AL-KO CTA-060824 Electric Braked Axles Instruction Manual

AL-KO ELECTRIC BRAKED AXLES

OPERATING INSTRUCTIONS

SERVICE MANUAL
WARRANTY DETAIL
Save This Manual. Keep this manual for the assembly, operation and maintenance procedures. Keep this manual in a safe place for future reference.

WARNING
Read this manual before using this product.
RETAIN THIS MANUAL.

Dear Owner,
Congratulations on the purchase of your trailable unit.
The manufacturer has included this manual with the other documentation as an assurance to you that the complete running gear and braking system is supplied by AL-KO International.
AL-KO is the leading manufacturer and supplier of axles, electric brakes, brake drums and other products to provide the best rolling and stopping performance available.
The running gear and brake system on your trailable unit requires and deserves the same care and service as your towing vehicle. This manual will explain how the electric brakes and running gear work and the service required for best performance and road safety.
The AL-KO running gear and brake system is covered by a 12 months / 20,000 km limited warranty as detailed on Page 1 of this manual.
Please take the time to study the warranty details in this book.
Yours faithfully

GRANT DOUGLAS
Managing Director
AL-KO Electric brakes are covered by the following Component type approval(CTA) numbers

AL-KO INTERNATIONAL PTY LTD WARRANTY

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
AL-KO International Pty Ltd (ABN 96 003 066 813)(“AL-KO”) provides the following warranty in relation to its Electric Braked Axles (“Product”). The benefits of this warranty are in addition to any rights and remedies imposed by Australian State and Federal legislation that cannot be excluded. Nothing in this warranty is to be interpreted as excluding, restricting or modifying any State or Federal legislation applicable to the supply of goods and services which cannot be excluded, restricted or modified.

WARRANTY
AL-KO warrants that, subject to the exclusions and limitations below, the Product will be free from defects in materials and workmanship for a period of 12 months or 20,000 km, whichever occurs first, from date of purchase.
This warranty is not transferable to a subsequent person if the Product is sold by the original purchaser during the warranty period.
If a defect appears in the Product before the end of the warranty period and AL-KO finds the Product to be defective in materials or workmanship, AL-KO will, in its sole discretion, either:
(a) replace or repair the Product or the defective part of the Product free of charge; or
(b) cause the Product or the defective part of the Product to be replaced or repaired by a qualified repairer free of charge.
AL-KO reserves the right to replace defective parts of the Product with parts and components of similar quality, grade and composition where an identical part or component is not available.
Goods presented for repair may be replaced by refurbished goods of the same type rather than being repaired. Refurbished parts may be used to repair the goods.

WARRANTY CLAIMS

1. If a fault covered by warranty occurs, the customer must within 7 days contact the dealer from which the Product was purchased.

2.  Any warranty claim must be accompanied by:
   (a) proof of purchase;
   (b) full details of the alleged defect; and
   (c) any relevant documentation (such as maintenance records).

3. The customer must make the Product available to AL-KO or its authorised repair agent for inspection and testing within 14 days of contacting the dealer in accordance with this warranty claims procedure. If inspection and testing finds no defect in the Product, the customer must pay AL-KO’s costs of service work and testing.

4. The cost of transportation to or from AL-KO or the authorised repair agent is to be paid by the customer.

EXCLUSIONS
The warranty will not apply where:
(a) the Product has been repaired, altered or modified by someone other than AL-KO or an authorised repair agent;
(b) the Product was improperly installed;
(c) AL-KO cannot establish any fault in the Product after testing and inspection;
(d) the Product has been used other than for the purpose for which it was designed;
(e) the defect in the Product has arisen due to the customer’s failure to properly use and maintain the Product in accordance with AL-KO’s instructions, recommendations and specifications (including maintenance);
(f) the Product has been subject to abnormal conditions, including environment, temperature, water, fire, humidity, pressure, stress or similar;
(g) the defect has arisen due to abuse, misuse, neglect or accident;
(h) the defect has arisen due to a power surge or other fault in the supply of electricity; or
(i) unauthorised parts or accessories have been used on or in relation to the Product.
(j) the defect is a deterioration of the appearance of the Product
(k) the defect is a result of wear & tear.

