AL-KO AKS 3004 User manual

AKS 3004
STABILISER
HANDBOOK FOR THE AKS 3004
STABILISER

2
CONTENT
S
3 REGULATIONS
4 RESTRICTIONS OF USE
5 SAFETY WARNINGS
6 FITMENT INSTRUCTIONS
8 FITMENT NOTES
10 OPERATING INSTRUCTIONS
14 SERVICING CLEANING
19 FAQS
22 COMPLEMENTARY PRODUCTS

3
REGULATION
S
1. The AKS 3004 stabiliser must be used in conjunction
with 50mm dia. towballs which conform to EC
irective 94/20 ( IN 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 200kg and
a maximum permissible weight of 3000kg.
3. EC design approval has been given to the AL-KO AKS
3004 coupling under permit No.
e1*94/20*0930*00.

4
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 irective 94/20 ( IN
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) (e.g. spare
wheels, platforms etc.)
The clearance for the stabiliser lever must be at
least 330mm (B) + the stroke movement ( )
(85mm- 100mm), which equates to 440mm when
used in conjunction with an AL-KO overrun.
Max. 50mm (C) clearance between the centre of the
towball and top of the overrun assembly or fairing, to
ensure both coupling handle and stabiliser lever do not
foul on operation.
Maintain the same clearances for other
manufacturers’ overrun assemblies.
2. May not be suitable for use with overrun devices which can
revolve above 25° (Fig 2) 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 irective 94/20 and
have the required minimum 60mm clearance, measured from
the centre of the towball (Fig 2).
Fig 1 Necessary Clearances
A B D
C
MIN.
60mm
MIN.
67mm

5
1. In accordance with EC irective 94/20, couplings of type
A 50-1 cannot be used (see Fig 3), 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 4) 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.
Coated towballs must have the coating completely
removed (use 100 or 120 grain emery paper). If this is
not done increased towball wear will occur and may
cause damage, or reduce the efficiency of the stabiliser.
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 3 A 50-1 Couplings
Fig 2 Max suitable rotation of overrun device is 25°Fig 4 Bolted In Coupling
25°
Min.
60m
m
SAFETY
WARNINGS

6
FITMENT
INSTRUCTIONS
1 Before starting you must ensure the handbrake is on.
2 Unscrew the two nuts on the coupling head and remove
the front bolt.
3 Take the dowel provided and hammer it through the
coupling head to push the rear bolt out.
4 Once the dowel has replaced the bolt inside the
coupling head you should be able to remove the rear
bolt completely. You may need to push the coupling
head to ease the process.
5 Slide the coupling head off of the overrun.
6 O NOT place the AKS 3004 Stabiliser over the
overrun.
7 The new AKS 3004 Stabiliser slides onto the overrun.
8 Push the stabiliser until its holes line up with the holes
in the overrun.
9 Take the two new bolts supplied with the stabiliser, and
insert the bolt with the washer into the front hole.
10 Hammer the bolt without the washer into the rear hole,
forcing the dowel out of the other side.
11 Screw the supplied nuts onto both bolts.
12 Tighten both bolts with a torque wrench to 86Nm.

Step 1
Step 2
Step 3
Step 4

7
FITMENT
INSTRUCTIONS

Step 5
Step 6
Step 9
Step 10
Step 11Step 7
Step 8 Step 12

8
50mm
35mm
46mm
PLEASE NOTE THAT ON MOST OVERRUN ASSEMBLIES, THE
AMPER IS SECURE BY THE REAR RETAINING BOLT AN
TELESCOPES OUT IN EPEN ENTLY.
NOTE: The AKS 3004 is designed for 50mm draw
shafts. For smaller diameter shafts, spacers must be
used.
These are provided with your stabiliser kit.
Shaft ia. Requirements
No spacers required
7.5mm spacer
2.0mm spacer -
non AL-KO
1 Always insert the bolts from the right hand side (when
facing caravan), to ensure the correct clearances are
allowed if fitting AL-KO Security evice (sold
separately).
2 For non AL-KO overruns, with one horizontal and one
vertical fixing bolt, insert the front bolt through the
washer, overrun shaft and internal spacer (where used).
Finally, fit hexagonal self-locking nut and torque to
100Nm for 10,9 class bolts or 86Nm for 8,8 class
bolts.
Take Mushroom Headed Coachbolt and insert from
top, fit original curved washer (from your overrun) and
hexagonal self-locking nut and torque to 86Nm (8,8
class bolt supplied).
NOTE
The class of bolt will be stamped onto the bolt head.
FITMENT
NOTES

9
SPARE
PARTS
1 Spare parts are safety critical! For this reason when fitting
spare parts in our products we recommend the use of
original AL-KO parts. The reliability, safety and suitability
of parts designed especially for our products, has been
determined using a special test procedure. In spite of
constantly monitoring the market we are unable to assess
or vouch for any other products.
2 Repairs should only be carried out by trained and qualified
workshop personnel. A list of AL-KO Approved Service
Centres is available online at www.al-ko.co.uk.
3 Always quote the ETI number printed on this product,
when enquiring about spare parts.
It may also be necessary to replace the gaiter according
to the different diameter draw shafts, see below for details
(refers to AL-KO overruns only).
Shaft ia. Gaiter Amendments
35mm No amendments necessary, use existing gaiter.
Fit smaller diameter of gaiter flush to end of
stabiliser and secure larger diameter of gaiter
with the retaining ring included with this kit.
50mm Gaiters as per Fig 5/Item A, this is secured
immediately after the coupling and can
therefore be used again.
Gaiters as per Fig 5/Item B, cannot be used
again. Replace with gaiter included with this
kit.
FOR YOUR OWN SAFETY PLEASE CHECK THE
FOLLOWING:
a. Ensure in both cases that the damper is correctly
connected, push the drawshaft in and out - you will
feel resistance when the damper is correctly located.
b. Self-locking nuts must only be used once - if removed
replaced with new ones.
FITMENT
NOTES
Fig 5 Gaiter Amendments
A B

10
OPERATING
INSTRUCTIONS
AKS 3004 SPECIFICATIONS
Coupling Handle (Fig 7/Item 1)
Stabiliser Lever (Fig 7/Item 2)
PREPARATION FOR
COUPLING/UNCOUPLIN
G
The Stabiliser lever (Fig 7/Item 2) must be in
the uppermost position (open).
COUPLING UP
Pull the coupling handle (Fig 8/Item 1) up in the direction
of arrow. The coupling mechanism has an open position,
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 9/Item 2).
STABILISER UNIT
To operate the stabiliser (once coupled to the towball), simply
press the stabiliser lever down as far as it will go (Fig 9/Item
3).
To ensure the stabiliser is correctly coupled, check the
arrowhead lines up with the black line marked 2 (Fig 9 /Item 4
and Fig 13/C).
UNCOUPLING
Pull the stabiliser lever 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 10/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.