AL-KO Caravan Chassis Handbook User Manual
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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 as recommended by the vehicle manufacturer. They should be tightened in sequence, North, South, East, West and never clock or anti-clockwise. Always use a calibrated torque wrench and do not use a corner steady brace or power or electric wrench. It is as dangerous to overtighten wheel bolts as it is to not tighten them sufficiently. IMPORTANT NOTE The torque settings should be re-checked after 50 km. If other wheel bolts are used please ensure the torque settings are as follows: M10 - 49 Nm (36 ft. lb) M14 - 135 Nm (99.5 ft. lb) M16 - 210 Nm (155 ft. lb) SPECIAL NOTE - ALUMINIUM WHEELS The standard M12 x 1.5 60o Conical Wheel bolts are NOT SUITABLE for aluminium wheel rims. Special wheel bolts should be used. TYRES The legal requirements for tread depth on motor vehicles, also applies to caravan and trailers. ACCESSORIES
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 in the jacked position. The caravan should never be lifted by jacking up under the chassis member. If working under the caravan in an elevated position, axle stands must be used for safety. Wheel chocks for the opposite wheel(s) are also advisable. ACCESSORIES JOCKEY WHEEL All AL-KO Jockey Wheels are removable and stow neatly on the A-Frame when the caravan is being towed. AL-KO Jockey Wheels are hot dipped galvanised preventing corrosion and ensuring durability. They incorporate a thrust bearing which greatly reduces the effort required to manoeuvre the caravan. MAINTENANCE Lubricate screw thread and wheel spindle periodically. THE PREMIUM JOCKEY WHEEL The Premium Jockey Wheel is designed for use with motorised caravan movers and features extra wide, grooved rubber tyres, swing arm suspension and an integrated load indicator to gauge the noseweight of the caravan. This saves time and effort preparing for your journey. For more information about any of the AL-KO Jockey Wheels, please visit our website at www.al-ko.co.uk.
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 member to facilitate the fitting of a spare wheel carrier. The assembly is of a strong, lightweight construction and zinc plated for all-weather protection. There are 3 variants to suit most AL-KO chassis (record your tyre size on this booklet for future reference). The carriers can be fitted for left or right hand operation and are easy to fit. The telescopic frame tubes should be lubricated periodically.
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 Corrosion to braking system. Reset Brakes as pages 10-12. Check Handbrake has been released & the system is running freely. Lubricate and free off Reverse Lever. Check system as pages 10-12 and repair or renew parts as necessary. HANDBRAKE FORCE LOWIncorrect setting of the brakes. Linings not bedded in. Reset brakes as pages 10-12 and lubricate as necessary. Will pass after braking a few times. UNCOMFORTABLE RIDE OR UNEVEN BRAKING Loose braking adjustment. Damper defective. Axle shock absorbers defective. Reset brakes as pages 10-12. Check and replace damper if necessary. Replace shock absorber. TROUBLE SHOOTING & FAULT FINDING
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 setting. Braking system not fully released. Overrun lever stuck. Damage or Corrosion to braking system. Reset Brakes as pages 10-12. Check Handbrake has been released & the system is running freely. Lubricate and free off Reverse Lever. Check system as pages 10-12 and repair or renew parts as necessary. TOO MUCH PLAY IN THE COUPLING Coupling damaged or deformed. Ball too small. Replace if necessary. Fit new ball. TROUBLE SHOOTING & FAULT FINDING
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 gas strut. Incorrect setting of spring cylinder. Replace gas strut. Reset spring cylinder as pages 10-12. BRAKES APPLY DURING DECELERATION OR DOWNHILL TRAVEL Overrun damper is defective. Replace the overrun damper. TROUBLE SHOOTING & FAULT FINDING
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 a fault Don’t continue with ATC connected Remove 12S or 13 Pin plug and wait 5 seconds. Reconnect the plug. Green Red (Flashing) Ready for journey ATC faulty, and cannot be driven. Remove push-rod. Contact AL-KO. LED NOT WORKING ATC has no power LED Faulty Check push rod position before continuing. Remove 12S or 13 Pin plug and wait 5 seconds. Reconnect the plug. Check for constant live - refer to system requirements. Green Not working Ready for journey If power ok, check push rod position: Red line visible - do not drive vehicle. Red line not visible - possible to continue journey but contact AL-KO. TROUBLE SHOOTING & FAULT FINDING * ATC stores operating errors in a logfile which over time will become full and will result in the solid red light appearing. This needs to be erased and can be done easily by connecting the caravan to a 12 volt supply for a period of 12 hours. The\ power required to carry out this function is minimal. Most occurrences of these errors are due\ to power supply problems to ATC which could be due to low voltage, or an intermittent power supply fr\ om the towbar.
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