LIMITATIONS
AL-KO makes no express warranties or representations other than set out in this warranty.
The repair or replacement of the Product or part of the Product is the absolute limit of AL-KO’s liability under this express warranty.
AL-KO International Pty Ltd 67 Nathan Road, Dandenong South, VIC 3175

OPERATORS SERVICE & WARRANTY MANUAL

HOW YOUR ELECTRIC BRAKES OPERATE
The electric trailer brakes perform a similar function to the brakes on your car. The major difference is that the car brakes use hydraulic pressure to expand the brake shoes, whilst the trailer brakes use an electro magnet and lever system. Activation of the electric brakes is via a controller mounted inside your towing vehicle.
The controller should provide both manual application of the trailer brakes and automatic braking balanced to that of your towing vehicle (when you push the brake pedal in the car, the brakes on the trailer are also activated via the brake controller). When the  controller is activated high capacity electro magnets are energized and attract to the inside surface of the brake drum. Due to the rotation of the drum, the magnets move the lever arm in the same direction. This movement causes the actuating block at the top of the brake to push the front shoe against the drum. The force of the front shoe in turn pushes the back shoe into contact with the drum.
Brake performance is proportional to the load of the towing vehicle and the trailer. Ensure at all times that the towing capacity of the car and the manufacturers recommended laden weight are not exceeded.
Variations of wheel and tyre diameter can effect brake performance. For questions on capacity consult alko.com.au

HOW THE BRAKE CONTROLLER WORKS
AL-KO International only recommend ADR 38/05 compliant variable and proportional in cab brake controllers for smooth balanced brake performance, due to their operating properties.
Once properly installed and adjusted the brake controller can be operated both automatically and manually. When the brakes are applied the controllers electric circuit is operated automatically. As the tow vehicle slows down a sensor inside the controller reacts to the deceleration and increases the power to the trailer brakes, thus providing smooth and proportional braking of the trailer. For manual operation, the controller is provided with a sliding control. This activates the stop lights and the brakes, and the indicator light on the front of the controller panel glows from dim to bright the further the control is moved, indicating an increase in braking power.
WARNING
There are several different types of brake controllers available, some with motion sensors and some without a motion sensing device. If a brake controller without motion sensor is used the trailer brakes will not be applied in proportion to the tow vehicle and smooth balanced braking will not be achieved in all conditions.
More detailed information on the operation of the controller is available in the installation instructions supplied by the manufacturer.
FITTING TRAILER BRAKES
Electric trailer brakes when used and adjusted properly provide many kilometres of smooth, dependable braking operation.
Electric trailer brakes must have a complete electrical circuit, any broken or poor wire connections will prevent or interfere with the flow of electrical power resulting in poor or no braking.
Electric brakes use around 6.5 amps for every two magnets. Wiring should be used that is of suitable capacity for the total number of magnets fitted.
AL-KO International recommend that all electrical connections be soldered or made via screw type connectors.
On new trailers a break in period may be required to achieve maximum braking performance.
Proper Brake Balance Between Your Vehicle and Trailer
The brakes on your towing vehicle are designed to stop in a safe effective manner, similarly the electric brakes fitted to your trailer are designed to effectively stop the weight of the trailer to which they are fitted.
It is important that the performance of the brakes on both the towing vehicle and the trailer are balanced so that neither are overloaded. If the correct balance is not obtained between the braking systems, then overheating of either system may occur with a deterioration in brake performance. Correct brake balance is obtained when the trailer brakes have a slight lead over the brakes on the towing vehicle. This can be accomplished by the adjustment of the controller in the towing vehicle. When correctly adjusted there will be no sensation of the trailer pushing the vehicle, nor any excessive pull during braking.

EMERGENCY BRAKE REQUIREMENTS
AL-KO Electric brakes require a minimum of 6 volts for a period of 15 minutes to meet ADR 38/05 emergency brake requirements. It is critical that the system is capable and maintained to achieve this level of supply.
GENERAL MAINTENANCE
In order to maintain the safe reliable stopping power of your AL-KO brake system it is recommended that the brakes be serviced at regular intervals. Contact your local AL-KO International Service Centre or brake specialist for assistance.
For Assistance locating your nearest AL-KO Service Agent please visit alko.com.au/dealer-installer-locator
The following list of general maintenance items should be carried out as a periodic maintenance check. These are service functions, not warranty items.

