AL-KO Caravan Chassis Handbook User Manual

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SERVICING & CLEANING
Lubrication Points (Fig 37)
Clean Towball
Lightly grease or oil ball socket, joints and bearing points as 
appropriate. General purpose grease to DIN 6=51825 KTA 3K.
For Troubleshooting and Fault Finding see Table 2 on page 45.
Fig 37 Lubrication points
COUPLING TYPES AK7, AK10/2 OR AK252  

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In the importance of safety, please familiarise yourself with 
the operation of this overrun device BEFORE using your 
caravan/trailer. 
SAFETY PRECAUTIONS
When parking your tow vehicle and caravan/trailer on 
site, you must apply the caravan handbrake. If the unit is 
parked but disconnected from the tow vehicle, it is strongly 
recommended that each wheel is chocked using AL-KO or 
suitable wheel chocks.
If a ‘detachable’ type drawbar is fitted (as with catering 
trailers), the drawbar must not be...

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OVERRUN DEVICES
CAUTION
The breakaway cable operates the handbrake (emergency 
brake), in the event of the caravan/trailer becoming detached 
from the towing vehicle during towing. For this emergency 
brake to work correctly, it is absolutely essential that the 
following points are observed:
1. The breakaway cable MUST run through the breakaway 
cable guide.
2. The breakaway cable MUST NOT be wrapped around the 
jockey wheel, as this disables the emergency brake (Fig 40).
3. The cable MUST run as...

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EURO-OVERRUN DEVICES FITTED WITH  
AKS 3004 STABILISER
Fully retract Jockey Wheel inner tube so that it locks against 
Jockey Wheel outer tube.
Slacken Jockey Wheel Clamp handle and raise complete 
assembly through cutout in body to its highest position 
(ensure it doesn’t come into contact with the brake rod 
assembly), fully tighten Jockey Wheel Clamp handle to 
ensure the Jockey Wheel is firmly held in position. 
EURO HANDBRAKE
Ensure the handbrake is fully applied to ensure that the 
wheel brakes...

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EURO-OVERRUN DEVICE FITTED WITH 
AK160 OR AK300 COUPLING HEAD
Connect trailer electric plug controlling lights and indicators 
etc. into towing vehicle socket.
Wind the jockey wheel up fully and clamp securely in position, 
ensuring that it does not foul the brake rod or breakaway 
cable. Remove wheel chocks if fitted and stow safely.
CAUTION
Failure to comply with this could result in the brakes overheating.
EURO HANDBRAKE
Ensure the handbrake is fully applied to ensure that the wheel 
brakes will be...

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Fig 42 Lubricate/grease the parts indicated.
SERVICING
Every 10,000 - 15,000 km or every 12 months: 
Lubricate/grease all sliding and moving parts of the overrun 
device as show in Fig 42.
Recommended lubricant
General purpose grease to DIN 51825 KTA 3KA. 
Servicing and care of hot dip galvanized parts
The formation of white rust is only a surface coating and 
has no adverse effect on the anti-corrosion properties of 
galvanising. To minimise the potential for the formation of 
white rust the...

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AL-KO AMS MAMMUT
Mammut is the only fully integrated caravan manoeuvring 
system specifically designed to suit the AL-KO Chassis. 
Since April 2010,  AL-KO caravan chassis members have 
been manufactured with fixing hole positions for the  
AL-KO AMS Mammut Manoeuvring system pre-punched into 
the chassis. 
For more information about the AL-KO Mammut, please visit 
our website at www.al-ko.co.uk.
ACCESSORIES
AL-KO ATC TRAILER CONTROL
ATC Trailer Control is an electronic braking device for caravans...

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ACCESSORIES
AL-KO SECURE
AL-KO Secure is the Sold Secure Diamond Standard Wheel 
Lock for caravans with alloy wheels. Years of research and 
development have been undertaken to ensure that AL-KO 
Secure can withstand the maximum number of attack 
methods, and even deter thieves from approaching your 
caravan in the first place. 
Most caravans have the AL-KO Receiver fitted to the wheel 
drum as standard and some manufacturers include the 
wheel lock kit with the caravan at the time of purchase.  To...

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ACCESSORIES
Fig 43 Fitting AL-KO Secure Wheel Lock
1
6
2
7
3
8
4
9
5
10  

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CORNER STEADIES
Corner Steadies are as stated, for the purpose of steadying 
the caravan corners. They are NOT JACKS AND SHOULD 
NEVER BE USED AS SUCH. The screw and pivot pins 
should be lubricated periodically to ensure their satisfactory 
operation. (See also Jack Operation). 
SHOCK ABSORBERS
All AL-KO chassis have pre-punched holes to accommodate 
Shock Absorbers, in front of the axle. On the Euro-Axle 
System, axle swing arms have a removable rectangular 
plastic cap exposing a slot to...