Swift Owner's Handbook - Swift Group

SwiftOwner's Handbook

THE IDEAL COMBINATIONThe pleasures of caravanning startwith the caravan you choose and youcan’t make a better choice than Swift.The vehicle you use to tow yourcaravan is also a crucial factor. Heretoo Chartered Trust can help. Wehave a wide choice of motor financeprogrammes, each designed to meetthe varied needs of the private orbusiness motorist.So, when it comes to caravanning orjust motoring, Chartered Trust canprovide the ideal combination.Written quotations available on request.24-26 Newport Road, Cardiff CF2 1SRTelephone: (01222) 296863

IntroductionINTRODUCTIONDEAR OWNER,THANK YOU FOR DECIDING TO BUY ONEOF OUR NEW CARAVANS. WE ARE SUREYOU WILL ENJOY MANY HAPPY HOURSIN IT AND WE HOPE THE INFORMATIONAND HINTS IN THIS HANDBOOK WILLHEIGHTEN YOUR ENJOYMENT.THE HANDBOOK HAS BEEN DESIGNEDTO GIVE YOU A GENERAL GUIDE TO THECARE, USE AND MAINTENANCE OF YOURCARAVAN. WHETHER YOU ARE A NEW ORAN EXPERIENCED CARAVANNER THEHINTS WILL HELP TO PROTECT YOURINVESTMENT.THE INFORMATION CONTAINED WILLANSWER MOST OF YOUR QUERIES, BUTIF THERE ARE ANY ASPECTS WHICH ARENOT COVERED PLEASE CONSULT YOURAPPOINTED DEALER.HAPPY CARAVANNING!

The Towing CodeSafety and SecurityServicesElectrical EquipmentFitted EquipmentCONTENTSMaintenanceGeneral Data

THETOWINGCODEThe Caravan Towing Code ...................................................... 2Scope of the Code ................................................................. 2Caravan Terms .......................................................................... 2Weights .................................................................................. 2Towing Vehicle Terms .............................................................. 3Weights .................................................................................. 3Measurement of Noseweight .................................................. 4Type of Driving Licence Held ....................................................4Glossary & Checklist ................................................................ 4Preparing for the Road ............................................................ 6Checklist ................................................................................ 6Loading & Distribution ........................................................... 7Stability .................................................................................. 8Pre-tow Checklist ................................................................. 10Pulling Off ............................................................................... 13Reversing ................................................................................ 13Speed Limits ........................................................................... 13Caravan Handling ................................................................... 13Motorway Driving ................................................................... 13Changing a Wheel .................................................................. 13Jacking Points ........................................................................ 14Stopping on a Hill ................................................................... 14Arrival on Site ......................................................................... 15

The Towing CodeTHE CARAVAN TOWING CODEThis Code of Practice containsrecommendations jointly reviewed andagreed by the following organisations:The National Caravan CouncilThe Caravan ClubThe Camping and Caravanning ClubThe Caravan Writers GuildThe Department of TransportScope of the CodeThe Code applies to all trailer caravans ofmaximum laden weight not exceeding3500 kg (7,700 lbs), overall width notexceeding 2.3m (7ft 6in approximately) andoverall length not exceeding 7m (23ftapproximately), excluding the drawbar andcoupling.This is legally the maximum size of trailerthat can be towed by a motor vehicle with amaximum gross weight of less than 3500 kg.CARAVAN TERMSMass in Running Order:The mass of the caravan as stated by thecaravan manufacturer, as new with standardfixtures and fittings.Note: Because of differences in the weightof materials supplied for the construction ofcaravans, a tolerance of +3% of the weighthas been allowed in the Mass in RunningOrder weight.2User Payload:The maximum allowable weight to be putinto the caravan whilst it is being towed. Thisis made up of 3 sections:Personal effects, optional equipment andessential habitation equipment.The user payload is the difference betweenthe Maximum Technically Permissible LadenMass and the Mass in Running Order.Essential Habitation Equipment:Those items and fluids required for safe andproper functioning of the equipment forhabitation as defined by manufacturer of thecaravan.Personal Effects:Those items which a user can choose tocarry in a caravan and which are notincluded as Essential Habitation Equipmentor Optional equipment.Optional EquipmentItems made available by the manufacturerover and above the standard specification ofthe caravan.Maximum Technically Permissible LadenMass:The maximum weight for which the caravanis designed for normal use when beingtowed on a road, laden. This should not beexceeded. This mass takes into accountspecific operating conditions includingfactors such as the strength of materials,loading capacity of tyres etc.Nose weight:That part of the static mass of the caravansupported by the towing device on the rearof the towing vehicle.Notes:(i) When measuring the noseweight it isimportant that the caravan is fullyloaded. Do not place extra itemsindiscriminately into the caravan afterthis adjustment has been made.(ii) The caravan is intended to be towedslightly nose heavy. The nose weightcan be adjusted by distribution of theload within the caravan. The noseweight should be approximately 7% ofthe actual laden weight (but not greaterthan the hitch capacity) and at the sametime suit the towing vehicle. See sectionon Measurement of Nose Weight.(iii) It is not recommended that you tow withjust a battery, spare wheel and gasbottles as this may exceed the thepermitted nose weight. Additionalpayload must be placed behind the axleto compensate for this or considerrepositioning the wheel to a underfloorcarrier.

The Towing CodeTOWING VEHICLE TERMSKerb weight (Mass of Vehicle in RunningOrder):The weight of the towing vehicle as definedby the vehicle manufacturer. This is normallywith a full tank of fuel, with an adequatesupply of liquids incidental to the vehiclespropulsion, without driver or passengers,wihout any load except loose tools andequipment with which the vehicle is normallyprovided and without any towing bracket.Caravan to Towing Vehicle Weight Ratio:The towing vehicle to caravan weight ratiocan be determined by calculation and isequal to:actual laden weight of caravanx 100%Kerb weight of towing vehicleTHE LAW REQUIRES THAT CARAVANS &THEIR TOWING VEHICLES & THE LOADSTHEY CARRY MUST BE IN SUCH ACONDITION THAT NO DANGER ORNUISANCE IS CAUSED.(Regulation 100 of the Road and Vehicles[Construction and Use] Regulations 1986).Power to weight ratio:No hard and fast rules can be stated but,here is a general guide.(a) Conventional petrol engines with acapacity up to approximately 1500 ccshould be adequate for towing aYES85%Fig. A Car/Caravan Weight Ratioscaravan weighing around 85% of thekerb weight of the towing vehicle.(b) Above 1500 cc such engines shouldmanage a caravan weighing up to 100%of the kerb weight of the towing vehicleand still give adequate performance.MAYBENote: The towing vehicle manufacturer’s limitis, in some cases, less than the kerb weight.Vehicles with automatic transmission mayneed an oil cooler fitting or the SAE rating ofthe gearbox oil increasing when towing. Theadvice of the vehicle manufacturer should besought.Mass in Running Order:Caravanners can use a public weighbridge toestablish the mass in running order.EQUALNONote: Weighbridges have varying weighttolerance levels.Maximum Permissible Towing Mass:The weight defined by the vehiclemanufacturer as being the maximum thatthe vehicle is designed to tow.Train Weight (Combination Weight):The maximum combined weight of thetowing vehicle and trailer conbination asspecified by the towing vehicle manufacturer.3

The Towing CodeMEASUREMENT OF NOSEWEIGHTNoseweight may be measured using apropriety brand of noseweight indicator.Such equipment is obtainable at yourCaravan Dealer.Note: These indicators have a varyingtolerance level.Another simple method is to use bathroomscales under the coupling head with a pieceof wood, fitted between the coupling headand the scales, of such length that thecaravan floor is horizontal with the jockeywheel raised clear of the ground. (Fig. A)Noseweight can be adjusted simply bydistribution of weights in the caravan. Always4Fig. A Measuring Noseweightlower jockey wheel before entering thecaravan and then raise before measuringagain. (See Loading).Note: The height of the towball on thetowing vehicle, when laden, is also critical.TYPE OF DRIVING LICENCEHELDIn order to be able to tow a caravan a drivermust hold a Category B licence. Those cardrivers who passed their tests prior to 1January 1997 would have automaticallyobtained Category B+E. However, anyonewho passed their test after 1 january 1997will need to take a further test in order toobtain a Category B+E if they wish to tow acar and caravan combination whose trainweight exceeds 3,500kg, or up to 4,250 ifthe caravan is less than 750kg or if thecaravan’s Maximum Technically PermissibleLaden Mass exceeds the unladen weight ofthe car.Note: The unladen weight of a car isnormally less than the kerbside weight.GLOSSARY & CHECKLISTAwnings - Can consist of just a simple topsheet but may extend to a five sided frametent attached to the side of the caravan.Fire blanket - approved to BS 6575 is idealfor dealing with ‘fat pan’ fires.Fire extinguisher - It is stronglyrecommended that a fire extinguisher iscarried in the caravan. (For suitable typessee Safety and Security).Gas bottles - Bottled L.P. gas is the mostconvenient portable source of fuel. Twobottles are required for a constant supply. Aninitial deposit is payable on each cylinder.We recommend the use of 6kg Propane or7kg Butane bottles. One position for use andone for storage only. (For detailedinformation see Services - Gas).Jack - A suitable jack is essential (screw,scissor, side mounted or air jack type). Manycar jacks are unsuitable.Levellers - Levellers help level the caravanfrom side to side before unhitching.Proprietary products can be purchased fromyour caravan dealer and need to bepositioned as indicated by a spirit level.Spare Wheel - It is always advisable to carrya spare wheel for your caravan.Spirit Level -A spirit level is extremely usefulwhen siting the caravan.Stabiliser -Stabilisers help to dampen theside to side movement of the caravan. Oneend fits to the car’s towing bracket and theother end to the caravan. (See Stability)

The Towing CodeTorque Wrench - A torque wrench is theonly way that the exact recommendedtorque can be achieved for wheel nuts andbolts. (See Preparing for the Road)Towing bracket - Car manufacturersrecommend that their own bracket is fitted ata specialist dealer, to ensure that it is fixedto the correct mounting points. Never usecheap alternatives, obtain one manufacturedby a reputable company complying with therelevant standards.Wooden blocks - Wooden blocks typically25cm. square and 2cm. thick are ideal forplacing under corner steadies and jockeywheel when the ground is uneven or soft.Water Containers - Two containers arerequired, one to carry fresh water to thecaravan and one for waste water, whichneeds to be disposed of properly. Severaltypes are available including jerry cans,folding cans and wheeled containers.12N & 12S Sockets - Two socketsdesignated 12N and 12S are fitted to yourcar to accept corresponding plugs from thecaravan. These are necessary to energisethe road lights and caravan auxiliary circuitsrespectively.12 Volt Battery - A deep cycling, heavy dutyleisure type battery should be purchased toprovide back-up power for lights, refrigeratorand other electrical appliances. (SeeBattery).WARNING: Your caravan dealer shouldbe consulted if additional equipment isto be fitted as strong points may or maynot be provided in the design.Note: Fitting additional equipment willreduce the caravan allowable payload.Caution should also be exercised aselectrical cables may be damaged and couldpose a hazard.5

The Towing CodeUseful memory aid for other items.CarDistilled waterExternal mirrorsFan beltFire extinguisherJackJump leadsPetrol canSocket setSpare bulbsSpare keysSpare wheelTool kitTowball coverTow ropeTyre pressure gaugeWarning triangleTyre PumpCaravanAwning pegs and polesAwning ground sheetBattery 12 volt chargerBucketCorner steady braceCorner steady padsCoupling lockDoor matFire blanketFire extinguisherFresh water containerGas cylinderGas regulatorJackLevelling boardsMalletSite/caravan mains leadSpare bulbs(Mandatory in E.C.)Spare 12v fusesSpare gas hoseSpare wheelSpirit levelToilet fluidWaste water containerWheel bracePersonalAfter sun creamFirst Aid KitFlannelsHairbrush and combMake up. etc.RaincoatsToothbrushToothpasteScissorsShampooShaving kitShoe cleaning kitSoapSun tan oilWellington bootsDomesticAdhesive tapeAir freshenerAluminium foilAshtraysBin linersBinocularsBottle openerBreadboardBreadbinBrush and dustpanButter dishCamera and filmsCarving knifeCassette recorderChairsClockClothes brushClothes lineCoat hangersCoffee percolatorCoolboxColanderCrockeryCruetCorkscrewCutleryDish cloth and brushDusters and polishDisposable clothsEgg cupsElectrical extension leadFloor clothFly sprayFoodFood mixerFrying panGlassesGrill panJugsKettleKitchen rollKitchen toolsLitter binMatchesMeasuring jugMilk jugMixing bowlNeedles and threadOven glovesPegsPiezo Gas lighterPotato peelerPressure cookerRadioRubbish binSalad shakerSaucepansScissorsSieveSugar bowlShopping bagsSleeping bagsTea potTea strainerTea towelsTable clothsTable matsTelevisionTin openerTissuesToilet paperTorchTowelsToys & GamesVacuum cleanerWashing up bowlDocumentsBail Bonds(some Euro countries)Bank and credit cardsCaravan CertificateCheque bookCRIS documentDriving licenceGreen Card Insurance(some Euro countries)Maps and guidesMoneyMOT CertificateVehicle RegistrationDocuments6

