POWRWHEEL LIMITED MANUFACTURERS OF THE UK's No: 1

~ 1 ~

POWRTOUCH CARAVAN MOVERS

REMOTE CONTROL CARAVAN MOVER FAMILY

POWRTOUCH CLASSIC

INSTRUCTIONS for the Installation, Operation, Use,

Safety & Maintenance of the Powrtouch Classic

IF YOU HAVE PURCHASED DIRECT FROM POWRTOUCH your proof of purchase will state

your unique Powrtouch Classic Serial Numbers. Please write them on the front of this

document for your convenience.

IF YOU HAVE PURCHASED FROM ANOTHER SUPPLIER then they should register your

information with Powrtouch (ALWAYS ASK YOUR SUPPLIER TO MAKE SURE THAT THIS

HAS BEEN DONE).

PLEASE NOTE THAT YOUR POWRTOUCH CLASSIC GUARANTEE IS NOT

AUTOMATICALLY TRANSFERABLE TO A SECOND OWNER

see Section 5 – Paragraph 5.1 of this document.

BEFORE CONTACTING POWRTOUCH WITH A FAULT OR GUARANTEE ENQUIRY

PLEASE PAY SPECIAL ATTENTION TO SECTION 4 OF THIS DOCUMENT.

CUSTOMER NAME:……………………………………………………………………….……..

POWRTOUCH CLASSIC SERIAL No: CL/..…………………………………………………..

ELECTRONICS SERIAL No: CDFM/…………………………………………………………...

Truma Limited

Powrtouch – A Truma Brand

2000 Park Lane, Dove Valley Park, Foston, South Derbyshire, DE65 5BG United Kingdom

TELEPHONE: +44 (0)1283 587900 FAX: +44 (0)1283 587910

WEBSITE: www.powrtouch.com EMAIL: info@powrtouch.com

TWITTER: www.twitter.com/powrtouchuk FACEBOOK: www.facebook.com/powrtouchuk

ISSUE 5

~ 2 ~

CONTENTS

SECTION 1 – USING YOUR POWRTOUCH CLASSIC SAFELY

1.1 Safety Checks Required Prior to Using Your Powrtouch Classic

1.2 Emergency Switch Off/Stop

1.3 Safety and Technical Awareness

SECTION 2 – OPERATION OF YOUR POWRTOUCH CLASSIC

2.1 Powrtouch Classic Operation

2.2 Switching On the Powrtouch

2.3 Switching On the Handset

2.4 Handset Battery Replacement

2.5 Engagement of the Rollers On To the Tyres

2.6 Moving the Caravan (Handset Operation)

2.7 Decreasing and Increasing Speed

2.8 Precision Control of the Caravan Using the Electronic Soft Start Function

2.9 Retraction of the Rollers from the Tyres

2.10 Switching Off the Handset

2.11 Mapping Instructions

SECTION 3 – DIY FITTING INSTRUCTIONS (FOR UK SPEC CARAVANS ONLY)

3.1 Receiving Your Powrtouch Classic

3.2 Tooling & Equipment Required

3.3 Installing Your Powrtouch Classic

3.4 Checking Chassis Depth

3.5 Special Mounting Plates

3.6 Mechanical Assembly

3.7 Electrical Assembly

3.8 Connecting to the Caravan Battery

SECTION 4 – LOOKING AFTER YOUR POWRTOUCH CLASSIC

4.1 Cleaning Your Powrtouch Classic

4.2 Cleaning the Drive Rollers

SECTION 5 – GUARANTEE & FAULT FINDING

5.1 Powrtouch Classic Guarantee

5.2 Reporting a Fault with your Powrtouch Classic

5.3 Electronics Control Box (ECB) - LED Status

5.4 Checking the Charge State of Your 12 Volt Battery

5.5 Fault Finding on Your Powrtouch Classic

~ 3 ~

SECTION 1 – USING YOUR POWRTOUCH CLASSIC SAFELY

1.1 SAFETY CHECKS REQUIRED PRIOR TO USING YOUR POWRTOUCH CLASSIC

PLEASE READ CAREFULLY:

Before moving the caravan with the Powrtouch Classic, for safety reasons it should always be

tested first, to do this turn on the Powrtouch Classic at the Isolation switch – DO NOT PUT

THE ROLLERS ON TO THE TYRES. With the rollers off the tyres check the handset functions

drive the rollers correctly. Once this test has been satisfactorily completed only then should

you engage the rollers to the tyres and commence to move the caravan.

