iQ7 ACTUATOR & Control Installation & Operating Instructions
Contents
1. iQ7 ACTUATOR amp Control Installation amp Operating Instructions For use with Motion Sensing Brake Controllers AL KO INTERNATIONAL ABN 96 003 086 813 FOR DETAILS OF YOUR NEAREST AL KO AUTHORISED SERVICE AGENT PLEASE CONTACT OUR STATE OFFICES AS LISTED BELOW VICTORIA 67 91 NATHAN ROAD DANDENONG STH VICTORIA 3175 TELEPHONE 03 9767 3700 FACSIMILE 03 9792 0877 NEW SOUTH WALES 26 HALLSTROM PLACE WETHERILL PARK NEW SOUTH WALES 2164 TELEPHONE 02 8784 9400 FACSIMILE 02 9725 4557 QUEENSLAND 13 UNION CIRCUIT YATALA QUEENSLAND 4207 TELEPHONE 07 3386 6300 FACSIMILE 07 3386 6399 NEW ZEALAND 1 AIRPARK DRIVE AIRPARK OAKS MANGERE AUCKLAND TELEPHONE 09 255 5611 FACSIMILE 09 255 5612 This information MUST be distributed with the AL KO iQ7 trailer braking system and be kept with the towing vehicle for future reference General Operation The AL KO iQ7 has been designed to operate in all normal environmental conditions and it has been left to the discretion of the installer as to the location of the actuator Although the AL KO iQ7 housing is partly sealed to protect the internal components from the external environment when exposed to corrosive environments such as salt water fertiliser and other caustic materials care must be taken to protect the unit at all times Although water resistant the AL KO iQ7 unit is NOT waterproof and should NEVER be submerged at any time It is ther2. 1 o pies uone1 sI B z2 AjJue uPAA 92npoid TV t ETS Og O Ta _ e x 40 O TCL gt TOC cC oO Og S lt cote 2 29 o O lt Se p E ee 9 ges 2 T cts ia Oe COG Sg oo S Sec Os aor Woe one S n oO 0 Further information can be obtained by visiting www alko com au AL KO International Pty Ltd ABN 96 003 066 813 VIC 67 Nathan Road Dandenong South 3175 Phone 03 9767 3700 Fax NSW 26 Hallstrom Place WetherillPark 2164 Phone 02 8784 9400 Fax OLD 13 Union Circuit Yatala 4207 Phone 07 3386 6300 Fax NZ 1 Airpark Drive Airpark Oaks Mangere Auckland Phone 09 255 5611 Fax 97920877 97254597 3386 6399 2590612 3 2 7 9
3. contact address listed below or the retailer from which the Product was purchased Any warranty claim must be accompanied by proof of purchase full details of the alleged defect and any relevant documentation suchas maintenance records 3 The customer must make the Product available to AL KO or its authorised repair agent for inspection and testing If inspection and testing finds no defect in the Product the customer must pay AL KO s costs of service work and testing 4 AL KO will bear the cost of the transport of the Product to and from AL KO or the authorised repair agent where the defect is covered by this warranty AL KO will organise for the transport at the time the claim is made The customer must bear the cost of the transport from AL KO or the ooo authorised repair agent where the claim is not covered by this warranty EXCLUSIONS The warranty will not apply where a the Product has been repaired altered or modified by someone other than AL KO or an authorised repair agent b AL KO cannot establish any fault in the Product after testing and inspection c the Product has been used other than for the purpose for which it was designed d the defect in the Product has arisen due to the customer s failure to properly use and maintainthe Product in accordance with AL KO s instructions recommendations and specifications including maintenance e the Product has been subject to
4. abnormal conditions including environment temperature water fire humidity pressure stress or similar f the defect has arisen due to abuse misuse neglect or accident or g unauthorised parts or accessories have been used on or in relation to the Product LIMITATIONS AL KO makes no express warranties or representations other than set out in this warranty The repair or replacement of the Product or part of the Product is the absolute limit of AL KO s liability under this express warranty EXTENDED AL KO WARRANTY AL KO International will extend the warranty for a further 24 months therefore the warranty will be valid for 36 months from date of installation where the following conditions are satisfied a the Brake Controller In Car Kit has been installed by an AL KO International approved installer b the customer has completed the warranty form on the Product instruction manual and sent it back to AL KO International for registration c the customer has attached to the completed warranty form a copy of the original installation invoice provided to the customer by the AL KO International approved installer d the copy of the original installation invoice clearly shows the date of installation and the details of the AL KO International approved installer e The Brake Controller is an AL KO approved Motion Sensing Controller see page 6 and the Actuator AL KO iQ7 has been installed by an a
