EN
DURO
®
EM505FL 38
Ref: EM505FLV3-UM-TKI-0120-Rev.A.
Loosely fit the two clamping assemblies (9) to the chassis (Fig. 7) and attach. Use the bolts M10x60, nuts M10
and washers M10 (14,17,18) and put them in the diagonal positioned holes of the aluminium chassis clamp
plates. Nuts must be no more than finger-tight.
Assemble the pre-mounted manoeuvring system on the aluminium chassis clamp plates by using the two U-
shaped brackets (10), bolts M10x50, nuts M10 and washers M10 (15,17,18). Nuts must be no more than
finger-tight.
Make sure that aluminium drive rollers of the motors are approximately on the same altitude as the centre
(axle) of the caravan wheel (0mm~40mm, see Fig. 6). As well make sure that between the top of the motor
housing and the floor of the caravan is minimal 10mm space to make sure the motors can move freely. To
compensate a possible unevenness (and lower the motors), EN
DURO
®
has a set of distance plates available. One
set can compensate 15mm. In total three sets can be used so that an altitude of 45mm can be compensated.
Adequate ground clearance: Please notice that the min. distance between the lowest line of
motors and ground is 110mm, no matter what kinds chassis or install situation.
Make sure that the main cross bar is positioned in the middle of the caravan (the centre of the bar is marked).
With the main assembly is loosely fitted onto the chassis, slide the whole assembly along the chassis until the
rollers are 20mm away from the surface of the centre each tyre (Fig. 6). Two 20mm spacers (29) 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 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 gear cover (Fig. 8) is not too
close to the surface of the tyre/shock absorber. The minimum clearance when the drive
units swivelled in is 10mm.
Re-check that there is sufficient space available (minimal 10mm) between the top of the
motor housing and the floor of the caravan so the motors can move freely.
Fully tighten (10Nm torque) the four bolts (Fig. 4A) on the main cross bar and lock them by the additional nuts.
Fully tighten all the nylon nuts on both clamping assemblies (Fig. 7). First tighten the diagonal placed M10x60
bolts with a 20Nm torque, and then M10x50 bolts to a 40Nm torque.
Re-check the distance of 20mm from the rollers to the tires, the position of the aluminium rollers in addition to
the surface of the tire and finally the distance between the gear cover (Fig. 8) and the tires & shock absorbers
(>10mm). The weight of the caravan must be on the wheels when doing this. If necessary, loosen the bolts and
re-adjust the position of the assembly.
Re-check that all bolts/nuts have been tightened to the correct torque!
The main mechanical components have now been installed.
INSTALLATION – ELECTRICAL/ELECTRONIC COMPONENTS
Make sure the 12 Volt supply from the battery and any 230 Volt electricity supply are
disconnected.
Remove battery cable terminals and disconnect any external electrical power before starting work.
Find a suitable place for the control unit (5), such as a storage area, under a seat or a bed. Make sure this
place is dry and close to the battery (40cm to 60cm). The control unit can be mounted vertically on a side wall
or be mounted flat on the floor, see Fig. 16.1 to 16.4 for the available mounting possibilities (if another vertical
or horizontal installation is used as indicated, the level system will not function). When mounted vertically, the
connections must point downwards to avoid any short-circuits by objects falling into.
Fix the control unit securely into position with two screws M5x40 (33). Note: if the provided screws are not of
suitable length or type for the desired location/material please substitute these as appropriate.
Drill a 25mm hole through the floor of the caravan approximately 150mm centrally in front of the control unit
terminals.
Caution! Take extra care to avoid any chassis members, gas pipes and electrical wires!