PREPARING FOR THE ROADPRE-LOAD CHECKLISTCaution: Never enter the caravan withoutfirst lowering the four corner steadies withthe brace provided.BEFORE LOADING CHECK:- loose articles are stowed securely. Do notstow tins, bottles or heavy items inoverhead lockers prior to towing.- all lockers and cupboard doors areclosed and secured.- all bunks are secure.- all rooflights are closed and secured.- main table is stored in its transit position.- fridge is on 12v operation and door lockis set.- all windows are fully closed and latched.Never tow with windows on nightsetting.Leave all curtains and blinds open to aidrear visibility.- gas cylinders are correctly positioned,secured and turned off.- battery is secure and mains connectingcable is disconnected and stowed.- 12v distribution panel selector switch isset to centre position.WARNING: Isolate all gas appliancesbefore setting off.(a)(c)Fig. A Loading your caravanLOADING AND DISTRIBUTION OFWEIGHT IN THE CARAVANDo not exceed recommended maximumloading for your caravan.1. Load heavy items low down near thefloor and mainly over or just in front ofthe axle(s) (Fig. A).2. Load evenly right to left so that eachcaravan wheel carries approximately thesame weight.3. Do not load items at the extreme front orrear since this can lead to instability dueto the ‘pendulum effect’.4. Load remainder to give a suitablenoseweight at the towing coupling.Check noseweight.(b)(d)The Towing CodeNote: Do not overload car boot.Note: Please take care to ensure that youhave allowed for the masses of all items youintend to carry in the caravan7

The Towing CodeSensible Loading:How to apportion itFig. ALIGHTITEMSMEDIUMITEMSHEAVYITEMSFig. B Illustration of excessive deflection of vehicle’s rear suspensionTowing vehicle’s rear suspensionIt is important that the towing vehicle’s rearsuspension is not deflected excessively bythe noseweight on the tow ball. If it isexcessive the steering and stability will beaffected. (Fig. B)The greater the towing vehicle’s tail overhang(the distance between the rear axle and thetow ball) the greater the effect thenoseweight will have on the towing vehicle’srear suspension.After trying out the caravan it may be foundthat stiffening of the rear suspension isnecessary - but note that this may give thetowing vehicle a firmer ride when not towing.8There are a number of suspension aidsavailable and advice should be sought onwhich to use and how to fit. It is important toensure that the caravan is towed either levelor slightly nose down.If you have any doubts about the suitabilityof your towbar for towing a twin axle caravanconsult the towing bracket manufacturer.DO NOT exceed the:• Gross Vehicle Mass (G.V.M. on car plate).• Maximum Technically Permissible LadenMass (M.T.P.L.M.).• Gross Vehicle Combination Mass(Train Weight) (G.V.C.M. on car plate).• Maximum Permissible Towing Mass.STABILITYAll our models are of a well balanced designand should be exceptionally good towers.The most common causes of poor stabilityinclude:(a) Worn springs or loose spring fixings onthe towing vehicle.(b) Towing vehicle springs too soft.(c) Insufficient noseweight.(d) Nose of caravan is towing too high.Galvanised steel chassisDrilling of the galvanised steel chassis willinvalidate the warranty. If fixing a towing aid,in the first instance consult your dealer asregards suitability.

Never drill the coupling head to aid the fittingof a stabiliser.Suitable towing vehiclesThe caravan is manufactured for towingbehind normal road cars and is not suitablefor towing behind commercial vehicles. It isstrongly recommended that whenever acaravan is to be towed over rough terrain,e.g. a farmer’s field or track, great careshould be taken to ensure that no unduestress is placed upon the caravan via thehitch mounting, i.e. reduce speed. If indoubt, please consult the caravan manufacturerand the towing vehicle manufacturerwho will advise on the most appropriateshock absorbing hitch mounting.SnakingThis is a term used to denote an unstablecar and caravan combination where thecaravan ‘weaves’ from side to side oftencausing a similar swaying movement in thecar itself.Causes:i) Unsuitable or unbalanced outfit.ii) Incorrect loading or weight distribution.iii) Excessive speed especially downhill.iv) Side winds.v) Overtaking.vi)Being overtaken by a large fast movingvehicle.vii) Erratic driving.viii) Insufficient tyre pressures.ix) Mixing radial and cross ply tyres.Cures:Cases of persistent snaking can bealleviated by the use of a stabiliser, aboutwhich your dealer will advise you.On the roadIf you do find your outfit snaking, try to keepthe steering wheel in a central position as faras possible, decelerate and avoid braking ifpossible.OTHER IMPORTANT TOWINGCONSIDERATIONS THAT COULD AFFECTSTABILITYTypes of tyres fittedThe tyres fitted by the manufacturer aresuitable for towing at sustained speeds of upto 81 mph (130 kph).Radial and cross ply tyres should never bemixed. It is dangerous and can causesnaking.Periodically tyres should be rotated toequalise wear in the same manner as cartyres.Do not mix four ply/six ply/eight ply tyres onthe same axle.The Towing CodeTyre TreadThe law requires that tyres and pressuresmust be suitable for the use to which theyare being put. The minimum tread depth ofboth car and caravan tyres must be 1.6mmthroughout a continuous band comprisingthe central three quarters of the breadth oftread and around the entire circumference ofthe tyre.Tyre pressuresTowing vehicles’ tyres must be at thepressures recommended for towing or heavyloading as stated in handbook not on tyrewall. Towing stability may otherwise beaffected. The pressures can be found in thetowing vehicle handbook. The caravan tyrepressures should be as recommended in thespecification details in your handbook.Note: Although the caravan may be fittedwith the same type of tyre as the towingvehicle, the pressures specified are different.All charts show values for cars and aretherefore not applicable for caravans.Pressures displayed on tyre walls applyONLY in North America and Canada.WheelsCaravan wheel nuts should be tightened to atorque of 88Nm (65lb/ft) on steel wheels or115Nm (85lb/ft) on alloy wheels and shouldbe checked with the use of a torque wrenchregularly. Only use a spare wheel and tyrerecommended by the manufacturer.9

The Towing CodeWheel RimsThe majority of caravans manufactured since1993 have been fitted with steel wheel rimswhich are the wider 5J size incorporating adouble safety hump rim which conforms toEuropean standards of safety. The alternativeto steel wheel rims are alloy wheel rims.If you are in any doubt, have your wheelschecked by a competent tyre supplier.Hitch head load capacityThe maximum vertical static load which canbe put upon the hitch head when connectedis either 75kg or 100kg. Please refer to thetechnical data in your handbook.(But see also vehicle manufacturer’s weightlimits on towball loading.)PRE-TOW CHECKLIST AND HITCH-UPCheck Gas Locker, Battery Locker (if fitted)and Cassette Toilet (if fitted) door/s aresecure.Check wheelnuts, tyre pressures and tyreconditions.Fully raise all four corner steadies. (Fig. A).Pick up any levelling pads or levellingboards.Check rooflights/vents are securely closed.Switch off gas supply and change over toelectricity if required.Lock the caravan exterior door.Fig. A Winding Corner SteadyAn assistant can help in the hitchingoperation by standing on the left hand sideof the drawbar (facing rear of car) andextending an arm horizontally to indicateposition of the coupling. When reversing aimthe towball of the car directly at the caravandrawbar. Remove towball cover and keep incar.Adjust the jockey wheel to ensure the cup ishigh enough to slide over the towball.Release caravan handbrake.Position cup over greased towball, releasesafety catch and lift handle (Fig. B). The hitchhead is fitted with a visual indicator to showwhether or not it is properly connected to thetowball. A green band will show immediatelyFig. B Safety Catch and Handlebelow the red indicator button on the hitchhead when a proper connection has beenmade. (See Fig. D, Page 11)WARNING: Serious damage will occurunless the locking button is depressedfirst and the handle lifted forward beforethe caravan is lowered manually. Thisprevents the noseweight beingtransmitted through the locking button.WARNING: If the green band is showingwhen the hitch head is not connectedto the towball there is a fault - contactyour Dealer.10

The Towing CodeFig. A HandbrakeFig. B Checking Secure AttachmentFig. C Connections - 7 pin PlugAdjust jockey wheel to lower cup on to theball. A click indicates it is fully engaged. Ensurelocking button has returned to its free position.Secure caravan handbrake. (Fig. A)Connect breakaway cable (emergencybraking device) in the form of a noose tosuitable anchorage point on towbar. DO NOTattach to towball.Ensure that the jockey wheel is fully woundup and properly located in the slots, thenrelease the clamp handle, lift the whole unitas high as possible and retighten the clamphandle.Note: Ensure jockey wheel locates in recessprovided.Take hold of the caravan under the rubbergaiter behind the coupling and lift toascertain whether the caravan is properlyattached. (Figs. B & D.)Lock hitch if possible (see Safety andSecurity, page 20).Connect 7 pin plugs to car sockets ensuringthere is enough loose cable for cornering.(Fig. C)Check all car and caravan roadlights areworking. Check round the caravan foranything left behind.Release caravan handbrake, adjust allmirrors from driving seat and proceed.Fig. D Hitch Head Visual Indicator11

The Towing Code1212N AND 12S VIEWED FROM REAR OF PLUG12N (BLACK)TERMINAL COLOUR 12N PLUG1 YELLOW L/H INDICATOR2 BLUE REAR FOG LAMP3 WHITE COMMON RETURN (1-7)4 GREEN R/H INDICATOR5 BROWN R/H SIDE TAIL & No PLATE LIGHT6 RED STOP LAMP7 BLACK L/H SIDE TAIL & No PLATE LIGHT12S (GREY)TERMINAL COLOUR 12S PLUG1 YELLOW REVERSING LIGHT2 BLUE NO ALLOCATION3 WHITE NEGATIVE PIN 44 GREEN CONTINUOUS POWER SUPPLY5 BROWN NO ALLOCATION6 RED FRIDGE7 BLACK RETURN FOR FRIDGEVOLTA/JEAGER & MULTICON FEDER 13 PIN PLUGS (viewed from rear)VOLTA/JEAGERPIN NO COLOUR DESCRIPTION1 YELLOW LEFT FLASHER2 BLUE FOG HAZARD LIGHT3 WHITE EARTH FOR 1-84 GREEN RIGHT FLASHER5 BROWN RIGHT TAIL LIGHT6 RED STOP LIGHTS7 BLACK LEFT TAIL LIGHT8 ORANGE REVERSE LIGHTS9 BROWN/BLUE CAR +10 BROWN/RED FRIDGE11 WHITE/BLACK EARTH FOR 1012 NOT YET ALLOCATED13 WHITE/GREEN EARTH FOR 9WESTMULTICONFEDER 13KTUBESPINSPINSSTRIPSPIN NO COLOUR DESCRIPTION1 YELLOW LEFT FLASHER2 BLUE FOG HAZARD LIGHT3 WHITE EARTH FOR 1-84 GREEN RIGHT FLASHER5 BROWN RIGHT TAIL LIGHT6 RED STOP LIGHTS7 BLACK LEFT TAIL LIGHT8 ORANGE REVERSE LIGHTS9 BROWN/BLUE CAR +10 BROWN/RED FRIDGE11 WHITE/BLACK EARTH FOR 1012 NOT YET ALLOCATED13 WHITE/GREEN EARTH FOR 9ROAD LIGHTINGFor your information the wiring diagram of the12N and 12S connectors is shown opposite.These should be checked regularly and if inany doubt a qualified electrician consulted.Some European cars may be equipped withVolta, Jeager, West or multi-con sockets, anadaptor or replacement sockets may berequired. If so consult your dealer or qualifiedelectrician.The wiring allocations were changed in 1998and it is important that you check the car tocaravan connections are compatible prior tocoupling up to the car.WARNING: Always disconnect theelectrical connector between the towingvehicle and the caravan beforeconnecting a low voltage supply to thecaravan (mains) and before charging thebattery (EN 1648-1).PASSENGERSPassengers are forbidden to ride in a caravanwith the exception of authorised test personnel.BRAKES/BREAKAWAY CABLEA breakaway cable is required for caravansand the device must be such that the caravanstops automatically if the coupling breaks(Regulation 15 of the Road Vehicles[Construction and Use] Regulations 1986).Always ensure that the breakaway cable isconnected to the towing vehicle, not to thetowball.

