User Manual - Ego
Contents
1. PAN elektro technik User Manual REMOTE CARAVAN MOVER Installation guide and user information For use with Model Number EGO300 Ref EGO300 UM 1013 Rev A lt D J Q har e O 9 e G a4 Parts Identification amp Fitting Diagrams 1800mm to 2500mm max Caravan Floor L Profile U Profile Parts Identification amp Fitting Diagrams NN NN N N oN N an w NM Overhead View Parts Identification amp Fitting Diagrams Position Engaged Position Optional Fitting Adapters Additional chassis clamp adapters are available as follows Low Profile Chassis Adapter Plates Part No CM 029 If your chassis frame height is less than 140mm these plates must be fitted to lower the assembly to provide the correct height of 185mm Drilling of your chassis may be required Note In some countries the installation must be checked by a professional technician in order to adhere to local regulations Narrow Gauge Chassis Adapters Part No CM 030 These plates must be utilised if you have an AL KO Vario III AV chassis which has a frame thickn2. steady feet are fully raised Engage both rollers as described in Operation Motor Units This only needs to be done on one side of your caravan since the other side will automatically follow via the cross actuation bar Before operating the Mover release the handbrake Activate the mover by double clicking the power button Fig 3A on the remote control The LED Fig 3H on the remote control will illuminate Now you can choose the movements according the symbols shown on the remote control As soon as the buttons are released the caravan will stop The mover moves at one speed after the intitial soft start The speed can increase a little when going downhill and decrease a little when going uphill TIP The mover is more efficient when reversing the caravan up an incline After manoeuvring deactivate the mover by double clicking the power button on the remote control again The LED on the remote control will turn off Apply the handbrake first and then disengage the drive rollers from the tyres Store remote control in a safe place out of reach of children or other unauthorised people Ref EGO300 UM 1013 Rev A Ego Page 8 Operation Hitching and Unhitching A It is possible to position the caravan s hitch exactly over a stationery car s tow ball using the mover But please be very careful Use the button controls on the remote control to bring the caravan to the car It is better to reach the tow ball with several sh
3. The engagement mechanism utilises a simple over centre cam that pushes the rollers onto the tyres and then locks into place automatically If the mover has been installed correctly at exactly 20mm away from the tyres when disengaged the amount of force provided onto the tyre by the roller will be sufficient for most circumstances of use Fig 15 To disengage the rollers simply refit the tool onto one of the spindles and rotate away from the tyre Please note that you will feel a small amount of resistance initially as you disengage the cam from its locked position the spring will then do the rest of the work and pull the roller away from the tyre and into the fully disengaged position Fig 14 Operation Motor Units The mover has two Motor Units 1 amp 2 In general they are mounted in front of the axle of the caravan trailer Both units are identical but cannot be switched Please refer to Fig 2 Drive roller 12V Motor Connection Terminals and Base Unit Drive Unit Gear Housing Fig 2 T m O 0 2 gt Always ensure that you are close enough to engage the caravan s handbrake when manoeuvring on uneven terrain and gradients slopes in case of mechanical failure Do not use the mover as a brake when you have finished manoeuvring always engage the caravan s handbrake gt SAFETY FIRST Ensure that there are no persons or obstructions in the vicinity of the caravan prior to testing gt Ref EGO300 UM 1013 R
4. mover and the towing vehicle DO always make sure that the remote control is stored in a safe place out of reach of children or other unauthorised people DO always apply the handbrake after manoeuvring before disengaging the drive rollers from the tyres DO always ensure that children and pets are kept well out of the way during operation DO NOT rely on the mover to act as a brake DO NOT exceed the total Safe Working Load SWL DO NOT make any modifications on the caravan mover mechanical or electronically This can be very dangerous No warranty claim will be accepted and we cannot guarantee the function of the mover if any modifications are made We will not be liable for any damage whatsoever caused as a result of incorrect installation operation or modification gt gt gt gt gt gt gt gt gt Operation Set Up Before you use your mover system you need to locate the Carry Case 6 that contains the Control Unit 7 and cables in the caravan doorway or in an externally accessible locker First unwind the motor cable and connect both motor plug connectors onto both motors the plug connectors are col our coded Please refer to Fig 16 Safety First Only unwind the minimum amount of cable that is required between the motors and the Carry Case as it is important that the cable cannot get caught on any moving parts or does not drag on the ground The cable between the motors and the control unit should
