AL-KO AMC Handbook User Manual

							AMC CHASSIS
HANDBOOK FOR VEHICLES 
ON THE AL-KO AMC CHASSIS   
						

							Warranty 1
AL-KO Kober European Offices   3
Worldwide Leaders in Chassis Technology  4
AL-KO AMC Chassis Service Schedule  5
Introduction - AL-KO AMC Single Axle Chassis  7
Introduction - AL-KO AMC Tandem Axle Chassis  8
Towing with a Trailer  9
Wheel and Tyre Information  10
Suggested Tyre Pressures  11
Tyre Pressure and Tread Depth Information  12Changing the Wheel 
13
Workshop Jack/Vehicle Lift  15
Towing Information  15
AL-KO AMC Suspension, Steering & Braking Systems  16
Model Overview - AL-KO AMC Peugeot/Citroen/Fiat X250  17 
(Single/Tandem Axle)
Turning Circle  18
Vehicle Characteristics and Maintenance  19
AL-KO AMC - Partners for Service & Accessories in the UK  21
AL-KO AMC - Partners for Service & Accessories in Europe  23
AL-KO AMC Complementary Products  41
DEAR CUSTOMER,
YOUR VEHICLE IS FITTED WITH AN AMC-CHASSIS CONVERSION SUPPLIED AND FITTED BY 
AL-KO KOBER LIMITED. AS A RESULT THE BASE VEHICLE HAS UNDERGONE CERTAIN CHANGES.  
The purpose of this manual is to familiarise you with your vehicle. Please read the instructions 
printed in it carefully, as proper, regular care and maintenance will ensure that your vehicle keeps 
its value - in many cases regular maintenance is also a prerequisite in \
respect of warranty claims.
May we wish you a safe journey - wherever you may travel.
AL-KO Kober Limited
The User Manual and the Maintenance Instructions supplied by 
the manufacturer of the base vehicle, continue to be applicable.
The conditions laid down by the base vehicle manufacturer are 
only met if the correct spares are used;  the manufacturer‘s 
recommended spares are your guarantee that the necessary 
requirements are met.
Maintenance work that may be required on the AL-KO rear axle 
(see page 19 for more details): Lubrication must be carried out 
every 20,000 Km or once a year, which ever comes sooner.
Note: Country specific regulations must be taken into consideration.
CONTENTS
WARRANTY CONDITIONS
21   
						

							Since 1979, AL-KO has been at the forefront of leisure and 
commercial vehicle chassis conversions. Over 140,000 approved 
conversions have been commissioned throughout our manufacturing 
facilities in England, Germany, France and Italy. 
Our successes have now led us into global markets, where we can 
continue our passion for engineering excellence, innovative products 
of the highest qualit y and safet y standards.
WORLDWIDE LEADERS IN CHASSIS TECHNOLOGY
AL-KO KOBER EUROPEAN OFFICES
 AL-KO Kober Ltd. 
South Warwickshire,  
Business Park, 
CV47 OAL Southam
Tel:  0044 (0)1926 818500 
Fax: 0044 (0)1926 818562 
  AL-KO Kober Ges.Mbh 
Zellbergeben 23, 
6280 Zell am Ziller
Tel
: 0043-5282-2651-700 
Fax
: 0043-5282-2651-712 
  AL-KO Kober B.V. 
Noorderlaan 98, 
2030 Antwerpen
Tel
:. 0032-35436110 
Fax
: 0032-35436129 
  AL-KO S.A. 
Zone industrielle de Branges, 
71501 Louhans Cedex 
Tel
: 0033-385-7635-00   
Fax
: 0033-385-7635-81 
  AL-KO Kober GmbH 
Ichenhauser Straße 14, 
D-89359 Kötz
Tel: (0049) 0 82 21 - 97-0 
Fax: (0049) 0 82 21 - 97-5 60 
  AL-KO Kober GmbH 
Pustertalerstraße 9,   
39030 Vintl/Vandoies (BZ) 
Tel: 0039-0472-868711 
Fax: 0039-0472-868719   
AL-KO Kober B.V. 
Diamantstraat 33, 
7554 TA Hengelo
Tel: 0031-74 2559955 
Fax: 0031-74 2425615 
  AL-KO Kober NUF 
Postboks 44, 
1401 Ski
Tel: 0047-648874188 
  AL-KO Kober SP.Z.O.O. 
ul.Bukowska 10,   
62-081 Przezmierowo
Tel: 0048 61 814 19 60 
Fax: 0048 61 816 19 80   
AL-KO ESPAÑA, S.A 
Ctra. Logroño, Km.13, 
Pol.Ind. El Aguila 
50.180 Utebo (Zaragoza)
Tel: 0034 976-462280 
Fax: 0034 976-785241 
[email protected] 
  AL-KO Kober AB 
Trankärrsgatan 15, 
42537 Hisings-Kärra, Göteborg 
Tel: 0046 31 57 08 50 
  AL-KO Kober AG 
Industriestraße 176,   
8957 Spreitenbach 
Tel: 0041-56-418 31 50 
Fax: 0041-56-418 31 60
43  
						