IF IN DOUBT CONTACT POWRTOUCH

1.2 EMERGENCY SWITCH OFF/STOP

NB. In the unlikely event of the Powrtouch Classic malfunctioning, the system can be switched

off by pressing either D or F buttons on the handset. Then turn off the Powrtouch Classic at the

Isolation switch and remove the key. DO NOT switch the Powrtouch Classic back on before

consulting a qualified Powrtouch Engineer.

1.3 SAFETY & TECHNICAL AWARENESS

Please read the following instructions and technical information carefully and become familiar

with the various components and controls prior to assembly and/or operation. Safety must

always be the first consideration in fitting and operation. Failure to comply with these

instructions could invalidate your Powrtouch guarantee. If you are in any doubt about the

assembly or operation of the product consult a qualified Powrtouch Engineer, for which contact

details are shown on the front cover.

• The Powrtouch Classic Caravan Mover (except handset) is a 12volt DC powered device

and it should not under any circumstances be powered by any other power source than

a 12volt DC leisure battery. NB. Using the Powrtouch Classic with the caravan

connected to the 240volt mains could cause damage to the caravan internal

charging system.

~ 4 ~

• The 12volt leisure battery MUST be fully charged and in good condition to enable the

Powrtouch Classic to operate to its full performance specification – to check your

battery see Section 5 Paragraph 5.4 of this instruction manual.

• The handset is powered by a 9volt DC battery (PP3 or equivalent).

• The wiring and cabling supplied by Powrtouch for the installation of the Powrtouch

Classic are to the correct voltage and current rating, under NO circumstance should any

other wiring or cabling be used unless supplied by Powrtouch or written approval is

given for their use. If cutting motor cables (not recommended) these should be kept of

equal length, no cable joining system should be used to lengthen them.

• When the Powrtouch Classic is switched on and/or in use there will be 12volts at the

two battery terminals on the Electronics Control Box (ECB). Under no circumstance

should any metal object be allowed to touch these terminals.

• The Powrtouch Classic is not a caravan jacking point and should never be used as

such.

• The Powrtouch Classic is not a brake or braking system and should never be used as

such. When stopped always apply the caravan handbrake and remove the rollers from

the tyres.

• Be aware that the Powrtouch Classic adds weight to the caravan and the corresponding

weight of your mover must be considered when calculating your payload. If in doubt the

MTPLM of the caravan should be checked on a calibrated weighbridge.

• Never allow children or persons unfamiliar with the use of the Powrtouch Classic to

operate the unit.

• When operating the Powrtouch Classic, please ensure that no object (e.g. Body parts,

clothing, hair or any other objects carried on the body) can become trapped by any

moving parts of the mover (e.g. rollers).

SECTION 2 – OPERATION OF YOUR POWRTOUCH CLASSIC

2.1 POWRTOUCH CLASSIC OPERATION:

Carry out the Powrtouch Classic pre-movement safety checks as Section 1 Paragraph 1.1;

also ensure that the caravan is safe to move and that there are no obstructions to prevent the

engagement of the drive rollers to the caravan tyres.

2.2 SWITCHING ON THE POWRTOUCH CLASSIC

The Powrtouch Classic control system is switched on by inserting the key into the isolation

switch and then turning the key clockwise, the isolation switch is usually situated in the sealed

area of the caravan battery box. When the control board is switched on the unit first initialises,

and then looks/waits for the welcome/coding signal from the handset. The green light should

illuminate on the ECB situated in the caravan. (See Section 5 Paragraph 5.3)

NOTE: When the Powrtouch Classic is not in use it MUST always be turned off at the Isolation

Switch and the key removed. If left switched on it will stay live for 20 minutes (approx.) before

the ECB will go in to a hibernation mode. The ECB can only be reinitialised by the following: -

1) Turning off the isolation switch.

2) Remove the key from the switch.

3) Wait for a minimum of 20 seconds.

4) Then reinsert the isolation switch key and turn on.

5) Turn on the handset and use the Powrtouch Classic.

~ 5 ~

WHEN NOT IN USE ALWAYS SWITCH IT OFF AND REMOVE THE KEY

2.3 SWITCHING ON THE HANDSET

To switch on the handset press and release both D and F buttons at the same time. The LED

array will illuminate in the settings indicator window. Once it is ready to operate then one

green LED on the extreme right of the settings indicator window will remain on. If the top row &

bottom row of Red LED’s flash alternating, then this in an indication that the handset battery

voltage is low and the battery should be changed as soon as possible.

