Operating instructions

24
xi. Remove the slack in the brake rod by adjusting
the long ball nut, rear of the balance bar; ensuring
the overrun lever makes contact with the end of the
towing shaft. Over adjustment to the long ball nut
(Fig 10), could induce movement of the inner brake
cable, reducing the effective clearance of the brake
shoes. If the overrun lever will not make contact, it
is possible the two lock nuts, forward of the spring
cylinder, are incorrectly adjusted. Loosen the nuts
and adjust the brake rod as above (Figs 8 & 10).
xii. Adjust the two locking nuts, forward of the
spring cylinder (g. 10), (on some chassis a single
Nyloc nut is used) to give 1mm of clearance on
the spring cylinder. This cylinder (the energy store
for the handbrake operation) must be able to
rotate only, not slide on the brake rod. (See Fig.
10). If the overrun assembly is tted with a gas
strut handbrake then no spring cylinder is tted -
therefore ignore this paragraph).
xiii. Correct adjustment of the linkage is checked
by operating the handbrake lever so that when the
second or third tooth is engaged, a slight braking
force is felt on the road wheels.
xiv. Over adjustment of either the wheel brakes or
linkage, will result in difcult reversing causing the
wheels to ‘lock-up’.
xv. When parking, the handbrake lever must always
be engaged into the fully upright position (90°).
This is to compress the spring within the spring
cylinder and thereby create an energy store, which
will automatically engage the brakes further should
the caravan move.
xvi. If difculty is experienced in this operation, try
easing the caravan backwards with one hand while
engaging the handbrake fully with the other. This
manoeuvre should not be attempted on a rearwards
facing slope. In this case wheel chocks should be
used combined with the handbrake.
xvii. Finally, if the road wheels have been removed,
re-tighten using a calibrated Torque Wrench to
130Nm- on all M12 wheel bolts - in sequence, i.e.
North, South, East, West not clock or anticlockwise.
Remember to over tighten is just as dangerous as
to under-tighten, as this can distort the wheel rims.
Avoid the use of power wrenches.
The torque settings should be rechecked
after 50km /30 miles. Wheel bolts should
never be lubricated.
In order to operate the Al-KO braking
system correctly adequate traction
of caravan wheels is required when
reversing. Therefore surface conditions
that would result in a lack of traction should be
avoided. Example: Peas, shingle/loose gravel.
Care should be taken when traversing
ramps or other obstacles in order to
prevent damage to the caravan under
gear. When approaching such obstacles
reduce towing speed appropriately.
Chassis Lubrication Points
1. Grease the drawbar in the area of the bellows.
2. Grease the bearing bush through the grease
nipples on the housing and the cartridge.
3. Grease the pivot bolt of the overrun lever and
handbrake levers through the grease nipple.
4. Grease the joint of the brake rod and tting.
5. Oil the joints of the spring cylinder in the
handbrake lever.
Lubricant type: Multi-purpose grease to DIN 51825
KTA 3K4.
12. ROAD LIGHTS.
It is important that all the road lights on your
Bailey caravan are checked before you set out on
a journey.
All lights must be working in the correct manner for
the vehicle to be road legal.
Clean the outside of the lights with a non abrasive
or non aggressive cleaning solution.
Always replace a lamp which is showing any sign of
damage.
!