							KILOMETRESKILOMETRES
DATE DATE
SPECIALIST WORKSHOP
SPECIALIST WORKSHOP
SIGNATURE SIGNATURE
AL-KO AMC CHASSIS SERVICE SCHEDULE
65    
						

							INTRODUCTION:   
AL-KO AMC SINGLE  
AXLE CHASSIS
DESCRIPTION OF 
CONVERSION
The orginal rear frame has been 
replaced by a hot-dip galvanised 
AL-KO lightweight chassis.   
This chassis is connected to 
the cab by means of a special 
bracket assembly.
The AL-KO AMC Chassis and 
AL-KO Axle with torsion bar 
suspension is fitted in place 
of the original equipment 
manufacturers chassis, axle  
and leaf spring suspension.  
The AL-KO Air Suspension 
axle* can be fitted as an 
optional extra and integrated 
into the chassis frame  
side member.
*Dependent on version: must be 
specified at time of order.
INTRODUCTION: 
AL-KO AMC TANDEM 
AXLE CHASSIS
DESCRIPTION OF 
CONVERSION
The original rear frame has 
been replaced by a hot-dip 
galvanised AL-KO lightweight 
chassis.   
This chassis is connected to 
the cab by means of a special 
bracket assembly.
The AL-KO AMC Chassis and 
AL-KO Axle with torsion bar 
suspension is fitted in place 
of the original equipment 
manufacturers chassis, axle 
and leaf spring suspension.  
The AL-KO Air Suspension 
axle* can be fitted as an 
optional extra and integrated 
into the chassis frame  
side member.
*Dependent on version: must be 
specified at time of order.
87 
						

							DRIVING INFORMATION/TRAILER USE
To achieve optimum results when towing a trailer, please observe 
the following points:
Refer to base vehicle handbook for towing limits.
 
-
Do not tow with the vehicle empty and the trailer loaded.    
-
  If this is unavoidable, please drive slowly to allow for the      
  unfavourable weight distribution.
Always locate heavy objects close to the axle and secure.
 
-
Maximum speed limit is 60 mph. 
-
Ensure tyre pressure of vehicle is set at fully loaded setting. 
-
Use low gear when travelling downhill to avoid constant braking. 
-
TOWING WITH A TRAILER
GENERAL NOTES
Vehicles with an AL-KO Chassis are approved for use with a trailer.
TECHNICAL REQUIREMENTS
If the vehicle has been factory fitted with a tow bar, then all 
technical and legal requirements for operation have been taken into 
consideration.
If retrofitting a tow bar, use only ones that have been approved by 
AL-KO and ensure it is fitted correctly.  
When ordering a tow bar assembly, always indicate the vehicle 
type and the chassis number.  
You should ensure that the maximum train weight as shown in 
the registration documents is not exceeded.
Towing a trailer also reduces the maximum gradient capacity of 
the vehicle.
Suitable rear view mirrors, in accordance with road traffic 
regulations are to be fitted.
The electrical functions and the electrical circuit  diagram will be found in the operating instructions supplied by the base vehicle manufacturer.
GENERAL NOTES
We recommend using camping tyres for all mobile homes. 
-
Tyre pressures should always be checked with cold tyres. Do not   
-
  forget to check the spare wheel!
In order to make sure that tyres wear uniformly, we recommend  
 
-
  rotation of the tyres between front and rear axle every 6,000 - 9,000  
  miles. Change tyres diagonally.
On tandem axle conversions, tyre wear may increase slightly.
 
