AL-KO ESC Operating Instructions & Warranty Detail

Instructions for Use

The ESC must be connected to the power supply in the tow vehicle using a 12-pin trailer connector or a separate 2-pin connector.

Upon connection, the ESC automatically performs a self-test. The LED status light, located at the front of the caravan, will display red during this test. Once the test is complete, the LED status light turns green, indicating the ESC is operational.

Occasionally, the LED may flash green, requiring the vehicle to be driven a short distance for the test to complete. Recheck the LED status light for a solid green light to confirm correct operation.

During travel, if a sway or swerve occurs, the ESC will detect the critical movement of the caravan and automatically activate the brakes to a preset amount.

If the LED status light turns red at any time, a minor problem has been detected. While it is safe to drive, the ESC will not activate during a critical sway or swerve until the issue is resolved and the green light is restored. Refer to the Troubleshooting section for corrective steps.

If the LED status light flashes red continuously at 1-second intervals, a serious problem is detected, and the ESC will no longer operate. The ESC should not be used, and it must be disconnected before driving further. Refer to the Troubleshooting section for next steps.

Off-Road Use

The ESC should be disconnected for serious off-road use. Severe tilting and bumps can cause the ESC to inadvertently activate the brakes. For extreme off-road conditions, it is recommended to connect the ESC via a separate 2-pin connector rather than the standard 12-pin connector. This allows for easier disconnection. Reconnect the ESC immediately when returning to less severe road conditions. AL-KO ESC is safe for use on unpaved roads.

Maintenance

The connector on the caravan and tow vehicle must be lubricated with a water-dispersant spray and checked regularly for corrosion to ensure correct ESC function. Replace the connector if corrosion is evident. Otherwise, the ESC requires no maintenance or adjustment.

Note: Electric brakes must be correctly adjusted and functioning well for the ESC to operate effectively. Refer to your electric brake service manual for maintenance. Before each journey, operate the manual control of your electric brakes to confirm they are working correctly.

Frequently Asked Questions

Q. How do I know if the ESC has activated?

A. You should notice soft braking of the caravan in the car.

Q. Do the caravan brake lights function when the ESC is activated during a manoeuvre?

A. No. The ESC applies the caravan brakes to correct alignment rather than to stop the combination, so stop light illumination is not appropriate for either the caravan or the tow vehicle.

Troubleshooting

The ESC indicates problems via the LED status light: red for minor issues, flashing red for serious issues.

Red Status Light

Disconnect the ESC for 10 seconds, then reconnect. If the red light persists, check the following:

Loose Contacts

• Check that the ESC is connected properly and connectors are clean and free of corrosion. Clean or replace connectors and terminals.
• Check that power cables to the ESC are in good condition and undamaged. Repair damaged cables or replace the loom.
• Check that the ESC module under the caravan is securely attached. Reattach the ESC firmly in the correct location.

Electric Brakes Not All Connected

• Check that the ESC is connected to approved electric brakes. Fit approved electric brakes.
• Check that ALL brakes are connected correctly. Reconnect or replace brakes as required.
• Check that the brake magnets are not damaged. Repair or replace if necessary.

Under Voltage/Over Voltage

• Check that the tow vehicle has a 12-volt battery. Use only tow vehicles with 12-volt batteries.
• Check that power is supplied directly from the tow vehicle battery and the connection is good. Reconnect power supply directly to the battery.
• The 12-pin connector may have poor connection or damaged/undersized cables in the tow vehicle. Repair any damaged cables.
• Check with a voltmeter that 12 volts is reaching the 12-pin connector at the rear of the tow vehicle. Clean the 12-pin connector. Replace cables and/or connector if required.
• The ESC connector may have poor connection or damaged cables in the caravan. Clean the connector.
• Check with a voltmeter that 12 volts is reaching the connector at the ESC under the caravan. Replace the connector if necessary. Measure the voltage at the ESC connector; the power supply contacts are shown as [Positive] and [Negative]. Repair any damaged cables or replace cables if necessary.

After each check, reconnect the ESC. A green LED status light indicates the ESC is fully functional and the caravan is safe to tow.

Flashing Red Status Light

If the ESC status light flashes red constantly (1 second intervals), disconnect the ESC by unplugging the connector under the caravan before driving. Contact AL-KO for repair or replacement of the ESC module.

A rapid flashing red light occasionally when the ESC has no power is feedback from the brake controller and is not a problem.

Status Light is OFF

No Power to the ESC:

• Check that the 12-pin connector is plugged into the tow vehicle. Reconnect the 12-pin connector.
• Check that the ESC connector is plugged into the ESC under the caravan. Reconnect the ESC connector.
• Check for 12 volts at the 12-pin connector and check the fuse (if fitted). Repair any damaged cables, clean the 12-pin connector, replace fuse if required, or replace cables/connector if required.
• Check for 12 volts at the ESC connector. Clean the connector, repair any damaged caravan cables, or replace if necessary.
• Check that the cables are not damaged. Repair or replace the cables if necessary.

LED Status Light is Faulty:

• Check voltage supplied to the light is two volts. Replace LED status light.

Flashing Green Status Light

A flashing green light indicates the start-up test is complete, but the ESC has not yet detected movement to confirm sensor operation. The ESC will switch to solid green once movement is detected. If the flashing green light continues, contact AL-KO.

ESC Layout Diagram Description

The diagram shows the AL-KO ESC system components. On the caravan, there is an "ESC Module" typically located at the rear, and an "LED Status Light" visible on the front. The system connects to the tow vehicle via a trailer connector.