2.4 HANDSET BATTERY REPLACEMENT

To replace the handset battery the first step

is to remove the small cross head screw on

the back of the handset. When the small

cross head screw is removed the battery

box cover can be taken off providing

access to the battery. The battery can then

be removed from its connections and a

new battery can be installed and the cover

replaced. The battery required is a 9volt

DC PP3 (mn1604) or equivalent. NB. The

use of rechargeable batteries is not

recommended.

~ 6 ~

2.5 ENGAGEMENT OF THE ROLLERS ONTO THE TYRES

Engagement of the Rollers on to the Tyres Using the Supplied Wrench

To engage the rollers onto the tyres, locate the wrench onto the hexshaft (see picture above)

and turn in the direction shown, after 200 degrees the over locking cam system will lock the

rollers in the engaged position. On the Powrtouch Classic models the start position for the

wrench should be as low as possible to the ground with the handle pointing away from the

rollers. Always take great care with this operation as the over locking cam system together with

its return spring require some force to move the rollers into position against the tyres. This

operation only needs to be done from one side of the caravan as the Classic is fitted with a

Powrbar as standard. Your Powrtouch fitter or supplier will show you how to carry out this

operation safely.

If in doubt consult a qualified Powrtouch Engineer. NB. Always check that BOTH rollers

are fully engaged on to the tyres of the caravan before removing the handbrake.

Once the Rollers are engaged ONLY then disengage the handbrake when you are ready

to use the Powrtouch Classic.

- 6 -

~ 7 ~

2.6 MOVING THE CARAVAN (HANDSET OPERATION)

The caravan can be moved as required by pressing buttons A, B, C, G, H or I. The caravan will

move in the direction of the arrows printed on these buttons. Pressing opposite button A and I

or C and G will make the caravan rotate on its axis. The Electronics Control System also has a

continuous movement capability in that if button B is being pressed then buttons A or C can be

used, alternatively if button H is pressed then buttons G or I can be used, using this sequence

will allow the Powrtouch to redirect the caravan without stopping the forward or backward

motion.

Please note that the speed settings will always default to MAXIMUM – Speed changes

can only be made when the caravan is stationary.

2.7 DECREASING AND INCREASING SPEED

~ 8 ~

When the handset is first switched on the settings indicator window will always show an

illuminated green LED to the extreme right-hand side of the window and this is the default

position of maximum speed (100%). The speed can be decreased by pressing button J, each

time this button is pressed the speed will decrease by 25% and the green LED will move in the

window to indicate the speed setting selected. NB. The minimum speed setting is 25%. As the

speed decreases the torque decreases in the same ratio i.e. 50% speed is 50% torque. This

function of using a slow speed with lower torque setting is designed to maintain the

caravan/trailer’s manoeuvrability in very restricted and/or confined spaces.

If the Powrtouch in not at its maximum speed then the speed can be increased in 25%

increments by pressing button K. When changing the speed of the Powrtouch, the illuminated

green LED will move (a maximum four stages) from the left to the right of the meter; when the

LED is positioned at the extreme right of the display this indicates the Powrtouch has returned

to the maximum speed setting. The speed can only be changed when the caravan is not

moving.

2.8 PRECISION CONTROL OF THE CARAVAN USING THE ELECTRONIC SOFT START

FUNCTION

By utilising its very effective Electronic Soft Start System the Powrtouch Classic can easily

move the caravan a distance of 1mm at a time. This small movement can be achieved by

pressing and quickly releasing a direction button (stabbing the button), this facility makes

attaching the caravan to the tow ball of the car a very simple operation. Reducing the speed

will also give greater control of the caravan when using the soft start in this way. It is

recommended that a good practice session should be carried out on level ground and in an

open space before any difficult manoeuvres are undertaken.

~ 9 ~

2.9 RETRACTION OF THE ROLLERS FROM THE TYRES

ALWAYS ENSURE THE CARAVAN/TRAILER HANDBRAKE IS ON BEFORE

DISENGAGING THE ROLLERS FROM THE TYRES

Retraction of the Rollers Off the Tyres Using the Supplied Wrench

Always ensure that the handbrake is ON prior to removing the rollers away from the tyres. To

retract the rollers off the tyres locate the wrench onto the hexshaft (see picture above) and turn

in the direction shown, after 200 degrees the over locking cam system will lock the rollers away

from the tyres. The correct retraction start position for the wrench will be the opposite of the

engagement positions as shown in Section 2.5. Always take great care with this operation as

the return spring will remove the rollers with some force that can snatch the wrench from your

hand and damage the system. Your Powrtouch fitter or supplier will show you how to carry out

this operation safely.

