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 automatic towing vehicles, place the 
selector lever in the ‘P’ position.
5 As an additional safety measure, chock the caravan 
wheel (back and front) on the opposite side to the one 
to be changed.
TECHNICAL INFORMATION
 
1 This product is suitable for use with caravans with a 
Maximum Gross Weight of 1600kg (800kg static load).
2 The jack brackets can be attached to caravans fitted 
with AL-KO Chassis, manufactured from 1980. 
 CARAVANS MANUFACTURED FROM 1980 - 1991
   Drilling of the chassis is required but only in accordance 
with the instructions printed in this handbook. 
  CARAVANS MANUFACTURED AFTER 1991
 No drilling is required as the chassis frame will 
already have the pre-punched holes.   
						

							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 onwards.
4 If your chassis was manufactured between 1980 and 
1991, it may be necessary to drill holes for the side 
lift jack. 
 There are two possible locations in which you should 
drill the holes, and the most suitable location for 
your chassis can be determined as follows. 
Position a (Fig 2/a)
If the criteria for 4a & 4b can be met then the holes should be 
drilled in position a, as illustrated at the top of Fig 2. 
4a The clearance from the rear of the wheel arch (Fig 2/item 1) 
to the centre of the spare wheel carrier mounting hole  
(Fig 2/item 2) must be a minimum of 95 mm.
4b  The lower face of the jack mounting bracket must hang 
below the lower face of the chassis member.
Position b (Fig 2/b)
If 4a & 4b cannot be met, the jack mounting brackets must be fit 
behind the spare wheel carrier, in holes drilled in position b, as 
illustrated at the bottom of Fig 2. Note the minimum clearance of 
55 mm from the centre of the spare wheel carrier mounting hole 
(Fig 2/item 3) to the centre of the hole for retro-fit set.
NOTE
Whether drilling in position a or b remember to apply corrosion 
protection (cold zinc galvanising spray) after drilling. 
CAUTION
Use in well ventilated area and follow instructions on tin.  
						

							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 (Fig 5/item 5) and torque up 
to 86 Nm.
Fig 6 Mounting the jack bracketsFig 5 Attaching the jack to the jack brackets
FOR LOW FRAME CHASSIS (158 MM)
9 Position the jack mounting bracket (Fig 6/item 1) with the short 
side on the chassis member (Fig 6/item 2) in such a way that 
the long side in positioned against the floor of the caravan.
10 Fit M13 washers (Fig 6/item 4) onto setscrews.
11 Insert M12x25 (Fig 6/item 4) and M12x45 (Fig 6/item 6)
setscrews from the outside.
12 Fit spacer (Fig 6/item 7) onto longer bolt before fitting to chassis.
13 Fit M12 self-locking nuts (Fig 6/item 5) and torque to 86 Nm.
11
22
3
3
6
7
4455  
						

							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 from storage bag (if applicable).
6 Extend spare wheel carrier (if applicable) to remove 
spare wheel.
7 If the ground is soft or likely to give way, put a plank or 
something similar under the base plate of the jack.
8 Slot the insert piece (Fig 7/item 1) into the jack mounting 
bracket (Fig 7/item 2) until it connects.
9 Holding the jack with one hand, turn the jack handle in a 
clockwise direction until the base plate reaches the ground.
NOTE
Wear gloves when winding up the jack to protect your hands.
10 Before operating jack, please check jack components are not 
catching on side overhang of caravan.
CAUTION
The base plate must sit flat on ground, vertical to chassis member . 
See fig 4. If these precautions are not observed; there is danger of 
damage to the vehicle jack or caravan.
11 Lift caravan by continuing to turn the handle in a clockwise 
direction (only lift the vehicle until the wheel is no longer in 
contact with the ground (Max. 375mm)).
2
2  
						

							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 put stress on the 
bracket and cause it to bend in use. 
HOW DO I STOP THE JACK SLIPPING?
If the ground is soft or likely to give way, put a plank or 
something similar under the base plate of the jack.
WHERE CAN I FIT THE JACK BRACKETS?
The jack brakets are only suitable for fitment in either of the 
locations as shown in Fig 2 on page 5.