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1. s purple ne Enduro Caravan Mover Model Number EM103 User Manual Ref EM103 UM 0808 A4 Rev F Package Contents Fig A Parts Identification 8 Fitting Diagrams AOO o E G ke O C Q D c p iL oj c O q O 2 E c D o E G A Parts Identification Fitting Diagrams Table of Contents Page 1 Page 2 Page 2 Page 2 Page 2 3 Page 3 4 Page 4 5 Page 5 6 Page 6 Page 6 7 Page 7 Page 7 8 Page 8 Page 8 Page 8 9 Package Contents Fig A Qty Ret Law 8 Chassis Clamp Washers tommo 6 Cable Spade Connectors Ref EBEN EN REM ENEM ERES pais ii Enduro Page 1 Ref EM103 UM 0808 Rev F UK Introduction Congratulations on choosing the Enduro 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 manua2. to reposition the assembly Operation Remote Control Handset The Remote Control handset 31 is powered by one PP3 9v battery and is activated by double pressing the red button Fig 5a Once activated the red LED Fig 5h 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 5 A On press button twice within one second red LED 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 E and right reverse F buttons or right forward D and left reverse G buttons may be pressed at the same time to turn the caravan around on its own axis without moving forward or backward Changing batteries in the remote control Open the rear cover of the handset via the small screw Fig 7 Take out the dead old battery and dispose in the appropriate way Install a new replacement battery Fig 7 1 Make sure to use a leak proof PP3 9Volt battery No claims under guarantee can be considered for damage caused by leaking batterie
3. ack all the components and check for the presence of all parts see Package Contents List Write down on the guarantee section of this manual the 10 digit serial number this is located on an aluminium plate on the top of one of the motor units 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 10a as the unit will not fit correctly otherwise Note When fully disengaged only approx 3mm of yellow label will be visible Loosely assemble the left hand motor unit 1 right hand motor unit 2 and main cross bar 3 see Fig 1 The nuts Fig 1b on the cross bar 3 to secure both motor units must be no more than finger tight at this stage Place the assembly Fig 1 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 Fig 1 by 180 degrees Loosely fit the two clamping assemblies to the chassis see Fig 2a Fig 6a 8 Fig 12a and attach using the bolts nuts and washers 16 17 18 provided in the installation kit Nuts must be no more than finger tight Assemble the parts of the cross actuation bar 4 amp 5 and connect them to the motor units 1 amp 2 with th
4. e nylock nut and bolt factory fitted onto the cross actuation bar connectors see Fig 1 amp Fig 1a Nuts must be no more than finger tight at this stage Make sure that the Main Cross Bar 3 and the Cross Actuation Centre Bar 4 are positioned in the middle of the caravan mover the centre of the bar is marked Enduro Page 3 Ref EM103 UM 0808 Rev F UK With the main assembly is loosely fitted onto the chassis slide the whole assembly along the chassis until the rollers see Fig 4a are 30mm away from the surface of the centre each tyre See Fig 10 Two 30mm spacers 30 are provided It is vitally important that each roller is at exactly the same distance away from the tyre The whole assembly must be parallel to the caravan trailer axle Slide the motor units in or out of the cross bar 3 accordingly to ensure the 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 plastic chain guard Fig 4f is not too close to the inner surface of the tyre Fully tighten the four nylock nuts 17 on both clamping assemblies Fig 2 amp Fig 6 the four bolts Fig 1b on the Main Cross Bar 3 and the four bolts Fig 1c on Cross Actuation assembly 4 amp 5 Tighten the bolts to a torque setting of 40 ft lbs Re check the distance of 30 mm from the rollers to the tyres and if necessary loosen the bolts and re adjust the p
5. ery 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 reach the tow ball with several short 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 the drive units are fully disengaged into the automatic transit lock A Trying to drive away with the Mover still engaged will damage the mover your caravan tyres and strain your tow vehicle Maintenance To prevent the batterv from becoming totallv discharged during long periods of inactivitv it must be disconnected and recharged before using again Please check regulariv that the rollers of the drive units are free of anv dirt or debris that mav have been picked up from the road Anv 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 about 30 mm Once a year have your Enduro 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
6. he case reset the electronics of the mover by switching off the mover via the isolation switch for at least 15 seconds and then turning it on again Then re establish the connection with the remote control press the red button two times Roller will not engage spindle rotates freely Chain is broken contact your Enduro Mover supplier Rollers slip on wheels Check distance of rollers to tyres You can move the rollers closer to the tyre The distance can be adjusted on both sides or only on one side as necessary In certain circumstances one of the caravan s wheels may be moving on a surface with less traction than the other in which case select the Single mode on that side and move the roller further into the tyre as necessary A In case of any doubt please call your Enduro Mover supplier Enduro Page 9 Ref EM103 UM 0808 Rev F UK Guarantee This product is covered by a 2 year parts guarantee if fitted correctly in accordance with the fitting instructions Please note that our guarantee covers reasonable use of the Mover it does NOT cover any damage caused by misuse This also applies to a malfunction or failure of the mover that has been caused by poor or incorrect installation To ensure the validity of the guarantee please carry out maintenance in accordance with the maintenance section We reserve the right to make a call out and or repair charge for any work required to be undertaken to rectify faults tha