The Towing CodeMIRRORSThe driver of the towing vehicle must have anadequate view of the rear.If there is no rear view through the caravan itis essential that additional exterior towingmirrors are fitted. This is mandatory is someEuropean countries and drivers can faceinstant fines if extension mirrors are not fitted.Caution: Any rear view mirror must notproject more than 200 mm outside:a) the width of the caravan when beingtowed.b) the width of the towing vehicle whendriven solo.Note: Any rear view mirror fitted shall be ‘e’marked and cover the field of view asstipulated by type approval requirements(Regulation 33 of the Road Vehicles[Construction and Use] Regulation 1986).PULLING OFFLet the clutch in smoothly.Allow more engine speed to produce thepower to move the additional weight of thecaravan.Reduce wear and tear on clutch andtransmission by taking extra care.Change gears smoothly.Try not to jerk the clutch.Fig. A ReversingREVERSINGProficiency at reversing can only be achievedwith practice and should be first attemptedin a large open area (Fig. A).SPEED LIMITSNormal road towing: 50mphMotorways (including dual carriageways):60mphCARAVAN HANDLINGAllow for caravan being wider than car.Do not bump kerb with caravan wheels.When passing other vehicles allow more thanthe normal clearance for driving solo.Allow longer to get up speed to pass.Allow for the outfit being twice its normallength.Do not suddenly swing out.Carry out all manoeuvres as smoothly aspossible.Use nearside wing mirror to check caravanhas cleared when overtaking.IMPORTANT POINTS ESPECIALLYFOR MOTORWAY DRIVING1. Caravans may not be towed in the outsidelane of a three or four lane motorway.(Reg. 12(2) of the Motorway Traffic[England and Wales] Regulations 1982).13

The Towing Code2. Reduce Speed:i) In high or cross winds.ii) Downhill.iii) In poor visibility.3. High sided vehicles cause air buffeting soextra care must be taken when passing orbeing passed. As much space aspossible should be given.CHANGING A WHEEL1. Leave caravan hitched to towing vehicleand ensure handbrake is applied.2. Lower corner steadies (as safetymeasure) on the side that the wheel isbeing changed to stabilise the caravan.3. Use wheel brace to slacken off wheelnuts on the wheel to be changed.4. Position jack under the axle at theappropriate jacking point (see fig. B) or inthe side jack socket (see fig. C).5. Jack up the caravan until the wheel forremoval is just off the ground.6. Remove the wheel nuts, wheel trims andremove the wheel.7. Fit spare wheel and reverse the aboveprocedure.8. Tighten all four nuts, according to Fig. A,to 88Nm (65lb/ft) for steel wheels or115Nm (85lb/ft) for alloy wheels using atorque wrench or have checked as soonas possible.14Fig. A Wheel Nut TighteningIMPORTANTWhen a wheel has been removed andreplaced the torque of the wheel nuts shouldbe re-checked after approximately 15 milesof running. (See 8 above).JACKING POINTSScissor JackWARNING: Only jack up your caravanwhen it is coupled up to the car with itshandbrake applied and in 1st gear(engine off).Ensure that the jack is located in the correctposition, i.e. on the axle tube inside thechassis member (Fig. B). The reinforced axlemounting plate can be used as an alternativebut the chassis member itself MUST NEVERbe used as a jacking point.AxleChassisFig. B Jacking PointAll caravans are provided with the facility tofit Al-Ko side jacking points and although ascissor or bottle jack may be used, it isrecommended that the side mounted Al-KoJacking System should be used.STOPPING ON A HILLPulling off again can sometimes present aproblem. The easy solution is(i) Carry a good sized wedge shaped pieceof wood with a rope or light chainattached.(ii) Attach the other end of the rope to thenearside rear grab handle.(iii) Place the wood behind the nearsidecaravan wheel.

The Towing CodeFig. C Al-Ko Side Jack(iv) Carefully reverse the car slightly backdown the hill, the caravan will stopagainst the wedge and turn.(v) Drive forward since this attempt to moveup the hill will now not involve pulling thefull weight of the caravan until the car hasgained some traction.ARRIVAL ON SITENote: Check and observe site regulations.1. Selecting a pitchDo not pitch in such a position that youroutfit will obstruct others coming in.Try to choose an area which is dry, reasonablylevel and preferably with a hard base.If you have no alternative but to pitch on aslope ensure that, for when you leave, youFig. D levelling Boardare facing down the slope.It is good practice to chock the wheels ofthe caravan when parked on a slope eventhough the caravan brakes are applied.2. Levelling the caravanLevelling must be carried out in bothdirections in order for the refrigerator andother equipment to function correctly. Thisshould be done before unhitching thecaravan. Levelling boards (Fig. D) can beused to raise one side of the caravan bydriving or reversing the caravan onto theboards. Apply the handbrake and chock thewheels.The positioning of the jockey wheel can beused to help level the caravan.Lower the corner steadies until they are infirm contact with the ground. DO NOT usethe steadies as a jack they are only a meansof stabilising the caravan.Levelling pads or boards should be usedunder the steadies where the ground is softor uneven.In extreme cases where it is necessary toraise a wheel off the ground for levellingpurposes, further adequate support shouldbe applied so that the steadies do not takeany undue strain.Exterior DoorTo prevent distortion of the body, the caravanmust be always correctly sited and levelled.Failure to site the caravan correctly mayprevent the exterior door from closingproperly.3. UnhitchingApply the caravan handbrake.Lower the jockey wheel to the ground.Disconnect the breakaway cable and roadlighting plugs.Operate the handle by depressing the lockingbutton on the lever mechanism and lift thehandle upwards and forwards, at the sametime winding down the jockey wheel, toassist in lifting the caravan clear of thetowing vehicle.When this operation is complete, replacetowball cover.Park your vehicle alongside the caravan onthe offside.15

SAFETYANDSECURITYFire .......................................................................................... 18Notice ................................................................................... 18In Case of Fire ...................................................................... 18Dicon 300AP Smoke Alarm....................................................18Smoke Alarm......................................................................... 18Fire Extinguishers.................................................................. 19Children ................................................................................... 19Ventilation .............................................................................. 19Security ................................................................................... 20Caravan Theft ....................................................................... 20Chassis Number.................................................................... 20Additional Security ............................................................... 20Security Chips....................................................................... 20

Safety & SecurityFIREImportant: Your attention is drawn to thenotice affixed inside the caravan advising onfire precaution, ventilation and what to do incase of fire.IN CASE OF FIRE1. Get everyone out of the caravan asquickly as possible using whichever exit isthe quickest, including windows. Do notstop to collect any personal items.2. Raise the Alarm. Call the Fire Brigade.3. Turn off the gas supply valve if it is safe todo so.4. Turn off the electricity supply at supplypoint.DICON 300AP SMOKE ALARMThis smoke alarm is approved for use incaravans and mobile homes. (Fig. A)The National Caravan Council requires thatall new or used caravans sold by itsmembers be fitted with a smoke alarmfeaturing an alarm silence facility.FEATURES• Battery operated. No need for mainspower wiring.• Operating Light (LED)Flashes approximately every 45 secondsconfirming unit is powered.18Fig. A Smoke Alarm• Low Battery WarningUnit “beeps” approximately every 45seconds for up to 30 days when thebattery needs replacing.• Sensitivity Test ButtonTest sensitivity, circuitry, battery and horn.• Loud 85 Decibel Piezo Electric AlarmAutomatically resets when hazardouscondition has passed.• Precise Sensitivity• High Quality Solid State ComponentsCONNECTING THE BATTERYYour alarm requires one 9 volt battery topower the smoke detector portion of theunit. Under normal use the battery poweringthe smoke detector should lastapproximately one year.WARNING: Ensure that batteries arecorrectly installed. Positive terminal topositive contact (marked +), negativeterminal to negative contact. Reversinga battery in its compartment willimmediately drain the battery andcould damage the smoke alarm.HOW TO TESTPress test button until alarm sounds, thenrelease. Repeat test weekly.Note: Always test smoke alarm operationafter vehicle has been in storage, before eachtrip and at least once per week during use.

WARNING: The electronic test buttonprovides a full test of the unit’sfunctionality. DO NOT try to test thealarm with a naked flame, as this maypresent a potential fire hazard.FALSE ALARMSAbnormal air conditions may cause thehighly sensitive smoke alarm to give a“false” alarm. DO NOT DISCONNECT THEBATTERIES. If no fire is apparent, ventilatethe caravan and/or blow fresh air into theunit until the alarm stops. Once cleared thesmoke alarm will automatically reset.MAINTENANCEDust can lead to excess sensitivity thereforeit is recommended that the unit bevacuumed every 6 months to help keep theunit working efficiently.Open cover and gently vacuum interior ofdetector trying to keep the nozzle fromtouching the unit.WARNING: Never use portable cookingor heating equipment other than electricheaters that are not of the direct radianttype, as it is a fire and asphyxiationhazzard.FIRE EXTINGUISHERIt is recommended that a 1kg (2lb) minimumcapacity dry powder fire extinguisher becarried inside your caravan at all times.When using a dry powder extinguisher it issuggested that the caravan be evacuateduntil the powder has settled, to avoidinhalation.A fat pan fire should not have a fireextinguisher aimed at it. It should besmothered with a fire blanket.WARNING: Provide one dry powder fireextinguisher of an approved type orcomplying with ISO 7165, of at least 1kgcapacity, by the main exterior door anda fire blanket next to the cooker.Familiarise yourself with the instructionson your fire extinguisher and the localfire precaution arrangements.ESCAPE PATHSIt is important that you do not block escapepaths to emergency exits with obstructionsor hazzards.CHILDRENDo not leave children alone in the caravan inany event. Keep potentially dangerous itemsout of reach, as at home e.g. matches, drugsetc.VENTILATIONAll caravans comply with BS EN 721. Theventilation points on your caravan are fixedSafety & Securitypoints of ventilation which are required bythe European Standards.All caravans have ventilation at high leveland low level which have been calculated tosuit the individual needs of your caravan.High level ventilation is achieved by meansof the roof lights and washroom roofventilators. The low level ventilators arepositioned underneath the oven housing. Allmodels with sliding doors have two ventslocated underneath the sliding doors.Under no circumstances must these ventsbe blocked or obstructed.It is advised that fixed ventilation points arechecked and cleaned (if necessary) on aregular basis using a small brush and adomestic vacuum cleaner.Additional night time ventilation is obtainedby releasing the window catches and placingthem in the second groove. Note thewindows are not sealed from rain in thisposition.As the ventilation levels are calculated to suiteach models requirements there should beno modifications made which may result inreduced ventilation levels.WARNING: Do not obstruct ventilation.19

Safety & SecurityPetrol/Diesel FumesThe fitting of a tail pipe to your car exhaustwill reduce the possibility of fumes enteringyour caravan through the ventilation points.Note: Never allow modification of electricalor LPG systems and appliances except byqualified persons at an authorised SwiftGroup dealership.SECURITYCaravan theftThe theft of a caravan can occur in the mostunlikely circumstances; from a motorwayservice area, even from an owner’s driveway.Secure all windows and doors when yourcaravan is unoccupied even if only for a shortlength of time.Chassis numberRecord your caravan chassis number whichcan be found on the front offside section ofthe drawbar (Fig. A) or any of the eye levelwindows.Make a note of this number in the spaceprovided at the front of this handbook andmake separate note of the number to keepsafe at home.Additional securityConsider fitting any device which might deteror prevent intrusion by thieves.Fig. A Chassis NumberA hitch lock cover prevents towing of thecaravan.A wheel lock prevents towing of the caravanand removal of the wheel.Customers are advised to identify theircaravan with a method for subsequentidentification if other forms of identificationhave been altered or removed.Free crime prevention advice about securingyour caravan, protecting your valuables,property marking, either at home or whilst onsite, can be obtained from the CrimePrevention Officer through your local PoliceStation.SECURITY CHIPSA special security chip is concealed withinthe body of every caravan. This chip containsthe individual identity of your caravan andcan only be read by using a special decoder.Your local police can obtain the use of adecoder by contacting C.R.I.S. on telephoneno: 01722 41143020

SERVICESConnection of Services ......................................................... 22Water ....................................................................................... 22Whale Watermaster System...................................................22Inboard Water Tanks and On-line Water Systems.................22Whale Aqua-Source ...............................................................23Whale Supersub System........................................................23Whale 'Elite' Microswitch Taps ..............................................24Reich 'Charisma' Single Lever Mixer Tap ..............................25Whale 'Elegance' Microswitch Mixer Tap ..............................26Gas ........................................................................................... 27General Information................................................................27Types of Gas ..........................................................................28Gas Safety Advice..................................................................28Electricity ................................................................................ 30Instructions for Electricity Supply ..........................................30Overseas Connection.............................................................31

ServicesConnection of services is dealt with underthe separate headings.In all cases users should become familiarwith the equipment manufacturers’instructions.Advice and leaflets, if not supplied with thecaravan, can be obtained from the suppliersof the equipment.Before making connections of anydescription to the caravan or its equipment,ensure that ALL equipment is turned off.The caravan can use three separate systemsfor its water supply.1. Inboard water tank (for winter useessential).2. External water carrier.3. Watermaster Aqua Source (mains water).WHALE WATERMASTER SYSTEMFresh water is supplied to the caravan froman external water container by the WhaleWatermaster system, which consists of asocket in the offside exterior wall of thecaravan and a separate plug-in pumpassembly.The wall socket is protected by a hinged lidwhich should be kept shut when the pump isnot connected. Never tow the caravan withthe lid open. The lid is easily opened by grippingthe lower edge and pulling outwards.22To operate the system from the externalpump, switch the pump control switch onthe electrical panel to external position.The system will operate as a normal microswitchedsystem when the taps in thebathroom or kitchen are opened.INBOARD WATER TANKS ANDON-LINE WATER SYSTEMSTo fill the inboard/underslung tank from anexternal container follow these simpleinstructions:1. Insert water master pump into container.2. Plug pump hose connection into watermaster socket.3. Ensure the inline stem shut off valve is inthe open position. This is locatedadjacent to the tank or T-connectorfeeding the tank.4. On control panel located inside caravan,switch on external pump and the rockerswitch above the electrical panel or in thebattery compartment, dependant onmodel. Turn ON the Pump Run switchand the tank will fill.5a.Automatic shut-off will take place whenthe tank is full (some models) or5b.When water starts to flow from overflowon underside of caravan, or when thecontainer is empty, pull out pump hoseconnection immediately and turn offswitch.6. On control panel located inside caravan,switch to internal pump and turn on acold tap for a few seconds to relievepressure in the tank.To use an on-line water system (“Aqua-Source”) with an inboard/underslung tank,isolate the tank facility by turning the in-linestem shut-off valve to the OFF position.Note: It is advisable to check the system forleaks on the first occasion using an on-linewater system as they work at slightly higherpressure than pump systems.The internal and external pumps should NOTbe switched on when an on-line pressuresystem is plugged into the caravan.WARNING: It is not recommended totow with water in the onboard orunderslung water tank as this couldaffect stability.To drain the underslung water tank, reachunder the floor and unclip the drain hose,feed the pipe through the chassis holes (ifrequired) to ensure the pipe has a natural falland open the tap on the end of the drainhose

