Al-Ko Braking System Adjustment - AL-KO CARAVAN CHASSIS Handbook

AL-KO BRAKING SYSTEM ADJUSTMENT

1. Ensure the towing shaft with coupling head is pulled
FULLY FORWARD. (Fig 11).
2. Release the handbrake to the FULLY OFF position. If the
handbrake will not go down the whole way because of
the fairing or any other obstruction; then the fairing must
be cut away and/or the obstruction removed to achieve
this desired position. It will not be possible to set up the
braking system properly when the handbrake is not in the
FULLY OFF position. (Fig 11).
3. Jack up one side of the caravan, using the AL-KO Side
Lift Jack System. (See Jack Operating Instructions).
4. Remove the inner plastic bung from the backplate to
expose the 'starwheel' adjuster access. (Figs 11 & 12).
5. ALWAYS rotating the road wheel in the forward direction
- NEVER backwards; adjust the starwheel with a suitable
screwdriver, in the direction of the arrow embossed
on the backplate until there is resistance in the wheel
rotation. (Fig 12).
6. Slacken off the starwheel adjuster until the road wheel
turns freely in the FORWARD direction. (Fig 12).
10
7. Check the adjustment at the end of the brake cable where it
is secured to the abutment (bracket), welded to the centre of
the axle. When the inner cable is pulled out it should extend
between 5 and 8 mm. (Fig 13a\b). (On tandem axles a double
abutment (bracket) is fitted to the front axle ONLY).
8. Repeat for other wheel or wheels.
9. On tandem axles the brake cables from the rear axle should
pass over this axle and cross over each other before being
connected to the abutment (bracket) on the front axle. Where
ATC is fitted to a tandem axle caravan, the brake cables
SHOULD NOT be crossed over.
10. Ensure the balance bar (compensator) is being pulled evenly
(Figs 11 & 13a\b). Excessive movement to this bar (double on
tandem axles) would indicate possible incorrect adjustment
(if appropriate, repeat step No. 7 - Fig 13a\b).
11. Check the brake rod support bracket, (fixed to the floor) IS
supporting the brake rod evenly. The brake rod MUST ALWAYS
run straight, NEVER bent or curved under any fittings. On
tandem axles, using the double balance bar, a brake rod
support tube (Part No. 228827) MUST ALWAYS be fitted on the
end of the brake rod, passing through the centre aperture on
the abutment.