The AL-KO AKS 3004 Stabiliser is a device designed to enhance the safety and stability of towing caravans and trailers. It works by suppressing small swinging and pitching movements of the trailer, thereby increasing the critical driving speed by approximately 20%. This makes for a safer and more comfortable towing experience.

Function Description

The AKS 3004 Stabiliser operates by applying friction to the towball, creating a damping force that counteracts trailer sway. It features a coupling handle for attaching to the towball and a stabiliser lever to activate the friction pads. When the stabiliser lever is pressed down, friction pads (side and front/rear) engage with the towball, generating the necessary stabilising and damping force. The device is designed to be used in conjunction with specific towballs and overrun devices that meet certain clearance requirements, ensuring proper articulation and preventing damage.

Usage Features

Coupling and Uncoupling: To couple, the stabiliser lever must be in the uppermost (open) position. The coupling handle is then pulled up, and the opened coupling is placed onto a clean towball. A visible green edge on the safety indicator button confirms correct engagement, accompanied by an audible click as the handle returns to its flat position. For uncoupling, the stabiliser lever is pulled up, the coupling handle opened, and the AKS 3004 lifted from the towball. Using the jockey wheel can assist with lifting, especially with larger nose loads.
Activating the Stabiliser: Once coupled, the stabiliser is activated by pressing the stabiliser lever down as far as it will go. An arrowhead on the lever aligning with a black line indicates correct coupling of the stabiliser unit.
Manoeuvring: For easier manoeuvring in situations like campsites, the stabiliser lever should be pulled to the 'up' position to disengage the friction pads. It's crucial not to use the stabiliser lever as a manoeuvring handle; instead, use the caravan's handles or an AL-KO manoeuvring handle fitted to the jockey wheel.
Safety Precautions: The AKS 3004 should only be operated by one person when opening or closing the handle to minimise injury risks. The stabiliser lever should be pressed down by hand force only; using a foot or an extension bar can damage components. When operating the stabiliser lever, care must be taken to avoid trapping fingers with the coupling handle.
Towball Compatibility: The stabiliser requires a clean, grease-free towball. Towballs with paint or other coatings must have these completely removed using emery paper (100 or 120 grain) to prevent contamination of friction pads and ensure effective stabilisation. Certain types of towballs, such as A50-1 couplings, are not compatible, and their use will invalidate the warranty. Bolted-in ball couplings are only permissible if the thread is locked or welded. The device is not suitable for use with overrun devices that revolve above 25° or specific BPW overruns. Swan Neck towbars are suitable if they comply with EC Directive 94/20 and have the required minimum 60mm clearance.
Noise During Driving: Clicking, creaking, or squeaking noises during driving usually indicate issues such as foreign bodies/dirt between the friction pad and towball, dry operation of the drawshaft, or excessive play in the locking mechanism of a detachable towball. Remedial actions include cleaning the towball and friction pads, lubricating the drawshaft sleeve, and checking the towball for damage or play.

Maintenance Features

Friction Pad Maintenance: The friction pads are subject to wear over time but have a long service life (approximately 30,000 miles) if well-maintained. They should be kept free of grease and dirt. Before each journey, the towball and friction pads should be cleaned by lightly rubbing their surfaces with fine emery paper (100-120 grit) or using brake cleaning fluid to remove build-up.
Checking Friction Pad Efficiency (Side Pads): The efficiency of the side friction pads can be checked by ensuring the stabiliser is correctly coupled and the red indicator button is raised. Pushing the stabiliser lever down until resistance is felt allows for checking the arrowhead's position on the stabiliser arm. If it aligns with two green lines, the pads are like new. If it aligns with two red lines, the pads are worn and require immediate replacement.
Checking Friction Pad Efficiency (Front/Rear Pads): For front/rear pads, couple the stabiliser without activating it. A green indicator on the handle signifies new condition or pads/towball within permissible limits. A red indicator suggests the towball has reached its lowest limit (49.61mm), the stabiliser pads show wear, or new towball (50mm) with high wear on front/rear pads. The towball diameter should be checked to assess pad wear, ensuring it's not less than 49.61mm.
Friction Pad Replacement (Side): Side friction pads should be replaced one at a time. This involves uncoupling the stabiliser, removing protective caps with a small screwdriver, pressing the worn pad inwards (using a punch and hammer), and inserting a new pad from below, ensuring any shim washers are re-inserted.
Friction Pad Replacement (Front/Rear): Front/rear friction pad replacement requires uncoupling the stabiliser, removing the soft dock, pressing the safety indicator outwards and securing it with a SW14 hex spanner, removing a cheese-head screw with a special torx tool, pressing the friction lining recess inwards, opening the coupling handle, removing a countersunk head cap screw with a special torx tool, pressing the worn pad inwards with a screwdriver, and finally fitting new pads in reverse order, tightening screws to 5Nm, and replacing the rubber soft dock.
Lubrication: If lubrication of stabiliser parts becomes necessary, all parts must be thoroughly cleaned first. Areas should only be covered with a thin film of multipurpose grease (DIN 51825 KTA 3K). It is critical to ensure no grease gets into the friction pad or towball holding area during lubrication.
Winter Maintenance: In winter, only the visual indicator should be carefully sprayed with de-icer.
Self-locking Nuts: Self-locking nuts are single-use and must be replaced with new ones if removed.
Repairs: Repairs should only be carried out by trained and qualified workshop personnel. AL-KO provides a list of approved service centres online. When enquiring about spare parts, the ETI number printed on the product should always be quoted. AL-KO recommends using original AL-KO spare parts for safety and reliability.

The AKS 3004 Stabiliser is part of the AL-KO Formula for Optimum Safety, which, when combined with AL-KO ATC Trailer Control and responsible driving, aims to provide the safest possible driving conditions and unparalleled towing stability for caravan owners.

AL-KO AKS 3004 - Original Instructions For Use Manual

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