1. Brake Adjustment Procedure
   The brakes fitted to an axle or independent rubber suspension system supplied by AL-KO International are adjusted prior to supply. A brake clean and adjustment should be carried out between the first 300 to 1000 kilometres and then at the service intervals recommended on Page 8. Located in the back of the brake backing plate is a small opening covered by a protective plug. With the trailer wheels off the ground, rotation of the star wheel, (as shown in the diagram below), will result in correct brake adjustment. With a screw driver or adjusting tool rotate the star wheel until the brake drag makes it difficult to turn the wheel (i.e. the road wheel is almost locked up). The star wheel can then be turned in the opposite direction to allow the trailer wheel to turn 3/4 to 1 revolution freely when spun. (i.e. the brakes can drag lightly but the road wheel should spin freely for about 1 revolution before stopping on its own).
   
   Park Brake Cable Adjustment
   In the laden condition it is imperative that the park brake lever engages and secures the brakes in, it’s recommended, within 2 notches of full engagement (see photo).
   Failure to adjust the cable tension in this manner will, through suspension movement on both independent suspension and beam axle with leaf springs, cause the brake shoes to be partially actuated and excessive heating of the brake and drums to occur. Prolonged use, if incorrectly adjusted, will cause initially the back (secondary shoe) to overheat to the extent of disintegration of the brake lining and will result in deterioration of brake performance until eventual brake failure.

2. Brake Drum / Hub
   The brake drum should be checked for excessive wear in accordance with the periodic maintenance check list on page 8.
   • If the drum has heavy scoring, or has a run out that exceeds 0.5mm it should be machined by your local AL-KO International Service Centre.
   • If the bore of the drum exceeds the maximum diameter cast on the drum, it should be replaced.
   • Brake drums that have been machined must be thoroughly cleaned and checked (by AL-KO International) before installation.
   • If the magnet wearing surface on the inside of the drum is unevenly worn or badly scored, we suggest that the drum be referred to AL-KO International for machining or replacement.
   NOTE: Any time that the drum is replaced a new magnet should also be installed.

3. Wheel Bearings
   Bearings must be inspected and lubricated periodically to ensure reliable, safe operation of your trailer. We recommend that your trailer be taken to your local AL-KO International Service Centre where correct wheel bearing service can be undertaken.
   If you need to remove a hub drum from your trailer, the diagram below shows the component relationship.

1- Grease Seal
2- Inner Bearing
3- Inner Cup
4- Hub/Drum
5- Outer Cup| 6- Outer Bearing
7- Spindle Washer
8- Spindle Nut
9- Cotter Pin
10- Grease Cap
---|---

• Seals should be checked and replaced if found to be nicked, torn or worn.

• If the bearings are damaged or worn they should be referred to your local AL-KO
  International Service Centre where replacement maybe recommended.
  NOTE: It is recommended to replace the bearings and cups in sets. Manufacturers part numbers are stamped into the bearing cup and cones for identification.

• Always lubricate the bearings on your trailer with high quality wheel bearing grease.

• Every time the wheel hub is removed, the wheel bearings must be adjusted.

To Adjust the Wheel Bearings
Turn the hub slowly to seat the bearings while tightening the slotted nut until firm.
Loosen the slotted nut and then re-tighten by hand (not with a wrench) to a “finger-tight” condition to align the first notch with the hole in the shaft and insert the split pin. It is recommended that bearing adjustment be carried out by your local AL-KO International Service Centre to ensure that correct bearing adjustment is maintained.

Brake Linings

Periodic inspection for lining wear or contamination from oil or grease should be undertaken by your local AL-KO International Service Centre.

• If the lining is worn to within 0.8mm of the rivet or to a minimum thickness of 1.5mm on bonded linings or shows irregular wear or contamination from a foreign substance, shoes should be replaced with original parts from your local AL-KO International
  Service Centre.

Magnet Assembly

The magnet assembly can be inspected for wear without removing it from the brake, by laying a straight edge over the length of the magnet space as shown.

Magnets may be used with normal wear until the white plastic under the friction element is barely visible. For off-road application AL-KO have developed a unique magnet specifically designed to prolong magnet life. This magnet is identified by a special high tech plastic core in the centre of the magnet.
This core should be periodically inspected for wear and the magnet replaced if excessive clearance or wear is evident. As the off-road magnet does not use a magnet retaining clip, we suggest it is held in place for service installation by a light rubber band which will disappear on the first brake application.
Replacement magnets are available from your local AL-KO International Service Centre.

 Wheel Mounting

It is important to maintain proper torque specifications to provide safe and secure attachment of the wheel to the hub drum.

