Operating instructions

20
11. THE AL-KO CARAVAN
CHASSIS
Chassis members
The recommended tow vehicle coupling height is
385 +/- 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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