EE100 manual A5.indd
Contents
1. s c c sc c cs s s s s c sc ocoooo esescec sc sc s sos oseseo OHHH HEHEHE HEHEHE HEHEHE HHH OHH OHHH HEHEHE HEHE HEHEHE HHH ORE o 6 EEE ETHER EHH HEHEHE HHH HEHE EEE s st s c c s s c c c cesoseeeoooeeeee s e sesvesvesvescescesvc esc s s c c c c c c c c c c sc sc s sc sceoo eoooovoeve es scec sc c s osc ceeceseoe des c c sc sc sc s sc sc ceceoocesceoeeeevecesc esc es sc seocecvesceooecesee eoesceoc ec sc ce ececeocescecesc c ce esce ecesc ec eceooeeooeeseees oooceoeooe ee ec c c c sc c c c c sc c ce ec c ececesce ec s s sc s sc oseeceooseceec c sc s s sc osveosceoceoeoee6666 66c c c sc cooseoeoceoeoeooeeo ee ee eee se ee e d s c c sc s s sc s sc se esesvesc sc sc sc cs sc sc s sc sc osevevec sc sc ec c c c c sc sc c c s s s s c sesesce esg ec eeeveevesc esc sc ec coce ee 6 Ref EE100 UM 041 1 Rev A Ref EE100 UM 041 1 Rev A EE100 Page 10 EE100 Page 11 elektro technik S purple ne design innovate improve Copyright 2011 Purple Line Limited Web www purpleline co uk E mail admin purpleline2. co uk Tel 01473 601200 Photographs for illustration purposes only Actual product may differ slightly Purple line Limited reserve the right to alter product specification without prior notice
3. EE100 il WN INK WG NG HN Mh Wy 27 277 Model Number elektro technik Y HN A N N Hi IWAN iN i MN dn 7 HNN ii l i AUTOMATIC ENGAGEMENT KIT Installat lon de and user informati lon gul EE100 UM 0411 Rev A Ref 01 0 UOMAS UORETOS A neg HUN 0101 Meeg ounsie7 1 0 1400 00144 Ref 100 0411 EE100 Page 3 Ref 100 0411 EE100 Page 2 Introduction The EE100 has been designed to be an upgrade to your Ego mover to enable the automatic engagement and disengagement of the traction rollers onto the caravan s tyres The EE100 has been designed to simply bolt onto the existing main cross bar of the Ego mover Installation Safety Guidelines A CAUTION 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 mea
4. e Switch Plate only fits onto the shaft of the switch in one position as it has a tongue that fits into a notch to ensure the correct orientation of the Switch Plate this also inhibits rotation The pre wired 3 core cable from the switch needs to be routed back to the Con troller and should be secured using suitable p clips or similar Attach the switch terminal block onto the Controller terminal 3 this only fits in one way Because the battery cables had to be removed from the main Control Unit during installation it may be necessary to pair the Handset with the Control Unit again Please refer to the main Ego User Manual for instructions on pairing reseting The EE100 Automatic Engagement System is now installed Operating the Automatic Engagement System First switch on the system by turning on the Power Isolation Switch A red LED will illuminate on the Controller To engage the traction rollers move the On Off Switch to the Engage position lift switch up the switch is spring loaded and will return to the centre position on release The Automatic Engagement System will now begin to operate and will automatically stop when the rollers have achieved the correct pressure onto the caravan s tyres You may novv operate your Ego mover by double pressing the povver svvitch on the handset After you have finished your manoeuvring you need to push the On Off Switch Ref EE100 UM 041 1 Rev A EE100 Page 9 Operatin
5. g the Automatic Engagement System down to the Disengagement position and the rollers will automatically retract Once fully retracted the system will change rotation briefly so that the engagement gear mechanism is not left under any strain whilst not in use c sc sc c sc c sc sc sc se e cs s e cs sc c coc sc c c c sc c sc sc c c oce eococe eoc ce cc esc s c ec c c oce ec c c c sce oc scs c c c sc oc oeoceooeoooo eoeo6o666s ee 66 Once the operation has been completed turn the Povver solation Svvitch off Installation for a Four Motor QuattroG System The EE100 can be utilised to automatically engage two sets Wier g stalling a full four motor Quattro system on a twin axle caravan For this installation an additional EE100 will need to be purchased and installed in an identical fashion apart from the On Off Switch wiring It is only necessary to use one On Off Switch to operate both EE100 Controllers The 3 core cable that is CoCo ooo Heo Mee HEHEHE HOT EEE EHO HEHEHE HEHEHE OHO HOHE E EHH EHO HEHEHE H EHO TOME EEE HEHEHE HEH OTOH EOE OE OHO EEO o EEO attached to the switch must be removed and then both 3 core cables connected TOONS WNO III L a aaa a ura In this way only one switch has to be used to control both EE100 systems d s c sc s s c s s s ct s c c c sc s s s s sc s sc sc sce esce ec ec c sc s s s s s sc
6. ge 5 Ret aw ln lm sl sl l Installation Mechanical These instructions are for general guidance Installation procedures may vary depending on caravan type Working under a vehicle without appropriate support is extremely dangerous 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 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 after installation of the EE100 system If you are conducting this installation as an upgrade it is first necessary to disconnect the cross actuation bar from the Ego mover assembly Once this has been done locate the motor and bracket assembly 1 onto the middle section of the main cross bar in a position that is away from any obstructions such as pipes vents or the handbrake mechanism The usual location will be just off centre Once satisfied with the location the bracket is attached to the cross bar using the supplied M8 65mm bolts spring washers washers and nylock nuts 7 8 9 amp 10 Assemble together as shown in Fig B Tighten to a torque setting of 25Nm Now we need to re use the original cross actuation bar part ref E and D x 2 in your main Ego User Manual T
