AL-KO ESC: Operating Instructions & Warranty Detail
Save This Manual. Keep this manual for the assembly, operation, and maintenance procedures. Keep this manual in a safe place for future reference.
About AL-KO ESC
AL-KO ESC (Electronic Stability Control) is a sway and swerve stability control system for caravans. The ESC gives assurance to drivers that, even in the most difficult driving scenarios, the stability of their caravan is being monitored by the ESC, providing unparalleled safety during the journey.
The ESC is only approved for use on trailers and caravans fitted with approved electric brakes, axles, and approved suspensions.
How it Works
AL-KO ESC is an electronic braking system that works similarly to ESC systems in some cars. The AL-KO ESC constantly senses the lateral (side-to-side) movement of the caravan while towing. When a critical sway or emergency swerve is detected, the ESC partially applies the caravan brakes. Braking of the caravan pulls it into line behind the tow vehicle and prevents further swaying, allowing the driver to remain in control.
Diagram Description: Illustrates AL-KO ESC operation:
- 1. Critical swerve or sway is detected by the ESC.
- 2. ESC partially applies the caravan brakes. The caravan is pulled into line behind the tow vehicle.
- 3. The sway is stopped and the caravan brakes are released.
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.
The ESC automatically completes a self-test when power is connected. The LED status light, located at the front of the caravan, displays red during the test. Once complete, the LED status light turns green, indicating the ESC is operational.
Occasionally, the LED may flash green, requiring slight movement for the test to complete. If this occurs, drive a short distance and recheck the LED status light for a solid green light.
When a sway or swerve occurs, the ESC detects the critical movement and automatically activates the caravan brakes to a preset amount.
If the LED status light turns red, a minor problem has been detected. Driving is safe, but the ESC will not activate for sway/swerve until the issue is resolved and the green light is restored. Refer to the Troubleshooting section.
If the LED status light flashes red continuously at 1-second intervals, a serious problem is detected, and the ESC will no longer operate. Do not use the ESC and disconnect it before driving further. Refer to the Troubleshooting section.
Off-Road Use
For serious off-road use, the ESC should be disconnected because severe tilting and bumps may cause inadvertent brake activation. It is recommended to connect the ESC to the tow vehicle using a separate 2-pin connector (e.g., a 50AMP connector, Part number: 350350) instead of the standard 12-pin connector for easier disconnection during extreme off-road periods. 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. Replace the connector if corrosion is evident. Otherwise, the ESC is maintenance-free and requires no adjustment.
Note: Electric brakes must be correctly adjusted and functioning well for the ESC to operate effectively. Refer to the electric brake service manual for maintenance. Before each journey, operate the manual control of your electric brakes to ensure they are working.
Frequently Asked Questions
- Q: How do I know if the ESC has activated?
A: Soft braking of the caravan should be noticed 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.
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 and reconnect. If the red light persists, check the following:
- Loose Contacts: Ensure connectors are clean and properly connected. Check power cables for damage. Ensure the ESC module is securely attached under the caravan.
- Electric Brakes Not All Connected: Verify the ESC is connected to approved electric brakes and that all brakes are correctly connected and functional.
- Under Voltage/Over Voltage: Ensure the tow vehicle has a 12-volt battery. Check power supply is direct from the battery with a 30A fuse. Verify 12 volts is reaching the 12-pin connector and the ESC connector. Check for damaged or undersized cables.
Flashing Red Status Light
If the ESC status light flashes red constantly each second, disconnect the ESC before driving by unplugging the connector under the caravan. Contact AL-KO for repair or replacement.
If the ESC status light flashes red very quickly occasionally when the ESC has no power, this is feedback from the brake controller and is not a problem.
Status Light is OFF
- No Power to the ESC: Check 12-pin connector is plugged in. Check ESC connector is plugged into the ESC module. Check for 12 volts at the 12-pin connector and fuse. Check for 12 volts at the ESC connector. Check cables for damage.
- LED Status Light is Faulty: Check voltage supplied to the light.
Flashing Green Status Light
A flashing green light indicates the start-up test is complete, but the ESC has not yet detected movement. The ESC will switch to solid green once movement is detected. If the flashing green light continues constantly, contact AL-KO.
Diagram Description: Illustrates the ESC layout, showing the location of the LED Status Light at the front of the caravan and the ESC Module under the caravan.
Wiring Diagrams
Electric Brake Wiring Diagrams:
- Option 1: ESC power supply via 12-pin connector.
- Option 2: ESC power supply via 2-pin connector.
Vehicle Wiring: The tow vehicle must have power supply for the ESC wired directly to the battery with a 30A fuse or circuit breaker. Connection is typically via a standard 12-pin plug or 2-pin connector. Consult your caravan manufacturer for specific 12-pin plug configurations.
12-Pin Connector Wiring:
- PIN #: 10, Cable Colour: Red, Description: ESC Power supply – 2 red cables
- PIN #: White, Cable Colour: White, Description: ESC Earth – 2 white cables
Diagram Description: Shows two wiring options for ESC power supply (12-pin and 2-pin connectors) and details the 12-pin connector pinout for ESC power and earth connections.
AL-KO International Pty Ltd Warranty
AL-KO goods come with guarantees that cannot be excluded under the Australian Consumer Law. Customers are entitled to a replacement or refund for a major failure and compensation for other reasonably foreseeable loss or damage. Goods are also entitled to repair or replacement if they fail to be of acceptable quality and the failure does not amount to a major failure.
AL-KO International Pty Ltd (ABN 96 003 066 813) provides this warranty in addition to statutory rights.
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.
This warranty is not transferable.
Warranty Claims
- If a fault occurs, contact the dealer or AL-KO within 7 days.
- Claims must include: proof of purchase, details of the defect, and relevant documentation (e.g., maintenance records).
- The Product must be made available for inspection and testing within 14 days of contact. The customer may be liable for service costs if no defect is found.
- Transportation costs to/from AL-KO or an authorised repair agent are the customer's responsibility.
Exclusions
The warranty does not apply if:
- The Product has been repaired or modified by unauthorized personnel.
- The Product was improperly installed.
- No fault is found after testing.
- The Product was used for a purpose other than intended.
- Defects arose from failure to use or maintain the Product according to instructions.
- The Product was subjected to abnormal conditions (environment, temperature, water, fire, humidity, pressure, stress, etc.).
- Defects arose from abuse, misuse, neglect, or accident.
- Defects arose from power surges or electrical faults.
- Unauthorized parts or accessories were used.
Limitations
AL-KO's liability is limited to the repair or replacement of the Product or its defective part.
Contact & Support
AL-KO International Pty Ltd
67 Nathan Road, Dandenong South, Victoria, 3175
Phone: (03) 9767 3700
Email: info@alko.com.au
Website: www.alko.com.au
For more information, visit: www.alko.com.au
When unpacking, ensure the product is intact and undamaged. If any parts are missing or broken, please call (03) 9767 3700 as soon as possible.
Branch Contact Information:
- 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.
