AL-KO 2 Tonne Scissor Jack User Manual

							ASSEMBL
Y AND OPERA TING
INSTRUCTIONS FOR  AL-KO
2 T ONNE SCISSOR JACK
PLEASE ENSURE  YOU READ THESE INSTRUCTIONS CAREFULL Y,
BEFORE COMMENCING T O OPERATE THIS PRODUCT .WARNINGS:1) Never lie underneath a jacked-up vehicle, as this is highly dangerous and could result in serious injury or even death! 2)  The caravan  MUST be attached to the towing vehicle and the handbrake on both the towing
vehicle and caravan  MUST be applied.
3)  The  AL-KO Caravan Jack is not designed to be used as a permanent steady , but it can be
used as an aid to levelling the caravan, in additional to changing the wheel.4) In the case of manual towing vehicles, select 1st or reverse gear; with automatic towing vehicles, place the selector lever in the ‘P’ position. 5)  As an additional safety measure, chock the caravan wheel (back and front) on the opposite
side to the one to be changed.TECHNICAL  INFORMATION:1) This product is suit able for use with caravans with a Maximum Gross W eight of 2000 Kg
(1000 Kg st atic load).
2)  The jack bracket s can be attached to caravans fitted with  AL-KO Chassis, manufactured
from 1980 onwards (drilling of the chassis required but only in accordance with the instructions printed in this handbook). 3) Caravans fitted with  AL-KO Chassis manufactured af ter 1991, already have the pre-punched
holes in the chassis frame.KIT CONTENTS: 1 x Scissor jack 1 x Scissor Jack Handle
2 x Jack Bracket 4 x M13 Washer
2 x M12x50 Bolt 4 x M12x25 Bolt
4 x M12 Nylock Nut 2 x Spacer
1 x S torage bag (if applicable)
2.9 Holding the jack with one hand, turn thejack handle in a clockwise direction until thebase plate reaches the ground. NOTE :  Wear gloves when winding up the jack
(protection against hand injury).2.9.1  Before operating jack, please check jack component s are not catching on side overhang
of caravan. CAUTION :
The base plate must sit  flat on ground, vertical
to chassis member .  See fig 4.
If these precautions are not observed; there is danger of damage to the vehicle jack orcaravan. 2.10  Lif t caravan by continuing to turn the
handle in a clockwise direction (only lif t the
vehicle until the wheel is no longer in cont act
with the ground (Max. 340mm)). 3.  W ARNING
3.1  Never lie underneath a jacked-up vehicle, as this is dangerous and could result in seriousinjury .
4.  TECHNICAL  DATA Fig 6aAL-KO Kober Lt d
South W arwickshire Business Park
Kineton Road SouthamW arwickshire, CV47 0AL
01926 818500   01926 818562www .al-ko.co.uk
Fig 5
        Min.      Max.  Static
 Ground Clearance Lifting Ht.             Load
    A (mm) Fig 6a B (mm) Fig 6b  (Kg)
    1 10 340 1000
A
 Fig 6b
B
Part No. 1385039 Iss. 03/01       
						

							1. INSTALLATION OF JACK MOUNTING
BRACKETS 1.1  The jack mounting bracket s can be fitted to
both single and t andem axle caravans, on both
sides of the chassis, behind the axle(s).Note : Care should be t aken to ensure the
bracket s do not interfere with any other
equipment fitted in this area.1.2 On  AL-KO chassis manufactured from
1991 onwards, the mounting holes are already incorporated into the longitudinal chassismembers as st andard.
1.3  This jacking system can be fitted to most
AL-KO chassis manufactured from 1980onwards. 1.4 Drilling ‘C’ section chassis members (if necessary) Before you st art to drill the chassis members,
please note the following:1.4.1 When drilling in position “a” the clearance from the rear of the wheel arch(fig 1/item 1) to the centre of the sp are wheel
carrier mounting hole (fig 1/item 2) must be aminimum of 95 mm. 1.4.2  The lower face of the jack mounting
bracket must hang below the lower face of the chassis member .
1.4.3 If the criteria in a) and b) cannot be met,the jack mounting bracket s must be fitted
behind the sp are wheel carrier using holes as
shown in position “b”.  Note minimum clear-ance dimension of 55 mm from the centre ofthe sp are wheel carrier mounting hole (fig 1/
item 3) to the centre of the hole for retro-fit set.
1.5 Drilling according to position “a” (C Section Chassis Members) Frame Hole Spacing Hole Dia.
 Height    A (mm) B (mm)           C (mm)  D (mm)
    158 30        45     13
    215 40        55     131.6 Drilling according to position “b” (C Section Chassis Members) FrameHole Spacing Hole Dia.
 Height    A (mm)  E (mm)           F (mm)  D (mm)
    158 30        45     13
    215 40        55     131.7  Apply corrosion protection (cold zinc
galvanising spray -  CAUTION: use in well
ventilated area and follow instructions on tin). 1.8  Inst allation of jack mounting bracket s
on high frame chassis (215 mm)1.8.1 Position the jack mounting bracket (fig 2/ item1) with the long side on the chassismember (fig 2/item 2) lining up the holes inthe bracket, with those in the chassis mem-ber , positioning the short side of the bracket
against the floor of the caravan. 1.8.2  Insert set screws M12x25 (fig 2/item 3)
through both holes with bolt heads on out side
of chassis member .
1.8.3  Fit M13 washers (fig 2/item 4) onto set screws.
1.8.4  Fit the M12 self-locking nut s (fig 2/item
5) and torque up to 86 Nm.Fig 1 Fig 2
Fig 3
1.9 Inst allation of jack mounting bracket s
on low frame chassis (158 mm). 1.9.1 Position the jack mounting bracket (fig 3/ item 1) with the short side on the chassismember (fig 3/item 2) in such a way that thelong side in positioned against the floor of thecaravan. 1.9.2 Insert M12x25 (fig 3/item 3) and M12x45 (fig 3/item 6) set screws from the out side.
1.9.3 Fit sp acer (fig 3/item 7) onto longer bolt
before fitting to chassis. 1.9.4  Fit M13 washers (fig 3/item 4) onto set screws
1.9.5  Fit M12 self-locking nut s (fig 3/item 5)
and torque to 86 Nm. 2.  JACK OPERA
TING INSTRUCTIONS
2.1  Attach caravan to the towing vehicle and
apply the handbrake on both towing vehicleand caravan. 2.2 In the case of manual towing vehicles, select 1st or reverse gear; with automatictowing vehicles, place the selector lever in the‘P’ position. 2.3  As an additional safety measure chock the
caravan wheel (back and front) on the opposide to the one to be changed. 2.4 Clean jack mounting bracket s on the
caravan if necessary .
2.5  Remove jack from storage bag (if applica- ble). 2.6  Extend sp are wheel carrier (if applicable)
to remove sp are wheel.
2.7  If the ground is sof t or likely to giveway,
put a plank or something similar under the base plate of the jack. 2.8 Slot the insert piece (fig 4/item 1) into the jack mounting bracket (fig 4/item 2) until itconnect s.
Fig 4
2
1