caravan mover user`s manual P1 Automatic P1 Manual Safety precautions

Transcription

1 caravan mover user`s manual P Automatic P Manual Safety precautions Read this manual before fitting or first use Use only approved jacking equipment when fitting Check the tyres pressure and condition (new tyres recommended) Check the chassis is in undamaged, rust-free condition Apply caravan hand brake before fitting Always apply caravan hand brake prior to disengagement of drive rollers and after the mover operation is complete (you cannot rely on rollers to act as hand break) Apply torque settings specified Perform a dry run in an open area after fitting to familiarise yourself with mover`s operations Keep the remote out of reach of children Manual Version can easily be upgraded to Automatic Version at a later date. It is as simple as fitting roller actuators and Roller Controller (RC). Your Caravan Controller system (CC) and the remote will automatically recognise the upgrade and are ready to work. Ask your dealer for further details.

2 What`s inside the boxes Description Quantity Description Quantity Description Quantity drive unit left and right side 8 caravan controller (CC) 2 centre bar 3 U-bolt with washers and nuts 4 clamp kit 2 5 fitting kit: p-clips, cable ties, screws 9 emergency jack-jack cable 4 0 remote actuator-to-cc 4m white cable kit 2 roller controller (RC) 6 cable terminals Amp fuse 7 battery-to-caravan controller.5m cables P Manual only P Automatic only black and red 5 emergency key per side 6 wooden check block 7 9mm key 8 3mm screw and washer 9 extention tube 2 20 cross link tube 2 main motor-to-cc 4m cables 2 2 black and red per side

3 Technical specs Caravan axle setup ) Roller engagement setup 2) Max permissible weight 3) P weight without battery Max velocity 4) Max torque (at drive roller) Min battery capacity Radio frequency Remote battery Single or Twin Axle caravan Manual (mechanical) or Automatic (electric) 800 kg (25% slope) 34.5 kg (Manual Version: 36.5 kg) appr. 5cm/s 7 Nm 80Ah 2V 868 MHz bi-directional communication 9V (PP3-type) ) Cross-grade possible, ie. Single Axle Version can be upgraded to Twin and Twin can be down-graded to Single. Ask your dealer. 2) Manual Version can be upgraded to Automatic Version. Ask your dealer. 3) Max permissible caravan weight increases considerably with slope ratio decrease. The actual performance may vary depending on individual circumstances. Adverse circumstances, which may lower expected performace, include surface condition (eg. rough or muddy ground), weather (moisture or snow), battery charge, tyre condition (wear or underinflation), drive roller normal wear&tear. 4) Velocity decreases with load increase (load depends on caravan weight and slope steepness) Chassis critical dimentions Standard kit allows fitting to vast majority of caravans available (will fit both L-plate type and U-plate type chassis). If in any doubt please check that the chassis of your caravan complies with the standard dimentions as shown besides. For non-standard caravans special adapters are available check with your dealer. Tools needed open-end or ring 0 mm wrench: 2 No open-end or ring 3 mm wrench: 2 No open-end or ring 7 mm wrench: No small pozi/cross screwdriver torque wrench 6mm 2 cable crimper Mechanical assembly order

4 Fitting in front of caravan axle is preferable, however in some cases (e.g. no space) the mover can be fitted behind the axle. Put your P on a clean flat surface Mark a middle point of centre bar 2 with a marker (75cm from either end) and fit it into both drive units Place the P underneath the caravan and support it up to caravan chassis Remove M0 nylock nuts and washers from U-bolts 3. Place U-bolts through clamps, replace washers and secure loosely with nuts as shown beside. Use a 7mm wrench. Allign the mover as shown below. Use supplied wooden blocks 6 to determine correct clearance between caravan tyres and drive rollers Make sure the clamps are placed in such a way that they touch the chassis walls as shown below. This is a critical step. Tighten up nylock nuts on clamps to 28Nm with a 7mm wrench. This is a critical step: make 3 round-checks with torque wrench to ensure correct torque is achieved on all 4 nuts each side (to overcome aluminium limited flexibility) Make sure centre bar 2 is in the middle and tighten up M8 screws (4No) on drive units to 2Nm with a 3mm wrench. Tighten up counter-nuts. Loosen M6 screws (with 0mm wrench) on cross link tube 20 and slide extention tubes 9 onto side couplings on drive unit Insert M8 screws 8 through extention tubes and side couplings and tighten nylock nuts to 27 Nm with 3mm wrenches. Make sure cross link tube 20 is set in the middle and tighten up M6 screws (4No) to 2Nm with a 0mm wrench and secure with counter-nuts. Electronic control system assembly and operations Avoid short-circuits! Always secure the positive battery cable with an insulator during fitting. Connect the positive battery cable 7 red as last cable. Check the electronic caravan controller box 8 is switched off before fitting. Rollers must be disengaged during fitting. Caravan controller 8 ( and Roller Controller 2 ) should be installed in a dry place, best inside the caravan, enabling access. Never shorten/add extra lenght of aerial (stock length has been tuned for best communication) It is recommended to use a battery of minimum capacity of 80 Ah. Ensure the battery is fully charged before operation. Mind that all batteries discharge slowly with time on their own.

