CARE & MAINTENANCE INSTRUCTIONS FOR …

1 Part No. 1386853 Iss. 1 06/03It is recommended that the chassis/components are washed off, using apressure washer on an annual basis(especially after winter usage), toavoid undesirable build up of salt anddirt galvanised chassis should not bepainted or subjected to any otherprotective the galvanising becomesuperficially damaged exposing thesteel core, this should be cleaned andtreated with a Cold GalvanisingSpray obtainable from vehicleaccessory to chassis members throughimpact etc, MUST NOT bestraightened or welded.

2 Damagedchassis members MUST be Information:The AL-KO lightweight chassis hasbeen perfected by many years ofresearch and development, supportedby an exhaustive test from high quality steel,the chassis has extra deep sectionsto provide strength at points ofmaximum stress. Large elongatedholes are punched in the longitudinalchassis members, to reduce weightto a minimum. Each hole incorporatesa return flange to maintain the requiredstrength and provide rigidity in theextra deep chassis frame is of a boltedconstruction which allowsreplacement of individual parts shouldthe need chassis is Hot DippedGalvanised.

3 This is regarded as oneof the best forms of corrosionprotection. It does however requireminimal MAINTENANCE in new, the chassis is of a brightand shiny appearance. As thegalvanising cures during the initial 2/3 month period, this will graduallychange to a medium/dark grey grey finish is the ideal, giving thecorrect protective coating. During thiscuring period the surface should beprotected to avoid possible wetstorage stain, in the form of a soft,light coloured, porous, oxidation the chassis members are in contactwith any salt deposits from roads thisshould immediately be washed off witha high pressure washer.

4 Salt attractsmoisture allowing the surfaces toremain wet, this prevents curing andalso allows formation of wet on Coupling Heads,Overrun Assemblies andAxles:The permitted nose weights of thecoupling head/stabiliser, overrunassembly and drawbars, must neverexceed the lowest value stamped onthe maximum axle loading is thatstamped on the oval (Fig. 1), (orsquare, if German production ( )), plate located in the centre of theaxle, facing rearwards. The third linedown marked Capacity (on Germanplates Achlast ) is the maximumpermitted axle loading and mustnot be or Welding of Parts orDrilling or Welding of Partsor Accessories:The chassis is designed and built toprecise tolerances and must not bedrilled or welded (except inaccordance with certain AL-KOAccessory Operating INSTRUCTIONS ).

5 Failure to comply will invalidate Suspension:The AL-KO rubber suspension isdesigned and developed to suit alltypes of road conditions and ismaintenance free. Three rubberelements are contained within ahexagonal axle tube. These providesuspension and have inherentdamping characteristics. (Only thehubs and wheel brakes requireattention - see axle section).Where the Caravan Manufacturerstates a maximum loading weight,then this is the maximumpermitted load. This figure mustnot exceed the maximum axleload. Enter your Axle details for future reference:1AL-KO Kober Limited, South Warwickshire Business Park, Kineton Road, Southam, Warwickshire, CV47 0 ALTel: 01926 818500 Fax: 01926 818562 RECORD YOUR SPARE WHEEL CARRIER INFORMATION HERE: Caravan Make (eg Bailey): Caravan Model (eg Pageant): Year of Manufacture: Tyre Size (eg 195R 13): Dimension X in mm: (taken from following diagram)Jockey Wheel:Lubricate screw thread and wheelspindle Wheel Carriers.

6 Each caravan has a set of punchedholes in the chassis member tofacilitate the fitting of a spare wheelcarrier. The assembly is of a strong,lightweight construction and zincplated for all-weather are 3 variants to suit mostAL-KO chassis (record your tyre sizeon this booklet for future reference).The carriers can be fitted for left orright hand operation and are easy telescopic frame tubes shouldbe lubricated :The Corner Steadies Shouldnever be used to jack up thecaravan. When jacking becomesnecessary use the AL-KO Side LiftJack or 2-Tonne Jack : It is essential that the car& caravan are hitched togetherbefore commencing jacking.

7 AllAL-KO chassis from 1992 onwardshave 2 holes punched in the chassismembers, each side (rear of theaxle); to accept the brackets for theJack(s). (See Accessory Price List).Corner Steadies may be used forstability ONLY, when the caravan isin the jacked caravan should never be liftedby jacking up under the LiftJack2-TonneJackIf working under the caravan in anelevated position, axle stands mustbe used for safety. Wheel chocksfor the opposite wheel(s) are :The legal requirements for treaddepth on motor vehicles, also appliesto caravan and Wheels:In most instances the road wheelsand tyres are supplied by the CaravanManufacturer.

8 The condition ofwheels and tyres should be checkedregularly, particularly for distortion offlanges and the wheel dish. Wheelsthat are damaged or distorted, orhave wheel bolt seatings cracked ordeformed must not be repaired orused in service - these must - Standard AL-KOcaravan chassis use M12 wheelbolts. These must always only betightened to the correct torque settingof 88 Nm (65 lbs/ft), in sequence,( North, South, East, West);NEVER clock or use a calibrated torquewrench, do not use a corner steadybrace, power or electric wrench.

9 It isas dangerous to overtighten wheelbolts as it is to not tighten themsufficiently. Important - The torquesettings should be re-checked after50 other wheel bolts are used pleaseensure the torque settings are asfollows:M10 - 49 Nm (36 ft. lb)M14 - 135 Nm ( ft. lb)M16 - 210 Nm (155 ft. lb)Special Note -Aluminium WheelsThe standard M12 x 60o ConicalWheel bolts are NOT SUITABLE foraluminium wheel rims. Special wheelbolts should be & MAINTENANCE INSTRUCTIONS FORYOUR AL-KO CHASSIS AND COMPONENTST rouble Shooting & Fault Finding:Table 3 Overrun Devices: FaultCauseRemedy Poor BrakingOverrun shaft overrun shaft replace any damagedBody housing Brakes Overheating DuringHandbrake not fully handbrake.

10 TowingBraking system incorrectly brakes as page (4).Incorrect attachment of breakawayEnsure correct attachment as page (12) or refer to Braked TrailersUse of Breakaway Cables sheet. Handbrake Force LowDefective gas gas setting of spring spring cylinder as page (4). Brakes Apply DuringOverrun damper is the overrun damper. Deceleration or Downhill TravelLoading:Loads to be carried in the caravanshould be placed directly over, or asclose as possible to the axles,otherwise the handling will gross weight, as advisedby the caravan manufacturer, mustnot be exceeded without approvalfrom loading is defined as thedifference between ex-works weightand the permitted total Too Far Forward Fig and braking ability loading on the rear axleand chassis of the tow Too Far Back Fig.