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ASSEMBLY INSTRUCTIONS FOR AL-KO AKS 3004 STABILISER

Please ensure you read all instructions etc from Alko before proceeding. Below is a rough guide and example only.

 

Easy Job 30 min.

 

Tools needed:

Couple of spanners.

Big Hammer (Needed on every job)

 

 

The AKS 3004 must be used in conjunction with 50 mm dia. tow balls which conform to EC Directive 94/20 (DIN 74058 or local equivalent).  Suitable for attachment to draw bars or approved overrun braking equipment for single (and tandem axle) caravan/trailers, with a minimum weight of 200 Kg and a maximum permissible weight of 3000 Kg.

Assembly Instructions:

 

Please note that on most overrun assemblies, the damper is secured by the retaining bolt and telescopes out independently.

 

 

1) Release gaiter from coupling head and loosen and remove self-locking nuts

 

Remove front bolt only.

 

Ok we had a slight mishap and removed wrong bolt first. The damper then slipped out of place and it took a good bit of messing to get the pin in and lined up so beware.

 

 

 

 

 

2) Using the 10 mm dia. retaining pin provided, knock through rear bolt and leave the pin in the shaft to secure the damper.

 

3) Remove coupling head.

 

 

 

 

4) The AKS 3004 is designed for 50mm draw shafts. For smaller dia. shafts,spacers must be used. These are provided with your stabiliser kit.

 

Shaft Diam. Requirements

50 mm No spacers required

40 mm Use 5 mm spacer (a)

35 mm 7.5 mm spacer (Use a (5mm) & c (2.5mm))

45 mm Use 2.5 mm spacer (c)

 

5) It may also be necessary to replace the gaiter according to the different diameter draw shafts, see table below for details (refers to AL-KO overruns only).

 

6) Place AKS 3004 (plus spacers if required) onto draw shaft, ensuring fixing holes 1 & 2 line up

 

NB: Always insert bolts from right hand side (when facing caravan), to ensure correct clearances are allowed if fitting AL-KO Security Device (not included in kit).

 

Take second M12 Allen Bolt and use it to knock through the 10 mm retaining pin used at step 2) - knock it all the way through. Finally fit the two hexagonal self-locking nuts and torque to 120 Nm.

 

For your own Safety please check:

 

To ensure in both cases that the damper is threaded-on, push the draw shaft in and out - you will feel resistance when the damper is correctly located.

When we did ours we noticed that when the caravan was hitched and we braked the car the hitch would catch on the handbrake handle and lift the hitch handle up. To remedy this a slight kink is needed to be put in the handbrake lever.