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Camec ELITE EM303 User manual

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ELITE Caravan Mover
For Professional Installation Only
Ref: ELITE EM303-0814-Rev.A.
CAMEC ELITE EM303
EM303
User Manual
Model: ELITE
Part No: 042373
“More information https://www.caravansplus.com.au"
40 6
39 12
38 6
37 6
Chassis Clamp Plates (Pair) , nuts and washers
with bolts M8
x70
chassis
TABLE OF CONTENTS
Package contents (parts list) Page 2
Introduction Page 4
Intended use Page 4
Specifications Page 4
Installation - safety guidelines Page 4
Installation - mechanical components Page 5
Installation - electrical/electronic components Page 6
Operation - safety guidelines Page 12
Operation - motor units Page 13
Operation - remote control handset Page 13
Operation - electronic control unit Page 14
Operation - getting started Page 15
Operation - hitching and unhitching Page 16
Page 16
M
aintenance
Trouble-shooting Page 16
PACKAGE CONTENTS
Ref Qty Description
1 1 Motor unit (A)
2 1 Motor unit (B)
3 1 Main cross bar
4 1
5 2
6 1
7 2
8 4
9 2
10 1
11 1
12 2
13 2
14 1
15 1
16 8
17 12
18 24
19 20
20 10
21 10
22 4
23 2
24 4
25 3
26 3
27 4
28 10
29 1
30 2
31 1
32 1
33 2
34 1
35
36
2
Cross actuation centre bar
Cross actuation insert bars
Engagement tool
Aluminium clamp plates (set)
Bolt - M10x60
Chassis U plate
Instruction manual
Convoluted cable trunking
Positive (+) red motor cable 5m
Negative (-) black motor cable 5m
Positive (+) red battery cable 1.8m including fuse holder & 80A
fuse Negative (-) black battery cable 1.6m
Bolt - M10x50
Nylon nut M10
Washer 10mmØ
Screw - M4x15
Cable trunking P-clips 19.2mm
Cable P-clips 10.4mm
Battery terminal connector 8mmØ
Battery terminal connector 6mmØ
Spade fork connector
Cable number markers (1,2,3,4)
Cable polarity markers (+,-)
Motor unit cable ties 8x400
Cable ties 2x70
Battery isolation switch, cover & key
Roller distance spacers 20x20
Remote control handset with lanyard
Electronic control unit
Rubber isolation shell for battery isolation switch
Remote control handset wall holder
Screw – M5x40
CAMEC ELITE EM303 Ref: ELITE EM303-0814-Rev.A.
2
CAMEC ELITE EM303 Ref: ELITE EM303-0814-Rev.A.
2
Spring washer
Washer 8mmØ
Nylon nut M8
Bolt - M8x70
8mmØ
“More information https://www.caravansplus.com.au"
1
2
3
4
5
6
32
31
10
11 12 13
14 15
16
20
25 29 30
7
3
3
3
3
4
4
4
4
2
2
2
2
+
+
+
+
1
1
1
1
-
-
-
-
9
17
18
24
22
23
26
21
8
B
A
Package Contents
33
34
L
L
MAX
28
27
19
35
CAMEC ELITE EM303 Ref: ELITE EM303-0814-Rev.A.
36
36
3
Fig.1
40
37
2
38
39
“More information https://www.caravansplus.com.au"
INTRODUCTION
Congratulations on choosing the Camec Elite® EM303 caravan manoeuvring system. This has been
produced according to very high standards and has undergone careful quality control procedures.
By using the remote control handset you can move your caravan effortlessly into any position required within
operating guidelines. Soft start and soft stop technology allows you to manoeuvre your caravan accurately
without any shocks.
The caravan manoeuvring system consists of two 12V motor-power rollers, a 12V electronic control unit and a
remote control handset. 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 manoeuvring system 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.
Before proceeding with installation and starting to use the manoeuvring system, 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.
INTENDED USE
The Camec Elite® EM303 caravan manoeuvring system is suitable for single axle and double axle caravans.
Suitable only for L-profiled and U-profiled chassis with a chassis thickness between min. 2.8mm and max.
3.5mm.
Depending on the weight of the caravan, the manoeuvring system cannot overcome obstructions that are more
than about 2cm in height without assistance (please use wedges as a ramp).
The standard installation kit only provides parts for installing the caravan manoeuvring system within the
measurements given in Fig. 16.