5. the direction of the arrow Fig 5 Take out the depleted old batteries and dispose in the appropriate way check with your local authority for correct disposal of batteries Install new replacement batteries Make sure to use leak proof batteries No claims under guarantee can be considered for damage caused by leaking batteries Slide the rear cover on gently and it will click into place Operation Electronic Control Unit The Electronic Control Unit 7 which is mounted inside your caravan is responsible for controlling the caravan mover The control unit has three LED s Fig 7 and one recessed button Fig 7A Green LED This will illuminate when receiving the signal The LED will flash if the remote control is out of range the maximum range is 100 metres without obstruction Blue LED This will illuminate if the temperature of the control unit is too high or if the battery voltage is too low or too high The Red LED will specify the error as follows Red LED Voltage too low lt 10V LED will flash twice slowly Voltage too high gt 15V LED will flash fast 5 times Electric current is too high 120A LED will constantly flash Temperature is too high gt 80C LED is on permanently Reset Button Fig 7A This only needs to be used when replacing a remote control handset Refer to the Before First Use Pairing the Handset and Control s section for reference on this procedure When the Control Unit is
6. be taut but not overtight in order to avoid straining any plug connectors You can then unwind the battery cable from the Carry Case and connect to your 12V battery power source Caution Make sure that you do not reverse the Positive and Negative connections Incorrect connection reverse polarity may result in damage to the Control Unit Ego Page 5 Ref EGO300 UM 1013 Rev A Operation Detaching Attaching the Motors The motor units are designed to be easily attached detached if you do not wish for them to remain in position during transit or if you only envisage yourself using the mover system at your home rather than during your holiday If you have opted for temporary fitment then each motor must be fitted onto the cross bar before operation Locate the appropriate side motor 1 or 2 and slide onto each end cross bar 3 amp 4 then secure into position by insert ing the wire lock pins 9 You must ensure that the pin is locked in place with the spring wire fully locked Please refer to Fig 10 and Fig 11 for reference Engaging the Rollers In order to engage the rollers fit the end socket of the Engagement Tool 20 on the spindle Fig 2G on the right or left drive unit Position the engagement tool parallel to the ground then rotate the tool through approximately 180 degrees Note to engage the rollers you always rotate the tool towards the tyre irrespective of which side you are operating the engagement from
7. comply with these rules could result in serious injury or damage to property These symbols identifiy important safety precautions They mean CAUTION WARNING SAFETY FIRST IMPORTANT INFORMATION Ref EGO300 UM 1013 Rev A Ego Page 2 Before starting installation under the caravan DO only use adapters and accessories that are supplied or recommended by the manufacturer DO check that the tyres are not over worn fitting to new or nearly new tyres is the best option DO make sure that the tyre pressures are correct to the manufacturer s recommendation DO make sure the chassis is in good condition without any damage and is free from rust dirt etc DO stop work immediately if you are in doubt about the assembly or any procedures and consult one of our engineers DO NOT remove change or alter any parts of the chassis axle suspension or brake mechanism DO NOT operate the unit if you are under the influence of drugs alcohol or medication that could impair your ability to use the equipment safely Installation Mechanical Components caravan type Use appropriate support Working under a vehicle without appropriate support is extremely dangerous If you are fitting the mover system yourself it is advisable that the installation is conducted by two people as the mover will need to be raised up to the bottom of the caravan s chassis before the clamps can be installed A These instructions are for general guidance Installation pr