If in doubt consult a qualified Powrtouch Engineer.

~ 10 ~

2.10 SWITCHING OFF THE UNIT

The handset does not need to be turned off manually except in the case of an emergency (See

Section 1 Paragraph 1.2). If the handset is left unused for 3 mins approximately it will

automatically turn itself off. However, once you have finished using the Powrtouch Classic

caravan mover, ensure the unit is switched OFF with the isolation switch and the key is

removed.

2.11 MAPPING (Tuning/Coding) INSTRUCTIONS – Given for Information ONLY

All electronics systems are supplied with the handset mapped (tuned/coded) to the ECB,

should you require to map or remap the system the sequence is as follows: Using the plastic

needle provided (attached under the hinged lid of the ECB) press the remap button through the

small hole (labelled ‘R’) in the lid of the box, this enables the control board to search for a

signal. Then switch on the handset, and it will transmit a welcome mapping signal to the

control board and the system will automatically code.

~ 11 ~

SECTION 3 – DIY FITTING INSTRUCTIONS

Key To Parts

1 – Left Hand Unit

2 – Right Hand Unit

3 – Electronics Control Box (ECB)

6 – Handset Lanyard

7 – Wrench

8 – Motor Wires

9 – Battery Wire Set

10 – Clamp Set

11 – Stop Blocks

12 – Isolator Switch With Key

13 – Spare Motor Crimps

15 – Screw Set

16 – Inter Shafts

17 – Powrbar Outer Sections

18 – Powrbar Centre Section

Centre Bar (not shown)

Side Covers

Electronics Handset

Fig 2. Pictures Showing

Component Parts

~ 12 ~

SECTION 3 – DIY FITTING INSTRUCTIONS

3.1 RECEIVING YOUR POWRTOUCH CLASSIC

When unpacking the box there is a checklist of the components for the mover. Please check

that all parts have been received before commencing the installation work (See Fig 2 showing

component parts). If in doubt, please contact a qualified Powrtouch Engineer. Contact details

are on the front page of this document.

3.2 TOOLING AND EQUIPMENT REQUIRED

To install the Powrtouch the following tooling and equipment will be required (not supplied):

• 10mm Socket & Ring Spanner

• 13mm Socket & Ring Spanner

• 17mm Socket & Ring Spanner

• Power Drill with 3mm & 10 mm Drill Bits suitable for wood

• 25mm Hole Saw for Plastic (for fitting isolation switch)

• Various Screwdrivers

• Multi-Purpose Silicone Sealant

• Lighting as necessary

• Trolley Jack or Axle Stands (for raising unit into position)

• Support Blocks, Wheel Chocks for Safety (to ensure the caravan cannot move

during the fitting operation)

• Torque Wrench

• Safety Goggles

3.3 INSTALLING THE POWRTOUCH CLASSIC

NB. – VERY IMPORTANT: BEFORE COMMENCING, PLEASE ENSURE THAT THE

CARAVAN IS DISCONNECTED FROM IT’S 12 VOLT D.C. LEISURE BATTERY SUPPLY

AND ANY OTHER ELECTRICAL SUPPLIES (INCLUDING 240 VOLT MAINS).

All electronic and electrical controls of the system are carried out by the Electronics Control

Box (ECB) and isolation switch; please note the ECB has an inbuilt safety thermal fuse (set at

90 deg C). Should this fuse operate it will automatically reset itself when the system cools to

an acceptable temperature.

The Isolation Switch must be accessible at all times when parking and moving the

caravan/trailer, please be aware of this when selecting the location for the switch (See Section

3 Paragraph 3.8).

Please check that the tyres are of the same size and design (preferably from the same

manufacturer) and not over worn (fitting to new or nearly new tyres is the best option). It should

be noted that as the caravan tyres wear, the roller to tyre gap will increase, this could allow the

Powrtouch rollers to slip when driving the tyres, should this occur, the Powrtouch will require

adjustment. Also ensure the tyre pressures are correct to the manufacturer’s recommendation

prior to commencing the fitting of a Powrtouch. Also check that the chassis is in good

condition without any damage and free from rust or corrosion etc.