SPECIFICATIONS
D
esignation
Operational voltage 12 Volt DC
Average current consumption 20 Ampere
Maximum current consumption 100 Ampere
Transmitting frequency remote control 868MHz
Speed approx. 9cm per sec.
Weight (2 motor set) approx. 37kg (exclusive battery)
Permissible overall Weight single axle (2 motors) 1800kg (1500kg on 18% gradient)
Permissible overall Weight double axle (2 motors) 1800kg (1500kg on 18% gradient)
Permissible overall Weight double axle (4 motors) 2500kg (1800kg on 18% gradient)
Minimum width (caravan/trailer)
Maximum width (caravan/trailer)
Maximum tyre width
Power source (battery)
1800mm
2500mm
205mm
LiFePO4: 12V, 20Ah (recommended Camec Elite®
EM303) Lead acid: 12V, 80Ah (min.)
INSTALLATION - SAFETY GUIDELINES
Read this user manual carefully before installation and use. Failure to comply with
these rules could result in serious injury or damage to property.
These symbols identify important safety precautions. They mean CAUTION! WARNING!
SAFETY FIRST! IMPORTANT INFORMATION!
Before starting installation under the caravan:
Check the towing load of your vehicle and the gross weight of your caravan in order to establish whether they
are designed for the additional weight. The manoeuvring system itself has a weight of about 37kg and a battery
has a weight of about 20-25kg.
Check the minimal installation dimensions of the manoeuvring system based on figure 16.
Camec Elite® EM303
4
CAMEC ELITE EM303 Ref: ELITE EM303-0814-Rev.A.
“More information https://www.caravansplus.com.au"
loosely fit the two aluminum clamp plates (7) to the plates (36) (Fig.
Fit the Chassis Clamp Plates(36) to the chassis using bolts(37),nuts(38), washers(39) and spring washers(40), then
Check that the caravan is disconnected from the battery supply and the mains electrical supply.
Only use adapters and accessories that are supplied or recommended by the manufacturer.
Check that the tyres are not worn and do have the same size and design (fitting to new or nearly new
tyres is the best option).
Make sure that the tyre-pressures are correct to the manufacturer’s recommendation.
Make sure the chassis is in good condition without any damage and is free from rust, dirt etc.
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).
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. Any drilling of
holes in the chassis is not allowed.
Do not install 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
FOR PROFESSIONAL INSTALLATION ONLY. These instructions are for general guidance.
Installation procedures may vary depending on caravan type.
Working under a vehicle without appropriate support is extremely dangerous!
Please refer to Fig. 16 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.
Unpack all the components and check for the presence of all parts (see package contents list). Write down, on
the product warranty registration card, the 10-digit serial number (this is located on an aluminium plate on the
side of one of the motor units).
Clean the area of your chassis where you need to mount all components to ensure a good fitting.
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 caravan manoeuvring system.
Ensure both rollers are in the DISENGAGED position (Fig. 12A), as the unit will not fit correctly otherwise (Note:
when fully disengaged, the pointer is positioned in the beginning of the yellow area).
Loosely assemble the left hand motor unit (1), right hand motor unit (2) and main cross bar (3) (Fig. 2). The
nuts (Fig. 2B), on the cross bar (3) to secure both motor units, must be no more than finger-tight at this stage.
Note: In principle, the unit should be fitted in front of the caravan road wheels, but if fitting in this position is
not possible because of obstacles or a too high hitch ball weight, it is permissible to fit it to the rear of the
wheels by rotating the whole assembly (Fig. 2) by 180° degrees.
M10 and washers M10 (8,17,18) 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 (7) by using the two
U-shaped brackets (9), bolts M10x50, nuts M10 and washers M10 (16,17,18). 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 (± 20mm). To compensate a possible unevenness (and lower the motors), Camec
Elite® 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.
5
CAMEC ELITE EM303 Ref: ELITE EM303-0814-Rev.A.
8
& 16) and attach. Use the bolts M10x60, nuts
“More information https://www.caravansplus.com.au"
Assemble the parts of the cross actuation bar (4 & 5) and connect them to the motor units (1 & 2) with the
nylon nut and bolt (factory fitted) onto the cross actuation bar-connectors (Fig. 2 & Fig. 2A). Nuts must be no
more than finger-tight at this stage.
Make sure that the main cross bar (12) and the cross actuation centre bar (4) are 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. 12). 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 gear cover (Fig. 13)
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. 2B) on the main cross bar (3) and the four bolts (Fig. 2C) on cross
actuation assembly (4 & 5).
