AL-KO G&S Chassis Caravan Product guide

This handbook contains important warranty and service information
concerning your new caravan chassis, suspension and other
components manufactured by G&S Chassis.
Warranty and Service
Hand book
ChassisNo:.........................
GandS GS Warranty Book AAC 2019.indd 1 22/10/2019 12:55:27 PM

GandS GS Warranty Book AAC 2019.indd 2 22/10/2019 12:55:27 PM
Identication Information .................................................................. 4
Introduction .................................................................................... 5
Purpose of this Handbook .................................................................. 6
The G&S Chassis Suspension Warranty .............................................. 11
Safety .................................................................................... 12
Before Towing .................................................................................... 12
Types of Use .................................................................................... 13
Tow Coupling Height .................................................................. 13
Towing .................................................................................... 14
“Limp Home” Capability ................................................................. 14
Jacking .................................................................................... 15
Off-road Use .................................................................................... 15
How should an off-road caravan be used? .............................................. 16
Suspension Types .................................................................. 19
Maintenance .................................................................................... 21
Service Schedule ................................................................. 21
The First Inspection .................................................................. 21
The First Inspection Checklist .................................................................. 22
After the First Inspection - Routine Service Schedule .............................................. 24
How to Tighten Wheels .................................................................. 28
Service and Maintenance Record .................................................................. 31
Table of Contents
GandS GS Warranty Book AAC 2019.indd 3 22/10/2019 12:55:27 PM

GandS GS Warranty Book AAC 2019.indd 2 22/10/2019 12:55:27 PM
Identication Information .................................................................. 4
Introduction .................................................................................... 5
Purpose of this Handbook .................................................................. 6
The G&S Chassis Suspension Warranty .............................................. 11
Safety .................................................................................... 12
Before Towing .................................................................................... 12
Types of Use .................................................................................... 13
Tow Coupling Height .................................................................. 13
Towing .................................................................................... 14
“Limp Home” Capability ................................................................. 14
Jacking .................................................................................... 15
Off-road Use .................................................................................... 15
How should an off-road caravan be used? .............................................. 16
Suspension Types .................................................................. 19
Maintenance .................................................................................... 21
Service Schedule ................................................................. 21
The First Inspection .................................................................. 21
The First Inspection Checklist .................................................................. 22
After the First Inspection - Routine Service Schedule .............................................. 24
How to Tighten Wheels .................................................................. 28
Service and Maintenance Record .................................................................. 31
Table of Contents
GandS GS Warranty Book AAC 2019.indd 3 22/10/2019 12:55:27 PM

Identication Information
The following information should be lled in by your
caravan manufacturer:
Chassis Number: ________________________________________________________________________________________
Date of Manufacture: ________________________________________________________________________________________
Suspension type: ________________________________________________________________________________________
Suspension Serial No: ________________________________________________________________________________________
(Control Rider and Road Rider only)
Aggregate trailer mass (ATM) rating: __________________________ kg
Gross trailer mass (GTM) rating: __________________________ kg
Tare mass: __________________________ kg
Load capacity: __________________________ kg
Note:
• Aggregate trailer mass and gross trailer mass assigned by the caravan manufacturer may be less than
the maximum rating for the chassis.
• The maximum GTM for which the chassis is rated may be found on the G&S Chassis plate afxed to
the A-frame.
Warranty and Service Hand book
04
GandS GS Warranty Book AAC 2019.indd 4 22/10/2019 12:55:27 PM

Identication Information
The following information should be lled in by your
caravan manufacturer:
Chassis Number: ________________________________________________________________________________________
Date of Manufacture: ________________________________________________________________________________________
Suspension type: ________________________________________________________________________________________
Suspension Serial No: ________________________________________________________________________________________
(Control Rider and Road Rider only)
Aggregate trailer mass (ATM) rating: __________________________ kg
Gross trailer mass (GTM) rating: __________________________ kg
Tare mass: __________________________ kg
Load capacity: __________________________ kg
Note:
• Aggregate trailer mass and gross trailer mass assigned by the caravan manufacturer may be less than
the maximum rating for the chassis.
• The maximum GTM for which the chassis is rated may be found on the G&S Chassis plate afxed to
the A-frame.
Warranty and Service Hand book
04
GandS GS Warranty Book AAC 2019.indd 4 22/10/2019 12:55:27 PM
Introduction
Congratulations on the purchase of your new caravan with its chassis and/or suspension system
manufactured by G&S Chassis. Your chassis may be equipped with the following:
• Control Rider independent suspension, or
• Control Rider TS independent suspension, or
• G&S Chassis leaf spring suspension, or
• One of several suspension systems manufactured by third party suppliers (eg Simplicity, AL-KO,
Torflex, Cruisemaster, etc).
If you purchased a suspension for tment to your own chassis, your suspension will be one of three
designed, manufactured and warranted by G&S Chassis:
• Control Rider independent suspension, or
• Control Rider TS independent suspension, or
• G&S Chassis leaf spring suspension.
Our products are designed and manufactured to ensure a rewarding, trouble free experience. Please take
the time to read this manual as well as the accompanying suspension and brake documentation supplied in
the front pouch. The more you know about your new purchase, the greater the safety and pleasure you will
derive from it.
Regular inspection and servicing of items such as wheel nuts, chassis frame, tow couplings, suspension,
brakes, bearings and tyres helps maintain safety, reliability and value.
www.gnschassis.com.au 05
GandS GS Warranty Book AAC 2019.indd 5 22/10/2019 12:55:27 PM

G&S Chassis Warranty and Service Handbook www.gnschassis.com.au
The purpose of this handbook is to complement the owner’s handbook supplied by the caravan
manufacturer, and that supplied by the tow vehicle manufacturer, and must be read in conjunction
with the information therein.
This handbook contains important information concerning your warranty and other consumer rights
and responsibilities.
Purpose of this Handbook
6
Purpose of this Handbook
The purpose of this handbook is to complement the owner’s handbook supplied by the caravan
manufacturer, and that supplied by the tow vehicle manufacturer, and must be read in conjunction with the
information therein.
This handbook contains important information concerning your warranty and other consumer rights and
responsibilities.
Warranty and Service Hand book
06
GandS GS Warranty Book AAC 2019.indd 6 22/10/2019 12:55:29 PM