-
Never travel with the vehicle overloaded - this can cause serious   
-
  damage to the vehicle and to the wheels and tyres.
WHEEL AND TYRE INFORMATION
109 
						

							TYRE PRESSURE
The correct tyre pressure not only affects the life of the tyre, it also\
 
affects vehicle safety, as it changes the behaviour of the vehicle on th\
e 
road.
The pressure of every tyre - including the spare - should be checked 
regularly, and especially before you undertake long journeys.
Incorrect tyre pressure causes irregular tyre wear.  
Please see illustration.   
TREAD DEPTH
The tread depth should be at least 3mm, although legislation only 
specifies 1.6mm minimum tread. Signs of wear in the tread (see arrow 
on diagram) at 1.6mm depth, signal that the European-wide legal limit 
has been reached.
The lower the depth of tread, the greater the risk of skidding.  For thi\
s 
reason we recommend that the tyre is replaced when the remaining 
tread has been reduced to 3mm.  
SNOW CHAINS
Snow chains must only be fitted to the front tyres (drive wheels) 
according to individual country regulations. Please also follow the 
instructions for use provided with the base vehicle. A 
 Correct tyre pressure: Uniform tread wear
B  Tyre pressure to low: Excess wear   
  at the shoulder
C  Excessive tyre pressure:    
  Increased wear at the    
  centre of the tread
  A  B C
MODEL BASIC VEHICLE  TYRES  TWIN AXLE  TRIPLE AXLE        
   Front Rear  Front Rear 
AMC 35L    215/70 R15C 4,1 4,5
  35 Light  225/70 R15C  4,1 4,5
AMC 37L    215/70 R15CP 5,0 5,5
AMC 35H  35 Heavy  215/75 R16C  4,5 5,0
AMC 38H    225/75 R16C 4,5 5,0
AMC 35HA  40 Heavy  225/75 R16CP  5,5 5,5
AMC 40H
AMC 42H     
AMC 45HT    215/75 R16C     4,5 3,8
  40 Heavy  225/75 R16C      4,5 3,8
AMC 50HT    225/75 R16CP     5,5 3,8
SUGGESTED TYRE PRESSURES (COLD) (BARS) TYRE PRESSURE AND TREAD DEPTH INFORMATION
1211   
						

							GENERAL NOTES
Do not use the jack for loads that are greater than the load given on 
the jack rating plate.
Ensure the vehicle is on a level, firm surface. 
CHANGING FRONT WHEELS
Select first or reverse gear (or P on automatic transmissions).   
Apply the handbrake and chock the remaining wheel.  
CHANGING REAR WHEELS
Select First or Reverse gear (or P on automatic transmissions). Do 
not apply the handbrake but fit chocks under the remaining wheels.
Onboard tools and chocks are usually located underneath the 
driver‘s seat.
SPARE WHEEL LOCATION
The spare wheel is normally located at the rear under the vehicle floor. 
If the vehicle is fitted with a special body, you may find the spare 
wheel is installed in a special compartment. Please read base vehicle 
manufacturers handbook in respect of wheel removal.  
SPARE WHEEL REMOVAL
Use a ratchet spanner and an extension to unscrew the bolts from the 
spare wheel carrier. Insert the wheel brace in the seat provided, diseng\
age 
the wheel carrier and then lower the spare wheel to the floor.
Remove the spare wheel from the carrier.
CHANGING THE WHEEL
1. Slacken wheel nuts by approximately one revolution.
2. Position the jack in the hole provided as shown on the adjacent image\
s.
 Vehicle Jacking Points:
  Rear - the jacking points are located in the shock absorber mounts  
  on the left and right, in front of the axle.
  For tandem axle vehicles always place the jack on the shock    
  absorber mounts, on the second axle.
3. Please note: If the jack is not positioned where indicated, then this\
  
