E&P HYDRAULICS LEVEL SYSTEM User manual

›English - Electronic Levelling System
Assembly Manual

70
›Contents
Foreword Page 71
Scope of delivery Page 72
Assembly is carried out in eight stages
1. Fitting the corner supports Page 73
2. Fitting the axle supports Page 75
3. Installing the pump Page 77
4. Laying the pipework Page 78
5. Installing the electronics Page 81
6. Taking the system into service Page 82
7. Programming the zero point Page 83
8. Finishing and maintenance of the installation Page 84
Five tips for the customer Page 84
Layout of the hydraulic pipework Page 85
General Terms and Conditions of Trade Page 86
Order list for the axle brackets Page 87

71
›Foreword
“Products must be 100% user-friendly and reliable”: that is the strategic vision of E&P Hydraulics, who
designed this levelling system.
But this philosophy doesn’t apply just to the customer; the fitters who install the system at our dealers
are of extreme importance to us as well. The quality of our products stands and falls with their being
installed professionally. That’s why E&P makes every effort to support its system fitters in all respects.
These installation instructions are one important reflection of this policy. In eight different steps, we
show how this system can be installed as well and as effectively as possible.
Naturally, this doesn’t mean that installing an E&P levelling system is an easy matter. For the installation
of this system, a high level of specialist knowledge is called for, as this is an item of equipment subject
to considerable forces, which are frequently underestimated by people without a corresponding
technical background. If installed without the necessary expertise, extensive damage may be caused
in a flash, to say nothing of personal injury. This is why the system may only be installed by properly-
trained fitters with extensive practical experience and who have been trained in this particular field. The
fitters themselves remain at all times responsible for the installation of the system.
This document is based on the findings gathered from countless hours of tests and successful
installation processes. The materials supplied are all together designed to ensure the easiest possible
installation of the system. Ninety percent of the activities are carried out underneath the caravan, in
other words, at floor level.
When you work your way through these instructions step by step, you will realise just what a high quality
and at the same time user friendly product the E&P levelling system really is. There are nonetheless
still features which are capable of improvement. Therefore if you have any suggestions, comments
or questions on these instructions, or on the product itself, it is possible for you to contact us by
telephone.
E&P Hydraulics,
Eric Klinkenberg & Pierre Blom

72
›Scope of delivery
Every set comprises three separate cartons, in which all the components are contained:
1 Pump including control unit (black box)
2 Four different corner supports
3 Two axle supports
4 Two adapters for the axle supports
(including container with the corresponding fixing materials)
5 Fuse-holder for battery and fuse (container 3)
6 Electric cable with four-pin plug
7 Nine numbered hydraulic pipes
a) Two type 2 hoses (for the axle supports)
b) Two type 2R hoses (for the return from the axle supports)
c) One type 3 hose (for the rear corner supports)
d) One type 3R hose (for the return from the rear corner supports)
e) One type 4 hose (for the front corner supports)
f) One type 4R hose (for the return from the front corner supports)
g) One type 5R hose (intermediate hose pump-crosspiece)
8 Fixing material for the hydraulic pipework
9 Six distributors for the hydraulic hoses
a) four T-pieces with three male threads.
b) one T-piece with two male threads and one union nut
c) one crosspiece with four male threads
10 Control unit including holder bracket
11 Eight aluminium plates for mounting the corner supports.
12 Further fixing material (nuts, bolts and screws)

73
›STEP 1 Fitting the corner supports
First of all, remove the corner supports already fitted. Identify the type of the old corner supports. If
the corner supports are of the AL-KO brand, then the new supports can be fitted in the same place in
the same way, and the chassis will not affect the fitting greatly.
With reference to the BPW brand, the existing cut-outs will always be suitable for fitting the replacement
supports. However, on caravans with dismounted BPW- supports, the chassis will be in the way, as
at one point on the support, the frame prevents the support being completely withdrawn. It will be
essential to find a solution for this problem.
Please make sure that in all cases and for all types of corner supports removed, the aluminium cylinder
can carry out its complete movement and does not press against the chassis. The power of the system
must not be allowed to work against the wrong points.
!! The new corner supports are all different, and the studs are located in mirror image with respect to
the corner supports. You will find details of the corner supports (front left, front right, rear left and
rear right) on a small sticker on the guide rails of the corresponding products.
Now fix the new supports in their corresponding positions, using two M8 bolts. Do not forget to place
the two aluminium spacers on the M8 drill-holes. When fixing the new corner supports, make sure to
bond the aluminium guide rails solidly to the base. Use the right adhesive for this, which means do not
use silicone. Degrease the rails as well as the areas where the guide rails are mounted, and allow the
glue to dry adequately before taking the system into service, although the aluminium guide rails will
also be fixed with the three steel set-screws supplied. The first hole (on the top edge, see arrow on the
following photograph) is directly visible. The other two holes will be seen when the support is extended,
but this can only be done when the system is being bled.
Proper fixing of the guide rails is an extremely important step, as very great stresses can be imposed
here extremely quickly.