WHALE AQUA-SOURCETo use an on-line water system (“Aqua-Source”) with an inboard tank.Note: It is advisable to check the system forleaks on the first occasion using an on-linewater system as they work at slightly higherpressure than pump systems.The internal and external pumps should NOTbe switched on when an on-line pressuresystem is plugged into the caravan.WHALE SUPERSUB SYSTEMThe separate plug-in pump assemblyconsists of a Whale Supersub pump, hoseand plug. The plug provides connection ofboth water supply to the caravan and 12V dcelectric power to the pump. A dust cover isfitted to the connecting dual hose to preventcontaminants falling into the water container.The Whale Supersub pump is a completelysealed unit designed for intermittent use. It isNOT self-priming and therefore to ensureproper performance, the pump MUSTALWAYS be fully submersed in waterBEFORE plugging into the wall socket.Initial connection to fresh water supply1. Fill the fresh water container and place italongside the Whale wall socket locatedin the offside external wall of the caravan.2. Ensure the pump isolator switch at thecontrol panel inside the caravan isswitched OFF.3. Open the ‘hot’ kitchen tap. Ensure allother taps are closed.4. Place the Whale Supersub pump into thewater container outside the caravan,taking care to ensure the pump reachesthe bottom of the container.5. Lift the lid of the Whale wall socket and fitthe pump assembly plug into the socket.Ensure it is pressed in fully.6. Adjust the dust cover to fit over theopening in the water container to keepcontaminants out.7. Switch ON the pump isolator switch atthe control panel inside the caravan.8. Wait until water flows freely from the ‘hot’Serviceskitchen tap. Allow to flow for a few moreseconds to ensure release of any trappedair in the water system, then turn the tapoff.Repeat the same procedure with the ‘cold’kitchen tap.After turning off the taps, check ‘pumprunning’ light at the control panel.If light is OFF — the system is ready for use.If the system has been drained, the aboveprocedure MUST be repeated EVERY timethe water container is filled.Leave the pump isolator switch at the controlpanel ON.Once a tap is turned on, the pump isactivated automatically by a micro switch.Fault Finding1. Pump runs very noisy but does notpump water. Likely to occur after watercontainer has been refilled. Pump is airlocked. Cure: unplug from socket allowingpump to flood, and reconnect by pluggingin again. The correct sequence whenrefilling the container is to unplug, replacepump in container, then reconnect.2. Pump does not run at all. If not due toblown fuse or faulty connections, thenmost likely cause is excessive continuousrunning. Cure: replace pump.Never allow the pump to run dry.23

ServicesNever allow the pump to run continuouslyfor more than 15 minutes.Note: When refilling the water container, thepump assembly may be left unplugged intothe wall socket so that the pump can be keptoff the ground by inserting the hose into thegroove on the underside of the plug. But, thepump assembly MUST be unpluggedBEFORE replacing the pump into the refilledwater container.WHALE ‘ELITE’ MICROSWITCHTAPSThe micro switch taps are used when thewater supply is not pressurised.When the tap is turned on the micro switch(which is fitted inside the tap) activates thepump to supply water.OperationSwivel the tap spout (a) to the desiredposition over the sink, lift the control lever (b)to activate the pump and allow water to flowsimultaneously. To adjust the temperatureswivel the lever (c) to the left or right asshown opposite.CleaningIt is recommended that a non-abrasive dampcloth is used for cleaning the EliteTap/Shower.Microswitch Replacement: A microswitchreplacement kit is available (ref. MT8000).24Note: Before commencing microswitchreplacement ensure instructions are readthrough thoroughly. The entire process canbe completed without the need to removethe tap from the worktop.Before you Start1. Ensure pump is isolated.2. Position lever in central, i.e. mixer, offlocation.Microswitch Replacement1. Carefully remove lever cap. A recess atthe back of the lever cap is provided toassist with this.2. Remove screw with No. 2 Poziscrewdriver. Note the position of the leverat this stage.ImportantNote position ofACTUATOR beforeremoving it.3. Lift off the lever.4. Note the position of actuator before removal.Flange should be facing forward.5. Remove actuator.6. To remove shroud, squeeze clips with onehand and slide shroud off with other hand.7. Remove microswitch, using finger andthumb, pull up and outwards.

Services8. Slide wire terminals off microswitch.9. Attach replacement microswitch andrelocate. Note: Ensure microswitch snapsfully home.10.Before relocating shroud ensure wires areneatly located in the front groove asshown.11.Replace shroud. Note: Ensure shroudlocating rib is aligned with the rear grooveof tap and snap fully home, ensuring clipsare retaining the shroud.12.Replace actuator in position noted in 4above.13.Replace lever and fix with screw.Note: Do not overtighten screw.14.Replace lever cap.WinterisingTo avoid damage as a result of freezing,drain the entire water system. To protect Elitetap or shower units, the tap control(s) andthe shower control should be opened whendraining the system to enable stored water inthe outlets to drain back through the controlvalves and out of the system. (Switch offpump at isolator). Ensure that both the hotand cold systems are fully drained bydraining separately. The cold drain plug is aseparate drain plug from the heater drainplug. The lever should be up and in thecentre to drain the hot and cold systemwhen not in use. Remove water filter if fitted.Please consult your dealer if in difficulty.If they are unable to solve the problem,contact Whale Customer Services:tel: 01247 270531 ext. 211 or 213.REICH ‘CHARISMA’ SINGLELEVER MIXER TAP1. Detach cover (1)2. Loosen screw (2) inside the handle3. Detach the handle (3)4. Turn out the rosette (4)5. Turn out the brass nut (5) with spannerSW 296. Pull out the ceramic cartridge (6)7. If the cartridge is defect please install anew one8. If the micro switch is defect please pullthe wire out of the mixer (7)9. Detach the cover (8) in front of the handle10.Loosen screw (9) inside the handle andpull-out the micro switch11.Install cartridge, micro switch, brass nut,rosette and handle in the opposite way3217Reich Charisma9 845625

ServicesWHALE ‘ELEGANCE’MICROSWITCH MIXER TAPSThe microswitch taps are used when thewater supply is not pressurised.When the tap is turned on, the microswitch(which is fitted inside the tap), activates thepump to supply water.Microswitch replacementBefore you start:• Ensure the pump is isolated.• Ensure the taps are in the OFF position.1. Remove the crimp terminals.2. Hold the sides of the microswitch clip withyour thumb and finger and gently pull offthe clip.3. The microswitch should slide off the tworetaining pins. Be careful not to break thepins off (see fig. 1).4. Replace in the reverse order.Dismantling the taps for maintenance1. Pull off knob(s) and spindle(s).2. Unscrew securing screw(s), using a 17mm(11/16") spanner.3. Control unit(s) can now be released forinspection (see fig. 2).KnobDriveSpindleOperationSwivel the tap spout to the required positionover the sink and turn on either the hot orcold tap to activate the pump and allowwater to flow. To adjust the watertemperature, open both taps to the requiredmix.CleaningIt is recommended that a non-abrasive dampcloth is used for cleaning the Elegance tap.26Fig. 1Fig. 2SecuringScrewControlUnit

WINTERISINGTo avoid damage as a result of freezing,drain the entire water system. To protectElegance Tap or Shower units, the tapcontrol(s) and the shower handset on/offcontrol should be opened when draining thesystem to enable stored water in the outletto drain back through the control valves andout of the system (switch off pump atisolator). Ensure that both the hot and coldsystems are fully drained, the cold drain plugis a separate drain plug from the heater drainplug. Tap spouts and shower heads shouldbe unscrewed, removed and stored in a dryplace. Please consult your dealer if indifficulty. If they are unable to solve theproblem, contact Whale Customer Serviceson 01247 270531 ext. 211 or 213.WARRANTYWhale products are guaranteed for 1 yearfrom the date of purchase against defects inmaterials and workmanship. If the unitproves faulty, return it to your supplier withproof of purchase and purchase date. Pleasenote that frost damage is not a validwarranty claim.The manufacturer retains the right to repairor replace the unit. The manufacturer cannotbe held responsible for claims arising fromincorrect installation, unauthorisedmodification or misuse of the product. Theabove does not affect your statutory rights.GASGENERAL INFORMATIONGas BottlesBottled Liquified Petroleum Gas (LPG) is themost convenient portable source of fuel foryour caravan.Make sure that heating and cookingappliances and the gas cylinders areswitched off before you move the caravan.Regularly check flexible gas hose, joints andconnections for tightness. Finally make surethat each gas appliance is working efficientlyto the recommendations of the appliancemanufacturers.The regulatorThe regulator (Fig. B) is a governing devicewhich adapts the bottle pressure to one thatsuits the equipment in the caravan.Note: Regulator valves should always be inthe ‘OFF’ position when towing.WARNING: Some industrial LPGappliances operate at high pressure andrequire a ‘high pressure’ regulator. Thisoften has an adjusting handle on it.NEVER use such a regulator on acaravan.Propane and Butane gas regulators are notinterchangeable.Cylinders and regulators are also notServicesinterchangable between different makesof gas cylinder.Fig. A Gas Bottle CompartmentFig. B Gas Regulator27

ServicesHosesHoses should be made from Neoprene andshould conform to BS 3212. Rubber hosingshould never be used. It is good practice toreplace hoses annually, and a jubilee clip is aworthwhile addition to prevent accidentalremoval of the hose.WARNING: Inspect flexible gas hoseregularly for deterioration and renew, asneccessary, with the approved type. Inany case the hose should be renewednot later than the expiry date markedon the hose. Flexible gas hose lengthshould not exceed 400mm.WARNING: Ensure hoses do notbecome entangled in door mechanism.TYPES OF GASButaneButane is supplied in the U.K. in green, blueor aluminium bottles.All these have a male left hand threadEXCEPT for Camping Gaz which has aspecial female right hand thread and Calor7kg and 15kg and aluminium bottles whichhave a special clip-on connection.A 7kg bottle is recommended for butanegas.Continental bottles usually have a male left28hand thread similar to but not identical withU.K. butane.Butane is suitable for use at temperaturesdown to 2°C but will not work below that.PropanePropane is supplied in Red, or partly redbottles which have a female left handthreaded connector.Scandinavian countries use the sameconnector.Germany and Austria supply propane with amale connection.Propane will work at temperatures as low as-40°C and is therefore suitable for all wintercaravanning.A 6kg bottle is recommended for propanegas.GAS SAFETY ADVICEWARNING: If you smell gas or suspecta leak and if it is safe to do so, isolatethe gas appliances and turn off the gasbottles at the regulator. Evacuate thecaravan and ventilate. Seek professionaladvice as to the cause of the leak.Facts about LPGLPG is not poisonous.Bi-products are harmless.There is danger if all air and oxygen wereexcluded.(Ventilation holes must be kept clear at alltimes).LPG has been given a smell by themanufacturers in order to identify leaks.Awning Spaces LPG Appliance ExhaustThere is no danger of pollution of anenclosed awning space by the LPG exhaustfrom a refrigerator venting into it, as awningspaces are generally well ventilated.Space heaters may produce sufficientexhaust to pollute the awning space, if it istotally enclosed, from a general comfort,smell and hygiene point of view. In theextreme case there could be a build up ofcarbon dioxide to a dangerous level.Caravan owners are advised to allow somefresh air circulation in the awning spacewhen such appliances are in use.PRECAUTIONSa) Never look for a leak with a match.Always use a soap solution or itsequivalent when testing connections. Donot operate any electrical apparatuswhatsoever, especially light switches. Ifthe leak is not obvious, the caravanshould be evacuated and qualifiedpersonnel consulted.b) Avoid naked lights when connecting orchanging a cylinder.

