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 removed from the trailer 
with the hand-brake applied.
CAUTION
Please note when parking the caravan/trailer, the wheelbrake 
auto reverse mechanism will allow the caravan/trailer to 
travel backwards for approximately 25 cm (please allow 
sufficient clearance when parking).    
OPERATION
AL-KO overrun devices are a mechanical type, using a  
hydraulic damper.
COUPLING UP
Manoeuvre towing vehicle or trailer to coupling point.
Overrun devices fitted with 50 mm coupling head:
- Fully open coupling head handle and secure hitch onto  
the towball. 
- Thread the breakaway cable through the breakaway cable guide 
provided (Fig 39) and connect it to attachment point provided 
on towing bracket (Fig 38). Please refer to ‘Braked Trailers Use 
of Breakaway Cables’ for further details.
Fig 38 Breakaway Cables
OVERRUN DEVICES  
						

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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 straight as possible and not  
be restricted.
4. Ensure the cable is long enough to allow for cornering 
and will not become taut or snag during use, as this 
could result in the handbrake operating whilst towing.
Please refer to ‘Braked Trailers Use of Breakaway Cables’ 
information sheet, supplied with your caravan/trailer.
Fig 39 Breakaway Cable Guides
Fig 40 DO NOT wrap breakaway cable around jockey wheel  
						

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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 will be automatically re-applied should the 
vehicle start to roll backwards.
CAUTION
If the handbrake is not fully applied as detailed above,  
there is a danger that the caravan could roll backwards.
TO RELEASE
Press the handbrake down until it is parallel with the fairing 
cover to ensure that the brake is correctly disengaged.
OVERRUN DEVICES
Fig 41 Handbrake lever operation
HANDBRAKE OFFHANDBRAKE ON  
						

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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 automatically re-applied should the vehicle start 
to roll backwards.
CAUTION
If the handbrake is not fully applied as detailed above, there is 
a danger that the caravan could roll backwards.
TO RELEASE
Press the handbrake down until it is parallel with the fairing 
cover to ensure that the brake is correctly disengaged.
OVERRUN DEVICES
SPARE PARTS
Spare parts are safety critical parts! For this reason when fitting 
spare parts in our products we recommend the use of original 
AL-KO parts or those parts that we have explicitly approved. The 
reliability, safety and suitability of parts designed especially for our\
 
products, has been determined using a special test procedure. In 
spite of constantly monitoring the market we are unable to assess 
or vouch for other products. 
If repair work or servicing is required, AL-KO have a large network 
of AL-KO service stations throughout Europe. To establish the 
correct spare parts required you should always quote the model 
and type of overrun device in question along with the ETI No. 
which is stamped into the overrun device housing. The ETI 
number for the Euro Overrun can be found on the handbrake lever.   
						

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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 following precautions should be taken: 
- Ensure there is adequate air circulation when storing hot
  dip-galvanized parts. 
- After winter journeys it is recommended that surfaces are 
washed with clean water. 
For Troubleshooting & Fault Finding see Table 3 on page 46.
OVERRUN DEVICES
AL-KO
  
						

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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 
and works in a similar way to ESP on some tow cars.  ATC 
monitors for instability and takes the necessary action to prevent 
the caravan from snaking by gently applying the caravan brakes, 
extending the distance between the tow car and caravan and 
bringing the caravan back into line.  ATC has been fitted as 
standard on a wide range of caravans since its launch in 2007 and 
is also available for retrofit. 
For more information on how ATC works, please visit our website 
at www.al-ko.co.uk. 
For a troubleshooting guide for ATC please see Table 4 on page 47.  
						

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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 
increase the security provided by the wheel lock, the lozenge 
is designed specifically to suit the alloy aperture and is 
therefore wheel rim specific. 
For more information about 
the AL-KO Secure Wheel 
Lock and to identify 
which wheel lock kit 
you need for your 
caravan, please visit 
our website at 
www.al-ko.co.uk.
FITTING AL-KO SECURE
1. We recommend the use of a Side Lift Jack for easier fitting 
and removal of AL-KO Secure. Lift the caravan slightly to allow 
the wheel to rotate freely. Align the wheel so that the receiver 
can be seen in the centre of the rim opening. Do not use the 
rim opening in which the tyre valve is fitted.
2. Unscrew the Plastic Cap from the receiver and store in the 
Lock Kit Box. (When AL-KO Secure is not in use, always screw 
the Plastic Cap in place).
3. Insert the Locking Bolt into the Rim Specific Insert.
4. Insert the Locking Bolt Socket Key.
5. Line up the Locking Bolts and assembly with the receiver.
6. HAND TIGHTEN the Locking Wheel Bolt using the Wheel 
Spanner provided as shown, or a Torque Wrench.
7. Remove the Locking Bolt Socket Key.
8. Insert Barrel Lock.
9. Push the key fully into the lock and turn to operate the lock 
and then remove the key.
10. The AL-KO Secure is now fitted.   
						

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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 accommodate retro-fit brackets 
for the Octagon Shock Absorbers. (See Accessory Price 
List). Delta Axles have Shock Absorbers fitted as standard 
which MUST NOT BE REMOVED. 
ACCESSORIES
STABILISERS
AL-KO overruns can be fitted with a range of AL-KO Stabiliser 
devices (if not already fitted as standard), dependent on the 
maximum gross weight of the caravan. AL-KO stabilisers operate 
on a friction type basis, whereby friction pads grip onto a Dry, 
Grease Free Towball. It is important to note that the AKS range of 
stabilisers are suitable for use with swan neck, fixed or detachable 
type towbars or the special AL-KO Extended Neck Bolt-On Towball. 
We do not approve the use of any other bolt-on type towball, other 
than the AL-KO Towball. Failure to use the correct towball may 
result in product failure and will invalid your warranty. 
The AKS range is available in two different models, the AKS 1300 
suitable for caravans with a maximum gross weight of 1360 Kg 
and the AKS 3004 which is suitable for caravans with a maximum 
gross weight up to 3000 Kg. 
Each Stabiliser can also be retro-fitted with an AL-KO Security 
Device and Safety ball, to ensure maximum theft deterrent (please 
see our accessory price list for further details). All ‘Red’ coloured 
AL-KO Security Devices have full TUV and Sold Secure Approvals 
and are available from good dealers or direct at www.al-ko.co.uk.