G&S Chassis Warranty and Service Handbook www.gnschassis.com.au
The purpose of this handbook is to complement the owner’s handbook supplied by the caravan
manufacturer, and that supplied by the tow vehicle manufacturer, and must be read in conjunction
with the information therein.
This handbook contains important information concerning your warranty and other consumer rights
and responsibilities.
Purpose of this Handbook
6
Purpose of this Handbook
The purpose of this handbook is to complement the owner’s handbook supplied by the caravan
manufacturer, and that supplied by the tow vehicle manufacturer, and must be read in conjunction with the
information therein.
This handbook contains important information concerning your warranty and other consumer rights and
responsibilities.
Warranty and Service Hand book
06
GandS GS Warranty Book AAC 2019.indd 6 22/10/2019 12:55:29 PM
The G&S Chassis 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.
G&S Chassis warrants to the owner that, subject to the exclusions below, it will at any time during the
periods and/ or distance travelled according to Table 1. below at its option repair, replace or adjust free
of charge any part of the goods which it nds to be defective in factory materials or workmanship under
normal use and operation within Australia provided that:
a) The goods have not become defective as a result or consequence of the owner’s failure:
i. To properly maintain, use or operate the goods in accordance with all recommendations and
instructions of G&S Chassis and the caravan manufacturer, and the capacity and operating
limitations specied by G&S Chassis and the caravan manufacturer; or
ii. To have the caravan, including its chassis and suspension properly, regularly and punctually
serviced in accordance with the instructions and recommendations specied for the goods by G&S
Chassis and the caravan manufacturer.
b) The goods are under normal circumstances delivered at the owner’s expense to the servicing dealer
to carry out the G&S Warranty Service as soon as possible after the need for such service becomes
apparent.
The terms of the G&S Chassis Warranty include the accompanying Explanatory Statement.
Exclusions
Unless G&S Chassis expressly agrees, this warranty will not apply to any defect in, or which is attributable
to, or to the use of, any modication made to the goods (including by the caravan manufacturer) unless
such modication has been made by or at the direction of G&S Chassis.
www.gnschassis.com.au 07
GandS GS Warranty Book AAC 2019.indd 7 22/10/2019 12:55:29 PM

The G&S Chassis Warranty
Should there be a warranty concern regarding any third party component supplied as part of your chassis
or suspension, G&S Chassis undertakes to provide reasonable assistance to the caravan owner to have the
matter resolved satisfactorily.
The terms of this Warranty will cease to apply to any caravan or chassis which G&S Chassis believes, on
reasonable grounds, has been written off.
Items not covered by the G&S Chassis Warranty are as follows:
a) Maintenance costs and wear and tear items including wheel balance and alignment, brake adjustment,
removal of rattles and squeaks and the general tightening up of components, addition of lubricants,
repair/rectication of paint damage, chips, dents, scratches and marks, repair/rectication of damage
to galvanising (where applicable) including chips, dents, scratches and marks.
b) Corrosion arising as a result of chips, dents, scratches and marks.
c) Any corrosion arising more than one year after the warranty commencement date.
d) Damage caused by overloading or incorrect load distribution.
e) Damage caused by use in off-road applications or over rough roads and terrain where the caravan is
not designed and equipped for such operation.
f) Damage caused by improper use of load levelling devices (e.g. using a load levelling device to correct
the front to rear attitude and/or towing behaviour of an incorrectly laden caravanand/or towing
vehicle).
g) Tyre replacement due to normal wear, damage such as cuts, snags, bruises and bulges, damage
caused by punctures or tyre repair, damage caused by improper inflation or alignment, speeding,
overloading or improper mounting or dismounting.
h) Damage due to impact with objects, persons, animals or other vehicle(s) unless it can be shown that
the impact was directly attributable to a defect in materials or workmanship covered by the G&S
Chassis Warranty.
i) Goods supplied by third parties. These include: wheel caps, wheels, tyres, jockey wheels, couplings,
springs, axles, wheel bearings, brakes, wheel hubs, wheel nuts, wheel studs and shock absorbers.
j) Damage resulting from and directly attributable to any work performed by the caravan manufacturer.
Warranty and Service Hand book
08
GandS GS Warranty Book AAC 2019.indd 8 22/10/2019 12:55:29 PM

