AL-KO Caravan Chassis Handbook User Manual

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

2
GENERAL INFORMATION
The AL-KO lightweight chassis has been perfected by 
many years of research and development, supported by an 
exhaustive test programme. 
Manufactured from high quality steel, the chassis has extra 
deep sections to provide strength at points of maximum 
stress. Large elongated holes are punched in the longitudinal 
chassis members, to reduce weight to a minimum. Each hole 
incorporates a return flange to maintain the required strength 
and provide rigidity in the extra deep...

3
HOT DIP GALVANISATION
The chassis is Hot Dipped Galvanised. This is regarded as one 
of the best forms of corrosion protection. It does however 
require minimal maintenance in certain circumstances. 
When new, the chassis is of a bright and shiny appearance. 
As the galvanising cures during the initial 2/ 3 month 
period, this will gradually change to a medium/dark grey 
colour. This grey finish is the ideal, giving the correct 
protective coating. During this curing period the surface 
should be...

4
DRILLING OR WELDING OF 
PARTS OR ACCESSORIES
The chassis is designed and built to precise tolerances and 
must not be drilled or welded (except in accordance with 
certain AL-KO Accessory Operating Instructions). Failure to 
comply will invalidate all warranties.
INDEPENDENT SUSPENSION
The AL-KO rubber suspension is designed and developed 
to suit all types of road conditions and is maintenance free. 
Three rubber elements are contained within a hexagonal axle 
tube. These provide suspension and have...

5
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. 
Maximum gross weight, as advised by the caravan 
manufacturer, must not be exceeded without approval 
from AL-KO. 
Maximum loading is defined as the difference between 
ex-works weight and the permitted total weight. 
Attention should be paid to the legal regulations 
regarding the permitted pressure exerted by the towbar 
on the towed unit.
AL-KO...

6
SAFETY PRECAUTIONS
No welding is permitted on AL-KO Axles. 
It is important that the wheel and hub/brake drum are 
compatible. This means that the PCD, wheelbolts and inset 
must all be compatible with both the hub/brake drum and 
the wheel rim. Particular attention must be paid to the 
recommended torque figures for the wheelbolts (page 16).
The axle type details shown on axle type plates must not be 
obscured or made illegible by application of any additional 
surface finish.
OPERATING INSTRUCTIONS...

7
MAINTENANCE AND CLEANING
Maintenance of Euro-Plus/Euro- Compact and Euro-Delta.
The above semi-trailing axles come fitted with maintenance 
free wheel bearings (greased and sealed for life) and no 
adjustment is necessary.
NOTE
The hub bearing is not protected against water ingress. 
Check wheel brake linings for wear every 10,000 kilometres 
or every 12 months via the inspection hole (Fig 6/Item 1).
Adjust if necessary. Where continuous travel in hilly regions 
or high mileage is experienced, earlier...

8
‘STANDARD AXLE’ MAINTENANCE 
(TAPER ROLLER BEARINGS)
After 1500 km or 6 months
Have the axial play of the hub bearing checked and adjusted 
if necessary. 
After 10,000 km or 12 months
Check quantity and quality of grease, renew if necessary. 
With boat trailers which are driven into fresh/salt water, the 
hub bearing should be regreased shortly after contact with 
the water (with the exception of waterproof hubs). Check the 
wear of the wheel brake linings every 10,000 km or every 
12 months through...

9
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. These provide suspension and have inherent 
damping characteristics.
Figs 8, 9 & 10 show the deformation of the rubber elements 
at the extremes of suspension movement.
The axle is designed to ride with the suspension drop arm at, 
or slightly below, the horizontal position.
For Trouble Shooting & Fault Finding...

10
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...