Ensure that the handbrake is in the ON position before the caravan is raised using the front

steadies and Jockey Post/Wheel, the back steadies are then lowered to make sure the

caravan is fully stabilised and no forward or backward movement can occur.

All work MUST be carried out to ensure personal safety.

~ 13 ~

3.4 CHECKING THE CHASSIS DEPTH

The Powrtouch Classic is designed to fit on standard chassis depths of 209mm. If you have a

150mm chassis you will require drop plates & extra-long U Bolts.

3.5 SPECIAL MOUNTING PLATES

On some recently manufactured caravans (in particular Hymer) special mounting plates may

be required. These plates can be supplied (for a small additional cost) and are fitted by nuts

and bolts using pre-drilled holes in the chassis. Once these plates are fitted then the

mechanical assembly of the unit will proceed as detailed below.

3.6 MECHANICAL ASSEMBLY

For safety reasons it is recommended that the fitting of the Powrtouch Classic should

be undertaken on a flat hard standing. Before raising the caravan, ensure the handbrake is

on and then it can be raised as required (using trolley jack and/or axle stands) and secured in

position using the caravan steadying legs with supporting blocks and wheel wedges as

necessary; it is then helpful to lay down a ground sheet. Remove all items from the packaging

onto the protective sheet. Ensure both rollers are in the DISENGAGED position, as the unit will

not fit correctly otherwise. Loosely assemble the left-hand motor unit, right hand motor unit and

alignment tube and place under the caravan/trailer.

Wherever possible the Single Axle Powrtouch Classic should be fitted in front of the

caravan/trailer road wheels, if this is not possible then it is acceptable to fit the unit behind the

road wheels.

Using appropriate support blocks raise the loosely assembled unit into an approximate

position, fit the clamps and U-Bolts (see Fig 3) to the chassis (do not tighten at this point).

Adjust to the correct place using the 20mm wooden spacer provided between the tyre and the

drive roller (on each side of the trailer). Please note the wood spacer blocks should be a sliding

fit between the tyre and the coarse drive roller.

Also adjust the position of the drive rollers in relation to the tyres by sliding the motor units on

the alignment tube until the maximum amount of roller is in contact with the tyre tread without

any part of the unit fouling the tyre or chassis. It is advisable to leave a minimum 10mm gap

between the Powrtouch Classic unit and the inside wall of the tyre, this is to allow for the

expansion of the tyre when the rollers are engaged. Before tightening the u bolts to the

recommended 35 ft lbs tighten the alignment tube pinch bolts and lock nuts making sure the

alignment tube is approximately centralised; it is then advisable to check the roller / tyre gaps

again. The assembly should then be secured by tightening the u bolts to the recommended

torque of 35 ft lbs using a torque wrench.

Check both the above alignments at least once during the process and on completion.

Once the motor assemblies are completed the stop blocks should now be fitted on the chassis

in a position directly behind the Powrtouch clamping plates to ensure that the motor

assemblies do not slide along the chassis away from the tyres when the drive rollers are

engaged to the tyres (see Fig. 3). Once correctly positioned they can be tightened using the

locking bolt and nut with a torque wrench spanner set at 35 ft lbs.

~ 14 ~

FIG 3: CLAMP ASSEMBLY WITH STOP BLOCK

~ 15 ~

Powrbar Installation

The Powrbar installation kit, as detailed in Fig 2

Slide the inter shafts over the inner section of the engagement shafts

Tap the 5mm dia spirol pin through securing the shaft in place.

Slide the outer square sections into the centre Powrbar section and leave the pinch bolts loose

Span the caravan with the loosely assembled square sections and slide the ends over the

inter shafts.

Tighten all bolts and nuts to secure.

Be sure that the Powrbar or Centre Bar does not foul any other system, such as the

brake cables, water tanks etc.

~ 16 ~

3.7 ELECTRICAL ASSEMBLY

AGAIN - PLEASE ENSURE THAT THE BATTERY AND MAINS LEAD ARE BOTH

DISCONNECTED FROM THE CARAVAN BEFORE COMMENCING INSTALLATION.

NB. The terms right hand (UK Nearside) and left hand (UK Offside) referred to on the

electronics control box are determined by standing in front of the caravan (at the hitch) facing

the caravan.