The G&S Chassis Warranty
Should there be a warranty concern regarding any third party component supplied as part of your chassis
or suspension, G&S Chassis undertakes to provide reasonable assistance to the caravan owner to have the
matter resolved satisfactorily.
The terms of this Warranty will cease to apply to any caravan or chassis which G&S Chassis believes, on
reasonable grounds, has been written off.
Items not covered by the G&S Chassis Warranty are as follows:
a) Maintenance costs and wear and tear items including wheel balance and alignment, brake adjustment,
removal of rattles and squeaks and the general tightening up of components, addition of lubricants,
repair/rectication of paint damage, chips, dents, scratches and marks, repair/rectication of damage
to galvanising (where applicable) including chips, dents, scratches and marks.
b) Corrosion arising as a result of chips, dents, scratches and marks.
c) Any corrosion arising more than one year after the warranty commencement date.
d) Damage caused by overloading or incorrect load distribution.
e) Damage caused by use in off-road applications or over rough roads and terrain where the caravan is
not designed and equipped for such operation.
f) Damage caused by improper use of load levelling devices (e.g. using a load levelling device to correct
the front to rear attitude and/or towing behaviour of an incorrectly laden caravanand/or towing
vehicle).
g) Tyre replacement due to normal wear, damage such as cuts, snags, bruises and bulges, damage
caused by punctures or tyre repair, damage caused by improper inflation or alignment, speeding,
overloading or improper mounting or dismounting.
h) Damage due to impact with objects, persons, animals or other vehicle(s) unless it can be shown that
the impact was directly attributable to a defect in materials or workmanship covered by the G&S
Chassis Warranty.
i) Goods supplied by third parties. These include: wheel caps, wheels, tyres, jockey wheels, couplings,
springs, axles, wheel bearings, brakes, wheel hubs, wheel nuts, wheel studs and shock absorbers.
j) Damage resulting from and directly attributable to any work performed by the caravan manufacturer.
Warranty and Service Hand book
08
GandS GS Warranty Book AAC 2019.indd 8 22/10/2019 12:55:29 PM
The G&S Chassis Warranty
k) Damage resulting from any failure of the caravan manufacturer to properly inspect and service the
caravan prior to delivery to the customer. It is expected that checklists or other documentary evidence
will be provided to and retained by the customer upon completion of this pre-delivery service and
inspection.
l) Damage to shock absorbers due to overheating (ie. towing over rough terrain for extended periods with
inadequate cooling off periods). Note it is recommended that the minimum rest period be 45 minutes
per 2 hours travel.
m) Damage caused by the use of an inappropriate tow vehicle (eg one which has insufcient towing
capacity, or the use of a tow vehicle having a gross vehicle mass exceeding 3.5 tonnes (unless your
chassis is designed and constructed for use with a vehicle up to 4.5 tonne GVM)).
n) Damage due to the use of a tow vehicle which is equipped with an inadequate or unsuitable tow bar,
tow hitch or coupling.
o) Damage due to the owner’s failure to correctly connect the tow vehicle to the goods being towed.
p) Any undesirable towing characteristics arising as a direct result of the caravan manufacturer’s layout
of items such as furniture, ttings, xtures and appliances.
q) Damage resulting from improper repairs or improperly installed parts by person other than an
authorised agent of G&S Chassis.
Warranty Claims
a) If a defect covered by this Warranty occurs, the customer must contact the dealership from which the
caravan was purchased as soon as possible after the defect becomes apparent. G&S Chassis is not
obliged or required to cover the cost of repairs or parts if prior authorisation by G&S Chassis has not
been received.
b) The customer must take the goods to any servicing workshop authorised by G&S Chassis for Warranty
service.
c) Any warranty claim must be accompanied by:
i. proof of purchase;
ii. full details of the alleged defect; and
iii. all appropriate documentation, including a log book of dates, distances and routes travelled,
locations visited, receipts of servicing and repair work performed during the warranty period.
d) Parts and labour used and supplied in carrying out any G&S Chassis Warranty Service at the servicing
workshop authorised by G&S Chassis are free of charge.
www.gnschassis.com.au 09
GandS GS Warranty Book AAC 2019.indd 9 22/10/2019 12:55:29 PM

The G&S Chassis Warranty
e) Unless you and G&S Chassis otherwise agree, you will be required to bear all costs and expenses
incurred in transporting the chassis to, and collecting it from, the servicing workshop’s premises.
f) The benets of the G&S Chassis 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 modied.
Table 1. Warranty Duration
Item Warranty Duration from the date of rst supply to
the owner
Chassis structural 5 years unlimited kilometres
Chassis corrosion – pre-coated steel, then painted
on completion 12 months unlimited kilometres
Chassis corrosion – hot dip galvanised 12 months unlimited kilometres
Control Rider suspension 3 years or 75,000 km whichever occurs rst
Control Rider TS suspension 3 years or 75,000 km whichever occurs rst
G&S Chassis leaf spring suspension 12 months or 25,000 km whichever occurs rst
Other suspensions not manufactured by G&S
Chassis
Not covered by G&S Chassis warranty – refer to
manufacturer’s warranty for details
Parts and accessories (eg, spare wheel holders,
jerrycan holders) 12 months unlimited kilometres
Warranty and Service Hand book
10
GandS GS Warranty Book AAC 2019.indd 10 22/10/2019 12:55:29 PM

The G&S Chassis Warranty
e) Unless you and G&S Chassis otherwise agree, you will be required to bear all costs and expenses
incurred in transporting the chassis to, and collecting it from, the servicing workshop’s premises.
f) The benets of the G&S Chassis 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 modied.
Table 1. Warranty Duration
Item Warranty Duration from the date of rst supply to
the owner
Chassis structural 5 years unlimited kilometres
Chassis corrosion – pre-coated steel, then painted
on completion 12 months unlimited kilometres
Chassis corrosion – hot dip galvanised 12 months unlimited kilometres
Control Rider suspension 3 years or 75,000 km whichever occurs rst
Control Rider TS suspension 3 years or 75,000 km whichever occurs rst
G&S Chassis leaf spring suspension 12 months or 25,000 km whichever occurs rst
Other suspensions not manufactured by G&S
Chassis
Not covered by G&S Chassis warranty – refer to
manufacturer’s warranty for details
Parts and accessories (eg, spare wheel holders,
jerrycan holders) 12 months unlimited kilometres
Warranty and Service Hand book
10
GandS GS Warranty Book AAC 2019.indd 10 22/10/2019 12:55:29 PM
The G&S Chassis Warranty
Should you have a warranty concern with your caravan chassis or suspension (the goods), you must
contact your caravan dealer as soon as possible. Your dealer will contact G&S Chassis on your behalf. The
contact details for G&S Chassis are as follows:
Postal address:
PO Box 931
SOMERTON VIC 3062
Physical address:
20-22 Ainslie Road
CAMPBELLFIELD VIC 3061
Telephone: [phone]
Contact: Warranty Manager
Email: [email protected]
G&S Chassis reserves the right to replace defective parts of the caravan chassis or suspension with parts
and components of similar quality, grade and composition where an identical part or component is not
available. Caravan chassis or suspension presented for repair may be replaced by refurbished units of
the same type rather than being repaired. Refurbished parts may be used to repair the caravan chassis or
suspension.
www.gnschassis.com.au 11
GandS GS Warranty Book AAC 2019.indd 11 22/10/2019 12:55:29 PM