5. d that before each use 1 Check the brake fluid level of the AL KO iQ7 system 2 Check all electrical leads and connectors for broken wires damaged or corroded connectors etc It is suggested that an appropriate corrosion preventive compound be periodically applied to all exposed wiring and connectors 3 Brake fluid should be replaced annually or more frequently in heavy use WARNING When not in use over extended periods of time please ensure the actuator is activated periodically approximately every four weeks to ensure moving components remain in good condition and seals remain lubricated Failure to do so may result in incorrect product performance and could result in serious damage or injury 7 AL KO INTERNATIONAL PTY LTD 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 AL KO International Pty Ltd ABN 96 003 066 813 AL KO provides the following warranty in relation to its AL KO iQ7 XTREME Actuator AL KO iQ7 Actuator and In Car Kit Product The benefits of this warranty are in addition to any rights and remedies imposed by Australian State and Federal legislati
6. efore suggested that the AL KO iQ7 unit be mounted towards the front of the towed vehicle and as high as practical i e the bow post if used in the marine environment Refer Fig 1 Page 2 WARNING Never submerge the AL KO iQ7 actuator at any time Submerging may cause system malfunction resulting in possible serious or fatal injuries and or property damage Submerging will void warranty WARNING Never apply solvents or adhesives including brake fluid to the actuator housing as this may weaken the housing resulting in possible serious or fatal injuries and or property damage Brake Fluid will damage any painted surfaces Installation Actuator IMPORTANT Under no circumstances should any control system other than approved AL KO iQ7 controllers be used in conjunction with the AL KO iQ7 Actuator Mounting Bracket The AL KO iQ7 actuator incorporates four mounting holes on the base of the unit Refer figure 3 Page 2 In order to attach the unit securely to the trailer and to minimise vibration a sturdy mounting bracket must be fabricated Use a 6mm or 1 4 bolt with a suitable locking nut to fix the actuator to the trailer It is important to ensure the mounting bolts are not over tightened during installation If the rubber mounting grommet appears oval shaped Refer figure 2 Page 2 it has become over tightened When choosing a location for the mounting bracket consider positioning of additional trailer accessories
7. ervoir incorporates an air pressure dump valve As soon as the braking system is deactivated i e ignition is turned off trailer breaks away from the vehicle the trailer brakes are automatically activated In order to release the trailer brakes the air pressure dump valve must be pressed CAUTION The service brake is not intended to be used as a park brake Under no circumstances should the trailer be left detached from the vehicle with only the service brake activated Either the wheels should be blocked or an independent park brake applied and then the actuator reservoir air dumped Failure to do so could result in serious damage or injury Breakaway System A breakaway system is often required on a braked trailer The breakaway system must be designed to automatically apply the brakes to the towed vehicle in the event that the trailer becomes separated from the tow vehicle The AL KO iQ7 does NOT require a separate power source for the activation of the breakaway system In the event of a breakaway situation the disconnection of the power supply results in the trailer service brake being activated automatically In order to deactivate the brakes press the air pressure dump valve Please check regulations in your area as to the requirements of trailer breakaway systems MAINTENANCE The AL KO iQ7 is an intelligent trailer braking system This does not however mean that the system should not regularly be maintained It is recommende