•  Start all nuts by hand to prevent cross threading.

•  Tighten nuts in three stages using a cross star pattern.

• Whenever wheels are removed and refitted the wheel nut torque should be checked.
  Wheel nuts should be tightened to the torque specified by the wheel manufacturer.
  Please ask the supplier of your caravan or trailer for the correct torque setting. Always use a quality torque wrench to check wheel nut torques.
  It is recommended that the wheel nut tension be checked every 100kms for the first 400kms of your initial trailer use and then as per the periodic maintenance check list on page 8.

•  Tighten wheel nuts using a cross star pattern as shown:

PERIODIC MAINTENANCE CHECK LIST

CHECK| FUNCTION REQUIRED| DAILY| Every
5000 km
or
6 months| Every
10000 km
Or
12
months| PAGE
Number
---|---|---|---|---|---
Trailer Brakes| Test that they are functioning properly.| ✓| | |
Air Pressure| Inflate tyres to manufacturer’s specifications.| ✓| | |
Wheel Nuts’| Tighten to proper torque specifications.| | ✓| | 7
Wheel Rims| Inspect for dents, damage, or out of round.| | ✓| |
Brake Adjustment”| De-Dust. Inspect for lining wear and adjust.| | | ✓| 4
Brake Magnets| Inspect for uneven wear.| | | ✓| 6
Wheel
bearings and cups| Inspect for wear or damage and lubricate.| | | ✓| 5
Hub/Drum| Inspect for heavy scoring or wear.| | | ✓| 5
Seals| Inspect for damage or wear.| | | ✓| 6
Brake linings| Inspect for lining wear and contamination.| | | ✓| 6
Park Brake| Inspect for excessive travel and adjust.| | | ✓| 4

• Tighten wheel nuts every 100 km for the first 400 km and after every change in wheel mounting. Refer Page 7.
  ** Adjust brakes and de-dust after first 300 to 1000 km then at above intervals. Refer Page 4
  For Assistance locating your nearest AL-KO Service Agent please visit alko.com.au/dealer-installer-locator

TROUBLE SHOOTING GUIDE

Blown fuse Controller setting
No Brakes| Worn magnets| Replace with genuine  from AL-K0
No Brakes| Incorrect brake shoe clearance| Adjust brakes
Weak Brakes| Loose electrical connection
Check all| connections
Weak Brakes| Worn out linings| Replace with genuine
from AL-KO
Weak Brakes| Worn out drum
Remachine or| replace if oversize
Weak Brakes| Excessive load| Reduce trailer load
Weak Brakes| Lining contaminated| Replace linings and seals with genuine parts
Intermittent Brakes| Broken magnet wire| Bench check magnets and replace with genuine parts
Intermittent Brakes| Loose wire connections| Check all wireconnections
Intermittent Brakes| Out of round drum| Remachine drum
Locking Brakes| Loose wheel bearings
Check and adjust| wheel bearings
Locking Brakes| Malfunctioning controller| Check and replace if necessary
Locking Brakes| Stop lights connected in brake circuit| Check wiring of controller and trailer
Locking Brakes| Loose brake parts| Check for loose rivets, broken springs etc.
Locking Brakes| Worn wheel bearings| Examine bearings amine hub
Locking Brakes| Out of round drum| Remachine drum

PERIODIC MAINTENANCE SCHEDULE
(Refer Checklist Page 8)

1 St ServI.ce| 300 km
to
1000 km| Date:
Authorised Dealer Stamp:
Dealer Signature:
---|---|---
2nd
Service| 10,000 km
Or
12 months| Date:
Authorised Dealer Stamp:
Dealer Signature:
3rd
Service| 20,000 km
or
24 months| Date:
Authorised Dealer Stamp:
Dealer Signature:
4th
ServI.ce| 30,000 km
Or
36 months| Date:
Authorised Dealer Stamp:
Dealer Signature:
5th
Serviace| 40,000 km
Or
48 months| Date:
Authorised Dealer Stamp:
Dealer Signature:
6th
Service| 50,000 km
Or
60 months| Date:
Authorised Dealer Stamp:
Dealer Signature:

alko.com.au
Visit
www.alko.com.au
for more information

References

• AL-KO Vehicle Technology | Australian Trailer & Caravan Parts Manufacturer
• Dealer & Installer Locator | AL-KO
• AL-KO Vehicle Technology | Australian Trailer & Caravan Parts Manufacturer

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