Safety
Disclaimer: The following general information and recommendations concerning towing do not take
into account your particular vehicle, equipment and circumstances and should not be relied upon as a
substitute for professional advice for your specic circumstances. G&S Chassis provides no warranty
in relation to the accuracy or currency of the information contained in this Handbook, and accepts no
responsibility for this general information or for any loss or damage arising out of use or reliance on it.
For detailed advice concerning towing, consumers must consult their specic towing vehicle owner’s
handbook.
WARNING
The instructions supplied by the tow vehicle manufacturer must be read, understood and adhered to
at all times. The operator has a responsibility to be familiar with the instructions regarding towing.
Noncompliance with the instructions in this handbook, the towing vehicle handbook, or the law may
result in property damage or serious injury.
Before Towing
• Check that tyres are properly inflated to the cold inflation pressure recommended for the caravan load
over the wheels. See page 30 for more details.
• Check that wheel nuts are correctly tensioned. See page 29 for more details.
• Check the tow coupling and load levelling hitch (where tted) and electrical connections to ensure
the caravan is properly secured to your tow vehicle and that the caravan has a slightly “nose down”
attitude.
• Check that the tow coupling download is between 8% to 15% of the total mass of the load being towed.
A bathroom scale and bridge arrangement may be used to perform a check of tow coupling download.
It is understood relatively inexpensive electronic scales are now available to facilitate this check.
• Remove the jockey wheel
• Check operation of all lights and light signalling devices
• Check adjustment of rear view mirrors
• Check adjustment of park brakes
• Check operation of brakes and adjustment of brake controller
• Check operation electronic sway control if tted
Warranty and Service Hand book
12
GandS GS Warranty Book AAC 2019.indd 12 22/10/2019 12:55:29 PM

Safety
Disclaimer: The following general information and recommendations concerning towing do not take
into account your particular vehicle, equipment and circumstances and should not be relied upon as a
substitute for professional advice for your specic circumstances. G&S Chassis provides no warranty
in relation to the accuracy or currency of the information contained in this Handbook, and accepts no
responsibility for this general information or for any loss or damage arising out of use or reliance on it.
For detailed advice concerning towing, consumers must consult their specic towing vehicle owner’s
handbook.
WARNING
The instructions supplied by the tow vehicle manufacturer must be read, understood and adhered to
at all times. The operator has a responsibility to be familiar with the instructions regarding towing.
Noncompliance with the instructions in this handbook, the towing vehicle handbook, or the law may
result in property damage or serious injury.
Before Towing
• Check that tyres are properly inflated to the cold inflation pressure recommended for the caravan load
over the wheels. See page 30 for more details.
• Check that wheel nuts are correctly tensioned. See page 29 for more details.
• Check the tow coupling and load levelling hitch (where tted) and electrical connections to ensure
the caravan is properly secured to your tow vehicle and that the caravan has a slightly “nose down”
attitude.
• Check that the tow coupling download is between 8% to 15% of the total mass of the load being towed.
A bathroom scale and bridge arrangement may be used to perform a check of tow coupling download.
It is understood relatively inexpensive electronic scales are now available to facilitate this check.
• Remove the jockey wheel
• Check operation of all lights and light signalling devices
• Check adjustment of rear view mirrors
• Check adjustment of park brakes
• Check operation of brakes and adjustment of brake controller
• Check operation electronic sway control if tted
Warranty and Service Hand book
12
GandS GS Warranty Book AAC 2019.indd 12 22/10/2019 12:55:29 PM
Safety
Types of Use
A caravan is primarily designed as a home on wheels, not for the carriage of goods. It will have sufcient
load capacity for the carriage of a reasonable quantity of personal possessions, including food, utensils,
clothing and water. The load capacity of your caravan is assigned by the caravan manufacturer.
Unless tted to a caravan or chassis with features designed for off-road application, your caravan chassis
and suspension is designed to operate primarily on sealed highways. It may also be used intermittently on
well maintained unsealed roads. Use on unsealed roads in poor condition (e.g. corrugations) or off-road
(other than for short distances and at low speeds) will void warranty.
Tow Coupling Height
Check the tow vehicle owner’s handbook to ensure your vehicle is capable of towing the caravan or trailer.
Where load levelling hitches are specied, these must be used. Please note that load levelling hitches
are designed to return a correctly laden tow vehicle and caravan to a near level attitude – NOT to correct
changes in vehicle attitude due to overloading or incorrect load distribution. A tow coupling download of
between 8% and 15% of ATM is recommended. You should check the information supplied with your vehicle
or towbar to ensure your towbar and ttings are designed to withstand this load.
The suspension system on your trailer or caravan is designed to operate correctly with the chassis level or
with a slightly “nose down” attitude. It is therefore essential that the tow coupling height of the fully laden
tow vehicle and caravan be adjusted accordingly. A height adjustable hitch may be required.
Vertical measurement “A” is from 25 mm to 40 mm less than measurement “B” Illustration of “nose down”
attitude
www.gnschassis.com.au 13
GandS GS Warranty Book AAC 2019.indd 13 22/10/2019 12:55:29 PM

Safety
Towing
Begin by towing at low speeds to ensure brakes are working properly and controller is set correctly. The
ideal setting for the brake controller is achieved when the caravan is not either pulling up the tow vehicle or
pushing it along when brakes are applied.
“Limp Home” Capability
If tted, the independent suspension is equipped with bump stops so that in the unlikely event of failure
of a spring and/or shock absorber, your caravan may travel to the nearest suitable workshop for repairs.
Other suspension systems or types of failures may result in the caravan being unable to be moved if
broken. In all cases, a careful safety assessment must be carried out prior to moving a caravan with a
broken suspension. If there is a risk of further damage, loss of control or an impact, the caravan must not
be moved, except with extreme care to a place where it does not constitute a safety hazard to other road
users.
If moving a caravan with broken suspension, it may be benecial to temporally reduce tyre pressure to
the minimum recommended for your tyres to improve ride quality. Extreme care, low speeds and frequent
stops are required if towing under such conditions. Tyres must be inflated to their normal pressure on
completion of repairs.
Warranty and Service Hand book
14
GandS GS Warranty Book AAC 2019.indd 14 22/10/2019 12:55:29 PM