8. connected to power it will perform a self test automatically The 3 LEDs will illuminate for 0 2 seconds and turn off which means there is no error and the unit is functioning correctly As a safety feature the Control Unit will switch off automatically if no button is pressed within 60 seconds The Control Unit will also turn off automatically if the mover is working constantly in one direction for longer than 3 minutes Before First Use Pairing the Handset and Control Unit s Install only 2 of the 3 AAA batteries into the battery compartment of the Handset see Fig 5A Press the Reset button Fig 7A the green LED will flash press the reset button on both Control Units when using a full four motor Quattro system Ego Page 7 Ref EGO300 UM 1013 Rev A Hold down the corresponding button on the Handset Fig 3E for Single Axle Mode or Fig3 G for Twin Axle Mode and at the same time install the third battery Note Twin Axle Mode is used for twin axle caravan installations that use two or four motors The Handset will sound single beeps for Single Axle Mode or double beeps for Twin Axle Mode Keep holding the button down until the Handset stops beeping and the green LED s Fig 2C on the control unit s turn s off The control unit s will switch off Press the power button on the handset Fig 3A twice The Control Unit s will make a clicking noise to indicate the system is operational The pairing procedure
9. er action Check the cable connection between the mover battery and the control unit Ego Page 9 Ref EGO300 UM 1013 Rev A Trouble Shooting Check the distance between the remote control and the caravan is not more than 5 metres If there is no signal between the remote control and the control unit the mover will not function at all even though the LED on the remote control is on All error messages will reset automatically after 40 seconds If this does not occur reset the mover by disconnecting the mover power source battery for at least 10 seconds and reconnect Then re establish the connection with the remote control by pressing the power button on the handset twice within 1 second Unit fails to operate or moves intermittently Check the battery of the remote control If empty renew using three new AAA 1 5V batteries Mover battery could be empty Check electronics box Blue LED is on and Red LED is flashing twice slowly If empty recharge completely or renew mover battery before taking any further action Mover battery could be low with the rollers engaged Check the voltage drop on the caravan battery meter if this immediately drops well below 10 volts charge or renew mover battery Mover battery could be overloaded Check electronics box Blue LED is on and Red LED is flashing continuously Check your charging equipment and try to discharge the battery by connecting using a light or other load If this does not gi
10. ess of less than 2 8mm These must be positioned behind the axle using pre drilled holes already available on the chassis so your mover must be fitted behind the axle 16mm Spacers 1 pair Part No CM 028 Use spacers to lower the mover assembly if your chassis has a frame height of between 140 to 185mm A maximum of 3 sets of spacers can be utilised to achieve correct frame height of 185mm A set of extended clamp bolts must be used in conjunction with these spacers Part No 346 054 Set of 8 M10 x 100 Bolts Part No CM 031 Set of 8 extended clamp bolts for use with 16mm spacers Part No 346 051 Table of Contents Package Contents Parts List Page 1 Introduction Page 2 Fitting Guidelines Page 2 Specifications Page 2 Page 2 3 Page 3 4 Page 4 Installation Safety Guidelines Installation Mechanical Components Installation Electrical Electronic Components Operation Safety Guidelines Page 5 Operation Set Up Page 5 Operation Detaching Attaching the Motors Page 6 Operation Engaging the Rollers Page 6 Operation Motor Units Page 6 Operation Remote Control Handset Page 7 Operation Electronic Control Unit Page 7 Page 7 8 Page 8 Before First Use Pairing the Handset and Control Unit s Using Your Caravan Mover with Quattro Technology Operation Getting Started Page 8 Operation Hitching and Unhitching Page 9 Maintenance Page 9 Trouble Shooting Page 9 10 Package Contents Fig A Qt
11. ev A Ego Page 6 Operation Remote Control Handset The Remote Control handset 8 is powered by three AAA 1 5V batteries and is activated by double pressing the power button Fig 3A Once activated the green LED Fig 3H will illuminate and the directional controls can now be used If the handset has not been used for a period of 60 seconds then it will automatically switch itself off Fig 3 A On press button twice within one second green LED Fig 3H illuminates B Caravan forwards both wheels rotate in forwards direction C Caravan reverse both wheels rotate in reverse direction D Caravan left forwards right wheel rotates in forwards direction E Caravan right forwards left wheel rotates in forwards direction F Caravan left reverse right wheel rotates in reverse direction G Caravan right reverse left wheel rotates in reverse direction In addition the left forward 3D and right reverse 8G buttons or right forward 3E and left reverse 3F buttons may be pressed at the same time to turn the caravan around on its own axis without moving forward or backward Note this function is disabled when the electronics are in twin axle mode When pressing a directional button on the handset the mover will start slowly normal speed will be reached within 2 5 seconds Changing batteries in the remote control Open the rear cover of the handset by pushing gently and sliding the rear cover in
