AL-KO AKS 3004 Bedienungsanleitung

AKS 3004

STABILISER

HANDBOOK FOR THE AKS 3004

STABILISER

CONTENT

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

REGULATION

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.

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

MIN.

60mm

MIN.

67mm

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

SAFETY

WARNINGS

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

FITMENT

INSTRUCTIONS



Step 5

Step 6

Step 9

Step 10

Step 11Step 7

Step 8 Step 12

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

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

OPERATING

INSTRUCTIONS

AKS 3004 SPECIFICATIONS

Coupling Handle (Fig 7/Item 1)

Stabiliser Lever (Fig 7/Item 2)

PREPARATION FOR

COUPLING/UNCOUPLIN

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.

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