AL-KO CARAVAN CHASSIS Handbook

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CARAVAN CHASSIS

HANDBOOK FOR VEHICLES ON

THE AL-KO CARAVAN CHASSIS

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Page 1 CARAVAN CHASSIS HANDBOOK FOR VEHICLES ON THE AL-KO CARAVAN CHASSIS...
Page 2 Manufactured from high quality steel, the chassis has extra The process of fitting third party products to the AL-KO Chassis deep sections to provide strength at points of maximum therefore may invalidate the chassis warranty.
Page 3 AL-KO CARAVAN CHASSIS HOT DIP GALVANISATION The chassis is Hot Dipped Galvanised. This is regarded as one The galvanised chassis should not be painted or subjected to any of the best forms of corrosion protection. It does however other protective treatment.
Page 4 INDEPENDENT SUSPENSION one of the three shown below - Figs 1, 1a and 2, depending on The AL-KO rubber suspension is designed and developed date and location of manufacture. The line marked ‘Capacity’ to suit all types of road conditions and is maintenance free.
Page 5 AL-KO CARAVAN CHASSIS LOADING  Loads to be carried in the caravan should be placed directly over, or as close as possible to the axles, otherwise the handling will be impaired. Fig 3 Load Too Far Forward Maximum gross weight, as advised by the caravan Steering and braking ability reduced.
Page 6 AXLE TYPES SAFETY PRECAUTIONS Reversing No welding is permitted on AL-KO Axles. When the towing vehicle is reversing, the overrun device shaft It is important that the wheel and hub/brake drum are is pushing in, applying the brakes via the overrun lever, brake compatible.
Page 7 AL-KO for resetting of the toe-in and camber. No attempt should be made to remove the bearing. In the event of damage to the bearing or drum, only the drum complete with bearing and circlip will be available as a spare.
Page 8 With boat trailers which are driven into fresh/salt water, the If repair work or servicing is required, AL-KO have a large network hub bearing should be regreased shortly after contact with of AL-KO service stations throughout Europe.
Page 9 811... Fig 8 Rebound or Free Position Fig 7 Spare Part Identification Number The AL-KO rubber suspension axle has been designed & developed to suit all types of road conditions and is maintenance free. Three rubber elements are contained within an hexagonal axle tube.
Page 10 (bracket) on the front axle. Where 3. Jack up one side of the caravan, using the AL-KO Side ATC is fitted to a tandem axle caravan, the brake cables Lift Jack System.
Page 11 AL-KO BRAKING SYSTEM ADJUSTMENT Handbrake lever Overrun lever Axle side Rotation direction forwards  plate Rubber sprung axle Brake rod Brake shoe inspection bung ‘Starwheel’ adjustment access Stabiliser Balance Abutment Bowden cable Breakaway cable Fig 11 Brake Linkage Fig 12 Adjusting the Starwheel...
Page 12 AL-KO BRAKING SYSTEM ADJUSTMENT 12. Remove the slack in the brake rod by adjusting the long 15. Finally, if the road wheels have been removed, re-tighten all ball nut, rear of the balance bar, ensuring the overrun M12 wheel bolts using a calibrated Torque Wrench to 110Nm lever makes contact with the end of the towing shaft.
Page 13 AL-KO BRAKING SYSTEM ADJUSTMENT Axle Balance bar Bowden Cable Abutment 238576002 (welded to axle tube) 1- Brake rod 2- M10 Ball nut 2088890006 3- M10 Locknut 700109 4- Bowden Cables Fig 13a Standard Brake Linkage Axle Balance bar Bowden Cable Abutment...
Page 14 STABILISER AND COUPLING DEVICES Your caravan will be fitted with either an AKS 3004 stabiliser 25° 25° or an AK160/300 coupling head. SAFETY PRECAUTIONS Always ensure that the coupling head is properly connected to the tow vehicle’s towball every time you couple up. If this procedure is not carried out correctly, the caravan/ trailer may become detached from the towing vehicle! Maximum possible articulation of the coupling head must not exceed...
Page 15 (and tandem axle) caravan/trailers, with a minimum weight of 200 Kg and a maximum permissible weight of 3000 Kg. 3. EC design approval has been given to the AL-KO AKS 3004 coupling under permit No. e1*94/20*0930*00.
Page 16 330 mm (B) + the stroke movement (D) (85mm- 100mm), which equates to 440 mm when used in Fig 15 Necessary Clearances conjunction with an AL-KO overrun. 2. Not suitable for use with overrun devices which can revolve Max. 50 mm (C) clearance between the centre of the...