12. is now complete and the caravan mover system is ready for use Using your Caravan Mover with Quattro Technology It is of course impossible for a twin axle caravan to be manoeuvred in the same way as a single axle as the turning circle is greatly increased compared to a single axle caravan Also the amount of different manoeuvres required to locate park your caravan is increased However the advanced electronics of the Quattro electronics take care of the manoeuvring whilst also taking care of your caravan For example When the caravan is turning the motors provide lower rotational speed on one side to help enable direction change This enables the caravan to manoeuvre with minimal tyre scrub or being dragged along the ground which can cause undue stresses on its tyres wheel hubs and chassis It is also a possibility that when operating a two motor twin axle system on very uneven ground one of the wheels driven by the mover will not make adequate contact to continue progress If this occurs you will need to move the caravan in a different direction until adequate traction is regained Operation Getting Started N Please make sure you read the safety instructions very carefully and make sure that you follow these guidelines N Make sure that the battery that supplies the mover is fully charged and in good condition Make sure that the caravan is free from the vehicle and the handbrake is on Also make sure that the corner
13. just the position of the assembly If fitted the bolts that secure each motor unit should be tightened to a torque setting of 27ft IDs 37Nm Once satisfied with the position of the assembly fit and tighten the Chassis Stop Nuts amp Bolts 16 one pair in each of the Upper Chassis Clamp Plates see Fig 9 Tighten to a torque setting of 40 ft Ips 55Nm The Stop Bolts grip the lip of the chassis and help prevent the mover from sliding along the chassis The main mechanical components have now been installed Optional Cross Actuation Bar Assemble the parts of the cross actuation bar 24 amp 25 and connect them to the motor units 1 amp 2 with the nylock nut and bolt factory fitted onto the cross actuation bar connectors see Fig 1A Tighten the four bolts Fig 1C on the Cross Actuation assembly 24 amp 25 to a torque setting of 9ft Ibs 12Nm Installation Electrical Electronic Components All the electrical components are pre wired with weatherproof two pole plug connectors Each motor unit has a plug connector secured to the top which are pre wired to the positive and negative terminals of the motors The supplied carry case 6 contains the electronic control unit 7 which is also pre wired The cable that attaches to both motors is spooled around the cable storage hooks on the lid of the case The motor cable is a four core cable that splits into two connectors one for each motor The battery cable is also pre wi
14. ocedures may vary depending on Place the caravan on a hard level surface The use of a lifting ramp or an assembly pit is ideal for access and personal safety Clean the area of your chassis where you need to mount all components to ensure a good fitting Unpack all the components and check for the presence of all parts see Package Contents List Make sure the caravan is prepared for installation Check before installation that important areas such as drains spare tyre etc do not cause any obstruction to the function of the mover Ensure both rollers are in the DISENGAGED position Fig 14 as the unit will not fit correctly otherwise Loosely assemble cross bar 3 cross bar 4 and the centre cross bar 5 The nuts Fig 1B on each cross bar 384 must be no more than finger tight at this stage Place the assembly loosely under the caravan In principle the unit should be fitted in front of the caravan road wheels but if fitting in this position is not possible it is permissible to fit it to the rear of the wheels by rotating the whole assembly by 180 degrees Loosely fit the two clamping assemblies to the chassis see Fig 9 and attach using the bolts nuts and washers 13 14 15 provided in the installation kit Nuts must be no more than finger tight Make sure that the Centre Cross Bar 5 is positioned in the middle of the caravan mover the centre of the bar is marked With the main assembly loosely fitted onto the chas
15. ollers at the same time from one side of your caravan Once this is done the mover is ready for operation The remote control will allow you to move your caravan in any direction Fitting Guidelines The chassis clamps provided are suitable for fitment onto most standard caravan chassis that have an L shape or U shape profile Please refer to Fig 4 amp Fig 6 for reference on dimensions and clearances BEFORE you proceed any further with installation If your chassis has different dimensions to those shown in Fig 4 then various chassis clamp adapters are available to suit the majority of UK and Continental caravans please refer to the section entitled Optional Fitting Adapters Specifications Model Number EGO300 Operational Voltage 12 Volt DC Average Current Consumption 19 Ampere approx Maximum Current Consumption 84 Ampere approx Speed 11cm per sec approx Approx Net Weight inc all fixings amp accessories 40 Kg Safe Working Load SWL 2250Kg Minimum Width caravan trailer 1800mm Maximum Width caravan trailer 2500mm Power Source battery 12V Average Current Consumption readings when using an approx 1100Kg single axle caravan on a hard level surface Maximum Current Consumption readings when using an approx 1100Kg single axle caravan ascending a 1 4 25 gradient Installation Safety Guidelines Important Safety Instructions Read this User Manual carefully before installation and use Failure to
