Operating instructions

22
12. THE AL-KO CARAVAN CHASSIS
Chassis members
The recommended tow vehicle coupling height is 385mm
+/- 35mm from the ground to the centre of the ball.
Off Road vehicles are exempt from this towball
height specication.
Manufactured from high quality steel, the chassis has
extra deep sections to provide strength at points of
maximum stress. Large elongated holes are punched
in the longitudinal and towbar, (‘A’ frame) members, to
reduce weight to a minimum. Each hole incorporates
a return ange to maintain the required strength and
provide rigidity in the extra deep sections.
The chassis frame is of a bolted construction which,
should the need arise, allows replacement of individual
parts.
The chassis is Hot Dipped Galvanised. This is regarded
as one of the best forms of corrosion protection. It
does however require minimal maintenance in certain
circumstances.
When new the chassis is of a bright and shining
appearance. As the galvanising cures during the initial
2 to 3 month period, this will gradually change to a
medium to dark grey colour. This grey nish is the ideal,
giving the correct protective coating. During this curing
period the surface should be protected to avoid possible
wet storage stain, in the form of a soft, light coloured,
porous, oxidation layer. If the chassis members are in
contact with any salt deposits from roads this should
immediately be washed off with a high pressure washer.
Salt attracts moisture allowing the surfaces to remain
wet; this prevents curing and also allows formation of
wet storage stain.
It is recommended that the chassis be washed
off, using a pressure washer on an annual
basis (particularly after winter usage) to avoid
undesirable build up of salt and dirt deposits.
The galvanised chassis should not be painted or
subjected to any other protective treatment.
Should the galvanising become supercially damaged
exposing the steel core, this should be cleaned and
treated with a cold galvanising spray obtainable from
vehicle accessory outlets.
Damage to chassis members through impact etc.
Must not be straightened or welded. Damaged chassis
members must be replaced.
Drilling or welding of parts or accessories
This chassis is designed and built to precise
tolerances and must not be drilled or welded.
Independent suspension
The AL-KO rubber suspension is designed and developed
to suit all types of road conditions and is maintenance
free. Three rubber elements are contained within a
hexagonal axle tube. These provide suspension and have
inherent damping characteristics. (Only the hubs and
wheel brakes require attention - see axle booklet Part
No. 580458).
Coupling head
The ball couplings are entirely automatic in operation
and designed for one hand operation to suit the 50mm
international ball recommended by the British Standards
Institution, National Caravan Council and the Society of
Motor Manufacturers and Traders.
Secondary braking (Breakaway cable)
Please refer to details in Section 2.2.5, page 2-3.
Uncoupling
Having lowered the jockey wheel to the ground, operate
the handle as previously described. Lift the coupling
clear of the towing ball either manually or by operating
the telescopic jockey wheel.
Brake drum/hub assembly
The Euro Axle tted to your Bailey caravan comes
complete with maintenance-free wheel bearings greased
and serviced for life. Adjustment is not required during
the design life of the sealed bearing (100,000 km).
• If replacement of the brake drum or shoes is required,
this must be carried out by authorised AL-KO Service
Centres. Specialist tools and equipment are required.
The rear hexagonal bolt covered by a black plastic
cover must NEVER be touched.
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Fig 1.