7. he centre section of the cross actuation bar needs to be cut into 2 pieces This can be done using a standard hack saw or similar metal saw First measure the distances between the inside edge of one of the motor units up to the corresponding square spindle on the engagement motor unit 1 and repeat the measurement for the other side This will give an indication of where you will need to cut the bar The cross actuation bar assembly will still operate as before so that it provides telescopic width adjustment so there is a margin for adjustment Note if the engagement motor has to be fitted very off centre then it may be necessary to also cut one of the Cross Actuation Bar extensions Ref EE100 UM 041 1 Rev A EE100 Page 6 Installation Mechanical For reference before cutting the centre bar you must ensure that the narrower square tube extensions D slide into the centre sections by at least 100mm to ensure they are held securely by both 45 angled securing bolts and locking nuts on the bars Once satisfied with where the cut needs to be proceed with cutting the centre Please note that cutting your existing cross actuation bar will not affect the standard warranty To ensure safe installation it will be necessary to file off any sharp edges after the cut A hole needs to be drilled into the end of each centre section bar which will correspond with the holes on the square spindles that protrude from the engagement moto
8. hould be installed in the same manner as the existing motor cables that are fitted to the Ego motor assemblies To ease installation the cables should follow the same route as the existing cables where possible The cables can be secured along the cross bar by use of cable ties The cables need to be routed through or close to the aperture in the floor of the caravan that is already utilised for the Ego motor unit cables Once the Engagement Motor 1 cables are secured and enter the caravan through the same or close by aperture as the existing Ego cabling they will be in the cor rect proximity to connect to the Controller The Controller unit 2 should be installed either next to or on top of the existing main Ego Control Unit The use of double sided hook and loop tape could be utilised to attach the Controller to the top of the Ego Control Unit as it provides a secure non permanent installation or the Controller can be screwed into the floor of the caravan Cut the cables from the engagement motor 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 Connect the red cable to terminal 1 on the Controller and the black cable to terminal 2 on the Controller refer to Fig E The cables that provide power to the Controller need to have the smaller terminal spade connectors fitted to one e
9. n CAUTION WARNING AN SAFETY FIRST IMPORTANT INFORMATION Before starting installation under the caravan DO check that the caravan is disconnected from the battery supply and the 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 DO NOT remove change or alter any parts of the chassis axle suspension or brake mechanism Ref 100 0411 EE100 Page 4 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 ALWAYS consult the main User Manual supplied with your Ego mover to ensure correct and safe operation Specifications Designation Ego Automatic Engagement System No EE100 Power Source caravan leisure battery 12V 110Ah recommended 12V 85Ah minimum Package Contents ty Engagement Motor amp Bracket inc motor cables 2 x 5 2m On Off Toggle Switch inc switch cable with terminal block Ref EE100 UM 041 1 Rev A EE100 Pa
10. nd These cables will need to share the positive and Negative terminals of the main Control Unit so if you are installing the EE100 as an upgrade you will need to cut the spade terminals off the ends of the Ego mover s battery cables and refit new ones Supplied that also include the smaller gauge power cables for the Controller Attach the combined battery and power cables onto the positive and negative terminals of the main Control Unit and the other ends to the positive and negative terminals on the Controller Caution Make sure that you do not reverse the Positive and Negative connections Incorrect connection reverse polarity will result in damage to the electronic components Ref EE100 UM 041 1 Rev A EE100 Page 8 Installation Electrical Electronic Components Now the On Off Switch 3 needs to be installed Ideally this should be installed close to the Ego mover s Power Isolation Switch which is often installed within the battery compartment Choose the location for the switch carefully to ensure that it will not obstruct any other connections sockets such as the mains power hook up To install the switch a 12mm diameter hole needs to be carefully drilled through the wall of the battery compartment if that is the chosen location Once drilled fit the switch through the hole fit the Switch Plate 4 over the threaded shaft of the switch and secure into place with the narrow depth nut refer to Fig A Th
11. r shaft 1 These holes need to be 5mm in diameter using a suitable HSS or similar drill bit suitable for use with metal Please observe caution when drilling to avoid personal injury gt A template 7 is provided to enable you to easily mark the holes in from the end of each cut bar Position the template against the end of each bar you can either mark the hole remove the template and drill or secure the template in place using some form of clamp Note Drill only through one side of the square tube at this stage gt Once you have drilled one side you can then offer up the bar onto the motor s shaft and line up the drilled hole Once this is aligned you can drill through to the other side of the bar using the shaft spindle as a guide to ensure the holes are perfectly aligned and not drilled at an angle Once the holes have been drilled on both sections of the centre bar they can secured into place using the supplied M4 nuts and bolts 5 amp 6 The extension ends of the bars can be refitted using the original nuts and bolts to the Ego motor assemblies and then the four bolts and locking nuts on the bars can be tightened Installation of the mechanical components is now complete Ref EE100 UM 041 1 Rev A EE100 Page 7 Installation Electrical Electronic Components The engagement motor is supplied pre vvired vvith red positive and black nega tive cables that are approx 5 2 metres in length These cables s
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