AL-KO Enduro Touring Independent Trailing Suspension User Manual

AL-KO Enduro Touring Independent Trailing Suspension

Product Specifications

• Designed for on-road conditions including bitumen and well-maintained unsealed roads
• Independent trailing arm suspension
• Automotive grade maintenance-free bushes
• Integrated Toe & Camber adjustment
• Premium shock absorber
• Engineered and built in Australia for Australian conditions
• High-quality coil springs made of high-stress spring steel
• Maintenance-free polyurethane suspension bushes

Product Usage Instructions

General Information:
The AL-KO Enduro Touring suspension system is designed for both on-road and off-road applications. It is engineered to provide durability, control, and comfort in various terrains.

Maintenance:
Regular servicing of the suspension and braking system is essential to ensure optimal performance and longevity. Follow the recommended maintenance schedule provided by AL-KO to keep your caravan in top condition.

Recommended Checks:

• Trailer Brakes: Test for effective braking
• Tyre Pressure: Inflate to manufacturer’s specifications
• Wheel Nuts: Tighten to proper torque specifications
• Wheel Rims: Inspect for dents, damage, or irregularities
• Wheel Bearings & Cups: Check for wear and lubricate
• Brake Adjustment: Inspect and adjust if necessary
• Suspension Mounting Bolts: Ensure they are secure
• Shock Absorber Mounting Bolts: Check for tightness
• Suspension Bushes: Inspect for wear or damage
• Wheel Alignment: Check and adjust if needed
• Bump Stop Stub Mounting Bolts: Ensure they are properly secured

FAQ

• How often should I service my AL-KO Enduro Touring suspension system?
  AL-KO recommends servicing your suspension at regular intervals, with a minimum frequency as per the recommended maintenance schedule. Typically, servicing every 5000 km or 6 months is advised.

• Are the suspension bushes maintenance-free?
  Yes, the AL-KO Enduro Touring suspension system features high-quality maintenance-free polyurethane suspension bushes that require no additional grease after initial installation.

Engineered for Adventure

AL-KO Enduro Touring is an independent trailing arm suspension designed for on-road conditions including bitumen and well maintained unsealed roads.

Benefits of Independent trailing arm suspension

• Keeps the tyres in contact with the ground as much as possible. It is well suited for on road and off road applications.
• The low unsprung weight of Independent Suspension has less inertia and allows to follow road undulations easily, putting less loads into the chassis.
• It increases ground clearance in the centre of the vehicle and will allow for the fitting of ancillaries such as water tanks.

Automotive grade

• ENGINEERED AND BUILT IN AUSTRALIA FOR AUSTRALIAN CONDITIONS
  Designed, manufactured and rigorously tested for durability, control, comfort and choice of terrain.

• SUBJECTED TO AN EXTREME TESTING PROGRAM
  Extensive testing has been undertaken at dedicated research and development facilities.

• FITTED WITH AL-KO PREMIUM HEAVY DUTY SHOCK ABSORBERS

• HIGH QUALITY COIL SPRINGS
  Coil springs manufactured with high quality, high stress spring steel that is up to 30% lighter compared standard grade steel alternatives.

• MAINTENANCE FREE BUSHES
  High quality maintenance free polyurethane suspension bushes require no additional grease after their initial installation.

• NO-COMPROMISE APPROACH
  AL-KO is proud of its uncompromising approach. Each component within the AL-KO Enduro™ independent trailing arm suspension system is tested to ensure it meets the highest quality standards and to ensure compatibility with the latest caravan safety features, such as Tow Assist, AL-KO ESC & DEXTER sway control.

• DESIGNED BY THE GLOBAL MARKET LEADER
  AL-KO is the global market leader in caravan suspension technology

• AUSTRALIAN WIDE RECOMMENDED SERVICE NETWORK
  AL-KO has the most extensive service network in Australia, providing peace of mind that parts, service back-up and expert advice are never far away. For a full list of AL-KO Recommended Service Centres visit www.alko.com.au.

AL-KO Enduro Touring General Maintenance

Regular Servicing of your premium quality AL-KO Enduro Suspension and braking system will ensure you continue to have the peace of mind that any of our products offer.
AL-KO recommends that you service your caravan at regular intervals and that as a minimum you service your suspension as per the recommended maintenance schedule.

Tyre pressure
Ensure tyre pressures are set correctly for prolonged tyre life

Wheel Nuts
Whenever wheels are removed and refitted the wheel nut torque should be checked. Fit wheel nuts by hand to ensure correct fitment, prior to tightening to the torque specified by the wheel supplier.

Wheel bearings & cups
Every time the wheel hub is removed, the wheel bearings must be checked and adjusted.

Brake adjustment
Adjust park cable where fitted to allow sufficient slack to accommodate full suspension travel.

Suspension mounting bolts M16 (190 Nm)
Whenever suspensions are removed and refitted the bolt torque should be checked. Always use a calibrated torque wrench. Ensure new nyloc nuts are used for every installation.