The recommended site for the Electronics Control Box (ECB) is inside the caravan in the dry

(bedding) locker behind the battery box. The ECB should be screwed to the floor using the

screws provided. Please note some caravans have under floor cables and/or pipes,

checks must be made to ensure it is safe to drill. If safe to do so then drill four 10mm

diameter holes in the floor approximately 150mm from the control box for the motor wires to be

fed into the caravan. Start routing the wires from the motor, remembering to leave a small

amount of slack cable near the motors to allow for their movement when the drive rollers are

engaged. The motor wires (two each) can now to be routed along the underside of the caravan

floor using the P clips provided (securing of the cables can be made with a suitable staple gun

and the correct size staples – not provided). Care should be taken to ensure that the cabling is

securely fitted so that no chafing can occur and that it does not sag. Also ensure cables do not

make contact with the steel chassis (unless suitable cable clips are used – not provided). If the

Powrtouch is fitted in front of the wheels, then the ECB should be wired as shown below IN Fig

6A1.

Should the Powrtouch Classic be fitted behind the wheels then the motor wires for Motor 1

(LH) should be wired to M2 and the motor wires for Motor 2 (RH) should be wired to M1. The

polarity of M1 & M2 should be reversed from the positions shown in Fig 6A1.

~ 17 ~

~ 18 ~

~ 19 ~

Any excess motor cable should then be coiled up (secure with cable ties as necessary) in a

convenient position inside the caravan/trailer When coiling the motor cables please ensure that

the coils are kept as far away from the electronics box and aerial as possible. It is

recommended that motor cables should NOT be cut to ensure that: -

1) They are of equal length.

2) Should the Powrtouch Classic be removed and refitted to a new or different caravan

then the cables can easily be reused.

Please ensure the battery is in good condition (See Section 5 Paragraph 5.4), a fully charged

leisure battery MUST be used and can be either a lead acid or gel type (Please note that car

batteries are not suitable to operate Powrtouch Movers.) An 85-Ampere hour battery is

recommended for optimum operation of the Powrtouch Classic. Smaller batteries may be

utilised, but mover performance may be reduced. The aerial (thin black cable) should be let

through the caravan/trailer floor directly next to the ECB (drill a small 3mm hole as required)

and then run in a straight line away from the ECB and all motor cables. The aerial should be

clipped in place with the last 25mm (1 ins.) of the cable left dangling down. Under no

circumstances should the length of the aerial be changed either by cutting or extending by

splicing into it.

3.8 CONNECTING TO THE CARAVAN BATTERY

Please be aware of the need for access to the isolation switch when parking your

caravan/trailer. The switch should also be fitted to be in an accessible position whilst

the unit is in operation.

The Powrtouch is supplied with an inline switch which allows the isolation of the electrical

control box from the Battery. The suggested location for the fitting of this switch is in the sealed

side compartment within the battery box (see NOTE below), usually beneath the 240volt

mains connector. The reason for this location is to ensure that the Powrtouch isolation key will

obstruct the use of the 240-volt AC mains connector; under no circumstances should the

Powrtouch be operated while the caravan is connected to the 240volt AC supply. Drill a 25mm

hole with the hole-saw and the two 5mm clearance holes for the fixing nuts and bolts, when the

holes are drilled install the switch and tighten up the nuts and bolts.

The electronics control box & isolation switch & inline fuse MUST NOT be located in the

battery box or any compartments containing gas bottles. This is due to risk of explosion

caused by leaking gas and a spark generated by the electronics, isolation switch or

fuse.

The 10mm

battery cables are provided correctly terminated for their application and the length

of these cables must not be altered in any way. The battery cables have to pass through 10mm

dia. drilled holes in the battery box to gain access to the caravan.

(Cable 1) The negative battery cable, 1500mm Blue (Bare end – M6 ring terminal) is

connected directly from the negative terminal of the caravan battery to the negative terminal of

the ECB. NB. Starting from the non-terminated (bare end) this part of the cable must be

connected to the battery.

(Cable 2) The positive battery cable, 1000mm Brown (Bare end – M5 ring terminal) is used

to connect the positive terminal of the battery to one terminal of the inline fuse positioned in the

caravan. This fuse is provided to protect the ECB from overload or misuse. NB. Starting from

the non-terminated (bare end) this part of the cable must be connected to the battery.

(Cable 3) The 250mm Brown cable (M5 ring terminal – M8 ring terminal) connects the free

terminal of the inline fuse to a terminal of the isolation switch.

