en
duro
®
EM203 26
Ref: EM203-UM-EAL-0211-Rev.D.
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. 10). Two 20mm 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.
8) is not too close to the surface of the tyre/shock absorber. The minimum clearance when
the drive units swivelled in is 10mm.
Fully tighten the four bolts (Fig. 1B) on the main cross bar (3) and the four bolts (Fig. 1C) on cross actuation
assembly (4 & 5).
Fully tighten all the nylon nuts (17) on both clamping assemblies (Fig. 2 & Fig. 6). 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 chain 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 12V supply from the battery and any 230V electricity supply are disconnected.
Remove battery cable terminals and disconnect any external electrical power before starting work.
Find a suitable place for the electronic control unit (32), 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 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 25mm hole through the floor of the caravan approximately 150mm 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/axle 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
Motor A Positive (+) cable to terminal 3
Motor A Negative (-) cable to terminal 4
Motor B Positive (+) cable to terminal 1
Motor B Negative (-) cable to terminal 2
Table . B
REAR OF AXLE FITTING
Motor A Positive (+) cable to terminal 2
Motor A Negative (-) cable to terminal 1
Motor B Positive (+) cable to terminal 4
Motor B Negative (-) cable to terminal 3
Mark the motor cables (12 & 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 (24) 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 (27) 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.
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