8. nstructions as supplied by the manufacturer to establish smooth proportional braking Approved AL KO iQ7 Motion Sensing Controllers e Hayes Energiser Ill e Tekonsha Primus IQ e Tekonsha Prodigy P2 e Tekonsha P3 Contact AL KO for verification of all other controllers prior to use iQ7 used in conjunction with a Tekonsha P3 brake controller fulfills the requirements of providing visible warning of low operating pressure or break away by flashing a red No Connection display from the front of the controller This feature is required in some Australian states IMPORTANT WARNING Please ensure trailer plug socket is mounted in a position that does not enable water contact or pooling around terminals The trailer plug socket should be regularly sprayed with water dispersing agent or corrosion preventative Compound OPERATION Warning Always ensure the towed vehicle and its load is secured Failure to do so could result in possible serious damage or fatal injuries and or property damage To ensure that the AL KO iQ7 system is functioning correctly the brake actuator should be tested every time the towing vehicle is re attached to the towed vehicle Refer Testing page 6 6 Air The as aw to r Un will or dur Bre sys vel The of disi act In che M The Thi It is Wh IS 2 cor to anc sed nts his not ket ion ge ake to Air Pressure Dump Valve The AL KO iQ7 res
9. on 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 modified WARRANTY AL KO warrants that subject to the exclusions and limitations below the Product will be free from defects in materials and workmanship for a period of 12 months from the date of installation This warranty is not transferable to a subsequent person if the Product is sold by the original purchaser during the warranty period If a defect appears in the Product before the end of the warranty period and AL KO finds the Product to be defective in materials or workmanship AL KO will in its sole discretion either a replace or repair the Product or the defective part of the Product free of charge or b cause the Product or the defective part of the Product to be replaced or repaired by a qualified repairer free of charge AL KO reserves the right to replace defective parts of the Product with parts and components of similar quality grade and composition where an identical part or component is not available Goods presented for repair may be replaced by refurbished goods of the same type rather than being repaired Refurbished parts may be used to repair the goods WARRANTY CLAIMS 1 If a fault covered by warranty occurs lt the customer must first contact AL KO at the
10. pproved OEM manufacturer If anything listed in a to f above is not complied with then AL KO International reserves the right to limit the warranty to a 12 month period A list of the approved installers is available at www alkoiQ7 com au Failure to comply with the installation and verification instructions may result in incorrect operation or premature product failure that could lead to serious injury accident or death and will also void this product warranty CONTACT AL KO International Pty Ltd 67 Nathan Road Dandenong South VIC 3175 Phone 03 9767 3700 Email info alko com au gt not ne woo oyje MMM Q M eljessny ne woo oyje Mojul ewa GJLE EHOJDIA ynos Buou pued ZZ80 C626 19 XEd PeOYy UEUJEN 16 29 OOZE Z926 L9 uoud L8 990 00 96 NEV pP d Ieuoneuui lul Oy TV 0 UINJaY poO d SOUIAOId B E S AND ssalppy 1 e q weN Jaje9q poO d BOUIAOId B E S AND ss ippv OWEN BIDIUSA p AO JO WA9 SSEW J9IU A SSH Jayies Buimo eA Jad Wy 9BeJ AV Ju uu OB d l e SI SIU Ji PUIG JOU 1940 UBABIED SJOH Hodsuejil J 0g J e1 JO d L I UIDON S O Len ayaa MO JO Sd L JOUIO pepuswwosey pusli4 sOJeqpeumMO HJ9le q EO Jo Wes noA pip 1 uAA IM ONT SPAT 4eleed q p lle su p sey ndg 3Jeq WT oONIH 9S 8pON AO 9qQ SS IppEe OyY 1V BU o WIN OJ pue Ao q WO BU 9 9 duuo2 se jd aseudind noA 191SsI 6
11. ssure bleed gun socket Rub a small amount of brake fluid around the inside of the reservoir neck to assist fitting Screw the cap fully closed Attach the bleed gun to the actuator fluid reservoir as shown in diagram 1 and place the other end in a bottle of new brake fluid Diagram 1 rx Attaching the bleed gun to the actuator Diagram 2 Open the bleed screw on the trailer brakes start with the closest calliper brake at least one full turn Place a clear flexible hose over the bleed screw and immerse the other end into a container partially filled with brake fluid Squeeze the pressure bleed gun repeatedly not too fast or cavitation may occur ensuring that the bulk brake fluid tank and the reservoir do not run out of brake fluid or air will enter the hydraulic system At no stage let the fluid level in the reservoir fall below the minimum fluid level indicator 3 7 Continue squeezing the pressure bleed gun until the brake fluid in the flexible hose attached to the bleed screw is free of air bubbles and tighten the bleed screw 8 Repeat the process for any other callipers brakes on the same side of the trailer working away from the actuator 9 Bleed the other side of the trailer starting with the closest calliper brake to the actuator first as above 10 Connect the trailer to the tow vehicle and start the vehicle to activate the actuator Allow the compressor to fully charge the actuator appro