74
›STEP 1 Fitting the corner supports
1. Removal of the old corner supports
2. Degreasing the floor and the new corner supports
3. Apply adhesive (e.g. Sika 221) to the top surface of the aluminium guide-rails for the new corner
supports. Do not forget to apply to the two aluminium filler plates.
4. Fully tighten one of the three fixing screws.
8
Schritt1
1.DemontagederaltenEckstützen
2.EntfettendesBodensundderneuenEckstützen
3.Kleber(z.B.:Sika221)anderOberseitederAluminium-Laufschieneder
neuenEckstützenauftragen.DabeidürfendiebeidenFüllplattenaus
Aluminiumnichtvergessenwerden.
4.FestzieheneinerderdreiBefestigungsschrauben.
1
3
2
4

75
›STEP 2 Fitting the axle supports
When the system was ordered, you advised us of the make and type of caravan chassis to which our
system was to be fitted. Messrs. E&P Hydraulics have suitable adapters available for different caravan
types, and the correct adapter for your purposes was correspondingly supplied. If you still have
problems when positioning the adapter because the brackets do not fit, please make sure by reference
to the overview on Page 87 of these instructions that you have in fact been supplied with the correct
adapter.
If the caravan to which our system is to be fitted is a single-axle type, the fixing bracket must be
mounted so that the support is located behind the axle. If it is a tandem model, the cylinder must be
mounted on the rear axle, but facing forwards.
This will prevent the supports later on being subjected to an incorrect weight distribution. The axle
supports must be mounted as far away from the centre-line as possible, and you must also make sure
that the cylinder does not foul anything.
Fitting the axle supports
9
2.MontagederAchsstützen
SCHRITT2
BeiderBestellunghattenSieunsdieMarkeunddenTypdesChassisdesCaravans
genannt,andemunserSystemmontiertwerdensoll.DerFirmaE&PHydraulicsstehen
füralleCaravantypendiepassendenAdapterzurVerfügungundderfürihreZwecke
vorgesehenenAdapterwurdeentsprechendmitgeliefert.WennbeiderPlatzierungder
AdaptertrotzdemProblemeentstehen,dadieBügelnichtpassen,soinformierenSiesich
bitteinderÜbersichtaufSeite.....dieserAnleitung,obSieüberdiepassendenAdapter
verfügen.WennderCaravan,dermitunseremSystemversehenwerdensoll,nurübereine
einzigeAchseverfügt,müssenSiedenBügelsomontieren,damitsichdieStützehinter
derAchsebendet.HandeltessichumeinTandem-Modell,dannmussderZylinderan
derhinterenAchsemontiertwerden.Aberso,dassernachvornezeigt.Dadurchwird
vermieden,dassdieStützendasGewichtspäterineinemfalschenVerhältnisaufnehmen.
DieAchsstützenmüssennachMöglichkeitsoweitesgehtnachAussenmontiertwerden.
AchtenSiebittedarauf,dassderZylindernirgendwoanstösst.
MontagederAchsstütze

76
›STEP 2 Fitting the axle supports
Now clamp the adapter to the axle, but do not tighten the screws completely just yet, as you can still
adjust the position of the adapter by the amount that the axle supports are out of place due to the
bolts being too far apart. Thus the bolts should initially be partly tightened and then the axle supports
fitted at a height of about 12.5 cm (5”) from the ground. After this, the bolts are fully tightened. Finally,
check that the axle supports hang vertically and are inclined neither inwards nor outwards, nor to front
or rear.
!! Warning: Fixing the supports is probably the most important step of all in fitting the E&P
levelling system and therefore suitable expertise in this field is indispensable. The forces which act
on the system and the caravan must in no circumstances be underestimated. Do not drill any holes
in the chassis, and contact the dealer in all other cases of uncertainty, as the fitter himself is always
responsible for the installation of the system.

