AL-KO AKS 3004 Stabiliser Handbook User Manual

							AKS 3004 STABILISER
HANDBOOK FOR THE AKS 3004 STABILISER 
						

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CONTENTS
3 REGULATIONS
4 RESTRICTIONS OF USE
5 SAFETY WARNINGS
6 FITMENT INSTRUCTIONS
8
 FITMENT NOTES
10 OPERATING INSTRUCTIONS
14 SERVICING & CLEANING
19 FAQS
22 COMPLEMENTAR Y PRODUCTS  
						

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REGULATIONS
1. The AKS 3004 stabiliser must be used in conjunction 
with 50mm 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 (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.   
						

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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 Directive 94/20 (DIN 
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 (D) (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 Directive 94/20 and 
have the required minimum 60mm clearance, measured from the 
centre of the towball (Fig 2).
Fig 20 Clearances for Stabiliser lever
Fig 1  Necessary Clearances
ABD
C
MIN. 60mmMIN. 67mm  
						

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1. In accordance with EC Directive 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.
60mm
SAFETY WARNINGS  
						

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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 DO 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 2Step 3
Step 4  
						

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FITMENT INSTRUCTIONS
Step 5
Step 6Step 9
Step 10Step 11Step 7
Step 8 Step 12 
0032  
						

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PLEASE NOTE THAT ON MOST OVERRUN ASSEMBLIES, THE 
DAMPER IS SECURED BY THE REAR RETAINING BOLT AND 
TELESCOPES OUT INDEPENDENTLY.
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 Dia.   Requirements
50mm  No spacers required
35mm 7.5mm spacer
46mm 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 Device (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  
						

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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 Dia.   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
AB  
						

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OPERATING INSTRUCTIONS 
AKS 3004 SPECIFICATIONS
Coupling Handle (Fig 7/Item 1) 
Stabiliser Lever (Fig 7/Item 2)
PREPARATION FOR COUPLING/UNCOUPLING
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.