7. l Connector 22 amp 23 are provided for use as appropriate Caution Make sure that you do not reverse the Positive and Negative connections Incorrect connection reverse polarity will result in damage to the control box Cut the cables to an appropriate length and remove approx 5 mm of the insulation from the ends Fix the spade connectors by using crimping pliers A secure and good quality connection on each cable is essential Finally connect the Battery Cables 14 amp 15 to the Control Unit 32 Installation of the Enduro Caravan Mover is now complete 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 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 only use on single axle caravans or trailers 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 mover and the towing vehicle DO always make sure
8. l inside your caravan for future reference The caravan mover consists of two 12V motor power 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 supplied cross actuation device enables you to engage both rollers 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 You can even rotate the caravan on it s own axis without moving forwards or backwards Intended Use The Enduro EM103 Caravan mover is only suitable for single axle caravans Suitable only for L profiled chassis with a chassis thickness between min 2 8mm and max 3 5mm The standard installation kit only provides parts for installing the mover within the measurements given in Fig 14 Specifications 12V 105Ah recommended 12V 85Ah minimum Installation Safety Guidelines Important Safety Instructions Read this User Manual carefully before installation and use Failure to comply with these rules could result in serious injury or damage to property A CAUTION These symbols identifiy important safety precautions They mean CAUTION WARNING A SAFETY FIRST IMPORTANT INFORMATION Ref EM103 UM 0808 Rev F UK Enduro Page 2 Before starting installation under the caravan DO check that the caravan is disconnected from the battery supply and the
9. lease the handbrake Activate the Enduro Mover by double clicking the red button Fig 5a on the remote control The LED Fig 5h on the remote control will illuminate Now you can choose the movements according the symbols shown on the remote control Straight forward Fig 5b straight reverse Fig 5c left forward Fig 5d left reverse Fig 5f right forward Fig 5e right reverse Fig 5g In addition the left forward and right reverse buttons or right forward and left reverse buttons may be pressed at the same time to turn the caravan around on its own axis without moving forward or backward As soon as the buttons are released the caravan will stop The Mover moves at one speed 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 Enduro Page7 Ref EM103 UM 0808 Rev F UK Operation Getting Started cont After manoeuvring deactivate the Enduro mover bv double clicking the red 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 Turn off the Battery Power Isolation Switch Store remote control in a safe place out of reach of children or other unauthorised people Operation Hitching and Unhitching AN It is possible to position the caravan s hitch exactly over a station
10. mains electrical supply 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 Please refer to contact information on the last page of this manual DO locate the battery isolation switch to be accessible at all times when parking and moving the caravan 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 These instructions are for general guidance Installation procedures may vary depending on caravan type A Working under a vehicle without appropriate support is extremely dangerous Please refer to Fig 13 for an overview of the whole assembly fully fitted 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 Unp
11. nd dirt and through the drilled hole Secure the Cable Trunking 11 to the chassis or under body of the caravan by using the P Clips 20 and screws 19 Ref EM103 UM 0808 Rev F UK Enduro Page 4 Once the motor cables are through the drilled hole next to the Control Unit 32 cut the cables ensuring that they are same length Remove approx 5 mm of the insulation from the ends Fix the spade connectors 24 by using crimping pliers A secure and good quality connection on each cable is essential Attach the connectors to the terminals on the Control Unit see wiring diagram Fig 12 Route the Battery Cables 14 8 15 from the battery to the Control unit 32 Find a suitable place for the Battery Power Isolation Switch 29 which includes an external holder with hinged cover Important The switch must be mounted onto the exterior body of the caravan and be easily accessible from the outside of the caravan in case of any emergency The switch must be mounted close to the location of the battery in order to keep the length of the battery cables to a minimum Install the Isolation Switch 29 between the battery and the control unit on the positive cable Again it is recommended to use the supplied Trunking 11 to protect the cables against sharp edges Attach the trunking with P Clips 20 and P Clip Screws 19 Connect the Battery Cables to the existing battery terminals red positive black negative Two types of Battery Termina