Shock absorber mounting bolts M12 (85-90 Nm)
Whenever suspensions are removed and refitted the bolt torque should be checked. Always use calibrated torque wrench. Ensure new nyloc nuts are used for every installation and existing washers are reinstalled to the correct location.

Shock absorber visual check
Sweating, or just a small amount of fluid around the fluid filled tube is normal and not a fault. Defective shock absorbers should be replaced always in pairs. Ensure correct tightening torque of mounting bolts. Ensure new nyloc nuts are used for every installation.

Suspension bush
AL-KO Enduro Suspension bushes are lubricated by the initial suspension installer and are thereafter maintenance free. Re greasing at periodic maintenance inspection is OK but not mandatory.

Wheel alignment
Ensure recommended toe & camber values are set for prolonged tyre life. Adjustment of toe in or camber should be done by suitably qualified technician.

Stub Mounting Bolts M14 (180 Nm)
Whenever the stub axle is removed and refitted the nut torque should be checked. Fit nuts by hand to ensure correct fittment, prior to tightening to the torque 180Nm.

Axle Pivot Suspension Bushes

• Lubrication is performed during assembly and should not be required on an ongoing basis.
• Bushings can be subject to damage from external sources, so should be periodically visually checked for impact damage. Regreasing or internal inspection of the bushes would only be deemed necessary if noises or free play were evident.

Bump Stops
As these are the hardest working parts in the suspension, these require visual checks at regular service intervals. Bump stops should be visually inspected for:

• Deformation or compression
• Cracking around the contact area
• Splitting in the body of the bump stop
• Alignment to ensure correct contact angles
  If any of these conditions exist it is recommended the bump stops be replaced on both sides.

Wheel Alignment Toe & Camber

The Enduro Suspension fitted to your RV or trailer will have had the appropriate “zero load” toe in and camber set during manufacture of the RV or trailer. Incorrect adjustment of either toe in or camber can affect tyre wear. Should you experience any irregularities we would suggest, prior to contacting an AL-KO Recommended Service Centre, that at least the parameters below be checked first:

1. RV or trailer laden weight (Must not exceed manufacturer’s trailer plate rating)
2. Correct tyre inflation pressure
3. Correct tyre capacity for the load being carried
4. Wheel balancing
5. Tyre condition
6. Wheel bearing adjustment
   If you continue to experience tyre wear, please visit www.alko.com.au for a list of AL-KO Recommended Service Centres for AL-KO Enduro.

Recommended assembly torque

• Please consult your AL-KO Recommended Service Centre for any considerations regarding assembly torque settings.
• Please visit www.alko.com.au for a list of AL-KO Recommended Service Centres for AL-KO Enduro suspension.

Servicing your AL-KO Enduro Suspension

• AL-KO recommends that you service your RV or Trailer at regular intervals and that as a minimum you service the suspension at the suggested intervals as follows Initial Checks & Wheel Alignment inspection 100 – 1000km 1st Service 5,000km 2nd Service 10,000km
• Thereafter we recommend your suspension be serviced at a minimum of once every 10,000km

Warranty

AL-KO ENDURO PRODUCT 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 AL-KO Enduro product (“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 60 months from date of purchase. AL-KO may, at its discretion, offer a longer warranty term on certain products. 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: 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 PROCESS
1. If a fault covered by warranty occurs, the customer must within 7 days contact the dealer from which the Product was purchased, or AL-KO at the contact address listed below. 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 AL-KO or 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:

1. the Product has been repaired, altered or modified by someone other than AL-KO or an authorised repair agent;
2. the Product was improperly installed or used;
3. AL-KO cannot establish any fault in the Product after testing and inspection;
4. the Product has been used other than for the purpose for which it was designed;
5. 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);
6. the Product has been subject to abnormal conditions, including environment, temperature, water, fire, humidity, pressure, stress or similar;
7. the defect has arisen due to abuse, misuse, neglect or accident;
8. the defect has arisen due to a power surge or other fault in the supply of electricity; or
9. unauthorised parts or accessories have been used on or in relation to the Product;
10. the defect is a deterioration of the appearance of the product;
11. 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.

CONTACT

• AL-KO International Pty Ltd
• 67 Nathan Road, Dandenong South, Victoria, 3175
• Phone: (03) 9997 4500
• Email: info.aus@alko-tech.com

Register your warranty at www.alko.com.au
Scan this code to register your warranty

• “The personal information disclosed to us by you will be used for the purposes of identifying you if you wish to make a claim under the warranty, and for dealing with that claim. We may also use your information to communi-cate with you about our product and promotions.
• Your information will only be disclosed to third parties where necessary to assess or complete your claim such as suppliers or distributors of our products, or to government bodies such as Vic Roads (or equivalent). If you do not complete all the information contained on the card, we may not be able to provide you with a warranty.
• If you would like to access the personal information held by us about you, please contact our Privacy Officer on (03) 9997 4500.”

References

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

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