringed by special attachments then the use must be checked separately 3 Not suitable for use with overrun devices which revolve above 25 4 For Swan Neck towbars fixed or detachable refer to clearances on separate towball sheet WARNINGS 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 attached reversing lever on the left side when facing direction of traffic A 50 1 94 20 EG This type of coupling must be locked to ensure it cannot revolve 1 PLEASE CHECK THE CONDITIONS FOR ATTACHMENT BY FOLLOWING THE STEPS LISTED BELOW Towing vehicle with towball attachment The equipment may
10. king nuts may only be used once Depending on design of gaiter may either be put over coupling linked into space bracket fixed over retaining ring IMPORTANT In any operating condition there must always be free room of approx 25 mm between the AKS controls and the operating parts of the overrun device so that a hand can be inserted Figs 11 11a This should be checked as follows a AKS 2700 stabiliser handle closed stabiliser handle open Overrun device drawshaft telescoped out drawshaft telescoped in handbrake lever on handbrake lever released The free room is required to guarantee correct functioning and ease of operation b 3 OPERATING INSTRUCTIONS AKS 2700 Delivery Specifications Fig 12 Item 1 Stabilising Lever Fig 12 Item 2 Coupling Handle Coupling Uncoupling Please Note When coupling or uncoupling the stabiliser lever must be in the top position Open Pull stabiliser 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 position on its own However press down with the hand as well Closure and fastening are automatic Safety Warning If the stabiliser is correctly cou
11. pled to the towball then the green edge of the safety indicator is visible The coupling mechanism is correctly positioned when the hand lever can no longer be pressed down even 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 towing vehicle Press the stabilising handle down until it is over centre and against the end stop Uncoupling Lower the jockey wheel Detach breakaway cable and electrical plugs Pull stabilising lever up right to stop Fig 13 ltem 1 Pull coupling handle hard up in direction of arrow Fig 14 Item 2 Lift coupling head from towball of towing vehicle This process can be carried more easily if the towbar is set high with the jockey wheel when the coupling handle is opened Safety Tips During coupling and uncoupling the AKS 2700 must only be operated by one person Warning Never operate with foot or extension bar The components will be overloaded and damaged Fig 16 Only press stabilising handle down or pull it up with one hand only Warning The stabilising lever must not be used as an aid for manoeuvring Caution When opening or closing stabilising handle do not leave hands on the coupling handle Fig 17 5 Important Operating Factors The towball should be completely free of grease and other residue Clean thoroughly with Thinners White Spirit or Brake Cleaning flui
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