iQ7 XTREME ACTUATOR Installation & Operating Instructions
Contents
1. 107 XTREME ACTUATOR Installation amp Operating Instructions AL K0 INTERNATIONAL ABN 96 003 086 813 FOR DETAILS OF YOUR NEAREST AL K0 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 alltimes 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 mounted2. Actuator Bow post Figure 1 Mounting Position Figure 2 Mounting Bush Actuator Bow post Mounting bush Rubber grommet Over tightened Correct 6 0mm 1 4 Figure 4 Actuator Fluid Reservoir Pressure Dump Valve Master Cylinder Port 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 Diagram 1 glass Attaching the bleed gun to 2 Place the pressure bleed gun the actuator 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 3 Do not push on with excessive force or damage may be caused to the reservoir or the O
3. 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 Diagram 2 5 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 6 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 approx 120 seconds Once the compressor has stopped app
4. 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 107 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 such as a winch etc Figure 1 Mounting Position
5. MO WAD SSEW 55015 1284 Jed wy e SI SIU pueJq Jeuo Hodsuei 204 jo d L Uh JO d L 4 919eqpeuwo J le q 410 Jo ujee pip ONT SPAT Aq p sguS9imnmq eq IV ONIeues I pON sseJppe OyY 1V 24 pue woz eu eseejd aseyoind ino 1 1sIB 1 OL pieS uonjessiBay AJueuupAA 19npoid Further information can be obtained by visiting www alko com au AL K0 International Pty Ltd ABN 96 003 066 813 VIC 67 Nathan Road Dandenong South 3175 Phone 03 9767 2700 Fos 03 9792 0877 NSW 26 Hallstrom Place Wetherill Park 2164 Phone 02 87849400 Fax 02 97254657 QLD 13 Union Circuit Yatala 4207 Phone 07 3386 6300 Fax 07 3386 6399 NZ Airpark Drive Airpark Oaks Mangere Auckland Phone 09 255 5611 Fax 09 255 5612
6. 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 approved 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 q AA m ne woo oye ojul GLLE enop unos 1180 2646 19 XE peoy UEUJEN 16 29 OOLZE 1926 19 euoud 218 990 200 96 Nav jeuoneujeyu 10 uinjoM epo9 d BOUIADId 5 A sseJppy Jejeeq oweN poO d 8JEJS sseJppv P
7. 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 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 fores
8. eeable 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 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 qualif
9. he unit without fluid will ingest air into the brake system that must be removed by bleeding 4 Wiring Loom The AL KO iQ7 Wiring Loom has been designed to simplify the installation process Refer to figure 5 for pin layout Figure 5 Plug Socket Wiring Trailer Plug Male Actuator PinNo Colour Function 8 Red 12 Volt Power Supply ve 10 Black Earth ve 11 Brown Fault Signal 12 Blue Control Voltage Pin No s 11 amp 12 refer to iQ7 hydraulic actuator only 10 11 12 12 Pin Plug Vehicle Socket Female Wiring loom PinNo Colour Function 8 Red 12 Volt Power Supply ve 10 Black Earth ve 11 Brown Fault Signal 12 Blue Control Voltage Pin No s 11 amp 12 refer to iQ7 hydraulic actuator only 12 Pin Socket Testing Hydraulic AL KO iQ7 actuator only After the initialisation sequence has been completed see iQ7 XTREME In Car Kit Installation amp operating Instructions page 6 test the system set up as follows a Turn on the ignition The mouse will produce the fault signal indicating that a sufficient pressure has not yet been achieved in the actuator This signal will last for approximately 30 40 seconds until a working pressure has been reached This audible alarm can be silenced by pressing the panic button but please note that in doing so the trailer brakes will be activated If you choose to silence the alarm do so only when a stationary position The fault signal will sti
10. ied 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 the customer must first contact AL KO at the contact address listed below or the retailer from which the Product was purchased 2 Any warranty claim must be accompanied by a proof of purchase b full details of the alleged defect and anyrelevantdocumentation such as 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 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 mod
11. ified 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 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
12. ll be active by way of the flashing LED Once the fault signal has stopped 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 Set the gain control slider on the mouse to the middle position Driving at approximately 50km per hour apply the service brake via the pedal Take note of the braking proportionality between the towing vehicle and the towed vehicle If they are not similar repeat steps 1 and 2 in the Initialisation Sequence until this is achieved When proportional braking has been established the system is ready for use 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 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
13. ly 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 Minimum LEVE 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 Diagram 3 Maximum Fluid Level 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 t
Download Pdf Manuals
Related Search