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 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. 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.

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). 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).

HiHave a AKS 2000 Stabiliser fitted to my. I downloaded a 3004 manual from alko thinking. To know an aks 2000 is also otherwise known as an aks. Genuine al-ko aks stabaliser side friction pads. Includes new shims & dust caps – to fit models – aks 2000, aks 3004, aks 2004.alko part number – 1220755.comes with fitting instructions.note – they do not fit 2500 or 2700 model!!!note – if your replacing worn parts on the 3004 model the you may also need the front and. Apr 12, 2010. Thanks Trevor, there are no shims that I could find in this head, but I have now completed the task, so I hope this helps others, Early alko AKS 2000, changing pads. On either side of the coupling there are two circular “25mm nuts” with holes around the edge, the end of the shaft of the friction pad can be. Caravan -Alko Aks Stabiliser Friction Pads 2000 / 2004 / 3004 – Part No.1220755. Genuine al-ko aks stabaliser side friction pads. Includes new shims & dust caps - to fit models - aks 2000, aks 3004, aks 2004. Comes with fitting instructions. Alko part number; 1220755. Note - they do not fit 2500 or 2700 model!!!

Fig 20 Clearances for Stabiliser lever Fig 1 Necessary Clearances ABD C MIN. 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. For UK use, use the extended neck towball (type A50-X). A bolted-in type ball coupling (Fig 4) is only permissible if the thread is locked or welded. The AKS 3004 cannot be used with a laterally attached reversing lever, on the left side, when facing the direction of traffic. 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. If friction pads become contaminated with grease, they should be replaced.

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. 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 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. 8 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. 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. 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. Actia Multi Diag 2013 Keygen here. 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). 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. 10 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.