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Old 22 May 2018, 02:22   #31
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I'm just passing on what I was told & shown by someone who's been servicing & repairing caravans full time for over 30 years.
By 'slack' we're talking just in contact with the cable ends to be sure that none of the cables are tensioned - not several mm of free movement.
Leave it with you.
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Old 22 May 2018, 06:40   #32
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Comments are appreciated - thnx.
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Old 26 May 2018, 17:30   #33
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OK ... another all day on this ...
All 4 hubs off again, expander clutches lubricated, and the auto reverse cams.
Fitted 4 new Bowden cables
4 new cable ends and 4 half shell covers.
Had 2 mates come and check adjustments & setup.

Adjusted exactly as per AL-Ko manual .... same again, brakes fine, hand brake fine ... but When reversing as soon as coupling at end of stroke ( bellows compressed) ... i.e. as soon as I reverse up a slope ... brakes lock on.
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Old 27 May 2018, 03:29   #34
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When you back up are you backing hard enough to roll the shoes back to release i regularly tow a 3.5t goods trailer and occasionally have to drop into low range if backing a heavy load up a slope just to overcome the initial brake effect and get the shoes to release.

My other thought is do they release then re apply because of extra travel on the hitch maybe more slack required at hitch end?
It may be you need more slack until everything beds in after a few runs
Another thought is is the damper working correctly?
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Old 27 May 2018, 03:54   #35
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Damper goes through full travel - in under pressure, and return out fine ... so don’t see any issue there.
Had this trailer for 5 years ... always reversed up drive no problem previously.
Had a mate with 3.5t pick up try ... in low rate he could push it , one hell of a force, basically skidding wheels, and they still did not release.

Tried. Putting 3, 5 and 20mm slack in actuating rod, still same.
After full set up yesterday, 2 thing I notice.

1. Is that when I apply handbrake is is not exactly vertical (90) it is at about 11 o’clock position.
Thinking I may back off brake adjustment by equal amount on all 4 wheels (maybe 2 clicks) and see if that brings it to 90 degrees and test again.
Brakes certainly set correctly ..adjusted until almost locked, and backed off just enough that if you spin wheel .. it will do 1.5 rotations before drag stops it. (AlKo described method)

2. When I reverse and they lock on, looking at compensator, the swivel sections are not remaining in line showing that auto reverse is not releasing.
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Old 27 May 2018, 04:10   #36
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Id do as you plan and back off in the drums untill everything has run a little then readjust as needed
I always set brakes so they apply later ie under heavier braking rather than just with a dab on the pedal
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Old 27 May 2018, 13:07   #37
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Slackened off all 4 brakes .. it did put handbrake in fully 90 degree position ... thought it looked promising ... but no, the rear brakes lock on as soon as I reverse up a slope (my drive). ...which is by no means steep.
Double checked, there is around 5mm of plat in actuating rod.

Frustrating.
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Old 27 May 2018, 13:50   #38
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Why not try going the other way and back off the actuating rod untill it will reverse then see if you have brakes? If you do then great your sorted if not then back to the drawing board
Clearly following the recommended procedure isnt working so maybe an alternative might work
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Old 27 May 2018, 16:33   #39
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The only thing is .. AlKo state there should be zero play .... I have increased it in stages to 5+mm
It is already loose & rattling .... if I open anymore I may lose normal braking ?
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Old 27 May 2018, 17:46   #40
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Quote:
Originally Posted by Sargan View Post
The only thing is .. AlKo state there should be zero play .... I have increased it in stages to 5+mm
It is already loose & rattling .... if I open anymore I may lose normal braking ?
Like i said the standard setup procedure isnt working hence my suggestion to try a different tack
Obviously if you end up with no braking then its no good but i always seem to have loads of slack in my trailers operating rods which whilst maybe not to speck it works for me.
My background is motor trade & I've done brakes on lots of trailers and to be honest I've never read a set of set up instructions i just adjust so they work as i want them to work.
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