c) Check the flexible hose frequently.d) The gas is heavier than air and thereforesinks to the lowest point.e) Keep bottle gas containers outside (andprotected against frost). If they must bekept inside make sure they are well awayfrom heat.VentilationAll ventilation complies with BSEN 721 andvents should not be obstructed in anymanner as this could lead to insufficientfresh air. In this case the confinedatmosphere becomes depleted of oxygenwhich leads to the formation of the highlypoisonous gas ‘carbon monoxide’. CarbonMonoxide is odourless, colourless andtasteless and will rapidly causeunconsciousness and death with little or nowarning prior to collapse. THERE IS NODANGER WHEN ADEQUATE VENTILATIONIS PROVIDED.Roof-mounted Flue installationsAll flue installations should be inspectedonce a year throughout their length forcorrosion. Flues should be replaced if anysign of perforation is found. Ensure that thereplacement is of an approved type.CONNECTIONEnsure that the gas regulator is correctlyconnected to the gas cylinder in gas bottlecompartment and that the hose is tight.Before turning on the gas supply, ensure thatall gas operated equipment in the caravan isturned off.All gas equipment is supplied through acentral Gas Manifold System which hasindividual isolation taps for each appliance,as follows:RED - Cascade Water HeaterWHITE - Space HeaterBLUE - FridgeGREEN - Hob & Oven (combination)GREEN - Hob (Separate)YELLOW - Oven (Separate)YELLOW - Barbecue (if fitted)Thermal insulation heatingYour caravan has been designed to achievea thermal insulation and heating level forspecific climatic conditions. Theclassifications are as follows:GRADE 1A caravan with an average thermaltransmittance (u) that does not exceed1.7w/(m 2 k).GRADE 2A caravan with an average thermaltransmittance (u) that does not exceed1.7w/(m 2 k) and which can achieve anaverage temperature difference of at least20k between inside and outside temperatureswhen the outside temperature is 0°C.ServicesGRADE 3A caravan with an average thermaltransmittance (u) that does not exceed1.2w/(m 2 k) and which can achievean average temperature difference of atleast 35k between inside and outsidetemperatures when the outside temperatureis -15°C.29

ServicesELECTRICITYAs with electricity in the home, care must beexercised when handling mains electricity.Your attention is drawn to the followingnotice as laid down by the Institute ofElectrical Engineers.INSTRUCTIONS FOR ELECTRICITYSUPPLYOn arrival at caravan site1. Before connecting the caravan installationto the mains supply, check that(a) both 12N & 12S plugs and hitchhave been disconnected from thetowing vehicle,(b the mains supply is suitable for yourinstallation and appliances, i.e.whether it is a.c. or d.c. and whetherit is at the correct voltage andfrequency,(c) your installation will be properlyearthed. Never accept a supply froma socket outlet or plug having onlytwo pins, or from a lighting outlet,and(d) any residual current device (earthleakage circuit breaker) in the mainssupply to the caravan has beentested within the last month.In case of doubt, consult the site owner orhis agent.302. MAKE SURE THAT THE SWITCH ATTHE SITE SUPPLY POINT IS OFF.3. Lift the cover of the electricity inletprovided on the caravan, and insert theconnector of the supply flexible cable.4. Remove any cover from the socket outletprovided at the site supply point, andconnect the plug at the other end of thesupply flexible cable to this. Switch onthe main switch at the site supply point.Note: Use mains cable fully uncoiled andprotect from traffic.IT IS IMPORTANT THAT THE MAINSWITCH AT THE SITE SUPPLY POINTSHOULD BE SWITCHED OFF, THESUPPLY FLEXIBLE CABLEDISCONNECTED, AND ANY COVERREPLACED ON THE SOCKET OUTLET ATTHE SITE SUPPLY POINT BEFOREDISCONNECTING THE FLEXIBLE CABLEFROM THE CARAVAN. IT IS DANGEROUSTO LEAVE THE SUPPLY SOCKET ORSUPPLY FLEXIBLE CABLE LIVE.Because touring caravans are generally leftunused for long periods in the open, it isstrongly advised that the mains installation isinspected periodically to ensure that it issafe to use. The IEE Wiring Regulationsrecommend that mains installations intouring caravans are re-inspected every 3years by a qualified person (see list) whoshould sign and issue a periodic inspectionreport. (The manufacturer recommendsannual inspections).Suitably qualified persons acceptable to theNCC to sign and issue inspection andcompletion certificates are:• an approved contractor of the NationalInspection Council for ElectricalInstallation Contracting* or• a member of the Electrical Contractors’Association• a member of the Electrical Contractors’Association of Scotland• a qualified person acting on behalf of theabove (in which event it should be statedfor whom he is acting).*The names and addresses of ApprovedContractors in any locality (there are over10,500 in the UK) can be obtained fromElectricity Shops, or direct from:NICEICVintage House37 Albert EmbankmentLondon SE1 7UJTelephone: 0171 582 7746

ServicesThe names and addresses of members ofthe Electrical Contractors’ Associations canbe obtained direct from:ECAEsca HousePalace CourtLondon W2 4HYTelephone: 0171 229 1266ECA of Scotland23 Heriot RowEdinburgh EH3 6EWTelephone: 0131 225 7221WARNING: CURRENT CONSUMPTIONIN THE CARAVAN MUST NOT EXCEED16 AMPS OR THE PITCH PERMITTEDMAXIMUM IF THIS IS LESS THAN 16AMPS.IT IS DANGEROUS TO ATTEMPTMODIFICATIONS AND ADDITIONSYOURSELF. LAMPHOLDER—PLUGS(BAYONET-CAP ADAPTORS) SHOULDNOT IN ANY CIRCUMSTANCES BEUSED.(items) greater than the supply as thismay cause an overload and the circuitbreaker to trip.OVERSEAS CONNECTIONNote: Connection to a mains voltage supplyOVERSEAS requires particular attention.Care must be taken when connectingsupplies abroad since the supplies can be ofREVERSE POLARITY.The significance of REVERSE POLARITY isthat when equipment is switched off it maynot be electrically isolated.The only certain way of making equipmentsafe is to unplug it.It is useful to have a means of checkingpolarity of the mains supply, especially whentouring overseas. There are available severalproprietary makes of equipment for testingpolarity.If it can be achieved, it is preferable toconnect live to live, and neutral to neutral tomaintain full electrical protection.CAUTIONThe Fanmaster has the potential to draw8 amps at 2kW. A primus heater has apotential drain of 3kW/13amp. It is,therefore, advisable to check the supplyrating before switching on two loads31

ServicesWIRING OF CONNECTING CABLE AND CARAVAN MAINS INLETWARNINGIT IS ESSENTIAL THAT CONNECTIONS ARE MADE EXACTLY AS SHOWN. IF TERMINAL MARKINGS ARE NOT IN ACCORDANCE WITH THE DIAGRAMTHEY MUST BE IGNORED. IF IN DOUBT CONSULT A QUALIFIED ELECTRICIAN.THE LEGAL LENGTH OF THE MAINS INLET CABLE IS 25 ± 2 METRES. WHEN IN USE IT MUST BE FULLY UNCOILED AND PROTECTED FROM TRAFFIC.32

ELECTRICALEQUIPMENTPower Modular Systems..........................................................34PMS2000GC and PMS2000GP .............................................35ESM 2 - Electrical Supply Module ........................................ 37ECM - Electrical Control Module .......................................... 38Battery ..................................................................................... 39Habitation Relay ..................................................................... 40Generator Guidelines ............................................................. 40ESM2000....................................................................................40KT9/2000 Indicator Module .....................................................41Alarm Module IDM 2000 ..........................................................4212V Electrical Supply ............................................................. 46Wiring of 12S Socket to Towing Vehicle .............................. 46

ElectricsKT9/2000GLFPESM2000KT9/2000GTFPPMS2000GCPMS2000GPKT9/2000GXFP34

POWER MODULAR SYSTEMS-PMS2000GC and PMS2000GPThe Power Modular System is a 240 volt acand 12 volt dc power control unit. It providesall the necessary features for control of theelectrics and security in a caravan. The unitprovides the following features:Mains 240v ac - Mains Modulewith • Earth leakage protection• Overcurrent protection (RCD)• Reverse polarity indication12 volt dc - Fully AutomaticTransformer/Chargerwith • Overcurrent protection• Short circuit protectionAlarm Modulewith • Programmable keypad• Motion sensor• Tilt sensor• Tow vehicle detection• F.N.C.Indicator Modulewith • Battery/water test switch• Battery charger switch• Water pump switch (Int./Ext.)• Internal and External “PumpRunning” indicator lights• Water auto-fill switch• Car/Van battery switch• “Pump Running” indicator• Heater 'ON', heater “fault” and“low voltage” indicators (GC only)Switch Modulewith • Battery charger switch• Car/Van battery switch• Water pump switch (Int./Ext.)• Battery/Water Test Switch• Water heater switch• Water/Water & heating switch• Ignition 'ON' switch• 1kW switch• 2kW switchFuse Modulewith • 8 fused dc output circuitsUNIT DESCRIPTIONMains ModuleThe PMS2000 and PMS2500 is designed tooperate on a mains supply of 207-253 voltsac (making it ideal for use with lowcontinental voltages). The 40 amp RCD(Residual Current Device) gives protectionagainst earth faults and also acts as the mainswitch. The mains module also has threeMCB’s (Miniature Circuit Breakers) which arebasically resetable mains fuses, to protectagainst overcurrent. Allocation of the MCB’sis as follows:MCB1 - Sockets/Fan Master (if fitted)MCB2 - Cascade/Lights (if fitted)MCB3 - Fridge/ChargerPolarity IndicatorThis red neon light mounted below the mainsmodule will illuminate if the mains input tothe unit has become reversed and will requireElectricscorrection. Note: this indicator may illuminatewhilst using certain generators, this is quitenormal and safe.Using a generatorWhen using a generator in conjunction withthe PMS the following must be observed,failure to do so may result in damage to theunit:i) Always start the generator with the mainsisolator in the caravan turned OFF.ii) Allow the generator to warm up for a fewminutes before energising power in thecaravan, as the output voltage can behigher when cold.iii) Check the generator output voltageregularly to ensure it is within thespecification of the PMS system(i.e. 230 volts ±10%).Transformer/ChargerThe PMS2000 employs a fully automaticmains to 12 volt dc transformer and batterycharger, able to operate with a wide range ofinput voltages and provide a stable outputvoltage even under load. The unit canprovide up to 12 amps maximum, after whichit will begin to shut down to protect itself.Battery/Water Level Meter(PMS2000GC and PMS2000GP)This meter indicates the amount of freshwater remaining in the inboard water tank35

Electricsand battery voltage. To check the watercontents simply press the test switch to thewater position and the meter will display alevel on the following scale:Empty - 1 ⁄4 - 1 ⁄2 - 3 ⁄4 - FullTo test battery voltage simply press the testswitch to the battery position, readingsshould be taken as follows:Green region - Fully charged (no chargenecessary)Yellow region - Adequate charge(re-charge if desired)Red region - Low charge (turn oncharger switch to re-charge)Modules have a water pump runningindicator light.Cascade/Pump IndicatorsThis module provides indicators for theCascade water heater fitted in your caravan.The three indicators show the following:Green LEDRed LEDYellow LED36- Heater is switched on- There has been a heaterfault, probably a low gassupply- DC voltage supply is toolow for the heater to operateAlso included is a pump running indicator.This red indicator will light up as a warningwhen the water pump has been activated foreither INT or EXT pumps.SWITCH MODULEThis module contains the control switchesfor electrical facilities within the caravan.Pump switchThis switch merely energises whicheverpump is required (i.e. internal or external).On the panels there are two indicator lightsto show which pump is running.Car/Van selector switchThe car/caravan changeover switch providedin this module should be used in thefollowing way:Caravan positionWhen in this position dc power is availablefrom the caravan battery to power all 12 voltelectric circuits. If the charger is switchedon, the caravan battery will be charged upvia the charger/transformer unit.Central positionWhen in this position with the charger switchon, power is provided to all 12 volt circuitsvia the charger/transformer only. With thecharger off, all dc circuits are isolated. Note:The switch should be placed in this positionwhen the van is being towed.Car positionThe switch can be placed in this positionshould the caravan battery becomedischarged and no mains power is available.Note: First of all the towing vehicle should beelectrically connected to the caravan via the12S socket.Battery/Water test switchThis switch should be pressed to the batteryposition to test battery voltage or the waterposition to indicate the water remaining inthe inboard tank.Auto-fill Water SystemThe system controls the automatic filling ofthe internal fresh water tank from an externalpump.The Auto-fill water system is controlled bytwo switches:1. A start and stop switch sited in thePMS2000 indicator module.2. A manual override switch sited on thecontrol box positioned near the freshwater tank.OperationThe process begins when the Start-Stopswitch is briefly pressed at the side marked‘Start’, thus starting the external pump, theprocess can be stopped at any time bybriefly pressing the Start-Stop switch at theside marked ‘Stop’. The pump will run forapproximately 3 minutes or until the freshwater tank is full, at which point the Externalpump will automatically stop.Manual Override:- If the Automatic filling isnot required, an override switch has beenincluded on the Auto-Fill unit, situated nearthe internal fresh water tank.This switch has three positions:-