77
›STEP 3 Laying the pipework
Take the pump unit and unscrew the cap. Seek a suitable position for the pump with its cap removed
under the caravan floor. Make sure that the pipework connections point towards the rear and that the
fitting is mounted at a right-angle (parallel to the axle).
!! This is important to allow the controls to function properly.
The pump must be located as closely as possible behind the rear axle and with respect to the width
as close to the middle as possible. The purpose of this is to make optimum use of the length of the
pipework supplied, which is above all important in long caravans.
Before it is installed, the pump must have adhesive applied all the way round in the groove provided.
In addition, a strip of adhesive must be added in the middle directly underneath the control as this is
important for the control. To avoid malfunctions, the pump must stand level and the floor next to the
control absorb the load over the entire surface. Bonding the pump unit is absolutely essential. After
bonding, the container must be fixed with a total of nine bolts.
11
3.MontagederPumpe
SCHRITT3
NehmenSiediePumpeneinheitundschraubendenDeckelab.SuchenSienacheiner
geeignetenStellefürdiePumpe(beiderdieKappeentferntist)aufdemBodendes
Caravans.SorgenSiedafür,dassdieAnschlüssederLeitungennachhintenstehenund
dieAnlagerechtwinklig(parallelzurAchse)montiertwird.Diesistwichtig,damitdie
Steuerungordnungsgemäßfunktioniert.DiePumpemusssichsodichtwiemöglichhinter
derHinterachsebendenundauchinBezugaufdieBreitesogeringwiemöglichausder
Mitteherausragen.DiesdientdemZweck,dieLängedermitgeliefertenLeitungenoptimal
nutzenzukönnen.DiesistvorallembeilangenCaravanswichtig.
DiePumpemussvorihrerInstallationringsumindendafürvorgesehenenRandgeklebt
werden.ZudemmusseinStreifenKleberinderMittedirektunterderSteuerunggegeben
werden,denndiesistfürdieSteuerungwichtig.ZurVermeidungvonStörungenmussdie
PumpeebenstehenundderBodenbeiderSteuerungdieLastüberdievollständigeFläche
aufnehmen.DasklebenderPumpeneinheitistunbedingterforderlich.BefestigenSieden
Behälternachdemklebenmitinsgesamt9Schrauben.
Entfettendespumpgehäuses EntfettendesBodens
KlebendesPumpgehäuses MontagedesPumpgehäuses
11
3.MontagederPumpe
SCHRITT3
NehmenSiediePumpeneinheitundschraubendenDeckelab.SuchenSienacheiner
geeignetenStellefürdiePumpe(beiderdieKappeentferntist)aufdemBodendes
Caravans.SorgenSiedafür,dassdieAnschlüssederLeitungennachhintenstehenund
dieAnlagerechtwinklig(parallelzurAchse)montiertwird.Diesistwichtig,damitdie
Steuerungordnungsgemäßfunktioniert.DiePumpemusssichsodichtwiemöglichhinter
derHinterachsebendenundauchinBezugaufdieBreitesogeringwiemöglichausder
Mitteherausragen.DiesdientdemZweck,dieLängedermitgeliefertenLeitungenoptimal
nutzenzukönnen.DiesistvorallembeilangenCaravanswichtig.
DiePumpemussvorihrerInstallationringsumindendafürvorgesehenenRandgeklebt
werden.ZudemmusseinStreifenKleberinderMittedirektunterderSteuerunggegeben
werden,denndiesistfürdieSteuerungwichtig.ZurVermeidungvonStörungenmussdie
PumpeebenstehenundderBodenbeiderSteuerungdieLastüberdievollständigeFläche
aufnehmen.DasklebenderPumpeneinheitistunbedingterforderlich.BefestigenSieden
Behälternachdemklebenmitinsgesamt9Schrauben.
Entfettendespumpgehäuses EntfettendesBodens
KlebendesPumpgehäuses MontagedesPumpgehäuses
Degreasing the pump housing
Bonding the pump housing
Degreasing the floor
Fitting the pump housing

78
›STEP 4 Laying the pipework
Now all components are fixed in place and the pipework can be laid. Use the nine separate pieces
of hose, the six distributors, and the fixing materials supplied for fitting the hoses in their appointed
places.
!! Please note: all cylinders are already filled with oil, so make sure they do not drain out and that
the hoses do not hang downwards. The quantities of oil have been carefully measured so that the
system does not need bleeding. If an unexpected leak does occur (more than 5 cc), please contact
Messrs. E&P.
!! Possible intermediate step. For unusual situations, we have developed an extension set.
In principle, all the hydraulic hoses are of a sufficient length for all standard types of caravan. For non-
standard situations in which a length greater than the standard pipework of 8 m is needed, E&P offers
you a special extension set. This set comprises two ready-to-use hoses (including the corresponding
couplings) with an overall length of 1000 mm each. If this length is still insufficient, further extension
sets can be ordered to obtain the necessary length of pipes.
Please refer to the layout shown on Page 85. Begin laying the hoses from the pump and make sure
that there are no kinks in the hoses, as every kink is associated with a marked weakening of the
system.
!! Please note: particular attention should be paid to the couplings on the corner supports; please
ensure that the hoses cannot possibly be squashed by the corner supports when the system is in
operation.
First of all, screw the T-piece with the number b (see Page 72 of the list of contents in the set) with
two male threads and a union nut onto the crosspiece.
Next, lay the return hoses. Pay attention to the numbering on the hoses and connect them up in
accordance with the layout. Take off the sleeve and fit the hose. All hoses already have a connection
and can be fastened by hand, while final tightening is carried out using the 14 mm spanner. All return
hoses are now connected with each other. On the front and rear, this is done with two of the four
identical T-pieces. Now connect all the pipes with the five-way distributor (cross-connector with T-piece).
The last connection is provided for the hose 5R, which has to be connected at the other end at the rear
inlet to the pump.