Safety
Towing
Begin by towing at low speeds to ensure brakes are working properly and controller is set correctly. The
ideal setting for the brake controller is achieved when the caravan is not either pulling up the tow vehicle or
pushing it along when brakes are applied.
“Limp Home” Capability
If tted, the independent suspension is equipped with bump stops so that in the unlikely event of failure
of a spring and/or shock absorber, your caravan may travel to the nearest suitable workshop for repairs.
Other suspension systems or types of failures may result in the caravan being unable to be moved if
broken. In all cases, a careful safety assessment must be carried out prior to moving a caravan with a
broken suspension. If there is a risk of further damage, loss of control or an impact, the caravan must not
be moved, except with extreme care to a place where it does not constitute a safety hazard to other road
users.
If moving a caravan with broken suspension, it may be benecial to temporally reduce tyre pressure to
the minimum recommended for your tyres to improve ride quality. Extreme care, low speeds and frequent
stops are required if towing under such conditions. Tyres must be inflated to their normal pressure on
completion of repairs.
Warranty and Service Hand book
14
GandS GS Warranty Book AAC 2019.indd 14 22/10/2019 12:55:29 PM
Safety
Jacking
If it is necessary to jack your caravan you may do so using the jacking points on the chassis and
recommended jacking procedure as follows:
• Park the caravan and towing vehicle on a level or near level site, as far off the road as practicable.
• Leave the caravan attached to the tow vehicle if possible.
• Choose a rm site that will support the load without the jack sinking into the ground.
• Turn hazard lights on. In low light conditions, also turn on parking lights.
• Apply the parking brakes on the caravan and tow vehicle.
• Chock the caravan wheels on the opposite side of the van to the side being jacked.
• Slightly loosen the wheel nuts of the affected wheel before jacking.
• Locate the correct jacking point on the caravan chassis, generally choosing the one closest to the
affected wheel.
• Jack the caravan until the affected wheel is clear of the ground and is able to be removed.
• Remove and replace the wheel and re-tighten wheel nuts (see page 29 for correct wheel tightening
procedure).
• Check wheel nut tension with wheel lowered to the ground.
WARNING
Never get under a caravan supported by a jack as serious injury may occur.
Off-road Use
Caravans designed for off-road use will be tted with a special tow coupling to enable more relative
movement between the tow vehicle and caravan. The chassis will be of stronger design and ground
clearance will be greater than normal. Heavy duty light truck or 4WD tyres will be tted.
WARNING
Many caravan owners have found to their cost that their caravan is unsuitable for extended use over
rough terrain, including unmade and/or poorly maintained roads. Before undertaking such journeys, the
owner must obtain specic advice from their caravan manufacturer that their caravan is designed and
warranted for such use.
www.gnschassis.com.au 15
GandS GS Warranty Book AAC 2019.indd 15 22/10/2019 12:55:29 PM

Safety
How should an off-road caravan be
used?
The caravan operator has a duty of care to themselves, their passengers and other road users to use
their caravan in a manner that eliminates as far as practicable the risk of accidents, injury or failure of
components. This means that off–road caravans must be operated as follows:
• Off-road caravans must be towed using a suitable vehicle having adequate towing capacity. This
normally means using a vehicle with features designed for 4 wheel drive operation, as well as a heavy
duty tow hitch. So-called “soft” off road vehicles are generally regarded as unsuitable for towing
caravans in out of the way places.
• To access off-road sites, it may be necessary to traverse rough, unmade areas, damaged (e.g. deeply
rutted) tracks, or steep inclines. To avoid both cosmetic and structural damage, owners must travel
slowly and carefully in such situations. It may be necessary at times to have an observer stationed
outside the towing vehicle, positioned so they may easily communicate with the driver.
• Adjust speed to the conditions. Generally the more rugged the terrain or the rougher the road, the
slower the speed should be. For example, increasing speed in an attempt to have the caravan become
airborne (“float”) over corrugations can result in failure of springs, shock absorbers, A-frames and
other structural and non-structural components.
• As the terrain becomes more rugged, increase the frequency of stops to inspect the caravan for signs
of damage.
• As always, ensure that tyres are inflated to the correct pressure for the load being imposed on each
tyre. Under inflation, while appearing to improve ride quality, makes tyres more prone to impact
damage and damage due to overheating. Over inflation compromises ride quality and increases stress
on suspension components, chassis structure, and ttings and xtures such as plumbing, electrical, air
conditioning, refrigerator, gas equipment, etc.
• Tightness of wheel nuts must be checked more frequently. The wheel tightening procedure is fully
explained later in this Handbook.
• Check tyres frequently for signs of uneven or abnormal wear, or damage to tread or sidewalls. Uneven
wear usually means wheel alignment is required, while damaged tread or sidewalls usually occurs as a
result of under inflation and/or impact. Travelling over gravel roads for extended periods will result in
decreased tyre life.
Warranty and Service Hand book
16
GandS GS Warranty Book AAC 2019.indd 16 22/10/2019 12:55:29 PM