16. ort trips rather than trying to do it in one trip When the hitch is right above the tow ball of the vehicle lower the hitch to the ball and engage in the normal way using the jockey wheel Hitch the caravan in the normal way ready for towing Release the rollers from the caravan s tyres You cannot tow the caravan with the Mover engaged Make sure that both rollers are fully disengaged Trying to drive away with the mover still engaged will damage the mover your caravan tyres and strain your tow vehicle MEULE E a To prevent the battery from becoming totally discharged during long periods of inactivity it must be disconnected and recharged before using again Please check regularly that the rollers of the drive units are free of any dirt or debris that may have been picked up from the road Any further maintenance is not required Please check regularly the distance between the rollers and the tyres In the neutral fully disengaged position this must be 20 mm When your caravan is stored for an extended period of time over winter for example it is recommended to remove the battery from the caravan Make sure you keep it charged to ensure it is in good condition the next time you want to use it Once a year have your Ego caravan mover maintained and visually inspected This inspection must include all the bolt nut connections the cables and electrical connections and lubrication of movable parts joints A In ca
17. red to the Control Unit 7 and is stored in the same manner as the motor cable The motor connections are pre configured for installation of the motors in FRONT of the wheels axle see Table A Please refer to table B below for fitment of the motor units to the REAR of the axle Note If you are fitting two sets of motors onto a twin axle caravan to form a full Quattro system then both Table A amp Table B wiring will be utilised Please refer to Fig 21 A motor cable extension 21 is supplied so that both motors can be plugged in on one side of the caravan trailer When installing the cross bar it needs to be determined which side is most convenient for you to plug into the motors In normal circumstances during operation the carry case containing the electronics and cables would be located in the doorway of your caravan or in an externally accessible locker The motor cable extension should be connected to the plug on top of the motor on the opposite side to where you want to be able to access both motor plugs and should be cable tied to the cross bar assembly That means that when you connect both motors to the Control Unit it can be done from just one side for convenience Please refer to the wiring schematic to determine the correct configuration as the plug connectors for motor A and B are colour coded The wiring schematic Fig 16 shows the configuration for front of axle fitting with the Extension Cable 21 connected to locate both mo
18. se of any failures or problems please contact your Ego Caravan Mover supplier Trouble Shooting Should your mover fail to operate please check the following Unit fails to operate does not function at all Is the Remote Control Handset paired with the Control Unit To pair the Handset and Control Unit please follow the procedure detailed in the section Before First Use Pairing the Handset amp Control Unit s regarding the Reset Button Fig 7A Check the batteries of the remote control If empty renew using three new AAA 1 5V batteries Caravan battery could be empty Check electronics box Blue LED is on and Red LED is flashing twice slowly If empty recharge completely or renew caravan battery before taking any further action Advice on battery voltage Even though batteries are rated at 12V a fully charged battery will provide a charge nearer to 13V depending on battery type A voltimeter reading of 12 7V or higher means that the battery is 100 charged 12 5V is three quarters charged and 12 4V can mean your battery is only 50 charged The caravan mover needs at least 12 5V to function correctly Mover power source battery could be overloaded Check electronics box Blue LED is on and Red LED is flashing continuously Check your charging equipment and try to discharge the battery by connecting using a light or other load If this does not give any result renew caravan battery before taking any furth