Auto = Automatic Filling system active.Off = Off.Man = Manual Override, in this position theExternal pump will be on and will stay onuntil the switch is moved to the Off or Autopositions.Charger switchWhen the caravan battery requires charging,press this switch to the on position (it shouldthen illuminate). Also ensure the SelectorSwitch is in the van position.Heater switch (GC only)This switch energises the Carver waterheater. When switched to the on position,the green indicator marked heater on shouldilluminate.Heating and WaterSee Primus Aquaflex instructions. (Page 63)Fuse ModuleEight fuses are provided in this module toprotect all dc circuits, the fuse allocation isshown below. Fuses must be replaced onlywith the specified values.Fuse 1 - Front roof lightingFuse 2 - Rear roof lightingFuse 3 - FanmasterFuse 4 - RadioFuse 5 - 12v sockets/Hitchlight/TV ampFuse 6 - Fan circuitsFuse 7 - Water pumps/Water sensorFuse 8 - IgnitionsSPECIFICATIONMains Input 230 volts +15%,-20% ~ acFrequency 50HzOutput voltage 13.8 volts DCOutput curren 12 amps (max)BatteryrecommendedDimensionsHeightWidthDepthWeightRe-chargeable lead-acid12 volt battery, 6 cells,leisure type. 60 amperehoursminimum444mm102mm230mm (max)3.2KgProduct SupportPlug-In-Systems Ltd offer the customer anOn-Site Service, available for both Warrantyand Non-Warranty repairs (on the CEC andPlug-In-Systems range of equipment only).If you would like to take advantage of thisservice then please ring Plug-In-Systems(direct) on:HULL (01482) 659309and ask for PRODUCT SUPPORTESM2ElectricsESM 2 ELECTRICAL SUPPLYMODULEThe ESM 2 Electrical Supply Module fromPlug-In-Systems Ltd is a 240V mains and12V DC power supply unit, providing all thenecessary features for supply of electric inyour caravan. The unit provides the followingimportant features.ConnectionsPlug & socket input/outputsMains 240V ACMains module withEarth leakage protection (RCD)Overcurrent protection (MCBs)37

Electrics12V DCFully automatic transformer/charger withOvercurrent protectionShort circuit protectionCharger on/off switchUNIT DESCRIPTIONMains ModuleThe ESM 2 is designed to operate on amains supply of 185-265 volts ac (making itideal for use with low continental voltages).The 40 amp RCD (Residual Current Device)gives protection against earth faults and alsoacts as the main switch.The mains module also has three MCBs(Miniature Circuit Breakers) which arebasically resettable mains fuses, to protectagainst overcurrent. Allocation of the MCBsis as follows:MBC1- Sockets/Fanmaster (if fitted)MCB2- Cascade/Lights (if fitted)MCB3- Fridge/ChargerTRANSFORMER/CHARGERThe ESM 2 employs a fully automatic mainsto 12 volt dc transformer and batterycharger, able to operate with a wide range ofinput voltages and provide a stable outputvoltage even under load.The unit can provide up to 12 ampsmaximum, after which it will begin to shutdown to protect itself.To use the charger simply place the rockerswitch to the ON position, at which point itshould illuminate and charging willcommence.ROADS LIGHTS FUSESThe fuses are located on the front bulkheadof the right hand front bed.Fuse Ratings1 LH ROAD 5A2 RH ROAD 5A3 LH INDICATOR 7.5A4 RH INDICATOR 7.5A5 FOG 7.5A6 STOP 7.5AECM ELECTRICAL CONTROLMODULEPUMP SWITCH & INDICATORIncluded on this panel is a pump isolationswitch and pump running indicator. Thepump isolation switch is used to isolatepower to the water pump in the event of apump fault or merely as a safeguard againstunwanted pump operation. The red pumprunning indicator will light up as a warningwhen the water pump has been activated.AUX SWITCHThis switch may be used to power anyauxiliary dc circuits the user may wish tohave added to the system.Battery Condition MeterThis meter indicates the power remaining inyour caravan battery.Readings should be taken as follows:Green region - Fully charged(no charge necessaryYellow region - Adequate charge(re-charge if desired)Red region- Low charge(turn on charger switchto re-charge)38

ElectricsA car/caravan changeover switch is providedin this module and should be used in thefollowing way:Caravan positionWhen in this position dc power is availablefrom the caravan battery to power all 12 voltelectric circuits.If the charger is switched ONthe caravan battery will be charged up viathe charger/transformer unit.Central positionWhen in this position with the charger switchON, power is provided to all 12 volt circuitsvia the charger/transformer only.With the charger OFF all dc circuits areisolated.Note: The switch should be placed in thisposition when the van is being towed.Car positionNote: First of all the towing vehicle shouldbe electrically connected to the caravan viathe 12S socket.The switch can be placed in this positionshould the caravan battery becomedischarged and no mains power is available.BATTERYIt is recommended that a good qualityleisure battery is always in circuit when thesystem is in use.A deep cycling heavy duty 12v batteryshould be purchased to provide power forlights and other electrical appliances. Aproprietary brand leisure battery with either a60 or 90amp capacity is recommended.Note: 90 amp batteries and above should bechecked dimensionally before purchasing, toensure fitment within the batterycompartment, as brands vary in size.It should be remembered that batteriessuitable for the electrical demands of acaravan differ in design from those for usewith a car, and whilst the system mayoperate with a car battery it is stronglyrecommended that only a leisure typebattery, maintained in good condition isused. The battery should be kept topped upat all times.The battery should be positioned in acompartment vented to the outside andshould be properly secured.WARNING: When connecting the battery,ensure that the correct polarity isobserved (black is negative and red ispositive) and that the terminals aresecurely fastened.Under normal circumstances it should not benecessary to remove the battery other thanfor routine inspection of terminals and“topping up”.WARNING: Explosive gases may bepresent at the battery. Take care toprevent flames and sparks in the vicinity.Your caravan has been fitted with an in-linefuse between the battery terminal and stripconnector. It is recommended that the fuserating fitted in this location does not exceed20 amps.WARNING: Switch off all appliancesand lamps before disconnecting thebattery.Smoking is prohibited around thebattery compartment.To preserve the life of your leisure batteryand charger please observe the following:i) Do not leave all 12v lights powered at thesame time as this will drain your leisurebattery more rapidly.ii) If all 12v lights must be powered together,ensure the battery is 'in-circuit' i.e.selector switch in the 'van' position andthat the battery charger is turned on.iii) For optimum performance use thetransformer/charger unit with a leisurebattery attached.39

ElectricsSUPPORT SERVICEPLUG-IN SYSTEMS LIMITED PROVIDE ANON-CALL SERVICE FOR WARRANTY ORNON-WARRANTY REPAIRS.IF YOU WISH TO TAKE ADVANTAGE OFTHIS SERVICE FOR PLUG-IN-SYSTEMSONLYTelephone (01482) 652523 and ask forPRODUCT SUPPORT SERVICE.HABITATION RELAYTo conform with European Safety Standards(EMC) all caravans have been equipped witha habitation relay.This relay is actuated when the 12N/12Splugs are connected to the car’s sockets andthe car ignition is turned on.The relay automatically isolates all 12Vequipment within the caravan, excluding thefridge’s 12V power supply, from the car.GENERATOR GUIDELINES• Lack of regular servicing can be thecause of most generator problems,gensets under 2kW are mainly dependenton engine speed for output frequencyand voltage, poor or no servicing maycause the engine speed governor to runthe genset engine too fast. Thereforefrequency and output voltage can riseabove the specification of the machinedata plate i.e. 240v at 50Hz, this may40cause damage to electrical/electronicequipment (such as battery chargers).• A generator should always be run for afew minutes prior to connection with thecaravan or motorhome electrics, to allowit to warm up and the output to settle to asteady level.• The AC output of generators is oftenderived from an AC alternator, rectified toDC then inverted back to AC. In essencethis means the output sinewave may notbe very smooth and may not runsophisticated electronics efficiently. Someof the new wave of gensets are moresophisticated in their production of asinewave output and are more suited torun electronic equipment.• If in doubt consult your genset dealer ormanufacturer for advice.ESM2000The ESM2000 electrical Supply Module is a240 volt ac and 12 volt dc power controlunit. It provides all the necessary featuresfor control of the electrics in a caravan. Theunit provides the following features:Mains 240v ac - MAINS MODULEwithEARTH LEAKAGE PROTECTIONOVERCURRENT PROTECTION (RCD)REVERSE POLARITY INDICATION12 volt dc - FULLY AUTOMATICTRANSFORMER/CHARGERwith OVERCURRENT PROTECTIONSHORT CIRCUIT PROTECTION- SWITCH & FUSE MODULEwith BATTERY CHANGEOVER SWITCHCHARGER ON/OFF SWITCH8 FUSED DC OUTPUT CIRCUITSUNIT DESCRIPTIONMains ModuleThe ESM2000 is designed to operate on amains supply of 207-253 volts ac (making itideal for use with low continental voltages).The 40 amp RCD (Residual Current Device)gives protection against earth faults and alsoacts as the main switch. The mains modulealso has three MCR's (Miniature CircuitBreakers) which are basically resetablemains fuses, to protect against overcurrent.Allocation of the MCB's is as follows:MCB1 - SOCKETS/FAN MASTER (if fitted)MCB2 - CASCADE/LIGHTS (if fitted)MCB3 - FRIDGE/CHARGERUsing a generatorWhen using a generator in conjunction withthe ESM2000 the following must beobserved, failure to do so may result indamage to the unit:

i) Always start the generator with the mainsisolator in the caravan turned off.ii) Allow the generator to warm up for a fewminutes before energising power in thecaravan, as the output voltage can behigher when cold.iii) Check the generator output voltageregularly to ensure it is within thespecification of the ESM2000 system (i.e.230 volts +/- 10%)Transformer/ChargerThe ESM2000 employs a fully automaticmains to 12 volt dc transformer and batterycharger, able to operate with a wide rangeof input voltages and provide a stable outputvoltage even under load. The unit canprovide up to 12 amps maximum, afterwhich it will begin to shut down to protectitself.SWITCH & FUSE MODULECar/Van Selector SwitchThe car/caravan changeover switch providedin this module should be used in thefollowing way:caravan position - When in this position dcpower is available from the caravan batteryto power all 12 volt electric circuits.If the charger is switched on, the caravanbattery will be charged up via thecharger/transformer unit.central position - When in this position withthe charger switch on, power is provided toall 12 volt circuits via the charger/transformeronly. With the charger off all dc circuits areisolated.Note: The switch should be placed in thisposition when the van is being towedcar position - The switch can be placed inthis position should be caravan batterybecome discharged and no mains power isavailable.Note: First of all the towing vehicle shouldbe electrically connected to the caravan viathe 12S socketCharger switchWhen the caravan battery requires charging,press this switch to the on position (it shouldthen illuminate). Also ensure the SelectorSwitch is in the van positionDC FusesEight fuses are provided in this module toprotect all dc circuits, the fuse allocation isshown below. Fuses must be replaced onlywith the specified values.Fuse 1 - Front roof lightingFuse 2 - Rear roof lightFuse 3 - FanmasterFuse 4 - RadioFuse 5 - 12v sockets/Hitchlight/TV ampElectricsFuse 6 - Fan circuitsFuse 7 - Water pumps/Water sensorFuse 8 - IgnitionsKT9/2000INDICATOR MODULEBattery/Water Level meter(KT9/2000GT only)This meter indicates the amount of freshwater remaining in the inboard water tank.Simply press the test switch to the waterposition and the meter will display a level onthe following scale:Empty - 1 ⁄4 - 1 ⁄2 - 3 ⁄4 - FullTo test battery voltage simply press the testswitch to the battery position, readingsshould be taken as shown below.Battery Condition Meter(KT9/2000GL/GX only)This battery condition meter indicates thepower remaining in your caravan battery.Readings should be taken as follows:Green region - Fully charged(no charge necessary)Yellow region - Adequate charge(re-charge if desired)Red region - Low charge (turn on chargerswitch to re-charge)41

ElectricsCascade/Pump IndicatorsThis module provides indicators for theCascade water heater fitted in your caravan.The three indicators show the following:Green LED - Heater is switched onRed LED- There has been a heaterfault, probably a low gassupplyYellow LED - DC voltage supply is too lowfor the heater to operateAlso included in this module is a pumprunning indicator. This red indicator will lightup as a warning when the water pump hasbeen activated.SWITCH MODULEThis module contains all the control switchesfor electrical facilities within the caravan.12V Isolation SwitchThis switch will effectively isolate 12 voltpower to all dc circuits by opening a relay.This switch should be used only whenwishing to isolate power for reasonably shortperiods (e.g. when going out for the day).For isolation during storage the Car/Vanswitch on the ESM2000 unit should be used(place Car/Van switch to the centre 'off'position).Pump switchThis switch merely energises the inboardwater pump ready for use. In caravans withan outboard pump, this switch will be a twoway type for energising whichever pump isrequired (i.e. internal or external)Entry Light switchThis switch energises an internal entry lightBattery/Water test switch(KT9/2000GT only)This switch should be pressed to the batteryposition to test battery voltage or the waterposition to test the water remaining in theinboard tank.Water Heater switchThis switch energises the gas ignition on theCarver water heater. When switched to the'on' position, the green indicator marked'heater on' should illuminate and the ignitionshould energise.ALARM MODULE - IDM 2000ImportantThis handbook should be read throughcarefully before any attempt is made toinstall and use the system. For case ofunderstanding it is suggested that thishandbook is read whilst viewing the keypad.Your alarm system, when new, contains themanufacturers code 1234. For securityreasons this should be changed as soon aspractical. (See 'Changing the PersonalCode').Factory SettingsEntry Delay - 0:00 (0 secs)Exit Delay - 0:20 (20 secs)Siren On Time - 1:00 (1 minute)ManufacturersPersonal Code - 1234Changing the Personal Code1. Press "F", press "1"2. Enter the current code. (1234 if new).3. Enter desired 4 digit code.4. Press "F".5. This operation can be cancelled at anytime before step 4 by pressing "C".Changing the Entry Delay Time1. Press "F", press "0".2. Enter your personal code.3. Enter the new entry delay as 3 digits, i.e.10 seconds is entered 010.4. Press "F".5. This operation can be cancelled at anytime before step 3 by pressing "C".Note: The Entry Delay Time must be asshort as possible to prevent compromisingsecurity.42

