AL-KO VT caravan payload increase services
Increasing the payload of your caravan – safely and professionally
Find out what a payload increase means, when it makes sense and what options AL-KO VT offers for your caravan
For more than 25 years, we have used our expertise as a chassis manufacturer to support customers with caravan payload increases. We carry out an individual assessment of your caravan to determine the measures needed to achieve your desired permissible gross weight. You can find detailed information on the available options in our blog. Michael Duckek, head of the customer centre in Kötz, also answers questions about caravan payload increases in a podcast by our partner CamperStyle. Listen now!
Want to know whether your caravan is eligible for a payload increase at AL-KO VT? Simply fill in our enquiry form and the checklist below. We will assess your request individually and get back to you shortly.
When is a payload increase worthwhile?
More payload means greater flexibility on your camping holiday
A payload increase is worthwhile whenever your caravan's permissible gross weight is no longer sufficient. Additional equipment, more luggage or changing travel habits can quickly exhaust the available payload. Increasing the permissible gross weight gives you additional payload reserves and allows you to adapt your caravan to your individual requirements.
Typical reasons for a payload increase:
- Retrofitting additional equipment: For example, air conditioning, awnings, solar panels or satellite systems all add to the weight of the vehicle and reduce the available payload.
- More luggage for holidays and leisure activities: Bicycles, kayaks, surfboards or other camping equipment require additional payload reserves.
- Changing travel habits: More people, pets or a more extensive camping set-up increase overall weight and make a payload increase worthwhile.
Overview of payload increase options
The available measures depend on the vehicle and the desired increase in permissible gross weight
Not every type of payload increase is suitable for every caravan. The decisive factors are the current and intended permissible gross weight, as well as the technical configuration of the axle, braking system, overrun device, frame, tyres and rims. As a general rule, the greater the desired increase in weight, the more extensive the required modifications to the chassis may be.
- Administrative increase (documentation only):
No technical modifications to the chassis are required for this type of payload increase. The caravan manufacturer checks the permissible gross weight for which the existing chassis is already designed and confirms this with a certificate of no objection. The manufacturer will usually also issue a new type plate.
This option is only possible for certain vehicles and normally results in a comparatively small payload increase.
- Replacing suspension components:
For this type of payload increase, the axles are removed and the existing rubber cords are replaced with stronger suspension elements. The length and hardness of the new axle rubbers are calculated according to the required weight increase. After installation, toe and camber are professionally adjusted.
- Replacing individual chassis components:
If replacing suspension components is not sufficient, further chassis components can be adapted. This may include axles, brakes, shock absorbers, the overrun device or frame parts. The vehicle's technical data are used to determine which components are already rated for the higher load and which need to be replaced.
By replacing individual chassis components, the permissible gross weight can be increased by up to 300 kilograms.
- Replacing the entire chassis:
If replacing individual components does not allow the required increase in permissible gross weight, the entire chassis can be replaced. In this case, the existing chassis is completely separated from the caravan body and replaced with a new chassis designed for the higher load.
Replacing the entire chassis can increase the permissible gross weight by up to 500 kilograms.
Important: Depending on the desired gross weight, the tyres and rims may also need to be replaced. You should also check that your towing vehicle remains suitable and that your driving licence category and any existing 100 km/h approval remain valid for the new weight limits.
Once the payload increase is complete, the new permissible gross weight must be approved by an authorised inspection body (e.g. TÜV or DEKRA) and entered in the vehicle documents. Depending on the new weight limit, your driving licence category, the 100 km/h approval and the permissible trailer load of your towing vehicle may also be affected.
Requirements for a caravan payload increase
Before any payload increase, we check which options are available for your caravan.
Not every caravan can undergo the same type of payload increase. The available options depend on the technical design of the vehicle and the desired permissible gross weight. That’s why, before any payload increase, we check which components are already rated for the higher load and whether technical modifications are necessary.
The following factors are assessed, among others:
- Vehicle data: Manufacturer, model, year of manufacture and current permissible gross weight.
- Chassis: Technical configuration of the axle, braking system, overrun device and frame.
- Tyres and rims: Load capacity and suitability for the intended gross weight.
- Existing additional equipment: For example, manoeuvring system, ATC anti-snaking system, GRP floor or other attachments.
- Available space: Sufficient wheel arch clearance and the technical feasibility of the planned payload increase.
Only after this technical assessment can we confirm which payload increase option is suitable for your caravan and which modifications may be required.
How does a caravan payload increase work?
Step by step to the right payload increase
To ensure the payload increase is tailored precisely to your caravan, we support you from the initial technical assessment through to the successful entry in the vehicle documents.
- Complete the checklist:
Fill in our checklist with the technical details of your caravan and send it to our service team. - Technical assessment:
Our experts check which payload increase options are available for your caravan and prepare an individual quote for you. - Approval from the manufacturer:
You then apply to your caravan manufacturer for approval of the planned payload increase. The manufacturer provides the required certificate of no objection and a new type plate. - Place the order:
Once all documents are complete, you can instruct AL-KO VT to carry out the payload increase. - Book an appointment:
We order the necessary components and arrange a suitable appointment with you at our customer centre. - Professional modification:
Our service technicians carry out all required modifications at our customer centre in Kötz or at another AL-KO VT customer centre. - Technical inspection:
Once the work is complete, your caravan will be inspected and approved by an authorised inspection body, such as TÜV or DEKRA. - Entry in the vehicle documents:
In the final step, you arrange for the new permissible gross weight to be entered in your vehicle documents by the registration authority. - More payload for your next holiday:
Once the new weight has been entered in the vehicle documents, you can use your caravan with its increased permissible gross weight and benefit from the additional payload.
Costs of a payload increase
Every payload increase is as individual as your caravan. As a chassis manufacturer, we cannot determine the available options or costs based solely on the caravan model. We therefore need your completed checklist as the basis for our assessment. This information allows us to identify the individual components in your caravan and their technical specifications, so we can prepare a customised quote. As a guide, the simplest type of payload increase, replacing suspension elements, starts at around €1,800, while the base price for a full chassis replacement is €5,800. Depending on which components need to be replaced or installed, additional costs may apply to each payload increase option.
Interested? Request a quote now!
Would you like to increase the payload of your caravan? Simply complete the enquiry form and checklist below. We will assess your request individually and get back to you shortly.
Our service team at the customer centres will also be happy to answer any questions you may have.
Legal notice
After a successful payload increase, the new permissible gross weight must be inspected and approved by an authorised inspection body (e.g. TÜV or DEKRA) and then entered in the vehicle documents. Depending on the payload increase, your driving licence category, the permissible trailer load of your towing vehicle and the 100 km/h approval may also be affected.