Page 17 OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER SAFETY WARNINGS 1. In accordance with EC Directive 94/20, couplings of type 25° A 50-1 cannot be used (see Fig 17), 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.
Page 18 OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER AKS 3004 DELIVERY INSTRUCTIONS STABILISER UNIT Coupling Handle (Fig 20/Item 1) To operate the stabiliser (once coupled to the towball), simply Stabiliser Lever (Fig 20/Item 2) press the stabiliser handle down as far as it will go (Fig 22/Item 3). PREPARATION FOR COUPLING/UNCOUPLING To ensure the stabiliser is correctly coupled, check the arrowhead lines up with the black line marked 2 (Fig 22 /Item 4 and Fig 24/C).
Page 19 OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER Fig 19 Coupling Handle & Stabiliser Lever Fig 21 Pull Coupling Handle Up Fig 20 Raise Stabiliser Lever Fig 22 Correct Engagement With Towball Fig 23 AKS 3004 Friction Pads...
Page 20 OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER CHECKING THE EFFICIENCY OF THE LEFT/RIGHT FRICTION PADS 1. Check that the stabiliser is correctly coupled by ensuring the coupling handle is fully down and the red indicator button is in the raised position. 2.
Page 21 ‘up’ position. Please do not use the stabiliser lever as a manoeuvring handle. Please use the handles on the Caravan or fit the AL-KO manoeuvring handle to your jockey wheel (available separately). 1. During opening or closing, the AKS must only be operated by one person.
Page 22 OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER NOISES WHILST DRIVING As a rule, the friction pads of the AKS 3004 do not make a noise during driving. Any clicking, creaking or squeaking noises that do arise may be due to the following: a.
Page 23 OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER SERVICING AND CLEANING Friction Pad Replacement (Replace one at a time) 1. Uncouple AKS 3004. 2. Remove protective caps (Fig 27/Item 1) with the aid of a small screwdriver. 3. Press worn out pad inwards and remove (use punch and hammer) (Fig 27/Item 2).
Page 24 OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER CHECKING THE EFFICIENCY OF THE FRICTION PAD REPLACEMENT (FRONT/REAR) FRONT/REAR FRICTION PADS 1. Uncouple the AKS 3004. 1. Couple the AKS 3004 to the towball but do not activate 2. Remove the soft dock (pull up & off), (Fig 30/Item 1 & Fig 30a.). the stabiliser.
Page 25 OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER Fig 33 Fig 28 Wear indicator - good condition Fig 30a Remove Cheese-Head Screws Fig 30 Friction Pad Replacement Fig 29 Wear indicator - poor condition Fig 31 Remove Head Cap Screw...
Page 26 OPERATING INSTRUCTIONS FOR AKS 3004 STABILISER IMPORTANT MAINTENANCE & CLEANING ADVICE LUBRICATION 1. The towball should be cleaned regularly to remove grease Should lubrication of the stabiliser parts become necessary, or other residue, the use of Thinners, White Spirit or then the following must be observed.
Page 27 COUPLING TYPES AK160 & AK300 OPERATING INSTRUCTIONS COUPLING UP Open coupling handle. To do this pull the coupling handle up (Fig 33) in the direction of the arrow. The coupling mechanism has a fixed open position, ie. as long as the coupling head is not placed on the ball the coupling will remain open.
Page 28 Both coupling head and towball are showing signs of wear. parts must be changed IMMEDIATELY. Towball is in good condition with 50mm dia, but the All maintenance work should be carried out by AL-KO coupling head is showing an excessive level of wear. Approved Workshops.
Page 29 COUPLING TYPES AK7, AK10/2 OR AK252 This type of coupling is normally fitted to trailers or older model caravans. OPERATING INSTRUCTIONS COUPLING UP Push the safety lever (Fig 35/Item 1) up with the index finger and lift the handle up and forwards. Put the opened coupling onto the towball with the handle pulled up and in addition press down by hand.
Page 30 The coupling head and towball must therefore be checked IMMEDIATELY before Fig 36 Wear indicator future use. Any faulty parts must be changed IMMEDIATELY. All maintenance work should be carried out by AL-KO Approved Workshops.
Page 31 COUPLING TYPES AK7, AK10/2 OR AK252 SERVICING & CLEANING Lubrication Points (Fig 37) Clean Towball Lightly grease or oil ball socket, joints and bearing points as appropriate. General purpose grease to DIN 6=51825 KTA 3K. For Troubleshooting and Fault Finding see Table 2 on page 45. Fig 37 Lubrication points...