(Cable 4) The 750mm Brown cable (M8 ring terminal – M6 ring terminal) then connects the

second terminal of the isolation switch to the positive connection on the ECB. Once connected

these cables will then need to be securely fitted using the ‘P’ clips provided.

~ 20 ~

When making the connections to the battery it is recommended that connections are

made to the electronics and isolator switch before connecting to the battery. Please

ensure that their polarities are correct (Brown Cables to Positive and Blue Cables to

Negative). Should they be connected incorrectly then this will result in damage to the

electronics box.

All remaining cables can then be connected to the ECB ensuring that they are fitted in

accordance with Fig 6A1. The electrical assembly is now complete. Check the roller rotation

corresponds to the handset controls. Any hole(s) drilled for motor wires to access the caravan

should now be sealed with the silicon sealant to prevent ingress of damp or water. The

Powrtouch Classic side covers can now be fitted by securely pushing into place.

Fitting the Side Covers

1) Push the cover into position and then lock in place by turning the securing bolt clockwise.

2) Place the arrowed indicator over the hex shaft and push into position ensuring the arrow is

pointing to the ‘0’ position.

If you are unsure about the installation consult a Qualified Powrtouch Engineer

Telephone: 01283 587900

~ 21 ~

SECTION 4 – LOOKING AFTER YOUR POWRTOUCH

4.1 CLEANING THE POWRTOUCH CLASSIC

It is recommended that after your Powrtouch Classic has been fitted the mechanical assembly

would benefit from being sprayed with a light coating of wax oil (this could be repeated on an

annual basis) by doing this you will be giving the mover better protection from water and rust

and potentially prolonging its life well beyond its full 5-year guarantee. If necessary, it can be

washed with clean water but under no circumstance should a pressure washer be used on a

Powrtouch Classic system. We recommend that your Powrtouch is cleaned, and lubricated

with a motorcycle chain lubricant, or similar, once every 5 – 6 months. Please refer to our

website support pages for instructions.

4.2 CLEANING THE ROLLERS

Ensure that the rollers are kept clean; this can be undertaken by washing with a hard brush.

For safety reasons it is recommended that the isolation switch is turned off and the key

removed prior to cleaning the rollers.

Also check that no stones or other debris are trapped in any part of the mechanism.

SECTION 5 – GUARANTEE & FAULT FINDING

5.1 GUARANTEE

A NEW Powrtouch Classic is covered by a FIVE YEAR no quibble parts and labour guarantee.

(DIY fitting is a parts only 5 year guarantee.)

NB. IT IS AT THE COMPANY’S DISCRETION WHETHER THIS GUARANTEE IS

TRANSFERABLE TO A SECOND OWNER, AND A CHARGE WILL BE MADE FOR ANY

AGREED TRANSFER. PLEASE CONTACT POWRTOUCH SALES TEAM FOR FURTHER

INFORMATION.

NB. Our guarantee covers reasonable use of the mover, it does NOT cover damage caused by

misuse. The guarantee cannot cover any malfunction caused by the fitting of the mover if the

fitting has been done on a DIY basis or purchased from/fitted by a non-approved dealer or

agent. Any unauthorised modifications, use of non-original Powrtouch spare parts or failure to

respect the installation or operating instructions will render this guarantee null and void.

Powrtouch reserve the right to make a call out and/or repair charge for any work required to

be undertaken to rectify faults that are outside of the company’s control,

e.g. caravan battery failure, incorrect or poor fitting, misuse, accidental damage etc.

5.2 REPORTING A FAULT

ALWAYS ENSURE THAT YOUR BATTERY IS FULLY CHARGED AND IF YOU ARE IN

DOUBT ABOUT BATTERY STATUS USING THE BATTERY GAUGE ON YOUR CARAVAN

CHECK WITH THE VOLTAGE CHART SECTION 5 PARAGRAPH 5.4.

PLEASE PAY SPECIAL ATTENTION TO TESTING THE BATTERY UNDER LOAD.

TO CARRY OUT THESE CHECKS THE CARAVAN MUST BE DISCONNECTED FROM ITS

240 VOLT SUPPLY.

~ 22 ~

Before you call Powrtouch to report a fault you should have the serial number of your

Powrtouch available, as you will be asked for this information. It allows a Powrtouch Engineer

to locate the full manufacturing status of the mover and be able to advise you accordingly.

