Chassis technology for caravans: chassis, axles and braking systems

    Travel safely in your caravan with AL-KO VT chassis technology

    What does the caravan chassis consist of?

    The chassis technology for caravans includes everything that supports, guides and brakes your caravan: caravan axle, overrun device, brake and shock absorber. The axle from AL-KO VT uses rubber cords for suspension and is maintenance-free. This page explains the construction and helps you find the right components.

    A caravan chassis involves a few, precisely matched components working together. These elements include:

    • Axle: The rubber suspension axle supports the caravan and provides suspension via rubber cords between the hexagonal outer tube and triangular inner tube.
    • Overrun device: When braking, the mass inertia causes the caravan to compress against the towing vehicle. The overrun device then actuates the caravan’s wheel brakes via the linkage.
    • Wheel brake: Each brake is operated via the overrun device and keeps the set-up secure.
    • Shock absorber: Dampens axle oscillation and ensures smooth operation.
    • Drawbar and towing connection: Connect the axle and coupling to the tow vehicle.

    The chassis: System lightweight chassis and VARIO X

    The chassis is the frame that supports your caravan. AL-KO VT manufactures it as a system lightweight chassis – a galvanised frame that can be adapted to the size and weight of your caravan. It connects the axle, drawbar and body into a stable unit and forms the basis of the entire chassis technology.

    The VARIO X is the optimised, weight-reduced version. Its design is inspired by nature: honeycomb-shaped webs near the drawbar and branch-like structures around the axle give high stability with less material. Less weight on the frame means more usable payload for your travel luggage.

    • Weight: With the same permissible gross weight, the lighter chassis can give you additional payload reserves.
    • Payload: The weight savings are available to you as additional payload.
    • Construction: Approximately 30 per cent less steel in the four frame components, with precise laser perforations.
    • Material: Steel remains the supporting material and is fully recyclable.

    Lightweight chassis system

    High stability at a low weight. Optimum driving comfort and high level of driving safety.

    VARIO X lightweight chassis

    VARIO X - inspired by nature

    Caravan axle: Euro Delta trailing arm axle and hexagonal rubber suspension

    Caravan technology for high driving stability

    When you travel with your caravan or transport valuable items, nothing should get damaged. That’s why good suspension of the chassis is important. The >hexagonal rubber suspension from AL-KO VT provides greater ride comfort thanks to longer suspension travel and smooth damping. This is ensured by the independent wheel suspension. It enables each wheel to move independently. As a result, the caravan technology effectively absorbs road irregularities.

    A trip to the mountains with your caravan is a special adventure. For safe handling, the chassis should sit firmly in corners and effectively counteract rolling motion. This helps maintain optimum road contact. For added safety on twisty routes, the AL-KO VT Delta trailing arm axle features toe-in correction. This ensures stable driving during overtaking, in side winds, on bridges and when cornering. During these manoeuvres, the load is mainly on the outer wheel. The trailing arm axle with AL-KO VT caravan technology transfers this force to the axle stub of the wheel. Toe-in and negative camber increase, so the wheel counteracts centrifugal forces. This keeps the vehicle stable through bends.

    Euro Delta semi-trailing arm axle

    The AL‑KO Delta semi-trailing arm axle acts counter to centrifugal force.

    Hexagonal rubber suspension

    Relaxed driving with low material wear

    Enduro X chassis for off-road applications

    The new off-road single-axle chassis solution and centre section

    Maximum off-road performance. Discover the Enduro X: an off-road solution setting new standards – for everyone who travels away from paved roads. Whether on rough terrain, in professional use or for demanding leisure activities: Enduro X impresses with its true off-road capability and individually adjustable toe and camber settings.

    AL-KO Enduro X – The new off-road single-axle chassis solution & centre section

    Maximum all-terrain performance with the AL-KO Enduro X solution for off-road use

    Maintenance and care

    The rubber suspension axle on your caravan is maintenance-free. It absorbs loads via rubber cords between the hexagonal outer tube and the triangular inner tube, operates without steel springs and has no grease points that need regular attention.

    By contrast, you should keep an eye on the brake: have the wheel brakes and overrun device checked and adjusted once a year or before the start of the travel season, to keep the braking distance short and the combination safe.

    Shock absorbers should also be checked, as worn dampers allow the axle to oscillate more. This work is carried out by an AL-KO VT service point, which knows your chassis and installs the correct original parts.

    Frequently asked questions about caravan chassis technology

    The chassis consists of the axle, the overrun device on the drawbar, the wheel brakes and the shock absorbers. The axle supports the weight and provides suspension, the overrun device controls the brake. Together, they ensure safe and smooth driving.

    The rubber suspension axle itself is maintenance-free, as it works without grease points or steel springs. In contrast, you should have the wheel brakes regularly checked and adjusted – ideally once a year or before the season starts. An AL-KO VT service point can carry out this work for you.

    Depending on the model, the VARIO X saves around 25 to 30 kg compared to a conventional frame. This weight is available to you as extra payload. This is made possible by a nature-inspired construction with around 30 per cent less steel in the frame.

    The permissible axle load is shown on the axle's type plate and in the vehicle documents. AL-KO VT axles cover loads from 750 to 3,500 kg per axle. You must not exceed this value, even by increasing the payload.

    Whether an upgrade is possible must be checked for each individual caravan. Depending on chassis, axle, brake system, tyres and wheels, a change of documents may be sufficient or a technical conversion may be required. The caravan manufacturer must approve the higher permissible gross weight. After any necessary conversion, a recognised inspection organisation will check the vehicle; the amended details are then added to the vehicle documents by the registration authority.