AL-KO IQ7 Manual

IQ7 XTREME IN CAR KIT
INSTALLATION & OPERATING
INSTRUCTIONS
Keep this manual for the safety warnings and precautions, installation, operation, maintenance and cleaning
procedures. For future reference, this manual should be kept in a safe place.
WARNING
Read this manual before
using this product. Failure
to do so can result in
serious injury or death.
SAVE THIS MANUAL.

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The AL-KO iQ7 XTREME Controller
incorporates a number of unique features
designed to maximise the performance of
your braking system.
Auto Detect
The AL-KO iQ7 XTREME incorporates
an ‘Auto Detect’ function that
enables it to identify which type of
braking system has been connected
and alters its electronic signal
automatically in order to achieve
maximum brake performance.
When in Electric Brake mode (if
installed) the LED on the mouse is
orange. The intensity will increase as
braking increases.
In AL-KO iQ7 XTREME mode the
LED on the mouse is green and will
change to orange when brakes are
applied. The intensity will increase as
braking increases.
IMPORTANT!
If changing between trailers utilising
varying actuator types (i.e. AL-KO
iQ7 XTREME to Electric), the tow
vehicle power supply will need to be
turned off then turned on again to
enable trailer detection.
Controller Components
Brake Pad
The patented AL-KO iQ7 XTREME
Pad is mounted onto the brake
pedal of the tow vehicle. A pressure
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the pad measures the force being
applied in a braking situation and
converts this into a variable voltage
signal.
Mouse
The AL-KO iQ7 XTREME Mouse is to
be mounted in the cab of the towing
vehicle within easy reach of the
driver.
The mouse serves a number of
functions:
Panic Button - The panic button
provides an antisway function.
Should the trailer get into a sway the
panic button is pressed, applying
a light braking force to the trailer
independent to the towing vehicle.
The brakes will be applied lightly for
3 seconds only and should assist in
the straightening of the trailer. The
tow vehicle & trailer stop lights are
also activated.
Variable Gain Control - Enables the
driver of the towing vehicle to set the
amount of trailer braking from within
the cab. Ideally the gain should be
set so as the towing vehicle and
trailer brake together.
Excessive braking of the trailer will
result in premature wearing of the
trailers brake shoes/pads.
AL-KO iQ7 XTREME Controller
(ECU)
The AL-KO iQ7 XTREME continually
monitors the state of the electric
system to ensure safe operation.
The early detection of potential faults
are all continually monitored with
the driver informed of any such
fault through the AL-KO iQ7 mouse
(audible and visual signals).

Page 3
Wiring Loom
The AL-KO iQ7 XTREME Wiring Loom has been specially designed to
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Figure 1. Generic Wiring Diagram
Figure 2. Socket Wiring
Vehicle Socket Female (Vehicle)
Pin No. 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 & 12 refer to Sensabrake™ hydraulic actuator only)
12 Pin Socket
3 5 6 1274
101112 9 8
30 amp resettable
circuit breaker
12 volt battery
RED to EVO BLACK to EVO
Figure 4. iQ7 Pad
iQ7 Pad
Backing plate
Brake pedal
Figure 5. Mouse
INSTALLATION
Towing Vehicle
Note: It is recommended that all in-vehicle
electrical work is undertaken by a registered
auto electrician, and that the bare copper
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IMPORTANT!
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2. The iQ7 XTREME must be mounted away
from all other electronic control
devices e.g. electric throttle control.
3. Route all wires as far from the radio
antenna as possible to reduce AM
interference.
It is critical that when installing the
AL-KO iQ7 XTREME Controller that
the factory supplied wiring loom is used.
4. Should additional wire be required make
sure that it is of similar or larger
gauge than supplied. Under no
circumstances should wire thinner than
the factory supplied loom be used as this
may affect product performance
and void the warranty.
5. The collection of water inside the
electrical trailer connection will reduce
the life of the connector and may result
in inadequate or intermittent braking.
To minimise corrosion build up inside
the connector, it is suggested that an
appropriate corrosion preventative
compound be applied to conductive
surfaces. Refer to maintenance section.
MAINTENANCE:
The AL-KO iQ7 is an intelligent trailer braking
system that has onboard diagnostic software.
Should the system detect a fault, the operator
will be informed via a visual and audible
alarm inside the tow vehicle. This does not
however mean that the system should not
regularly be maintained.
It is suggested that before each use:
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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. Always ensure the trailer plug and socket
are kept in good working condition. They
must be kept clean and dry to prevent
electrical leakage that may cause the
trailer brakes to provide indequate or
intermittent braking.
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or more frequently in heavy use.