12. such as a winch etc Figure 1 Mounting Position Actuator Bow post Figure 1 Mounting Position Figure 2 Mounting Bush Actuator Bow post Mounting bush Rubber grommet Over tightened Correct 26 0mm or 1 4 Figure 4 Actuator Brake Fluid Reservoir Master Cylinder Port HY Col to 1 Lor Cal nev whi gla bet nev Ble Ble Sr HYDRAULIC CONNECTION Connect the hydraulic brake line from the brake system on the towed vehicle to the brake port on the AL KO iQ7 actuator unit using a 3 8 UNF Brass Long Series Tube Nut Carefully fill the brake fluid reservoir by removing the filler cap Always use new brake fluid Never attempt to reuse brake fluid The reservoir is full when the fluid reaches the bottom of the reservoir neck the top of the sight glass Do not over fill the reservoir Be careful not to spill brake fluid between the reservoir and the front cover The brake fluid level must never fall below the minimum line indicated on the sight glass Bleeding Bleeding instructions using AL KO iQ7 Pressure Bleed Gun 1 Fill reservoir with clean Dot 4 brake fluid to just below the top of the sight glass Place the pressure bleed gun available from AL KO p n 350045 socket gently over the neck of the reservoir applying gentle pressure to locate the bleed socket O Ring in place Do not push on with excessive force or damage may be caused to the reservoir or the O ring on the pre
13. that the actuator is not run without fluid Running the unit without fluid will ingest air into the brake system that must be removed by bleeding 4 Wii The pro the Wiring Loom and The AL KO iQ7 Wiring Loom has been designed to simplify the installation process of ake ate rox 30 amp s 5 BLACK and 12 VOLT RESETTABLE S253 RED BATTERY CIRCUIT BREAKER 20S WHITE AL KO APPROVED ag BRAKE CONTROL BLUE brake control top GROUND VEHICLE SIDE XDOOOOO I IN A eee eee IN A owo RX ODOOOOO TRAILER SIDE BLUE the all ill Q7 atal LA s i 7 N C A I Qa D N ee gt BROWN NOT IN USE na ted as run ake Testing Hydraulic AL KO iQ7 actuator version designed for use with Motion Sensing Brake Controllers only After the vehicle brake controller installation has been completed test the system set up as follows a Turn on ignition The compressor inside the AL KO iQ7 Actuator will be heard running Wait a least 30 40 seconds before attempting to drive or move the vehicle This will allow for at least 50 braking power to become available b Wait a further 60 seconds before undertaking brake proportionality testing Find an appropriate stretch of road where brake testing can be undertaken without the disruption of other road users c Follow the motion sensing brake controller i
14. x 120 seconds Once the compressor has stopped apply the brakes and hold on for a 5 second period and release Repeat this 4 times 11 Check the brake fluid level in the reservoir It should not exceed the top of the sight glass maximum level See diagram 3 12 Insert and tighten the fluid reservoir cap IMPORTANT Before removing the pressure bleed gun from the reservoir make sure that there is no pressure in the system pressure bleed gun has fully returned to the Am Minimumi Fuia EEwel rest position or brake fluid spillage will occur causing paint damage Diagram 3 Maximum Fluid Level WARNING Correct bleeding of the actuator is critical as trapped air greatly reduces the efficiency of the brakes When the bleeding process is complete check all bleeder screws to ensure that they are secure and do not leak Failure to properly install bleed operate and maintain your AL KO iQ7 braking system can cause malfunction resulting in possible serious or fatal injuries and or property damage The IQ7 actuator should never be used to bleed the braking system as this may damage the compressor Drum Brakes If drum brakes are being used a residual line pressure valve obtain from a brake specialist must be installed in the hydraulic line This must be located BEFORE any split in the hydraulic line immediately after or as close as practical to the master cylinder port Note Monitor the brake fluid level in the reservoir so
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