ElectricsTestingA time limit of 2 minutes is imposed when inthe test modes described. After this timethe system will return to standby. This is topreserve battery power.Checking the Battery LifeBattery Life (between recharges) is eightmonths maximum. NEVER allow the batteryto completely discharge. Regular battery lifechecks are strongly recommended.1. Press "F", press "4".2. A number of pulses will be heard; 1 pulse= 1 month, 3 pulses = 3 months etc up toa maximum of 8 pulses. If, however, arandom flashing of indicators occurs, thisindicates that the battery is in need ofimmediate charging.3. If the battery is low, connect the batterycharger via the socket on the maincontrol box. This will be located underthe front offside bed-box. Batterycharging should be complete within 24hours (for a fully discharged battery).Please notei) avoid charging battery while the system isarmed.ii) reading the battery status whilst chargingthe battery will give a false indication ofbattery life, please wait 15 minutes aftercharging battery before taking a reading.44Testing the PIR1. Press "F", press "6".2. Walk in front of the PIR. The light on thekeypad marked PIR will illuminate fivetimes, and give an audible signal.Testing the Siren1. Press "F", press "7".2. The siren will sound. Press "C" to stopthe siren.Testing the Tow SensorThe towing vehicle must be connected to thecaravan via the 12S plug before this test canbe carried out. This sequence also assumesthat the towing vehicle is correctly wired.1. Press "F", press "9".2. The "FNC" light on the keypad will stayon.3. Disconnect the car from the caravan.The siren will emit a short burst followedby five flashes on the keypad sensorindicator, and give an audible signal.Testing the Tilt Sensor1. Press "F", press "9".2. Adjust the level or move the caravan untilone of the Tilt Sensor Indicators on thekeypad illuminates and gives an audiblesignal.3. Press "C".Troubleshooting1. When attempting to arm, on entering thepersonal code, sensor lights do notilluminate - The code entered is incorrect,or all sensors are active. Check the towvehicle is attached, that there is no-one inthe PIR's field of vision, connections tothe PIR are good and that the caravan islevel.2. The tilt sensor light does not illuminate onarming - The tilt sensor is active. (Press"C" to cancel then refer to section'Setting up the Tilt Sensor').3. The tow sensor light does not illuminateon arming - The 12S (grey) socket on thetowing vehicle must be correctly wired.Assuming this is the case then the vehiclemay have been disconnected from thecaravan (e.g. when on sit).4. The PIR sensor light does not illuminateon arming - Ensure no-one is in the PIR'sfield of view, including the person who isarming the system. Move everyoneoutside the PIR's field of view and press"1". If the PIR indicator still does not lightthen check PIR connections.5. On disarming the system the sensorindicators do not light - An incorrectpersonal code has been entered.6. If you are unable to resolve your problemplease contact Plug-In-Systems Product

Support Department; Tel: 01482 659309.Clearing the System back toManufacturers SettingsIf for any reason you wish to set theIDM2000 back to its factory settings then thefollowing procedure should be used:1. Press "F", keep finger on the "F" key until5 bursts are heard from the keypadbuzzer. The IDM2000 has now revertedto factory settings.This can only be done when the system isdisarmed.The Noise Pollution ActIf the alarm is activated continuously for 20minutes, the system will shut down. Thiseffectively disarms the system. This is arequirement of the Noise Pollution Act.Plug-In-Systems reserve the right to changeproduct specification at any time withoutprior notice.SPECIFICATIONMains InputFrequencyOutput voltageOutput currentBatteryrecommended230 volts +/- 10% ~ ac50Hz13.8 volts DC12 amps (max)Re-chargeable lead-acid12 volt battery, 6 cells,leisure type, 44 amperehoursminimumDimensionsHeightWidthDepthWeight193mm102mm210mm (max)2.28KgPRODUCT SUPPORTPlug-In-Systems Ltd offer the customer anOn-Site Service, available for both Warrantyand Non-Warranty repairs (on the CEC andPlug-In-Systems range of equipment only).If you would like to take advantage of thisservice then please ring Plug-In-Systems(direct) on:HULL (01482) 659309and ask for PRODUCT SUPPORTElectrics45

Electrics12 VOLT ELECTRICAL SUPPLYIf your car is fitted with the appropriate relay,please note the following points:1. The caravan battery will be charged by thecar charging system independently of thedistribution panel.2. If the caravan battery level is “low”, powerfor the caravan 12 volt system can beobtained from the car battery, byconnecting the 12S (grey) plug to the car,and setting the distribution panel selectorswitch to “car”. This will draw power fromthe car battery and care should be takennot to reduce the level of the car batteryso low that the car engine cannot bestarted. (The battery level indicator in thecaravan distribution panel will show thecondition of the car battery in thesecircumstances).3. When the car and caravan are connectedthrough the 12N and 12S plugs and thecar engine is running, 12 volt power willbe supplied to the refrigerator, providedthe refrigerator selector switch is set tothe 12v position, regardless of theposition of the distribution panel selectorswitch.4. If an extension lead from the 12S socketon a towing vehicle to the 7-coreconnecting cable is used while a caravanis parked on a caravan pitch, its lengthWIRING OF 12S SOCKET TO TOWING VEHICLENote:If using a combination relay, ensure the supply fuse is the correct amperage. A lower ratingwill ‘blow’ causing `e, if switched on, to be connected directly to the caravan battery. Whiletowing, the caravan battery will be discharged instead of being charged.should be kept to a minimum and notexceed 5 metres. The minimum crosssectional area of the supply and returnleads in the extension cable should be2.5mm 2 .46

FITTEDEQUIPMENTWhale Water Pump ................................................................. 48Shurflo Water Pump ............................................................... 48Cascade 2GE Water Heater .................................................. 48Refrigerator ............................................................................. 50Model RM4200 & RM4230 .................................................. 50Model RM4271 ..................................................................... 51Model RM4291 ..................................................................... 52Travel Catch ......................................................................... 54Stoves Hobs, Grills & Ovens ................................................. 54The Hob ............................................................................... 54The Grill ..................................................................................55The Oven................................................................................55Cleaning .................................................................................56Carver Space Heaters ............................................................ 58Carver 2000P, 2000A & Fanmaster ........................................58Carver 5500 Turbo Fanmaster ...............................................61Fanmaster ..............................................................................61Primus AQWE6 (Aquaflex) Heating System ......................... 63Programmable Heating Timer ...............................................67Thetford Cassette Porta Potti ............................................... 71Thetford Cassette C-200 CW & C-200 CE ............................74Thetford Cassette C-200 S ....................................................78Beds ......................................................................................... 82Cassette Blinds & Flyscreens ............................................... 85Doorscreen ............................................................................. 85Roof Lights, Windows and Air Conditioning ........................ 86Ash Framed Doors ................................................................. 87Shower .................................................................................... 87Tables ...................................................................................... 88Fixing of Awnings ................................................................... 89

Fitted EquipmentEquipment SpecificationFor details on type of equipment fitted inyour caravan, please refer to the SalesBrochure or Dealer.IMPORTANTTo maximise the use and life of all fittedequipment in your caravan it is essential thatany accompanying manufacturers’ literatureis read fully. All recommended maintenanceand preparation procedures should befollowed. The information provided in thishandbook is only intended as a guide. If inany doubt consult your manufacturerappointed dealer, particularly beforeattempting to install EXTRA EQUIPMENT.WHALE WATER PUMPThe Whale pump is a non self primingintermittently rated centrifugal pump whichdraws approximately two amperes from a 12volt battery and therefore maximumcontinuous operation should not exceed 15minutes.The pump should not be run without waterand should not be used to pump water of atemperature above 60°C.SHURFLO WATER PUMPFresh water is supplied to the caravan by aShurflo pump. This pump is a completelysealed unit designed for intermittent use andis self-priming.48Fig. AGREENYELLOWREDFig. BCASCADE 2 GE RAPIDE WATERHEATEROPERATING INSTRUCTIONSThe gas side of the Cascade 2 GE RapideWater Heater is operated by the controller onthe integrated control panel (Fig. A) exceptfor models with the separate control panelswhich are operated from the wall switch(Fig. B).Before switching on the gas burner or themains immersion heater make sure that waterflows from the hot taps. This indicates thatthe water heater is full.TO OPERATE THE HEATER ON GAS1. Close the window near the Cascade cowlwhen the heater is running on gas.2. Check that the 12 volt supply isconnected and switched on. DO NOT usea battery charger as the only source ofsupply.3. To light the heater, press the ON button.A continuous green light indicates thatthe heater is working satisfactorily.4. To switch the heater OFF press the OFFbutton.Light IndicationGreen. The heater is working satisfactorily.Green & Yellow. The DC voltage is below the10.5 volts that is required to operate theheater. Recharge the battery.Green & Red. The heater has failed to igniteor that the heater has gone to safety shutdown. This is usually due to failure of the gassupply or air in the gas system after fitting anew cylinder. Switch the heater off and WAIT3 MINUTES before attempting to relight theheater. If air in the gas system is the problemseveral attempts may be necessary beforethe heater ignites.

Temperature and adjustmentThe thermostat cannot be adjusted and ispre-set to approximately 70°C.Water heaters (as with all other gasappliances) should be switched off and thegas cylinders turned off when the caravan isin motion.TO OPERATE THE HEATER ON MAINSELECTRICITYEnsure that the caravan is connected to thesite mains and the supply is adequate. (Theimmersion heater uses approximately 3.75amps.)1. Switch on the isolation switch. If it is theilluminated type, the light should indicatethat the heater is working.2. To switch OFF, switch off the isolationswitch.Over TemperatureImportant: If the mains electrical supply tothe heater is switched on but the heater isnot working, the over temperature thermostatmay have operated.This can be due to:1) Switching the heater on without water inthe tank. Always check that the heater isfull of water before switching on.2) Failure of the normal operatingthermostat. Manually reset the overtemperature thermostat by pressing thebutton in the centre of the electricalFASTDRAINDRAINPLUGconnection box. If the operatingthermostat has failed the overtemperature thermostat will again trip out.If this occurs DO NOT USE THEIMMERSION HEATER and consult yourCarver Dealer.FROST PRECAUTIONSIMPORTANT:During periods when the heater is likely tofreeze (e.g. when the caravan is stored duringthe winter) it MUST be drained down toprevent damage.Fitted EquipmentTo fast drain the system:1. Park the caravan on level ground.2. Ensure that the gas and electricity areturned off.3. Open all hot and cold taps and showerheads if fitted.4. Remove drain plug and store in safe placein caravan (e.g. kitchen sink).5. Using a flat bladed screwdriver, turn thefast drain 90°.The water system will now drain - this islikely to take 5 minutes.Remember that at least 9 litres (2 gallons) ofwater should drain from the system.At the start of the season insert the drainplug and sterilise the system by using asterilising fluid, e.g. Chempro SDP or similar.DO NOT USE DOMESTIC BLEACH,CAMDEN TABLETS OR SODIUMMETASULPHIDE.If a filter is fitted it is recommended toreplace it at the start of the season.TO RECOMMISSION THE HEATERClose cold taps and drain plug andreconnect the pump. Let the system fill withwater until water flows steadily from the hottaps. About two gallons of water will berequired. Once the hot taps are flowing freelyclose them and switch on the Cascade 2 GEheater.49

Fitted EquipmentREFRIGERATORWhen using your refrigerator for the first time,it is advisable to wash the interior and itsaccessories.When the caravan is on tow, the refrigeratorshould be operated electrically, i.e. from the12V battery in the towing vehicle, and not bymeans of bottled gas.CONTROLSThe refrigerator can be run on either 240V,12V or LP gas. Changing between thesemodes of operation is carried out by meansof the controls shown on the relevant controlpanel.Caution!Only use one source of energy at a time.50A B C D EFig. A Control Panel - RM4200 & RM4230MODEL RM4200 AND RM4230Bottled Gas Operation - Lighting theburner1. Open the shut-off valve of the gas bottle(check that there is enough gas). Openany on-board shut-off valve.2. Check that the switches for mains and12V are off.3. Depress and turn on the gas controlsafety device knob (D) to the large flamesymbol.4. Depress the gas control safety deviceknob (D) and hold it down whiledepressing the piezo-electric igniterbutton (E) rapidly 3 or 4 times in quicksuccession.5. Check the flame viewer (located bottomleft of refrigerator) to see if the flame isalight.6. Keep the safety device control knobdepressed for a further 15-30 seconds.7. Release the safety device control knoband again check to see that the flame isalight.8. To terminate gas operation, turn knob (D)to ‘O’.ELECTRIC OPERATION240V Operation1. Turn off gas or 12V operation whenapplicable.2. Turn the knob (C) of the thermostat to itshighest (coldest) position.3. Set switch (B) to position I.12V OperationThere is no thermostat control on 12Voperation.Only operate your refrigerator on 12V whenthe engine of your vehicle is running.Note: Before operating the refrigerator on12V it should be pre-cooled, together withits contents, by running it on bottled gasor 240V for a few hours before changingover to 12V and starting on a journey.