  may lead to vehicle damage!
4. If the ground is soft, position the jack on a solid support.
5. After changing the wheel: retighten the wheel nuts cross-wise.
  Torque:   15 inch tyres = 160Nm
    16 inch tyres = 180Nm
6. Insert the wheel which has been in the spare wheel carrier. 
7. Engage the spare wheel carrier with the wheel brace.  
8. Lock the spare wheel carrier using the two bolts provided.
9. Now stow the jack and the tool set back under the driver‘s seat.
10. Check the Tyre Pressures (see pages 11 & 12).
CHANGING THE WHEEL  
FrontRear
Using the wheel brace 
makes it easier to 
disengage and re-engage 
the spare wheel carrier.ATTENTION
The vehicle jack must only be used when changing the wheel.  
On no account should it be used for repair work under the vehicle.
Never jack-up the vehicle by the rear axle, front axle, oil sump  
or transmission.
When working on a loaded vehicle, use a suitable hydraulic lift  
platform or work in an inspection pit.
Always consider the centre of gravity of the vehicle.
Before driving onto platforms, check for low lying vehicle parts.
1413 
						

							GENERAL NOTES
When a workshop jack is used, the vehicle must not be loaded and 
it must be lifted at the points provided on the vehicle sides which 
are illustrated on page 14.
To prevent damage, a suitable rubber interlayer should be used!
When working under the vehicle, the vehicle must be supported 
with suitable stands or placed on a vehicle lift.
TOWING
The vehicle is provided with towing eyes at the front right below the 
bumper and at the rear left, at the longitudinal frame member (this 
rear towing eye is not standard on motor homes).
Only attach a tow rope or rigid towbar to these brackets.
FRONT WHEEL SUSPENSION
Information on this section can be found in the Operating Instructions 
of the base vehicle manufacturers. 
REAR WHEEL SUSPENSION
Independent suspension: 
AL-KO trailing link torsion bar suspension axle with linear 
indentification shock absorber.
Optional - fully automatic and electronically controlled air suspension 
(must be specified at time of vehicle build).  
STEERING
Information on this section can be found in the Operating Instructions 
of the base vehicle manufacturers. 
BRAKING SYSTEM
Hydraulic dual-circuit system: 
Front: Disc brake.  
Rear: Disc brake.
ABS only  
Mechanical handbrake operational on rear wheels.
WORKSHOP JACK/VEHICLE LIFT  TOWING INFORMATION AL-KO AMC SUSPENSION, STEERING 
AND BRAKING SYSTEMS
Further towing information can be found in the 
operating instructions for the base vehicle.
1615 
						

							MODEL BASE   PERMISSIBLE  PERMISSABLE  PERMISSABLE PERMISSABLE MAX PERMISSABLE
  VEHICLE  WEIGHT  FRONT AXLE LOAD  REAR AXLE LOAD TRAILER LOAD GROSS TRAIN WEIGHT
   (kg)  (kg)  (kg) (kg)  (kg)
AMC 33L  33 Light  3300  1750  1900 2000 5300
AMC 35LB  33 Light  3500  1750  1900 2000 5300
AMC 35LH  33 Light  3500  1750  2000 2000 5300
AMC 35L  35 Light  3500  1850  2000 2000 5500
AMC 37L   35 Light  3700  1850  2000 2000
1) 5500
AMC 35H  35 Heavy  3500  2100  2400 2000 5500
AMC 38H  35 Heavy  3850  2100  2400 2000
1) 5500
AMC 35HA  40 Heavy  3500  2100  2400 2000 5500
AMC 40H  40 Heavy  4000  2100  2400 2000
1) 5500
AMC 42H   40 Heavy  4250  2100  2400 2000
1) 5500
AMC 45HT  40 Heavy  4500  2100  1500/1500 1600
1) 6000
AMC 50HT   40 Heavy  5000  2100  1500/1500 1600
1) 6000
1) Observe permissible car and trailer weights
MODEL OVERVIEW - AL-KO AMC PEUGEOT/CITROEN/FIAT X250  
(SINGLE/TANDEM AXLE) TURNING CIRCLE 
(BETWEEN PAVEMENTS)
SINGLE AXLE 
                   TANDEM AXLE 
WHEELBASE  TURNING CIRCLE  WHEELBASE TURNING CIRCLE
 
(mm)  (m)  (mm) 
 (m)
3000 11.1  3450 14.1
3200  11.7  3600 14.6
3450  12.5  3800 15.2
3600  13.2  4000 15.8
3800  13.5  4200 16.4
4000  14.3  4400 17.0
4200  14.9  4700 17.6
4400  15.5
4600  16.1
1817