12. onics of the mover by switching off the mover via the isolation switch for at least 15 seconds and then turning it on again Then re establish the connection with the remote control press the red button two times Operation Getting Started Please make sure vou read the safetv instructions verv carefullv and make sure that vou follow these guidelinesl Make sure that the batterv that supplies the mover is fullv 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 steadv feet are fullv raised Make sure that the Single Double Selector is in the Double position Factorv default setting is the Double position gt PPP Fit the end socket of the Engagement Tool 6 onto the engagement Spindle Fig 8a on the right or left hand Motor Unit This only needs to be done on one side of your caravan since the other side will automatically follow via the cross actuation bar Turn the handle until it will turn no more without excessive force The colour of the Traction Indicator Label Fig 11a should be into the green area Please note that in the beginning of spindle rotation there will be a small amount of resistance as the drive unit moves past the automatic transit lock mechanism that stops the drive units from accidentally moving towards the caravan s tyres during transit Turn on the Battery Power Isolation Switch 29 Before operating the Mover re
13. ool 6 on the spindle Fig 8a on the right or left drive unit The Spindle has a collar Fig 8b that is specially designed and developed to enable the user the engage or disengage the cross actuation bar 4 amp 5 This feature is called the Single Double Selector It is factory set as standard in the double mode so that when you turn the Engagement Spindle Fig 8a BOTH rollers move towards or away from the tyres If you select Single mode by pulling the collar Fig 8b out and to the right only the side you are next to will engage or disengage the roller the roller on the other Motor Unit will not move To select Double mode simply turn the collar to the left release and it will spring back into the Double function position The yellow green red Traction Indicator Label Fig 11a on the side of each Motor Unit indicates if the roller is depressing the tyre sufficiently to provide adequate traction The Indicator works as follows Fig 11 If you can only see Yellow Rollers are not touching or depressing the tyre sufficiently If you can see Yellow amp Green Rollers should be connecting correctly to the tyre margin of 15 mm If you can see Yellow Green amp Red Rollers are connected to the tyre but in an extreme position Seeing the Red area of the Indicator may mean that the tyre of the caravan has insufficient air pressure or the drive unit has been knocked out of position and a visit to a workshop is required
14. osition of the assembly Once satisfied with the position of the assembly fit the Chassis Stop Blocks 7 in front of and behind both clamping assemblies See Fig 2 The Stop Blocks prevent the mover from sliding along the chassis The main mechanical components have now been installed Installation Electrical Electronic Components Make sure the 12V supply from the battery and any 230V electricity supply are disconnected Find a suitable place for the Electronic Control Unit 82 such as a storage area under a seat or a bed Make sure this place is dry and close to the battery 30 cm to 60 cm The unit can be mounted on the bottom horizontal or on the wall vertical When choosing location ensure that the antenna can be completely extended and cannot easily be damaged Fix the Electronic Control Unit securely into position with four screws 19 Note if the provided screws are not of suitable length or type for the desired location material please substitute these as appropriate Drill a 25 mm hole through the floor of the caravan approximately 150 mm centrally in front of the control unit 32 terminals Caution Take extra care to avoid any chassis members gas pipes and electrical wires Route and connect the motor cables in accordance with wiring diagram Fig 12 red positive black negative The wiring diagram Fig 12 Table A see below depicts the wiring route when installing the motor units in FRONT of the wheels a
15. s Close the rear cover and secure with the small screw again Ref EM103 UM 0808 Rev F UK Enduro Page 6 Operation Electronic Control Unit The Electronic Control Unit 32 which is mounted inside your caravan is responsible for controlling the Enduro mover The control unit has three LEDs and one reset button see Fig 3 The Red LED Fig 3b illuminates continuously when the control unit is functioning correctly The Red LED illuminates continuously and Blue LED Fig 3c flashes quickly if the voltage is too high If the voltage is too low both Red and Blue LED illuminate continuously after 10 seconds the sequence changes with the Red LED continuously illuminated and the Blue LED flashing slowly If the current is to high the Blue LED illuminates continuously and the Green LED Fig 3c flashes ten times with a break After 15 seconds the Blue LED will flash quickly and the Green LED will flash ten times with a break After a further 5 seconds the electronics will automatically reset The Reset Button Fig 3a is only to be depressed if you have had to replace your remote control By pressing this button for about 5 seconds the Red LED will flash Press the red button on the remote control twice within one second so the remote control and the control box will be paired Every mover has a unique frequency for tuning In general all error messages will reset automatically after one minute If this is not the case reset the electr