www.alko.com.au
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Diagram
Figure 1. Generic Wiring Diagram
Figure 2. Socket Wiring
Vehicle Socket Female (Vehicle)
Pin No. 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 & 12 refer to Sensabrake™ hydraulic actuator only)
12 Pin Socket
3 5 6 1274
101112 9 8
30 amp resettable
circuit breaker
12 volt battery
RED to EVO BLACK to EVO
Figure 4. iQ7 Pad
iQ7 Pad
Backing plate
Brake pedal
Figure 5. Mouse
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
operating condition and seals
remain lubricated. Failure to do
so may result in incorrect product
performance and could result in
serious damage or injury.
FAULT SIGNALS
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Situation: Actuator pressure has not
been reached, trailer disconnected
while ignition still on, low voltage
alarm, or excessive moisture in
trailer socket causing short circuit.
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intervals followed by rest period of 4
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Situation: Compressor has been
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minutes while cooling).
VERIFYING ELECTRICAL
INSTALLATION
After completion of electrical
installation it is important to verify
correct installation using the
following procedure. For this test the
trailer needs to be connected to the
vehicle
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voltage at the tow vehicle battery.
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trailer connected, apply the trailer
brakes so as to engage operation of the
trailer mounted compressor. While the
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actuator supply voltage at the trailer plug
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c) Maximum voltage drop from the battery
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volts the battery should be tested, and
all electrical connections between the
battery, AL-KO iQ7 XTREME controller,
and trailer plug checked for correct
operation and repaired or replaced where
necessary.
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systems or digital signaling may require
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XTREME ignition and brake light supplies.
Power and earth supplies must come direct
from the battery. This should ensure that the
AL-KO iQ7 XTREME controller is independent
of the vehicles electronics.
Page 4

TESTING
Hydraulic AL-KO iQ7 Actuator only
After the Initialisation sequence has been
completed, test the system set-up as follows:
a) Turn on the ignition. The mouse will
produce the ‘fault signal’ indicating that
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achieved in the actuator. This signal will
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until a working pressure has been
reached. The compressor will however
remain on after the signal has stopped,
until working full pressure has been
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b) Once the ‘fault signal’ has stopped, wait
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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.
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apply the brakes. Take note of the braking
proportionality between the towing
vehicle and the towed vehicle. If they are
not similar then adjust the gain slider to
the right for more trailer braking or left
for less trailer braking. If the gain slider
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in the initialisation sequence (page 6). At
step 2 place less pressure on the brake
pedal.
e) When proportional braking has been
established the system is ready for use.
Electric Brakes only
After the Initialisation sequence has
been completed, test the system
set-up as follows:
a) Set the gain control slider on the mouse
to the middle position.
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apply the brakes take note of the braking
proportionality between the towing
vehicle and the towed vehicle. If they are
not similar then adjust the gain slider to
the right for more trailer braking or left
for less trailer braking. If the gain slider
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in the initialisation sequence (page 6). At
step 2 place less pressure on the brake
pedal.
c) When proportional braking has been
established the system is ready for use.
IMPORTANT!
Please ensure trailer socket is
mounted in a position that does
not enable water contact or pooling
around terminals.
Under no circumstances should the trailer
plug or socket be submerged under
water as this may result in inadequate or
intermittent braking.
IMPORTANT!
24 Volt Vehicles: Vehicles operating
a 24 volt system must utilize the
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void any warranty claim.
IMPORTANT
For Electric Brake Installation Only, a
separate 7 pin socket must be used
when connecting electric brakes.
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brake wire to pin 5 of the 7 pin
socket. The remaining 6 pins should
be looped into the corresponding
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Page 5