Fully tighten all the nylon nuts on both clamping assemblies (Fig. 8). 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 plastic gear cover (Fig. 13) and the tires & shock
absorbers (>10mm). The weight of the caravan musty 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 electronic control unit can be mounted
vertically on a side wall or be mounted flat. When mounted vertically, the connections must point downwards to
avoid any short-circuits by objects falling into it.
Fix the electronic control unit securely into position with two screws M5x40 (35). 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. 15) (red = positive, black =
negative).
The wiring diagram (Fig. 15 + 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 4
Motor A Negative (-) cable to terminal 3
Motor B Positive (+) cable to terminal 2
Motor B Negative (-) cable to terminal 1
Table . B
REAR OF AXLE FITTING
Motor A Positive (+) cable to terminal 1
Motor A Negative (-) cable to terminal 2
Motor B Positive (+) cable to terminal 3
Motor B Negative (-) cable to terminal 4
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.
6
CAMEC ELITE EM303 Ref: ELITE EM303-0814-Rev.A.
“More information https://www.caravansplus.com.au"
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.
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.
Remember to leave a small amount of slack cable near the motors to allow for their movement when the drive
rollers are engaged.
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 and 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).
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. 5mm of the insulation from the ends. Fix the spade fork connectors (24)
to the motor cables by using crimping pliers. A secure and good quality connection on each cable is essential.
Attach the spade fork connectors to the terminals on the control unit (see wiring diagram Fig. 15) and fix them
tightly by the screws. A safe and good quality connection on each cable is essential.
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.
Use the cardboard template to position the hole positions and the drill holes. Mount the switch and the housing
with the bolts, washers and nuts, and finally mount it on the caravan with stainless steel screws (19).
Route the positive (+) power cable (including fuse) from the battery to the battery power isolation switch (29)
and than further to the control unit (32).
The electronic connections of the battery power isolation switch (29) must be covered by the supplied rubber
isolation shells (33).
Route the negative (-) power cable directly to the control unit (32).
No cables may be routed over the control unit!
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).
Cut the cables to an appropriate length and remove approx. 5mm of the insulation from the ends. Fix the spade
connectors by using crimping pliers. Two types of battery terminal connector (22 & 23) are provided for use as
appropriate. A secure and good quality connection on each cable is essential.
Connect the battery cables (14 & 15) to the control unit (32): Attach the spade fork connectors to the positive
(+) en negative (-) terminal of the control box and fix them tightly by the screws.
Connect the battery cables to the existing battery terminals (red = positive, black = negative).
Caution! Make sure that you do not reverse the Positive (+) and Negative (-) connections.
Incorrect connection (reverse polarity) will result in damage to the control unit.
Seal the 25mm hole in vehicle under body using plastic body sealant.
Finally find a suitable place for the remote control handset wall holder (34) and fix this by the supplied screws
(out of reach of children or other unauthorised people).
Installation of the caravan manoeuvring system is now complete.
CAMEC ELITE EM303 Ref: ELITE EM303-0814-Rev.A.
CAMEC ELITE EM303 Ref: ELITE EM303-0814-Rev.A.
7
“More information https://www.caravansplus.com.au"
Fig.2
Fig.3
Fig.
Fig.5
X
X
A
B
C
D
F
C
A
C
B
A
F
C
4
A
Parts Identification & Fitting Diagrams
LL
MAX
A
B
C
D
E
F
G
H
IJ K
E
B
A
CAMEC ELITE EM303 Ref: ELITE EM303-0814-Rev.A.
8
A
Fig.6
A
B
Fig.7Fig.6.1
“More information https://www.caravansplus.com.au"
Ref: ELITE EM303-0814-Rev.A.
CAMEC ELITE EM303
9
Parts Identification & Fitting Diagrams
Fig.8Fig.8.1
Fig.9
Fig.10
“More information https://www.caravansplus.com.au"
Fig.15
+
+ -
A
B
Caravan
2 4
+ -
-
Front
| 1 | 2 | - DC 12V + | 3 | 4 |
BCD
A
S
T
| 1 | 2 | - DC 12V + | 3 | 4 |
1 3
10
CAMEC ELITE EM303 Ref: ELITE EM303-0814-Rev.A.
Parts Identification & Fitting Diagrams
Fig.14
Fig.13
.11
10mm
Fig Fig.1220mm
A
“More information https://www.caravansplus.com.au"