AL-KO Caravan Chassis Handbook User Manual

41
ROAD WHEELS
In most instances the road wheels and tyres are supplied 
by the Caravan Manufacturer. The condition of wheels and 
tyres should be checked regularly, particularly for distortion 
of flanges and the wheel dish. Wheels that are damaged or 
distorted, or have wheel bolt seatings cracked or deformed 
must not be repaired or used in service - these must be 
replaced.
IMPORTANT NOTE
Standard AL-KO caravan chassis use M12 bolts. These must 
always only be tightened to the correct torque setting...

42
JACKS
The Corner Steadies should never be used to jack up the 
caravan. When jacking becomes necessary use the AL-KO 
Side Lift Jack or 2-Tonne Jack system.
NOTE
It is essential that the car and caravan are hitched together 
before commencing jacking. 
All AL-KO chassis from 1992 onwards have 2 
holes punched in the chassis members, each side 
(rear of the axle); to accept the brackets for the 
Jack(s). (See Accessory Price List). Corner 
Steadies may be used for stability ONLY, 
when the caravan is...

43
Caravan Make
 _____________________________________________
Caravan Model 
 ____________________________________________
Year of Manufacture 
 ________________________________________
Tyre Size (eg R195 13) 
 ______________________________________
Dimension (X) in mm (taken from the following diagram) 
 ___________
Hole Cluster forSpare Wheel Carrier
275
ca. 700
X
RECORD YOUR SPARE WHEEL CARRIER INFORMATION HERE
ACCESSORIES
SPARE WHEEL CARRIERS
Each caravan has a set of punched holes in the chassis...

44
TABLE 1 AXLES
FAULTCAUSEREMEDY
POOR BRAKINGLinings worn or damaged.
Brake Linings not bedded in.
Brake set up incorrect.
Replace Brake Linings.
Will pass after braking a few times.
Reset Brakes as pages 10-12 & ensure system is lubricated.
DIFFICULTY IN REVERSINGBraking system set too tightly.
Auto-Reverse lever too stiff.
Reset Brakes as page pages 10-12.
Lubricate and free off Reverse Lever.
BRAKES OVERHEATINGIncorrect setting.
Braking system not fully released.
Overrun lever stuck.
Damage or...

45
TABLE 2 COUPLING HEADS
FAULTCAUSEREMEDY
COUPLING DOES NOT 
ENGAGE ONTO BALL
Ball diameter too large.
Ball could be damaged or deformed. 
Coupling head dirty or defective. 
Change ball to correct size.
Fit new ball.
Clean & Lubricate coupling and replace if necessary.
DIFFICULTY IN UNCOUPLINGBall damaged or deformed. 
Coupling damaged or deformed. 
Coupling head under pressure from damper.
Fit new ball.
Replace if necessary.
Pull forward a few inches to relieve pressure.
BRAKES OVERHEATINGIncorrect...

46
TABLE 3 OVERRUN DEVICES
FAULTCAUSEREMEDY
POOR BRAKINGOverrun shaft tight.
Overrun shaft corroded. 
Body housing damaged.
Lubricate overrun shaft and 
replace any damaged parts. 
BRAKES OVERHEATING 
DURING TOWING
Handbrake not fully released.
Braking system incorrectly set. 
Incorrect attachment of breakaway cable.
Release handbrake.
Reset brakes as pages 10-12.
Ensure correct attachment as listed on pages 32/33 or 
refer to Braked Trailers Use of Breakaway Cables sheet.
HANDBRAKE FORCE LOWDefective...

47
TABLE 4 ATC
LED COLOURAT CDIAGNOSISWHAT TO DOOUTCOMESTATUS
GREENATC ActiveEverything ok
GREEN 
FLASHING
ATC ActiveSelf test 
incomplete
Drive forward to detect movement to 
complete self test and re check LED
Green 
(Constant)
Ready for journey
REDATC 
Inactive
Possible to
continue  
journey
Remove 12S or 13 Pin plug and wait 
5 seconds.
 
Reconnect plug.
Green
Red
Ready for journey
ATC Error logfile memory exceeded. Caravan 
can be towed, but ATC will not function.* 
RED 
FLASHING
ATC has 
detected...

QUALITY FOR LIFE
AL-KO Kober Ltd, South Warwickshire Business Park, Kineton Road, Southam, Warwickshire, CV47 OAL
E-Mail: [email protected] www.AL-KO.co.uk Tel: 01926 818500
Due to a policy of continuous product improvement, AL-KO reserves the right to change technical specifications. Part No. 1386853 Iss. 8 08/11
CARAVAN CHASSIS
HANDBOOK FOR VEHICLES ON 
THE AL-KO CARAVAN CHASSIS