19. sis slide each motor unit 1 amp 2 onto each end of the cross bar assembly and secure using either the wire lock pins 9 or if you do not have the requirement to detach the motors everytime you use the mover system then secure the motors using the bolts 18 washers 17 and Nylock Nuts 19 With the main assembly loosely fitted onto the chassis slide the whole assembly along the chassis until the rollers Fig 2A are 20mm away from the surface of the centre each tyre Fig 14 Two 20mm spacers 23 are provided It is vitally important that each roller is at exactly the same distance away from the tyre The whole Ego Page 3 Ref EGO300 UM 1013 Rev A assembly must be parallel to the caravan trailer axle Loosen the locking bolts Fig 1B to enable you to slide the motor units in or out of the centre cross bar 5 accordingly to ensure each roller will have the maximum possible contact with the tread of the tyre Ensure that the position of each motor unit does not obstruct shock absorbers if fitted and that the gear housing Fig 2F has a minimum distance of 10mm to the inner surface of the tyre when the mover is engaged Fig 8 Fully tighten the four nylock nuts 13 on both clamping assemblies Fig 9 to a torque setting of 40 ft lbs 55Nm then the four bolts Fig 1B on the Cross Bars 3 amp 4 to a torque setting of 9ft Ilbs 12Nm Re check the distance of 20 mm from the rollers to the tyres and if necessary loosen the bolts and re ad
20. tor plug connectors on the left hand side of the caravan If you require the motor plug connectors to be located on the right hand side then you must swap the connections of the spade connectors on the Control Unit 7 in accordance with Table B Table A FRONT OF AXLE FITTING Table B REAR OF AXLE FITTING Motor A Positive cable to terminal 1 Motor A Positive cable to terminal 4 Motor A Negative cable to terminal 2 Motor A Negative cable to terminal 3 Motor B Positive cable to terminal 3 Motor B Positive cable to terminal 2 CG Motor B Negative cable to terminal 4 Motor B Negative cable to terminal 1 Ref EGO300 UM 1013 Rev A Ego Page 4 Operation Safety Guidelines Before use always check the mover for any damage When towing or moving the caravan please be aware at all times that ground clearance is reduced by 50mm when the Mover has been fitted To maintain signal strength always make sure that during manoeuvring the distance between the remote control and the caravan does not exceed 5 metres DO be aware that the mover increases your caravan or trailer weight So this reduces the payload of the caravan DO always make sure that the rollers are fully disengaged from the tyres when the mover is not in use This is better for the tyres and for the mover DO always make sure that the rollers are fully disengaged before towing moving the caravan by vehicle or manpower This can damage the tyres
21. ve any result renew mover battery before taking any further action Check the cable connection between the mover battery and the control unit Badly connected or corroded battery terminals can cause intermittent problems check battery terminals clean and connect again Check the distance between the remote control and the caravan is not more than 5 metres If there is no signal between the remote control and control box the mover will not function at all even though the LED on the remote control is on All error messages will reset automatically after 40 seconds If this does not occur reset the mover by disconnecting the mover power source battery for at least 10 seconds and reconnect Then re establish the connection with the remote control by pressing the power button on the handset twice within 1 second Rollers slip on wheels Check that the distance of the rollers to the tyres is 20mm on both sides Check for correct tyre pressure by referring to your caravan mnaufacturer s handbook If the pressure is low the roller would need to be pushed into the tyre further than usual to gain sufficient traction A In case of any doubt please call your Ego Caravan Mover supplier Ref EGO300 UM 1013 Rev A Ego Page 10
22. y Qty escription hassis Clamp Washers 10mm O hassis Stop Bolts amp Nuts 2 pairs z otor Unit Fixture Washer z otor Unit Fixture Bolt otor Unit Nylock Nuts ngagement Tool otor Unit Extension Cable able Ties oller Distance 20mm Spacers oss Actuation Insert Bars ross Actuation Centre Bar C ser Manual not illustrated 3 type 1 5V Batteries not illustrated IO ID ID N TIN IN J N J IN J gt hh Jh J NOOR TA N J JO J 0 N 9 JaA Ref _s l pe J pe J fo 2 s s L14 8 Ego Page 1 Ref EGO300 UM 1013 Rev A Introduction Thank you for choosing an Ego caravan mover This has been produced according to very high standards and has undergone careful quality control procedures Simply by using the remote control you can move your caravan effortlessly into any position required within operating guidelines Before proceeding with installation and starting to use the mover please read this manual very carefully and be aware of all the safety instructions The owner of the caravan will always be responsible for correct use Keep this manual inside your caravan for future reference The caravan mover consists of two 12V motor powered rollers a 12V electronic control box and a remote control To function the motor powered rollers must be engaged against the tyres of your caravan The optional cross actuation device enables you to engage both r
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