Page 32 OVERRUN DEVICES OPERATION In the importance of safety, please familiarise yourself with the operation of this overrun device BEFORE using your AL-KO overrun devices are a mechanical type, using a caravan/trailer. hydraulic damper. SAFETY PRECAUTIONS COUPLING UP When parking your tow vehicle and caravan/trailer on site, you must apply the caravan handbrake.
Page 33 OVERRUN DEVICES CAUTION The breakaway cable operates the handbrake (emergency brake), in the event of the caravan/trailer becoming detached from the towing vehicle during towing. For this emergency brake to work correctly, it is absolutely essential that the following points are observed: 1.
Page 34 OVERRUN DEVICES EURO-OVERRUN DEVICES FITTED WITH AKS 3004 STABILISER Fully retract Jockey Wheel inner tube so that it locks against Jockey Wheel outer tube. Slacken Jockey Wheel Clamp handle and raise complete assembly through cutout in body to its highest position (ensure it doesn’t come into contact with the brake rod assembly), fully tighten Jockey Wheel Clamp handle to ensure the Jockey Wheel is firmly held in position.
Page 35 Remove wheel chocks if fitted and stow safely. or vouch for other products. CAUTION If repair work or servicing is required, AL-KO have a large network Failure to comply with this could result in the brakes overheating. of AL-KO service stations throughout Europe. To establish the...
Page 36 OVERRUN DEVICES SERVICING Every 10,000 - 15,000 km or every 12 months: Lubricate/grease all sliding and moving parts of the overrun device as show in Fig 42. Recommended lubricant General purpose grease to DIN 51825 KTA 3KA. Servicing and care of hot dip galvanized parts The formation of white rust is only a surface coating and has no adverse effect on the anti-corrosion properties of galvanising.
Page 37 ESP on some tow cars. ATC monitors for instability and takes the necessary action to prevent Since April 2010, AL-KO caravan chassis members have the caravan from snaking by gently applying the caravan brakes,...
Page 38 2. Unscrew the Plastic Cap from the receiver and store in the Lock Kit Box. (When AL-KO Secure is not in use, always screw Most caravans have the AL-KO Receiver fitted to the wheel the Plastic Cap in place).
Page 39 ACCESSORIES Fig 43 Fitting AL-KO Secure Wheel Lock...
Page 40 STABILISERS Corner Steadies are as stated, for the purpose of steadying AL-KO overruns can be fitted with a range of AL-KO Stabiliser the caravan corners. They are NOT JACKS AND SHOULD devices (if not already fitted as standard), dependent on the NEVER BE USED AS SUCH.
Page 41 M14 - 135 Nm (99.5 ft. lb) M16 - 210 Nm (155 ft. lb) IMPORTANT NOTE Standard AL-KO caravan chassis use M12 bolts. These must SPECIAL NOTE - ALUMINIUM WHEELS always only be tightened to the correct torque setting as The standard M12 x 1.5 60o Conical Wheel bolts are NOT...
Page 42 JOCKEY WHEEL The Corner Steadies should never be used to jack up the All AL-KO Jockey Wheels are removable and stow neatly on the caravan. When jacking becomes necessary use the AL-KO A-Frame when the caravan is being towed. AL-KO Jockey Wheels Side Lift Jack or 2-Tonne Jack system.
Page 43 There are 3 variants to suit most AL-KO chassis (record your tyre size on this booklet for future reference). The carriers can be fitted for left or right hand operation and are easy to fit.
Page 44 TROUBLE SHOOTING & FAULT FINDING TABLE 1 AXLES FAULT CAUSE REMEDY POOR BRAKING Linings worn or damaged. Replace Brake Linings. Brake Linings not bedded in. Will pass after braking a few times. Brake set up incorrect. Reset Brakes as pages 10-12 & ensure system is lubricated. DIFFICULTY IN REVERSING Braking system set too tightly.
Page 45 TROUBLE SHOOTING & FAULT FINDING TABLE 2 COUPLING HEADS FAULT CAUSE REMEDY COUPLING DOES NOT Ball diameter too large. Change ball to correct size. ENGAGE ONTO BALL Ball could be damaged or deformed. Fit new ball. Coupling head dirty or defective. Clean &...
Page 46 TROUBLE SHOOTING & FAULT FINDING TABLE 3 OVERRUN DEVICES FAULT CAUSE REMEDY POOR BRAKING Overrun shaft tight. Lubricate overrun shaft and Overrun shaft corroded. replace any damaged parts. Body housing damaged. BRAKES OVERHEATING Handbrake not fully released. Release handbrake. DURING TOWING Braking system incorrectly set.
Page 47 Red line not visible - possible to continue journey but contact AL-KO. * ATC stores operating errors in a logfile which over time will become full and will result in the solid red light appearing. This needs to be erased and can be done easily by connecting the caravan to a 12 volt supply for a period of 12 hours.

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