MAINTENANCE
212
AL-KO BRAKING SYSTEM ADJUSTMENT
Figs. 7, 8 & 9 show the deformation of the
rubber elements at the extremes of
suspension movement.
The axle is designed to ride with the
suspension drop arm at, or slightly below,
the horizontal position.
For Trouble Shooting & Fault Finding please
see Table 1 on page 225.
Fig. 7
Fig. 8
Fig. 9
AL-KO braking system adjustment
1. Ensure the towing shaft with coupling head
is pulled FULLY FORWARD. (Fig. 10).
2. Release the handbrake to the FULLY OFF
position. If the handbrake will not go down
the whole way because of the fairing or any
other obstruction; then the fairing must be
cut away and/or the obstruction removed
to achieve this desired position. It will not
be possible to set up the braking system
properly when the handbrake is not in the
FULLY OFF position. (Fig. 10).
3. Jack up one side of the caravan, using the
AL-KO Side Lift Jack System. (see Jack
Operating Instructions).
4. Remove the inner plastic bung from the
backplate to expose the “starwheel”
adjuster access. (Figs. 10 & 11).
5. ALWAYS rotating the road wheel in the
forward direction - NEVER backwards;
adjust the starwheel with a suitable
screwdriver, in the direction of the arrow
embossed on the backplate until there is
resistance in the wheel rotation. (Fig. 11).
6. Slacken off the starwheel adjuster until the
road wheel turns freely in the FORWARD
direction. (Fig. 11).
7. Check the adjustment at the end of the
brake cable where it is secured to the
abutment (bracket), welded to the centre of
the axle.
When the inner cable is pulled out it should
extend between 5 and 8 mm. (Fig.12). (On
tandem axles a double abutment (bracket)
is fitted to the front axle ONLY).
8. Repeat for other wheel or wheels.
9. On tandem axles the brake cables from
the rear axle should pass over this axle
and cross over each other, before being
connected to the abutment (bracket) on the
front axle.
10. Ensure the balance bar (compensator)
is being pulled evenly (Figs.10 & 12).
Excessive movement to this bar (double
on tandem axles) would indicate possible
incorrect adjustment (if appropriate, repeat
step No. 7 - Fig. 12).
11. Check the brake rod support bracket,
(fixed to the floor) IS supporting the brake
rod evenly. The brake rod MUST ALWAYS
run straight, NEVER bent or curved under
any fittings. On tandem axles, using the
double balance bar, a brake rod support
tube ( ALKO Part No. 228827) MUST
ALWAYS be fitted on the end of the brake
rod, passing through the centre aperture
on the abutment.
12. Remove the slack in the brake rod by
adjusting the long ball nut, rear of the bal-
ance bar, ensuring the overrun lever makes
contact with the end of the towing shaft.
Note! Over adjustment to the long ball nut
(Fig. 12/Item 2) could induce movement
of the inner brake cable, reducing the ef-
fective clearance of the brake shoes. If the
overrun lever will not make contact, it is
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