5 Procedure lead cables from left/right motors 2 and the battery 7 ( and actuators ) to the area where Caravan Controller 8 ( and Roller Controller 2 ) will be installed (most commonly in front boot or inside e.g. under bed); instead of cutting cables to length we recommend leaving the original length and securing the excess with cable ties (in case of transfering the mover to your next bigger caravan you may need longer cables) terminate cables 2 with cable terminals 6 Ensure cables do not chaff especially when led through caravan`s floor (use protective grommet, tape, tube sleeve or the like if necessary not supplied). Use p-clips and cable ties to secure cables to underneath the caravan floor Remember to leave a length of slack cable by the drive motors to allow for rollers` engagement/ disengagement movement. Red colour cables denote positive (+) polarity secure Caravan Controller 8 ( and Roller Controller 2 ) in place and undo 4 long screws on top of 8. Remove lid carefully. connect Roller Controller 2 to Caravan Controller 8 as shown above. Insert supplied fuse 3 as shown above. Ensure jumper connector 4 is at RCU position. Remove brass nuts and upper washers inside 8 and connect motor cables 2 and battery cables 7 replacing washers and nuts. If P mover is fitted behind the caravan axle(s) polarity of motor cables 2 must be reversed, ie. black cables connect to P (positive) terminals and red cables connect to N (negative) terminals on 8. connect actuator cables to 2 as shown above. terminate the other ends of battery cables 7 with good quality battery clamps (not supplied) connect battery cables 7 to battery 22 and check operations of the mover by observing rollers movement (double-check the rollers are disengaged beforehand). ( check operation of IN/OUT movement of the rollers) Replace lid and tighten the 4 screws on Caravan Controller 8

6 Remote control operating manual To switch the remote ON press simultaneously + buttons for about 3 sec. All three LEDs (bi-colour LEDs are used) light up during pressing. Remote switches Off after no button has been pressed for min. Range/Remote battery level LED: (LED signalling normally in green; when remote battery level is low, LED signalling changes to red. There is min. 2 working hours left after LED changes to red). when remote out of range (or caravan control box (CC) switched Off) LED flashes in series of 4 times fast/no flash (searching for signal); when remote in range LED is lit up (constant); fast LED flashing indicates Drive buttons buttons pressed. Auto rollers IN/OUT buttons (active with only): press both buttons simultaneously to move rollers IN or OUT of the tyres. Rollers will stop as soon as the correct individual pressure on tyre is achieved (useful if both caravan tyres are not pressurised identically). Auto Rollers STOP button (active with only): during IN or OUT movement of rollers press this button to stop such movement (e.g. in case of emergency). After such stoppage the next time both Auto rollers IN/OUT buttons are pressed the rollers will always return to OUT position first. In case of a failure (e.g. discharged main battery) slide rubber grommets off the back of actuators and wind the actuators separately (anti-clockwise) out of the wheels using emergency key 5. Main (mover) battery level LED (active only when remote in range): - green LED lit up (constant): main battery charged; - red LED flashing: main battery appr. half-empty; needs charging, however system still fully operative for some time. - red LED lit up (constant): main battery level too low; system inoperative. Alert LED (active with only): green LED flashing indicates Auto Rollers IN or OUT movement. Both Main battery level LED and Alert LED flashing in green and red simultaneously indicate overload (may happen under extreme conditions eg. very heavy caravan trying to drive past a steep kurb). Manoeuvring Rollers engage simultaneously on both sides. Use 9mm key 7 and turn a protruding hexagonal shaft in a circular decided swing towards the tyre or press Auto Rollers buttons. You can manoeuver your caravan in directions represented by buttons with arrows on the remote. Pushing a button is confirmed by fast-flashing of Range/Remote battery level LED. Your caravan can be moved: backwards right forwards right It is also possible to spin your caravan by means of pushing simultaneously (active with single axis version only): backwards forwards + spin right backwards left forwards left + spin left

7 Caravan Controller operations Switch ON power switch 23 on the caravan controller 8 to activate the system. Green LED 26 blinks for 3 sec (internal self-test). Continuous green LED illumination denotes sytem ready to work. Green LED 26 flashes fast when receiving signal from the remote. Flashing red LED on 25 indicates main battery low (appr. half-empty). It is still possible to operate the system with red LED flashing, however it is recommended to charge the battery as soon as possible. Continuous red LED illumination denotes flat battery the system is inoperative (no reaction to the remote). Charge main battery. System goes into stand-by mode after 60s of no operation (reverts to normal mode if any signal received from remote). Although stand-by mode consumes minimal energy the power should be switched off 23 if mover not intended to be used for a longer time (e.g. after holiday). By overload operations of the system are suspended (both green and red LEDs flash simultaneously). Systems resumes operation if the cause of overload removed which is confirmed by continuous green LED illumination (red LED indicates main battery level irrespectively). Synchronising remote with main control box Your P control system comes ready to use. However, you will need to re-synchronise the remote 0 with caravan controller 8 in case of replacing either of them. Synchronising procedure creates a unique connection code assigning the remote to the particular CC (which prevents possibility of interference with other movers in the area).. Apply caravan handbrake and disengage rollers 2. Connect remote with caravan control box (CC) 8 using jack-jack cable Switch the (CC) and remote on 4. Push service button 27 on (CC) (using a match or other thin-tipped item as the button is placed deeper in the case to prevent accidental activation). Green LED 26 flashes slowly. 5. Push any arrowed button on the remote (green LED 26 flashes fast) and wait appr. 2 sec. Syncronising procedure is completed when confirmed by continuous green LED illumination on (CC) 26. Remove jack-jack cable system is ready to work. In emergency (e.g. strong radio interference in the area or flat remote battery) you can cable-operate your caravan (signal from remote passes via jack-jack cable to main control box). Dealer contact details