16. se of any failures or problems please contact your Enduro Mover supplier Trouble Shooting Should your mover fail to operate please check the following Unit fails to operate does not function at all Make sure that the Battery Power Isolation Switch 29 is turned on Check the battery of the remote control If empty renew the 9V battery Caravan battery could be empty Check electronics box Blue LED is on and Green LED is flashing 10 times with break If empty recharge completely or renew caravan battery before taking any further action Caravan battery could be overloaded Check electronics box Blue LED is on and Green LED is flashing 6 times with break 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 further action Check the cable connection between the caravan battery and the control unit Ref EM103 UM 0808 Rev F UK Enduro Page 8 Trouble Shooting cont 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 In general all error messages will reset automatically after one minute If this is not the case reset the electronics of the mover by switching off the mover via the isolation switch for at leas
17. t 15 seconds and then turn it on again Then re establish the connection with the remote control press the red button two times Unit fails to operate or moves intermittentiv Check the batterv of the remote control If emptv renew the 9V batterv Caravan battery could be empty Check control unit Check to LED sequence for low voltage page 7 If empty recharge completely or renew caravan battery before taking any further action Caravan 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 caravan battery Caravan battery could be overloaded Check control unit Check to LED sequence for high voltage page 7 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 further action Check the cable connection between the caravan 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 In general all error messages will reset automatically after one minute If this is not t
18. t are outside of the company s control i e caravan battery failure incorrect or poor fitting misuse accidental damage etc Please fill in the Enduro Serial Number and the Product Registration form and return to the appropriate address see overleaf Important Retain this manual for future reference Enduro Serial No on top of motor unit Date of Purchase of Purchase 000A duct registrati s purple ne product registration purp SU ke NN 1 Date of Purchase of Purchase Dealer Address aa a Vour Address Ref EM103 UM 0808 Rev F UK Enduro Page 10 Please return this slip to the address overleaf within 14 days of purchase Contact Information UK Purple Line Limited 2 Ladv Lane Industrial Estate Hadleigh Suffolk IP7 6BQ United Kingdom Tel 0044 0 870 444 8688 email supportOpurpleline co uk ENDURO REGISTRATION Purple Line Limited 2 Ladv Lane Industrial Estate Hadleigh Suffolk IP7 6BQ United Kingdom purple ne enduro
19. that after you have finished using the Mover the Battery Power Isolation Switch 29 is switched off and the key 29 is removed and stored in a safe place out of reach of children or other unauthorised people DO always make sure that the remote control 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 ppb PPPPPPPP Enduro Page5 Ref EM103 UM 0808 Rev F UK A DO NOT rely on the mover to act as a brake A DO NOT exceed the total Safe Working Load of 1800 Kg Laden Weight caravan including load 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 Operation Motor Units The Enduro 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 Drive roller 12V Motor Connection Terminals and Base Unit Drive Unit Chain Guard Fig 4 TUI OO mae In order to engage the rollers fit the end socket of the Engagement T
20. xle towards the A frame Please refer to table B below for fitment of the motor units to the REAR of the axle Table A FRONT OF AXLE FITTING Table B REAR OF AXLE FITTING Motor A Positive cable to terminal 3 Motor A Positive cable to terminal 2 Motor A Negative cable to terminal 4 Motor A Negative cable to terminal 1 Motor B Positive cable to terminal 1 Motor B Positive cable to terminal 4 C Motor B Negative cable to terminal 2 Motor B Negative cable to terminal 3 Mark the Motor Cables 12 amp 13 for both motor units using the cable markers 25 The cables for the left and the right motor should have the same length Avoid any loops Connect the spade connectors to the motors Please note that the red cable is connected to the terminal under the moulded symbol on the weatherproof terminal cover The motor cables are already fitted with small coils These coils must be positioned along the side of the motors Remember to leave a small amount of slack cable near the motors to allow for their movement when the drive rollers are engaged Use the large cable ties 28 to secure the motor cables to the motor This ensures that there is no force and movement on the spade connectors or movement of the cables during transit Route the motor cables along the underside of the caravan floor inside the supplied Convoluted Trunking 11 this will protect the electrical cables against sharp edges a
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