Problem with Alko ATC and brakes "locked on"

[BigTim]

I thought folk might be interested in a recent problem I had with my caravan ATC/Brakes.

I had ATC retrofitted to my Bailey Senator Arizona (2006) last summer by CMI, Alko's appointed agent. I had no problems with the system until recently. I have recently re-paved and widened the sloping, drive at our home and reversed the 'van on for the first time mid-March. On Saturday 4 April I tried to tow the 'van out with our Kia Sorento prior to setting off on our Easter Break. I was very surprised to find the 'van's brakes seized on. Despite rolling the 'van back and tapping the drums with a hammer the wheels remained firmly locked - skid marks on the new drive. I was particularly surprised as I had had new drums, shoes, etc, fitted last August after "burning them out" - handbrake came on whilst towing??

Tradetech, a mobile service agent, came out on the following Monday. Jacking up the 'van he found that the "actuation rod" on the ATC had "pulled out" locking the brakes. I was surprised to hear this as the ATC warning light was showing "green", ie, no fault. He felt that that the way the ATC had been connected meant that when the brakes were fully applied, in reverse, the ATC rod was too short. He, also, found that the brakes were unequally adjusted. He reconnected and adjusted the rod and the brakes and they then operated correctly.

Concerned that this problem might recur I phoned Alko the next day before setting off on holiday. The man I spoke to was very helpful and even phoned Tradetech to discuss his adjustments. The Alko man then phoned me back to reassure me that he was satisfied that Tradetech had dealt with the problem. The Alko man did say that if I did ever have a problem it is possible to disconnect the ATC so that the 'van could still be towed. However, I am a big bloke and I know that I would not find it easy to get under the 'van to do this.

I subsequently spoke with an engineer at CMI, fitters of my ATC. He said that it sounded as though the guy who fitted my the new brake shoes and drums to the 'van last August did not adjust the brakes correctly. He assured me that if, Tradetech has tightened up the locking nut on the brakes sufficiently there was no way that the ATC rod could "pull out" again. He pointed out that as the ATC system had operated properly on our 5 week/2K Mile trip around the Continent last summer indicated that the ATC and brakes were correctly set up at that time and that the problem only happened after the brakes had been repaired.

In mitigation of the guy who worked on the brakes I wonder how much Alko has made clear the brake adjustment necessary when ATC is fitted. The guy who repaired the brakes last August was very experienced and highly recommended.

Anyway the good news seems to be that the ATC worked correctly on our 200 mile Easter holiday journey. The bad news is no one accepted responsibility for the problem despite my having paid for £450 for brake repairs, £500 for the ATC and the cost of Tradetech rectifying the problem.

I would, however, say that I am still glad that I had ATC fitted as I think it provides a very useful operation which increases towing safety considerably.

Regards

Tim

 

[Paul_374295060]

Tim,

Thanks for your post on here and Caravantalk. Just in case you dont see it, I have sent you a private message on the caravantalk forum requesting further information.

As for the problem you experienced, I have discussed this internally with our Service Department and we would like to get an Engineer to come out and check over your brake system and at the same time we can connect ATC to the diagnostics to rule out any problems there. We can also confirm whether the Push Rod is actually the correct length or if it has been shortened for some reason. The push rod is a standard length for all variants of ATC and if it is shorter than normal then this will be investigated fully.

From the information provided here it and what you have posted on the Caravantalk forum it would seem that when the brakes were repaired, this wasnt carried out correctly given that Tradetech picked up the problem of poor adjustment almost immediately. I would be grateful if you would let us have the details of the AL-KO/Bailey Accredited Engineer that did the work for you, so that we can confirm how he carried out the repair to your brakes, as this will help us understand what might have caused the problem and why the push rod on ATC had come beyond the end of the guide tube.

We have been very explicit in our training provision regarding ATC and I personally held weekly training sessions over the past two winters, with our Service Centres and Bailey Service providers and made it clear that ATC does not need adjusting during brake servicing and repairs, unless there was a need to remove the brake rod to carry out repairs. When the brake rod is replaced for example, we provide the relevant adjustment information to ensure that everything is set correctly after this work is carried.

I think it is reasonable to say that ATC is not the cause of the problem, as you have done significant amounts of towing with ATC connected with no problem prior to this issue developing, and since then you have completed another 220 mile trip without the problem re-occuring.

Once again I apologise for not responding sooner, but if you can let me have a reply to my private message I will get our Service Manager, Angie Mears to give you a call and arrange a suitable time to visit you.

Thanks and best regards,

Paul Jones

Marketing Manager

AL-KO Kober Limited