AL-KO ATC Handbook User Manual

							AL-KO ATC OWNER 
INSTRUCTION MANUAL
QUALITY FOR LIFE 
						

							CONTENTS
PAGE CONTENTS
1.  GENERAL NOTICES
2.  ATC APPLICATION & SAFETY INFORMATION
3.  SYSTEM REQUIREMENTS & OPERATING INSTRUCTIONS
4.  LED OPERATION
5.  TROUBLESHOOTING, MAINTENANCE & WARRANTY
6.  PUSH ROD REMOVAL
GENERAL NOTICES
READ AND ACT IN ACCORDANCE WITH THE 
FOLLOWING OPERATING INSTRUCTIONS BEFORE 
ATTEMPTING TO USE AL-KO ATC. THIS INSTRUCTION 
MANUAL SHOULD BE KEPT EITHER IN THE CAR OR 
CARAVAN AT ALL TIMES.
AL-KO ATC is a safety related product and, 
therefore, should only be fitted by an authorised 
AL-KO trained technician with experience of 
working with electrical installations. 
Any evidence of removal or disassembly, other   
than by trained technicians, will immediately 
invalidate the product warranty.
1 2
AL-KO ATC TRAILER  
CONTROL SYSTEM
AL-KO ATC IS AN ELECTRONIC, EMERGENCY 
CONTROL SYSTEM FOR CARAVANS AND TRAILERS. 
IT AUTOMATICALLY RECOGNISES CRITICAL 
SWINGING MOTIONS AND APPLIES THE CARAVAN 
BRAKES ACCORDINGLY TO REGAIN CONTROL OF 
THE CARAVAN AND CAR.
 
SAFETY INFORMATION
AL-KO ATC IS A PASSIVE SAFETY PRODUCT 
THAT ACTIVATES THE BRAKING SYSTEM ON THE 
CARAVAN IN UNSAFE DRIVING CONDITIONS. 
The driver has a responsibility under law to 
ensure that the elements of towing safety are 
met, including driving within the legal speed limit, 
consideration of road, weather and other traffic 
conditions, correct loading and coupling of the 
caravan. 
AL-KO ATC is designed to fit only on AL-KO 
Chassis and is not suitable for non AL-KO Chassis.
AL-KO ATC only functions on caravans with a rigid 
towbar.
The electrical connection between the towing 
vehicle and caravan must be in good working 
order.  
						

							DISPLAY ATC  DIAGNOSIS  WHAT TO DO  OUTCOME STATUS 
COLOUR  CONDITION
 Green  ATC Active  Everything Ok
 