Safety
How should an off-road caravan be
used?
The caravan operator has a duty of care to themselves, their passengers and other road users to use
their caravan in a manner that eliminates as far as practicable the risk of accidents, injury or failure of
components. This means that off–road caravans must be operated as follows:
• Off-road caravans must be towed using a suitable vehicle having adequate towing capacity. This
normally means using a vehicle with features designed for 4 wheel drive operation, as well as a heavy
duty tow hitch. So-called “soft” off road vehicles are generally regarded as unsuitable for towing
caravans in out of the way places.
• To access off-road sites, it may be necessary to traverse rough, unmade areas, damaged (e.g. deeply
rutted) tracks, or steep inclines. To avoid both cosmetic and structural damage, owners must travel
slowly and carefully in such situations. It may be necessary at times to have an observer stationed
outside the towing vehicle, positioned so they may easily communicate with the driver.
• Adjust speed to the conditions. Generally the more rugged the terrain or the rougher the road, the
slower the speed should be. For example, increasing speed in an attempt to have the caravan become
airborne (“float”) over corrugations can result in failure of springs, shock absorbers, A-frames and
other structural and non-structural components.
• As the terrain becomes more rugged, increase the frequency of stops to inspect the caravan for signs
of damage.
• As always, ensure that tyres are inflated to the correct pressure for the load being imposed on each
tyre. Under inflation, while appearing to improve ride quality, makes tyres more prone to impact
damage and damage due to overheating. Over inflation compromises ride quality and increases stress
on suspension components, chassis structure, and ttings and xtures such as plumbing, electrical, air
conditioning, refrigerator, gas equipment, etc.
• Tightness of wheel nuts must be checked more frequently. The wheel tightening procedure is fully
explained later in this Handbook.
• Check tyres frequently for signs of uneven or abnormal wear, or damage to tread or sidewalls. Uneven
wear usually means wheel alignment is required, while damaged tread or sidewalls usually occurs as a
result of under inflation and/or impact. Travelling over gravel roads for extended periods will result in
decreased tyre life.
Warranty and Service Hand book
16
GandS GS Warranty Book AAC 2019.indd 16 22/10/2019 12:55:29 PM
Safety
• Off road caravans require more frequent servicing, and may require more frequent adjustment and/or
replacement of components subject to wear. Refer to the service schedule in the following pages.
• Due to the generally higher centre of gravity of off-road caravans, operators must take additional
care when cornering, braking, and overtaking or being overtaken by other vehicles, especially heavy
vehicles. Drivers must be vigilant and must attempt to anticipate situations so they may adjust their
speed well in advance.
• As the caravan load increases, so too does the stress and wear on suspension and structural
components. It is therefore recommended that owners carry only the quantity of food, personal
belongings, tools, water and equipment essential for a safe and enjoyable journey. An off-road caravan,
like all other caravans, is designed primarily as a home on wheels and for carriage of items essential
to safe and enjoyable holidaying. Therefore, owners must be aware of the load carrying capacity of
their van and must avoid overloading, or distributing the load incorrectly. The load capacity may be
found by looking at the compliance plate, where the tare mass and aggregate trailer mass is stamped
or engraved. The payload capacity is the aggregate trailer mass (ATM) minus the tare mass, and
includes the mass of water carried in the caravan and any aftermarket equipment tted to the caravan
or chassis. The mass of water in kilograms is equal to the number of litres of water being carried. In
many cases, it is not necessary to ll water tanks to capacity, as sufcient water is available at many
destinations.
• As with all caravans, load distribution is vital. Sufcient tow coupling download must be provided to
enable stable, sway free towing, while care must also be taken to ensure the towing capacity and rear
axle load capacity of the towing vehicle are not exceeded. Tow coupling download should normally be
between 8% and 15% of the mass of the fully laden caravan. Load levelling devices are encouraged, but
must not be used to correct the front to rear attitude of an incorrectly loaded caravan or overloaded
towing vehicle. Some levelling devices may be unsuitable for off-road operation. Check with the
manufacturer if in doubt.
• Setting up – choose a site that is a close to level as possible and use corner stabilisers, each of which
must be in proper contact with the ground. Ensure that the ground under each stabiliser is sufciently
stable to adequately support the van. If setting up on ground that is not level, it may be necessary to
use a spacer block between the stabiliser foot and theground. Blocks must be of solid timber or metal.
Do not use bricks, paving blocks, etc.
www.gnschassis.com.au 17
GandS GS Warranty Book AAC 2019.indd 17 22/10/2019 12:55:30 PM

G&S Chassis Warranty and Service Handbook www.gnschassis.com.au
How to orient stabiliser legs
For greater stability, stabiliser legs should be oriented outwards as shown above (circled).
Front legs inclined towards the front, rear legs inclined towards the rear.
Generally, 1 to 2 “clicks” from vertical is sufficient, depending on the height of the chassis above the ground.
WARNING
Stabiliser legs must not be used to jack any wheel or wheels clear of the ground, as structural damage and
cosmetic damage may occur. Such damage is not covered by the G&S Chassis warranty.
•Be extremely vigilant regarding the weather. Weather in remote locations may change rapidly, making it
impossible to leave when desired.
•Fire in Australia is an ever-present threat – know what fires are burning in the area in which you are
travelling, and always heed the advice of authorities such as fire service and police. Always have an escape
plan and choose locations that preferably have more than one escape route. In an emergency, be prepared
to leave your caravan behind if it means saving your life or those of your family and friends. If in doubt, do
not enter a fire affected or fire prone area.
•Make yourself aware of any fire restrictions and camping regulations and abide by these at all times.
Safety
18
acturer that their caravan
is designed and warranted
for such use.
Safety
How to orient stabiliser legs
For greater stability, stabiliser legs should be oriented outwards as shown above (circled).
Front legs inclined towards the front, rear legs inclined towards the rear.
Generally, 1 to 2 “clicks” from vertical is sufcient, depending on the height of the chassis above the
ground.
WARNING
Stabiliser legs must not be used to jack any wheel or wheels clear of the ground, as structural damage
and cosmetic damage may occur. Such damage is not covered by the G&S Chassis warranty.
• Be extremely vigilant regarding the weather. Weather in remote locations may change rapidly, making it
impossible to leave when desired.
• Fire in Australia is an ever-present threat – know what res are burning in the area in which you are
travelling, and always heed the advice of authorities such as re service and police. Always have an
escape plan and choose locations that preferably have more than one escape route. In an emergency,
be prepared to leave your caravan behind if it means saving your life or those of your family and
friends. If in doubt, do not enter a re affected or re prone area.
• Make yourself aware of any re restrictions and camping regulations and abide by these at all times.
Warranty and Service Hand book
18
GandS GS Warranty Book AAC 2019.indd 18 22/10/2019 12:55:31 PM

