AL-KO iQ7 Electric Hydraulic Brake Actuator Instruction Manual
- June 12, 2024
- AL-KO
Table of Contents
AL-KO iQ7 Electric Hydraulic Brake Actuator
AL-KO iQ7 ACTUATOR & CONTROL
The AL-KO iQ7 Actuator & Control is a trailer braking system designed to be
used with Motion Sensing Brake Controllers. It is important to read and
understand the installation and operating instructions provided in this manual
before using the product. This manual should be kept with the towing vehicle
for future reference.
Product Information
- Product Name: AL-KO iQ7 Actuator & Control
- Manufacturer: AL-KO
- Website: alko.com.au
- Warranty: 3 years
Installation
Actuator
When installing the AL-KO iQ7 Actuator, it is important to note the following:
- Only approved AL-KO iQ7 controllers should be used in conjunction with the actuator.
- The actuator should be securely mounted to the trailer using a sturdy mounting bracket.
- Use a 6mm or 1/4 bolt with a suitable locking nut to fix the actuator to the trailer.
- Avoid over tightening the mounting bolts to prevent damage to the actuator.
- Consider the positioning of additional trailer accessories when choosing a location for the mounting bracket.
Hydraulic Connection
To connect the hydraulic brake line from the towed vehicle’s brake system to the AL-KO iQ7 actuator unit, follow these steps:
- Use a 3/8 UNF Brass Long Series Tube Nut to connect the brake line to the brake port on the actuator unit.
- Fill the brake fluid reservoir by removing the filler cap and carefully pouring in new brake fluid. Do not 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 overfill.
- Ensure that no brake fluid spills between the reservoir and the front cover.
- Check that the brake fluid level does not fall below the “minimum” line indicated on the sight glass.
For further information and detailed instructions, please refer to the AL-KO iQ7 Actuator & Control Installation & Operating Instructions manual.
This information MUST be distributed with the AL-KO iQ7 trailer braking system and be kept with the towing vehicle for future reference.
When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken, please contact your purchase point immediately.
No part of this DOCUMENT may be reproduced without AL-KO’s permission. All part numbers, dimensions and specifications in this DOCUMENT are subject to change without notice.
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 therefore 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 the 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 I njuries and/or property damage. Brake Fluid will damage any painted surfaces.
INSTALLATION
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, below). In order to attach the unit securely to the
trailer and to minimize 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 to
Figure 2, below) it has become over-tightened. When choosing a location for
the mounting bracket, consider the positioning of additional trailer
accessories, such as a winch etc.
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
- Fill the 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
- Do not push on with excessive force or damage may be caused to the reservoir or the O ring on the pressure 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.4. 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
- 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.
- Open the bleed screw on the trailer brakes (start with the furthest calliper/brake) at least one full 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 At no stage let the fluid level in the reservoir fall below the minimum fluid level indicator.
- 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.
- Repeat the process for any other callipers/brakes on the same side of the trailer working away from the actuator. Bleed the other side of the trailer starting with the closest calliper/brake to the actuator first as above.
- Connect the trailer to the tow vehicle and start the vehicle to activate the actuator. Allow the compressor to fully charge the actuator (approx 120 seconds). Once the compressor has stopped, apply the brakes and hold on for a 5 second period and release. Repeat this 4 times.
- Check the brake fluid level in the It should not exceed the top of the sight glass maximum level. (see diagram 3).
- Insert and tighten the fluid reservoir
IMPORTANT: Before removing the pressure bleed gun from the reservoir, make sure that there is no pressure in the system (the pressure bleed gun has fully returned to the rest position), or brake fluid spillage will occur causing paint damage.
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 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
Wiring Loom:
The AL-KO iQ7 Wiring Loom has been designed to simplify the installation
process.
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:
- 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 th e vehicle. This will allow for at least 50% braking power to become available.
- 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.
- Follow the motion sensing brake controller instructions as supplied by the manufacturer to establish smooth proportional braking
APPROVED AL-KO IQ7 MOTION SENSING CONTROLLERS:
A full current list of approved controllers can be found at: alko.com.au/product/solutions/brake-controllers- actuation/iq7/ At the time of production of this manual the below are approved for use with AL-KO iQ7 actuators.
- Hayes Energiser III
- Tekonsha Primus IQ
- Tekonsha Prodigy P2
- Tekonsha P3
- REDARC Tow-Pro Elite
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 Co nnection’ 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 reattached to the towed vehicle (Refer to`Testing´ – page 6).
Air Pressure Dump Valve
The AL-KO iQ7 reservoir 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 damag e 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 recommended that before each use:
- Check the brake fluid level of the AL-KO iQ7 system.
- 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.
- 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
AL-KO INTERNATIONAL 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 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 beexcluded, 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:
- replace or repair the Product or the defective part of the Product free of charge; or
- cause the Product or the defective part of the Product to be replaced or repaired by a qualified repairer free of
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
- If a fault covered by warranty occurs ‘ the customer must first contact the installer of the Product, 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 (such as maintenance records).
- 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.
- 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 authorised repair agent where the claim is not covered by this warranty.
EXCLUSIONS
The warranty will not apply where:
- the Product has been repaired, altered or modified by someone other than AL-KO or an authorised repair agent;
- AL-KO cannot establish any fault in the Product after testing and inspection;
- the Product has been used other than for the purpose for which it was designed;
- the defect in the Product has arisen due to the customer’s failure to properly use and maintain the Product in accordance with AL-KO’s instructions, recommendations and specifications (including maintenance);
- the Product has been subject to abnormal conditions, including environment, temperature, water, fire, humidity, pressure, stress or similar;
- the defect has arisen due to abuse, misuse, neglect or accident; or
- unauthorized parts or accessories have been used on or in relation to the
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:
- The Brake Controller/In Car Kit has been installed by an AL-KO International-approved installer*;
- The customer has completed the online warranty form located at: alko.com.au/warranties/ copy of the original installation invoice can be presented clearly indicating the date of installation and the details of the AL-KO International approved installer*;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 approved OEM
If anything listed in (a) to (e) 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 67 Nathan Road, Dandenong South, Victoria, 3175 Phone : (03) 9997 4500 Email : info.aus@alko-tech.com
Register your warranty at www.alko.com.au
- Option 1. Scan the above QR code
- Option 2. Visit alko.com.au/warranties
- Option 3. Take this link (digital copy only)
SERIAL No. ALK
INSTALLER
DATE / /
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of identifying you if you wish to make a claim under the warranty, and for
dealing with that claim. We may also use your information to communicate with
you about our product and promotions.
Your information will only be disclosed to third parties where necessary to
assess or complete your claim such as suppliers or distributors of our
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not complete all the information contained on the card, we may not be able to
provide you with a warranty.
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please contact our Privacy Officer on (03) 9997 4500
Visit www.alko.com.au for more information
References
- AL-KO Vehicle Technology | Australian Trailer & Caravan Parts Manufacturer
- AL-KO iQ7 | AL-KO
- Warranties | AL-KO
- Warranties | AL-KO
- AL-KO iQ7 | AL-KO
- AL-KO Vehicle Technology | Australian Trailer & Caravan Parts Manufacturer
- Warranties | AL-KO
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