  Green Flashing  ATC Active  Self test incomplete 
  Red  ATC Inactive  Possible to 
     continue journey
  Red flashing  ATC has detected   Do not continue
   a fault  with ATC  
     connected
  LED not working  ATC has no power  Check push rod  
     position as shown  
   LED faulty  on page 5 before  
     continuing journey. Drive forward to 
detect movement to 
complete self test 
and re check LED.
Remove 12S or 13 
Pin plug and wait  
5 seconds.  
Reconnect plug.
Remove 12S or 13 
Pin plug and wait  
5 seconds.  
Reconnect the plug.
Remove 12S or 13 
Pin plug and wait 5 
seconds. Reconnect 
the plug.
Check for constant 
live - refer to system 
requirements. Green (Constant) 
Ready for journey
Green  Ready for journey
Red  ATC Error logfile memory  
   exceeded. Caravan can be  
   towed, but ATC will not apply  
   caravan brakes in the event of  
   instability. See below 
*
Green Ready for journey
Red (flashing)  ATC faulty, and cannot be  
   driven. Remove push-rod as  
   shown on page 5. Consult  
   AL-KO, see back page for  
   details.
Green  Ready for journey
LED not working  If power ok, check push rod  
   position: Red line visible - do  
   not drive vehicle. Red line not  
   visible - possible to continue  
   journey but consult AL-KO see  
   back page for details.
SYSTEM REQUIREMENTS
ATC draws power from the towing vehicle towbar and 
requires connection to either:
Twin 7-Pin Connection - ATC can be connected via the 
auxiliary 12S (white/grey) plug and requires power 
on requires power on Pins 4 (permanent supply) and 
3 (earth). Please ensure that your vehicle towbar is 
correctly connected to ensure correct ATC operation. 
This can be checked with the use of a multimeter.
Important - A 20 amp fuse is required for the constant 
12V supply to Pin 4 on the 12S socket. If only a single 
fuse is fitted to supply both Pins 4 and Pin 6, the power 
supply capability of the installation must be checked 
and a minimum fuse rating of 25 Amps must be used.
13 Pin Connection - ATC can be connected via the 13-Pin 
plug and requires power on Pins 9 (permanent supply) 
and 13 (earth). Please ensure that your vehicle towbar 
is correctly connected to ensure correct ATC operation. 
This can be checked with the use of a multimeter.  
OPERATING INSTRUCTIONS
After coupling the caravan correctly to the towing 
vehicle, connect the 12N & 12S plugs or the 13 Pin plug 
to the towbar.
Upon connection, ATC will carry out an initial self test 
and the LED light on the front fairing will light up RED. 
During the self test, the sound of the push rod moving 
inside ATC can be heard. When the self test is complete, 
the LED will turn GREEN or flashing GREEN to signal that 
ATC is active.
If the LED does not change to green, then ATC is not 
functioning correctly. The table provided on page 4 
details what to do in this case.
Prior to commencing any journey, ensure that the 
caravan lighting is fully operational and check the 
vehicle is loaded appropriately, the nose weight and 
tyre pressures are correct, and confirm that the caravan 
is coupled to the vehicle with the breakaway cable 
correctly applied.
Always re-check the ATC LED is green after any interval 
during a journey, such as a service station break.
ATC LED on fairing
LED OPERATION
3 4
* ATC stores operating errors in a logfile which over time will become full and will result in the solid red light appearing\
. This needs to be 
erased and can be done easily by connecting the caravan to a 12 volt sup\
ply for a period of 12 hours. The power required to carry out this 
function is minimal. Most occurrences of these errors are due to power s\
upply problems to ATC which could be due to low voltage, or an 
intermittent power supply from the towbar.     
						

							Using a 17mm spanner, slacken locking nut on push rod away 
from Bowden cable abutment as directed above.
Unscrew push rod from brake rod and slide it from the guide 
tube. Remove the locking nut from push rod using two 17mm 
spanners.
TROUBLESHOOTING
Should you experience a fault with ATC, the LED light 
on the fairing will change colour. Therefore, refer to the 
table on page 4 and follow the instructions.
If no illumination of the LED is evident, refer to system 
requirements on page 3 and check towbar wiring for 
permanent supply.
In the unlikely event that you receive a red flashing LED 
light and disconnecting and re-connecting the power 
does not alleviate the problem, check the push rod 
position as detailed below. 
Locate ATC on the axle and check the position of the 
push rod.
If no red line is visible, ATC is not active, and can be 
driven. However, we recommend that you contact AL-KO 
at the earliest convenience.
If the red line is visible on the push rod, as shown on 
the left, the caravan should not be moved.
The push rod needs to be removed to deactivate ATC.  
Using two 17mm spanners, the removal process is as 
shown opposite.
MAINTENANCE AND WARRANTY
ATC is maintenance free and requires no servicing. In 
case of any damage to ATC, please contact AL-KO. ATC 
is a sealed unit and any evidence of removal of ATC or 
the component parts including outer casing and fixings 
will immediately invalidate any product warranty.
ATC is covered by a 12 month warranty where it is 
retrofitted to a caravan. If ATC is fitted as standard by 
the vehicle manufacturer then ATC is covered for the 
same duration of the vehicle warranty or whichever is 
longer.
If ATC is subject to a call out under warranty and found 
to comply with the relevant specification or standard, 
then the cost of any testing or callout charges will be 
borne by the customer. We reserve the right to request 
credit card details to cover payment in advance.
REMOVAL OF PUSH ROD:
56
Re-apply the removed locking nut onto brake rod thread to 
secure ball nut as shown above. ATC is now deactivated.