G&S Chassis Warranty and Service Handbook www.gnschassis.com.au
How to orient stabiliser legs
For greater stability, stabiliser legs should be oriented outwards as shown above (circled).
Front legs inclined towards the front, rear legs inclined towards the rear.
Generally, 1 to 2 “clicks” from vertical is sufficient, depending on the height of the chassis above the ground.
WARNING
Stabiliser legs must not be used to jack any wheel or wheels clear of the ground, as structural damage and
cosmetic damage may occur. Such damage is not covered by the G&S Chassis warranty.
•Be extremely vigilant regarding the weather. Weather in remote locations may change rapidly, making it
impossible to leave when desired.
•Fire in Australia is an ever-present threat – know what fires are burning in the area in which you are
travelling, and always heed the advice of authorities such as fire service and police. Always have an escape
plan and choose locations that preferably have more than one escape route. In an emergency, be prepared
to leave your caravan behind if it means saving your life or those of your family and friends. If in doubt, do
not enter a fire affected or fire prone area.
•Make yourself aware of any fire restrictions and camping regulations and abide by these at all times.
Safety
18
acturer that their caravan
is designed and warranted
for such use.
Safety
How to orient stabiliser legs
For greater stability, stabiliser legs should be oriented outwards as shown above (circled).
Front legs inclined towards the front, rear legs inclined towards the rear.
Generally, 1 to 2 “clicks” from vertical is sufcient, depending on the height of the chassis above the
ground.
WARNING
Stabiliser legs must not be used to jack any wheel or wheels clear of the ground, as structural damage
and cosmetic damage may occur. Such damage is not covered by the G&S Chassis warranty.
• Be extremely vigilant regarding the weather. Weather in remote locations may change rapidly, making it
impossible to leave when desired.
• Fire in Australia is an ever-present threat – know what res are burning in the area in which you are
travelling, and always heed the advice of authorities such as re service and police. Always have an
escape plan and choose locations that preferably have more than one escape route. In an emergency,
be prepared to leave your caravan behind if it means saving your life or those of your family and
friends. If in doubt, do not enter a re affected or re prone area.
• Make yourself aware of any re restrictions and camping regulations and abide by these at all times.
Warranty and Service Hand book
18
GandS GS Warranty Book AAC 2019.indd 18 22/10/2019 12:55:31 PM
G&S Chassis Warranty and Service Handbook www.gnschassis.com.au
How to orient stabiliser legs
For greater stability, stabiliser legs should be oriented outwards as shown above (circled).
Front legs inclined towards the front, rear legs inclined towards the rear.
Generally, 1 to 2 “clicks” from vertical is sufficient, depending on the height of the chassis above the ground.
WARNING
Stabiliser legs must not be used to jack any wheel or wheels clear of the ground, as structural damage and
cosmetic damage may occur. Such damage is not covered by the G&S Chassis warranty.
•Be extremely vigilant regarding the weather. Weather in remote locations may change rapidly, making it
impossible to leave when desired.
•Fire in Australia is an ever-present threat – know what fires are burning in the area in which you are
travelling, and always heed the advice of authorities such as fire service and police. Always have an escape
plan and choose locations that preferably have more than one escape route. In an emergency, be prepared
to leave your caravan behind if it means saving your life or those of your family and friends. If in doubt, do
not enter a fire affected or fire prone area.
•Make yourself aware of any fire restrictions and camping regulations and abide by these at all times.
Safety
18
acturer that their caravan
is designed and warranted
for such use.
www.gnschassis.com.au
To assist identification and in ordering parts, suspensions manufactured by G&S Chassis are as follows:
Four(Leaf)SpringLoadSharingSuspensionwithBeamAxles G&S Chassis Control Rider TS Independent Suspension
G&S Chassis Control Rider Independent Suspension AL-KO ENDURO Outback or Cross Country Independent
Suspension(coloursmayvary)
AL-KOIndependentRubberSuspension(IRS) Torflex Rubber Torsion Independent Suspension
Cruisemaster CRS/XT/ATX Independent Suspension
(coloursmayvary)
Simplicity Load Sharing Independent Suspension
Should you have a warranty concern with your caravan chassis or suspension, you must contact your caravan
dealerassoonaspossible.YourdealerwillcontactG&SChassisonyourbehalf.
Suspension Types
19
Suspension Types
To assist identication and in ordering parts, suspensions manufactured by G&S Chassis are as follows:
www.gnschassis.com.au 19
www.gnschassis.com.au
To assist identification and in ordering parts, suspensions manufactured by G&S Chassis are as follows:
Four(Leaf)SpringLoadSharingSuspensionwithBeamAxles G&S Chassis Control Rider TS Independent Suspension
G&S Chassis Control Rider Independent Suspension AL-KO ENDURO Outback or Cross Country Independent
Suspension(coloursmayvary)
AL-KOIndependentRubberSuspension(IRS) Torflex Rubber Torsion Independent Suspension
Cruisemaster CRS/XT/ATX Independent Suspension
(coloursmayvary)
Simplicity Load Sharing Independent Suspension
Should you have a warranty concern with your caravan chassis or suspension, you must contact your caravan
dealerassoonaspossible.YourdealerwillcontactG&SChassisonyourbehalf.
Suspension Types
19
www.gnschassis.com.au
To assist identification and in ordering parts, suspensions manufactured by G&S Chassis are as follows:
Four(Leaf)SpringLoadSharingSuspensionwithBeamAxles G&S Chassis Control Rider TS Independent Suspension
G&S Chassis Control Rider Independent Suspension AL-KO ENDURO Outback or Cross Country Independent
Suspension(coloursmayvary)
AL-KOIndependentRubberSuspension(IRS) Torflex Rubber Torsion Independent Suspension
Cruisemaster CRS/XT/ATX Independent Suspension
