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.

11
OPERATING
INSTRUCTIONS
Fig 8 Pull Coupling Handle Up
Fig 7 Raise Stabiliser Lever Fig 9 Correct Engagement With Towball
Fig 6 AKS 3004 Stabiliser
Fig 10 AKS 3004 Friction Pads
1
1
2
3
3 2
1
AL- KO


AL- KO


2 4

12
OPERATING
INSTRUCTIONS
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. uring opening or closing, the AKS must only be
operated by one person.
2. Press stabiliser lever down by hand force only. O NOT
use your foot or an extension bar, this will damage the
components (Fig 11).
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 11).
Fig 11 How NOT to operate the stabiliser lever

13
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. ry operation of the drawshaft inside the overrun
device.
c. A detachable towball which has too much play in the
locking mechanism.
REMEDIAL ACTION
d. 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.
e. Lubricate the drawshaft sleeve via the grease nipples. In
addition, push the gaiter forward and grease ( IN 51
825 KTA 3K) the exposed part of the shaft (Fig 12).
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 12 Remedial Action
OPERATING
INSTRUCTIONS

14
CHECKING THE EFFICIENCY OF
THE SIDE 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 lever (Fig 13/Item 1) down until
resistance is felt (i.e. The friction pads are in contact with
the ball but not yet under pressure).
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 13/A).
4. If the arrowhead lines up with the two red lines then the
friction pads are worn and should be replaced immediately
(Fig 13/B).
NOTE
When the stabiliser lever is correctly applied, the
arrowhead should line up with the black line marked 2 (Fig
13/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 13 Checking Left/Right Friction Pads
SERVICING AND
CLEANING
1
2
1
A
2
1
1
B
2
1
1
C


1

15
SERVICING AND
CLEANING
FRICTION PAD REPLACEMENT (SIDE)
(Replace one at a time)
1. Uncouple the AKS 3004 stabiliser.
2. Remove protective caps (Fig 14/Item 1) with the aid of
a small screwdriver.
3. Press worn out pad inwards and remove (use punch and
hammer) (Fig 14/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 14/Item 3 & Fig 15).
Fig 14 Remove Worn Pads
Fig 15 Insert New Pads
2 3 1

CHECKING THE EFFICIENCY OF THE
FRONT/REAR FRICTION PADS
1. Couple the AKS 3004 stabiliser 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 16/Item
2).
3. If only a red indicator is visible (Fig 17/Item 3), then
this may have the following causes:
a. AKS 3004 is okay but the towball has reached
the lowest limit of 49.61mm.
b. AKS 3004 stabiliser shows signs of wear.
c. Towball is in a new condition (50mm) 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
49.61mm).
16
FRICTION PAD REPLACEMENT (FRONT/REAR)
1. Uncouple the AKS 3004 stabiliser.
2. Remove the soft dock (pull up & off), (Fig 20/Item 1).
3. Press the safety indicator outwards and secure with SW14
hex. spanner (not included), (Fig 20/ Item 2).
4. Remove cheese-head screw (Fig 20/Item 3 & Fig 18),
using special torx tool.
5. Press friction lining recess (Fig 20/Item 4) inwards and
pull down and out.
6. Open coupling handle (Fig 20/Item 5).
7. Remove countersunk head cap screw using special torx
tool (Fig 20/Item 6 & Fig 19).
8. Press friction pad inwards with a screwdriver and remove.
9. Fit new friction pads in reverse. Tighten screws to 5Nm (Fig 20/
Items 3&6)
10.Replace rubber soft dock, insert top section then bottom.
SERVICING AND
CLEANING

17
SERVICING AND
CLEANING
Fig 18 Cheese-head screw revealed
Fig 20 Friction Pad Replacement
Fig 19 Remove Head Cap Screw
Fig 16 Wear indicator - good condition
Fig 17 Wear indicator - poor condition
2
1
2
5
3
46
3

18
IMPORTANT MAINTENANCE CLEANING
ADVICE
1. The towball should be cleaned regularly to remove
grease or other residue, to maintain the efficiency of the
friction pads. The use of thinners, white spirit or brake
cleaner is recommended for cleaning the towball and
friction pads.
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 21 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 21).
c. Use multipurpose grease IN 51825 KTA 3K.
WARNING
When lubricating,
ensure none gets into
the friction pad or
towball holding area.
SERVICING AND
CLEANING

FAQ
S
STABILISER
CAN THE RE AN /OR GREEN IN ICATOR
BUTTONS BE REPLACE IF
BROKEN/MISSING?
This is usually caused by catching the button with the
hitch lock when fitting the hitch lock. The green section
can in some circumstances be replaced. Please contact
AL-KO for further advice.
The red part cannot be replaced.
THE STABILISER ARMS KEEP
LIFTING UP WHEN I TRAVEL.
The most likely cause is the handbrake handle catching on
the stabiliser lever when braking.
Gently tease the handle away from the contact point -
5mm should be sufficient. Whilst doing this, make sure
you support the base of the handbrake with a block of
wood to stop it coming off the ratchet plate.
FRICTION
PADS
WHEN SHOUL I CHANGE MY FRICTION PA S?
The friction pad life expectancy is around 30,000 miles and can be
prolonged by regular cleaning with fine grade emery paper.
Simply remove them according to the instructions on pages 15-
17, clean them and replace.
However, they will wear out and this can be monitored via wear
indicators on your stabiliser. See pages 14-17 for wear
indicator information, and instructions on changing them.
MY FRICTION PA S LOOK ‘GLASSY’
WITH BITS FLAKING OFF.
Contamination has built up on the pads. This could be due to
grease on the towball, spray from the road, diesel fumes or failure
to remove all of the coating on the towball.
You need to remove the friction pads according to the instructions
on pages 15-17, and rub them lightly with a fine grade emery
paper. AL-KO recommend cleaning the pads in this way after every
journey to prevent build up and prolong friction pad life.
19

FAQ
S
WHEN TOWING I CAN HEAR
LOU CREAKING OR
GROANING.
2 possible causes:
1 The incorrect towball could be fitted.
Check your towball
is compatible with your stabiliser, and if it isn’t replace
it immediately. Failure to do so could result in your
caravan becoming unhitched during towing.
The necessary clearances are outlined on page 4, and
AL-KO recommends the AL-KO extended neck towball
which complies to all the necessary specifications.
2 Contamination may have built up on the friction pads.
This could be due to grease on the towball, spray
from the road, diesel fumes or failure to remove all of
the coating on the towball.
You need to remove the friction pads according to the
instructions on pages 15-17 and rub them lightly with a
fine grade emery paper.
AL-KO recommend cleaning the pads in this way after every
journey to prevent build up and prolong friction pad life.
20
THE EN HAS SNAPPE OFF OF MY FRICTION PA .
This usually happens when the pads have not been fully
disengaged before dropping the stabiliser onto the towball. You
will need to replace the friction pad with a new one. To avoid
this in future always place, rather than drop, the stabiliser onto
the towball and ensure the stabiliser lever has been lifted fully.
FRICTION
PA S?
Yes, but AL-KO do not recommend it. It is the hitch handle that
attaches the stabiliser to the towball. If you do not activate
your friction pads then you will have no damping benefits.
TOWBAL
L
MY TOWBALL HAS GREASE ON IT. CAN I USE IT WITH
AN AKS STABILISER?
Under no circumstances can a greased towball be used with an
AKS stabiliser. Ensure you remove all grease before hitching up.
Use a cloth to remove the excess grease, and use brake cleaner
to remove any residue. We do not recommend methylated spirit
as this can leave a greasy residue.