Also, before reporting a fault you are requested to check through the fault-finding list Section 5

Paragraph 5.5 to see if any of them can solve the problem. Failure to comply to this may result

in you be asked to carry out some of these tests, thus delaying action to repair if required.

5.3 ELECTRONICS CONTROL BOX - LED STATUS

LED Status Array in Use

Red

Light

Green

Light

Power Up Normal

OFF

Incoming Data Transmission

OFF

Awaiting Configuration

FLASH

Alternating

LED Status Array - Fault

Diagnosis

PCB Over Heat

FLASH

Low Caravan Battery Voltage

FLASH

Over Current on MOSFET Drive

FLASH

Together

5.4 CHECKING THE CHARGE STATUS OF A 12 VOLT BATTERY

APPROX CHARGE

STATE

VOLTMETER READING

(No Load)

HYDROMETER READING

100%

12.7 v or over

1.27

75%

12.5 v

1.23

50%

12.4 v

1.20

25%

12.2 v

1.17

Discharged

12.0 v

1.10

Please Note: Voltage readings should be taken at least 4 hours (and could be up to 12 hours

depending upon charging rates) after recharging to obtain an accurate reading.

The above figures are for the battery when under no load, if a battery is on the point of failing

or not fully charged then the only test that will determine this is to take the readings under

load (drop test). This can be achieved by using the Powrtouch mover with the rollers

engaged to the tyres and driving both rollers forwards or backwards, if the reading drops to

12 volts or less the safety cut out on the ECB will stop the Powrtouch to prevent damage to

the battery. However, this is an indication of insufficient battery voltage to drive the

Powrtouch caused by an under charged or failing battery.

PLEASE BEAR SAFETY IN MIND AND THAT BEING IN THE CARAVAN WATCHING THE

METER YOU DO NOT DAMAGE THE CARAVAN BY RUNNING INTO AN OBSTRUCTION.

The above voltages are accurate at 25 degrees centigrade. In temperatures less than this the

battery performance and output decreases by 1.25% per degree.

~ 23 ~

5.5 FAULT FINDING CHART

ADDITIONAL INFORMATION TO NOTE

1. To the best of our knowledge these instructions were accurate at the date of publication.

2. Wherever the Powrtouch Classic is fitted this should be done in accordance with the local

standards applicable to the installation of a remote-controlled caravan moving system.

Truma Limited

Powrtouch – a Truma brand

2000 Park Lane, Dove Valley Park, Foston, South Derbyshire, DE65 5BG United Kingdom

TELEPHONE: +44 (0)1283 587900 FAX: +44 (0)1283 587910

WEBSITE: www.powrtouch.com EMAIL: in[email protected]

TWITTER: www.twitter.com/powrtouchuk

Symptom of Fault

Possible Fault and Method of Correction

Unit fails to operate

Reset the ECB by turning off the isolation switch

and removing the key for at least 20 seconds and

then turning on again. The green light on the ECB

should be illuminated.

Unit fails to operate –

seems completely dead –

Red Light flashing on ECB

Over heating - remove isolation key and leave 20

minutes to see if the thermal fuse will reset itself,

RED LIGHT WILL STOP FLASHING and the ECB

should not feel hot.

Unit fails to operate –

seems completely dead

Check that the green light is illuminated on the

electronics if not check that the in-line fuse is not

broken and 12volts DC is getting to the ECB.

Unit fails to operate or

operates intermittently

Check the battery voltage of the handset is

correct at 9.5 volts. If the 2 rows of Red LED’s

flash, then this is a sign the handset battery is low

Unit fails to operate or

moves intermittently

Badly connected or corroded battery terminals,

check battery terminals are clean and connected

as required.

Unit fails to operate or

moves intermittently –

Green light flashing on ECB

Caravan battery low - check voltage of battery

(see battery voltages chart Section 5 Paragraph

5.4). Charge or renew caravan battery.

Caravan fails to move or

moves intermittently

Caravan battery low - with the rollers engaged

move the caravan and check the voltage drop on

the caravan battery meter. If this drops below 12

volts, it is advisable to have the battery tested by

an accredited supplier, then as necessary charge

or renew caravan battery.

Rollers slip on wheels

Disengage rollers from the tyres and the gap

should be 20mm approx. Also check the tyre

treads are not badly worn and the tyre pressures

are correct.

IF IN DOUBT CONSULT A POWRTOUCH ENGINEER - TEL: 01283 587900