(coloursmayvary)
Simplicity Load Sharing Independent Suspension
Should you have a warranty concern with your caravan chassis or suspension, you must contact your caravan
dealerassoonaspossible.YourdealerwillcontactG&SChassisonyourbehalf.
Suspension Types
19
www.gnschassis.com.au
To assist identification and in ordering parts, suspensions manufactured by G&S Chassis are as follows:
Four(Leaf)SpringLoadSharingSuspensionwithBeamAxles G&S Chassis Control Rider TS Independent Suspension
G&S Chassis Control Rider Independent Suspension AL-KO ENDURO Outback or Cross Country Independent
Suspension(coloursmayvary)
AL-KOIndependentRubberSuspension(IRS) Torflex Rubber Torsion Independent Suspension
Cruisemaster CRS/XT/ATX Independent Suspension
(coloursmayvary)
Simplicity Load Sharing Independent Suspension
Should you have a warranty concern with your caravan chassis or suspension, you must contact your caravan
dealerassoonaspossible.YourdealerwillcontactG&SChassisonyourbehalf.
Suspension Types
19
www.gnschassis.com.au
To assist identification and in ordering parts, suspensions manufactured by G&S Chassis are as follows:
Four(Leaf)SpringLoadSharingSuspensionwithBeamAxles G&S Chassis Control Rider TS Independent Suspension
G&S Chassis Control Rider Independent Suspension AL-KO ENDURO Outback or Cross Country Independent
Suspension(coloursmayvary)
AL-KOIndependentRubberSuspension(IRS) Torflex Rubber Torsion Independent Suspension
Cruisemaster CRS/XT/ATX Independent Suspension
(coloursmayvary)
Simplicity Load Sharing Independent Suspension
Should you have a warranty concern with your caravan chassis or suspension, you must contact your caravan
dealerassoonaspossible.YourdealerwillcontactG&SChassisonyourbehalf.
Suspension Types
19
www.gnschassis.com.au
To assist identification and in ordering parts, suspensions manufactured by G&S Chassis are as follows:
Four(Leaf)SpringLoadSharingSuspensionwithBeamAxles G&S Chassis Control Rider TS Independent Suspension
G&S Chassis Control Rider Independent Suspension AL-KO ENDURO Outback or Cross Country Independent
Suspension(coloursmayvary)
AL-KOIndependentRubberSuspension(IRS) Torflex Rubber Torsion Independent Suspension
Cruisemaster CRS/XT/ATX Independent Suspension
(coloursmayvary)
Simplicity Load Sharing Independent Suspension
Should you have a warranty concern with your caravan chassis or suspension, you must contact your caravan
dealerassoonaspossible.YourdealerwillcontactG&SChassisonyourbehalf.
Suspension Types
19
www.gnschassis.com.au
To assist identification and in ordering parts, suspensions manufactured by G&S Chassis are as follows:
Four(Leaf)SpringLoadSharingSuspensionwithBeamAxles G&S Chassis Control Rider TS Independent Suspension
G&S Chassis Control Rider Independent Suspension AL-KO ENDURO Outback or Cross Country Independent
Suspension(coloursmayvary)
AL-KOIndependentRubberSuspension(IRS) Torflex Rubber Torsion Independent Suspension
Cruisemaster CRS/XT/ATX Independent Suspension
(coloursmayvary)
Simplicity Load Sharing Independent Suspension
Should you have a warranty concern with your caravan chassis or suspension, you must contact your caravan
dealerassoonaspossible.YourdealerwillcontactG&SChassisonyourbehalf.
Suspension Types
19
www.gnschassis.com.au
To assist identification and in ordering parts, suspensions manufactured by G&S Chassis are as follows:
Four(Leaf)SpringLoadSharingSuspensionwithBeamAxles G&S Chassis Control Rider TS Independent Suspension
G&S Chassis Control Rider Independent Suspension AL-KO ENDURO Outback or Cross Country Independent
Suspension(coloursmayvary)
AL-KOIndependentRubberSuspension(IRS) Torflex Rubber Torsion Independent Suspension
Cruisemaster CRS/XT/ATX Independent Suspension
(coloursmayvary)
Simplicity Load Sharing Independent Suspension
Should you have a warranty concern with your caravan chassis or suspension, you must contact your caravan
dealerassoonaspossible.YourdealerwillcontactG&SChassisonyourbehalf.
Suspension Types
19
Four (Leaf) Spring Load Sharing Suspension with Beam Axles
G&S Chassis Control Rider Independent Suspension AL-KO
AL-KO Independent Rubber Suspension (IRS)
Cruisemaster CRS/XT/ATX Independent Suspension
(colours may vary)
G&S Chassis Control Rider TS Independent Suspension
ENDURO Outback or Cross Country Independent
Suspension (colours may vary)
Torflex Rubber Torsion Independent Suspension
Simplicity Load Sharing Independent Suspension
Should you have a warranty concern with your caravan chassis or suspension, you must contact
your caravan dealer as soon as possible. Your dealer will contact G&S Chassis on your behalf.
GandS GS Warranty Book AAC 2019.indd 19 22/10/2019 12:55:39 PM

Maintenance
Your caravan chassis and suspension have been designed for years of trouble free operation with minimal
maintenance. However, to ensure safe and reliable operation the following routine maintenance must be
carried out. The service periods below are based on normal usage on sealed roads. For operation in hot,
dusty or muddy conditions or in corrosive environments, more frequent service intervals are recommended.
All maintenance must be carried out by competent, experienced personnel with access to the necessary
tools and equipment (e.g. correctly calibrated tension wrench) according to the schedule contained in this
Handbook.
WARNING
Maintenance or repair work carried out by inexperienced, untrained and/or inadequately equipped
personnel may result in property damage or personal injury. The items marked* are considered to be
user serviceable. All other procedures must be carried out by approved persons or workshops. If in
doubt, the caravan owner should always seek assistance from a specialist caravan service and repair
workshop.
Test “Shakedown” Journey
We recommend your new caravan be taken on a relatively short “shakedown” journey prior to undertaking
longer trips over extended periods. In this way, any minor issues with the chassis, suspension, caravan and
contents (should they occur) may be dealt with promptly and with a minimum of inconvenience.
Warranty and Service Hand book
20
GandS GS Warranty Book AAC 2019.indd 20 22/10/2019 12:55:39 PM