Electric Brake Wiring Diagram Description

The diagram illustrates two wiring options for the ESC power supply:

• Option 1: ESC power supply via 12-pin connector. This shows the tow vehicle battery connected through a fuse and the 12-pin plug to the ESC module and electric brakes on the caravan.
• Option 2: ESC power supply via 2-pin connector. This shows the tow vehicle battery connected through a fuse and a 2-pin plug to the ESC module and electric brakes on the caravan.

Both options include the LED status light connected to the ESC module.

Vehicle Wiring

The tow vehicle must have power supply for the ESC wired directly to the battery, with a 30A fuse or circuit breaker fitted. The ESC connects via a standard 12-pin or 2-pin connector. The layout of the 12-pin plug can vary by manufacturer; consult your caravan manufacturer for specifics.

For off-road use, a 50AMP 2-pin connector is recommended for disconnecting the ESC during extreme off-road driving. A suitable 2-pin connector can be supplied by AL-KO (Part number: 350350).

The tow vehicle should be fitted with an approved electric brake controller. Refer to the AL-KO website FAQ for a list of compatible controllers: www.alkoesc.com.au.

12-Pin Connector Wiring

(Check with caravan manufacturer regarding which pins are used for ESC)

Visual representation of plug and socket pinouts:

[Plug - caravan/trailer: Pins 8, 9, 10, 11, 12]

[Socket - tow vehicle: Pins 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12]

AL-KO International Pty Ltd Warranty

AL-KO 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 compensation for other reasonably foreseeable loss or damage. You are also entitled to have goods repaired or replaced if they fail to be of acceptable quality and the failure is not major.

AL-KO International Pty Ltd (ABN 96 003 066 813) provides this warranty for its Electronic Stability Control (ESC) Product. The benefits are in addition to statutory rights and remedies.

Warranty Period

AL-KO warrants the Product to be free from defects in materials and workmanship for a period of 3 years from the date of purchase, subject to exclusions and limitations.

This warranty is not transferable if the Product is sold by the original purchaser during the warranty period.

If a defect appears, AL-KO will, at its sole discretion, either:

• Replace or repair the Product or the defective part free of charge.
• Arrange for the Product or defective part to be replaced or repaired by a qualified repairer free of charge.

AL-KO may replace defective parts with parts of similar quality if an identical part is not available. Goods may be replaced by refurbished goods of the same type.

Warranty Claims

1. If a warranty fault occurs, contact the dealer from whom the Product was purchased, or AL-KO, within 7 days.
2. Warranty claims must include:
   • Proof of purchase.
   • Full details of the alleged defect.
   • Any relevant documentation (e.g., maintenance records).
3. The Product must be made available to AL-KO or its authorised repair agent for inspection and testing within 14 days of contact. If no defect is found, the customer must pay AL-KO's service and testing costs.
4. Transportation costs to or from AL-KO or the repair agent are the customer's responsibility.

Exclusions

The warranty does not apply if:

• The Product has been repaired, altered, or modified by an unauthorised person.
• The Product was improperly installed.
• AL-KO cannot establish any fault after testing.
• The Product has been used for a purpose other than its design.
• The defect arose due to failure to properly use and maintain the Product per AL-KO's instructions.
• The Product was subject to abnormal conditions (environment, temperature, water, fire, humidity, pressure, stress, etc.).
• The defect arose due to abuse, misuse, neglect, or accident.
• The defect arose due to a power surge or other electrical fault.
• Unauthorised parts or accessories were used.

Limitations

AL-KO makes no express warranties beyond those stated. The repair or replacement of the Product or part is the absolute limit of AL-KO's liability under this warranty.

Contact

AL-KO International Pty Ltd
67 Nathan Road, Dandenong South, Victoria, 3175
Phone: (03) 9767 3700
Email: info.aus@alko-tech.com

Register Your Warranty

Register your warranty at www.alko.com.au

Option 1: Scan the QR code (QR code excluded as per instructions).

Option 2: Visit alko.com.au/warranties

Option 3: Take this link (digital copy only).

Serial No.: [Serial Number Field]
Installer: [Installer Field]
Date: [Date Field]

Personal information collected will be used for warranty claims, communication about products, and promotions. Information may be disclosed to third parties (suppliers, distributors, government bodies) as necessary for claim assessment or completion. Failure to complete information may prevent warranty provision. For access to personal information, contact the Privacy Officer on (03) 9767 3700.

General Information & Contact

When unpacking, ensure the product is intact and undamaged. If parts are missing or broken, call (03) 9767 3700 as soon as possible.

Visit www.alko.com.au for more information.

Locations:

• VIC: 67 Nathan Road, Dandenong South, 3175 | Phone: (61) 3 9767 3700 | Fax: (61) 3 9792 0877
• NSW: 26 Hallstrom Place, Wetherill Park, 2164 | Phone: (61) 2 8784 9400 | Fax: (61) 2 9725 4557
• QLD: 13 Union Circuit, Yatala, 4207 | Phone: (61) 7 3386 6300 | Fax: (61) 7 3386 6399
• NZ: 1 Airpark Drive, Airport Oaks, Mangere, Auckland | Phone: (61) 9 255 5611 | Fax: (61) 9 255 5612

No part of this document may be reproduced without AL-KO's permission. All part numbers, dimensions, and specifications are subject to change without notice.

AL-KO International Pty Ltd (ABN 96 003 066 813)
67 Nathan Road, Dandenong South, VIC, 3175 Australia
Phone: (61) 3 9767 3700 | Fax: (61) 3 9792 0877
Web: www.alko.com.au
Email: info.aus@alko-tech.com