AL-KO 800 kg Side Lift Jack User Manual

AL-KO SIDE LIFT JACK
HANDBOOK FOR THE 800KG SIDE LIFT JACK
FOR CARAVANS WITH A MAXIMUM GROSS WEIGHT OF 1600KG 

2
CONTENTS
3 WARNINGS & TECHNICAL INFORMATION
4 FITMENT OF JACK BRACKETS
7 OPERATING INSTRUCTIONS
8 TECHNICAL DATA
9 FAQS
KIT CONTENTS
1 x Side Lift Jack
1 x Storage Bag (if applicable)
2 x Jack Brackets
4 x M13 Washers
2 x M12x50 Bolts
4 x M12x25 Bolts
4 x M12 Nylock Nuts
2 x Spacers
Fig 1 AL-KO Side Lift Jack Kit  

3
WARNINGS
1 NEVER LIE UNDERNEATH A JACKED-UP VEHICLE, AS 
THIS IS HIGHLY DANGEROUS AND COULD RESULT IN 
SERIOUS INJURY OR EVEN DEATH!
2 The caravan MUST be attached to the towing vehicle 
and the handbrake on both the towing vehicle and 
caravan MUST be applied.
3 The AL-KO Caravan Jack is not designed to be used 
as a permanent steady, but it can be used as an aid to 
levelling the caravan, in additional to changing the wheel.
4 In the case of manual towing vehicles, select 1st or 
reverse gear; with...

4
FITMENT OF JACK BRACKETS
1 The jack mounting brackets can be fitted to both 
single and tandem axle caravans, on both sides of the 
chassis, behind the axle(s).
NOTE
Care should be taken to ensure the brackets do not 
interfere with any other equipment fitted in this area. 
2 On AL-KO chassis manufactured from 1991 onwards, 
the mounting holes are already incorporated into the 
longitudinal chassis members as standard.
3 This jacking system can be fitted to most AL-KO 
chassis manufactured from 1980...

5
FITMENT OF JACK BRACKETS
Fig 3 Drilling according to position ‘a’ (C Section Chassis Members)
Fig 4 Drilling according to position ‘b’ (C Section Chassis Members)
 
FRAME HEIGHT HOLE SPACING  HOLE DIA.
 A (mm)  B (mm)    C (mm)   D (mm)
 158  30            45  13
 215  40            55  13
 
FRAME HEIGHT HOLE SPACING  HOLE DIA.
 A (mm)  E (mm)    F (mm)   D (mm)
 158  30            45  13
 215  40            55  13
Fig 2 Necessary cleanances for drilling holes
A
b
a
38
C
B
1
95MIN
D2
55MIN
D
F
E
A
A
3  

6
FITMENT OF JACK BRACKETS
FOR HIGH FRAME CHASSIS (215 MM)
5 Position the jack mounting bracket (Fig 5/ item 1) with 
the long side on the chassis member (Fig 5/item 2) lining 
up the holes in the bracket, with those in the chassis 
member, positioning the short side of the bracket against 
the floor of the caravan.
6 Fit M13 washers (Fig 5/item 4) onto setscrews.
7 Insert setscrews M12x25 (Fig 5/item 3) through both 
holes with bolt heads on outside of chassis member.
8 Fit the M12 self-locking nuts...

7
OPERATING INSTRUCTIONS
Fig 7 Mounting the jack brackets
1 Attach caravan to the towing vehicle and apply the 
handbrake on both towing vehicle and caravan.
2 In the case of manual towing vehicles, select 1st or 
reverse gear; with automatic towing vehicles, place the 
selector lever in the ‘P’ position.
3 As an additional safety measure ensure that you chock 
the caravan wheel (back and front) on the opposite side 
to the one to be changed.
4 Clean jack mounting brackets on the caravan. 
5 Remove jack...

8
TECHNICAL DATA
Fig 11 Never lie underneath a jacked vehicle
Fig 9 Min Ground clearance
Fig 10  Maximum lifting height
Fig 8 Technical data
 Min. Ground Clearance   Max. Lifting Ht.   Static Load
 A (mm) Fig 6a  B (mm) Fig 6b  (Kg)
 85  375 800 
WARNING
NEVER LIE UNDERNEATH A JACKED-UP VEHICLE, AS THIS IS 
HIGHLY DANGEROUS AND COULD RESULT IN SERIOUS INJURY 
OR EVEN DEATH!
A
B  

9
FAQS
HOW DO I KNOW WHICH JACK I NEED? 
There are two side lift jacks kits available, the 2000kg 
version and the 1600kg version. This figure is based on the 
maximum weight of the caravan. The jacks will lift a static 
load of 1000kg and 800kg respectively. 
WHY HAS MY BRACKET BENT?
Is is vital that the jack and brackets be lined up as shown 
in Fig 7 on page 7. The joining section must be directly 
underneath the bracket, and the joining section must not 
enter the jack bracket at angle as this could...