1. If applicable, turn off the gas operation.2. Set the 240V rocker switch (B) to ‘O’ andthe 12V rocker switch (A) to 1.Regulating the temperatureOnce the refrigerator has been started it willtake a few hours to become cold.On 240V operation the refrigerator iscontrolled by a thermostat and thethermostat knob (C) should be set at 3. If acolder temperature is required, set thethermostat to a higher number and viceversa.On LP gas operation the refrigeratortemperature is regulated by the gas controlknob (D). If the ambient temperature is above25°C and/or the door of the refrigerator isfrequently opened, the knob should be set inthe ‘max’ position. Below 25°C, the knobshould be set at ‘mid’ and below 10°C at‘min’ to avoid temperatures below freezing inthe main compartment.MODEL RM4271Two rocker switches are used to select theelectric power supply, one for 240V (B) andone for 12V (A) (See Fig. B).Refrigerator temperature is controlled by athermostat knob (C) when the refrigeratorruns on 240V.The gas supply is turned ON/OFF by meansof the knob (D). When lighting the gas, theknob must be pressed as explained in LPGas Operation.Refrigerator temperature is controlled by athermostat (E) when the refrigerator runs onLP gas. Please note that the thermostat hasno ‘OFF’ position.The gas flame is electronically lit, monitoredand re-lit if necessary. For this, the toggleswitch (F) should be ‘ON’ during gasoperation.STARTING THE REFRIGERATORLP Gas OperationBefore you start gas operation:1. Open the shut-off valve of the gas bottle(check that there is enough gas). Openany on-board shut-off valve.2. Check that the switches for mains and12V operation are off.3. Turn on gas supply by pressing knob (D)and turning it to the flame position.A BFitted EquipmentC D EFig. B Control Panel - RM4271F4. Set the thermostat knob (E) to the highestsetting.5. Turn on switch (F). A light in the switchshould now start to flash, indicating thatsparks are being generated at the burner.6. Press button (D). This opens the flamefailure device and allows gas to flow tothe burner.7. When the flame ignites, the sparkingstops automatically and the switch stopsflashing.8. Keep the knob (D) pressed for a further 10to 15 seconds to activate the flame failuredevice, then release it.51

Fitted Equipment240V Operation1. Turn off gas or 12V operation whenapplicable.2. Turn the knob (C) of the thermostat to itshighest (coldest) position.3. Set switch (B) to position I. The switch willlight up green when the power supply isconnected.12V OperationOnly operate your refrigerator on 12V whenthe engine of your vehicle is running. Installthrough a relay, otherwise your battery willsoon be discharged.Note: Before operating the refrigerator on12V, it should be pre-cooled, together with itscontents, by running it on bottled gas or240V for a few hours before changing over to12V and starting on a journey.1. If applicable turn off the gas operation.2. Set the 12V rocker switch (A) to I. Theswitch will light up red when the powersupply is connected.REGULATING THE TEMPERATUREThe position numbers refer to Fig. B.Once the refrigerator has been started it willtake a few hours to become cold.On 240V operation the refrigerator iscontrolled by a thermostat and thethermostat knob (C) should be set at 3-5. If alower (colder) temperature is desired, set thethermostat to a higher figure.On LP gas operation the refrigeratortemperataure is regulated by the gasthermostat knob (E), which should be set at3-5. If a lower (colder) temperature is desired,set the thermostat at a higher figure.On 12V operation the refrigerator workscontinuously.A BC D EFig. C Control Panel - RM4291MODEL RM4291 (86 litres)FTwo rocker switches are used to select theelectric power supply, one for 12V (A) andone for 240V (B) (see Fig. C).Refrigerator temperature is controlled by athermostat knob (C) when the refrigeratorruns on 240V.The refrigerator runs continuously on 12Voperation (no thermostat).The gas supply is turned ON/OFF by meansof the knob (D). When lighting the gas, theknob must be pressed as explained in LPGas Operation.Refrigerator temperature is controlled by athermostat (D) when the refrigerator runs onLP gas.52

The gas flame is electronically lit, monitoredand re-lit if necessary. For this, the toggleswitch (E) should be ‘ON’ during gasoperation.The RM4291 is fitted with an internal lightwhich is operated by the door.STARTING THE REFRIGERATORLP Gas OperationBefore you start gas operation:1. Open the shut-off valve of the gas bottle(check that there is enough gas). Openany on-board shut-off valve.2. Check that the switches for mains and12V operation are OFF.3. Turn on gas supply by pressing knob (D)and turning it to the highest flameposition.4. Press ON switch (E). A light in the switchshould now start to flash, indicating thatsparks are being generated at the burner.5. When the flame ignites, the sparkingstops automatically and the switch stopsflashing.6. Keep the knob (D) pressed for a further10 to 15 seconds to activate the flamefailure device, then release it.7. To terminate gas operation turn knob (D)to the ‘•’ position and put switch (E) tothe OFF position.240V Operation1. Turn off gas or 12V operation whenapplicable.2. Turn the knob (C) of the thermostat to itshighest (coldest) position.3. Set switch (B) to position I. The switchwill light up green when the power supplyis connected.12V OperationOnly operate your refrigerator on 12V whenthe engine of your vehicle is running. Installthrough a relay, otherwise your battery willsoon be discharged.Note: Before operating the refrigerator on12V, it should be pre-cooled, together withits contents, by running it on bottled gas or240V for a few hours before changing overto 12V and starting on a journey.1. If applicable turn off the gas operation.2. Set the 12V rocker switch (A) to I. Theswitch will light up red when the powersupply is connected.Fitted EquipmentREGULATING THE TEMPERATUREThe position numbers refer to Fig. A.Once the refrigerator has been started it willtake a few hours to become cold.On 240V operation the refrigerator iscontrolled by a thermostat and thethermostat knob (C) should be set at 3-5.If a lower (colder) temperature is desired,set the thermostat to a higher figure.On LP gas operation the refrigeratortemperature is regulated by the gasthermostat knob (D), which should be set atthe medium ‘flame’ position. If a lower(colder) temperature is desired, set thethermostat to the larger ‘flame’ position.On 12V operation the refrigerator workscontinuously.WINTER OPERATION (ALL MODELS)Please check that ventilation grilles or theflue outlet are not blocked.Ventilation grille covers are available fromElectrolux and can be fitted to protect theunit against very cold air. These coversshould be fitted when the temperature isbelow 10°C and when the caravan is laidup during winter months.53

Fitted EquipmentTravel CatchTRAVEL CATCHAll models are fitted with a travel catch tokeep the refrigerator door securely closedwhen the vehicle is on the move.Remember always to push the catch down,so that its lower end fully engages the plasticbush in the top of the door, before movingoff.FURTHER DETAILSConsult the accompanying literature to obtainthe full benefit of your Electrolux Refrigerator.In the event of failure, contact ElectroluxService. Details of which can be found inyour Yellow Pages Directory.WARNING: When you are cooking it isessential to provide additional ventilationsuch as opening windows near the grill,cooker and oven (EN 721).STOVES HOBS, GRILLS ANDOVENSTHE HOBCaution:• Do not use foil on the hob, as it creates afire hazard• Glass lids may shatter when heated, turnoff all burners before shutting the lid• Note: When positioning the pan support,ensure that the fingers are central to theburners (Fig 1).Always use the most appropriate size ofburner for the pan you wish to use. Usepans with a flat base of minimum 100mm/4ins diameter, and maximum 200mm/8 insdiameter, which are stable in use. Avoid oldor misshapen pans as these may causeinstability.Important: Any spillage of liquid should becleaned away immediately to reduce the riskof fluid entering the appliance.Ignition - Push in the control knob and turnanticlockwise to the large flame symbol.Keep the knob depressed, and press theStoves HobStoves Hobignition button (if fitted), or use a hand heldspark ignitor or gas lighter. The knob mustbe held in for 15-20 seconds beforereleasing.54

Fitted EquipmentTHE GRILL• Note: The door must be open when thegrill is used.• Caution: When the grill is being used,accessible parts may be hot; youngchildren should be kept away.• Never cover the grill pan or grid withcooking foil, or allow fat to build up in thegrill pan as this creates a fire hazard.• Keep all flammable material away from theappliance.To light the grillPush in the control knob and turnanticlockwise to the large flame symbol.Keep the knob depressed, and press theignition button (if fitted), or use a hand heldspark ignitor or gas lighter. The knob mustbe held in for 15-20 seconds beforereleasing.Detachable grill handle (if supplied)Place the handle (shield uppermost) over theedge of the grill pan at the recess and slidealong to position centrally between the twolocator bumps. To remove the handle, placethe grill pan down, and lift the handle slightlyas you slide it along the recess.Using the grillPush in the grill pan until it locates centrallyunder the grill burnerThere are three different grilling positions asthe trivet can be inverted to give a high orlow position or it may be removed.1. The high trivet position is suitable fortoasting bread.2. The low trivet position is suitable forgrilling all types of meat.3. With the trivet removed the food is placeddirectly on the base of the grill pan, eg;when cooking dishes such as whole fish.Always preheat the grill for 3 minutes forbest results.When you have finished grilling, check thecontrol knob is in the off positionTHE OVEN• Caution: When you are cooking, keepchildren away from the vicinity of theoven.• Important: A safety device stops theignition being used when the oven door isclosed.• Do no use foil on the oven shelves as thiscreates a fire hazard, and can hindercirculation of heat.• Keep all flammable material away fromthe appliance.55

Fitted EquipmentTo light the oven1. Open the oven door and turn the controlknob anticlockwise to the required gasmark. Push in and hold in the controlknob, and either press the ignition button(if fitted) or use a hand held spark ignitoror gas lighter.2. Once the burner has lit, close the ovendoor and hold the knob in for 15-20seconds.3. If the flame goes out, the flame sensingdevice cuts off the gas supply to theburner. To light the oven again, wait for 3minutes then repeat the above procedure.To turn off - Push in the control knob andturn clockwise.56PreheatingThe oven must be preheated for 10 minuteswhen reheating frozen or chilled food, andwe recommend preheating for all yeastmixtures, batters, soufflÈs and whiskedsponges.Using the ovenThe shelf positions in the oven can bealtered. If you prefer darker cooked results,cook on a higher shelf. For paler results usea lower shelf.The cake tray and roasting tin that aresupplied with this appliance are the largestwhich can be used for good results and evenbaking. Extra shelves, tins or trays can beordered from your supplier.Place food items on the tray and position thetray on the centre of the shelf, leaving oneclear shelf position between shelves to allowfor circulation of air.CLEANINGCaution: Any cleaning agent usedincorrectly may damage the appliance.Always let the appliance cool beforecleaning.Some cooking operations generate aconsiderable amount of grease. Thiscombined with spillage can become a hazardif allowed to accumulate on the appliancethrough lack of cleaning. In extreme casesthis may amount to misuse of the applianceand could invalidate your guarantee.Do not use caustic pastes, abrasive cleaningpowders, coarse wire wool or any hardimplements as they will damage thesurfaces.All parts of the appliance can be safelycleaned with a cloth wrung out in hot soapywater.Burner caps and headsImportant: Allow burners to cool beforecleaning.Caution: Hotplate burners can be damagedby soaking, automatic dishwashers (ordishwater powders/liquids), caustic pastes,hard implements, coarse wire wool andabrasive cleaning pastes.For the burners to work safely, the slots inthe burner head, where the flames burn,need to be kept clear of deposit. Clean witha nylon brush, rinse and dry thoroughly.Clean with a mild cream cleaner eg; Jif, oruse a moist soapy Brillo pad.Note: Fixed burners (if fitted): Some versionsincorporate fixed burners. These burners aresecured to the hob with 2 screws. Fixedburners must be cleaned whilst in position.Make sure that the gap between the burnerand the hotplate does not become blockedwith grease.

Glass parts (if fitted)DOOR PANELS, FACIA PANEL,HOTPLATE LIDDo not use abrasive cleaners or polishes.Use a mild cream cleaner, eg; Jif. Rinsethoroughly and dry with a soft cloth.The inner door glass panel can be removedfor cleaning; open the door wide, hold thebottom and top edges and slide out. Whenreplacing the glass panel, hold it level andstraight with the grooves in the door trimsbefore sliding back in.Painted, plastic and gold coloured partsDOOR FRAME & HANDLES, CONTROLKNOBSOnly use a clean cloth wrung out in hotsoapy water.Vitreous enamel partsGRILL PAN, HEATGUARD, OVEN/GRILLCOMPARTMENT(S), HOB SPILLAGE WELL,PAN SUPPORTSUse a mild cream cleaner. Look for one thathas the Vitreous Enamel Council'srecommendation seal, eg; Jif.Fig. 1 Chrome Plated PartsChrome plated parts (Fig 1)GRILL GRID, SHELVES, SHELF RUNNERSDo no use abrasives or polishes. Use amoist soap pad, eg; Brillo. Shelf runners canbe removed for cleaning. Grasp the runnersand slide out of the hanging holes as shownin fig 1.Stainless steel surfaces(stainless steel models only)Only use a clean cloth wrung out in hopsoapy water, and dry with a soft cloth. Donot use undiluted bleach or any productscontaining chlorides as they can permanentlydamage the steel.Fitted EquipmentSome foods are corrosive, eg; vinegar, fruitjuices and salt, and they can mark ordamage stainless steel if they are left on thesurface for any length of time. Wipe anyspillage immediately.Sharp objects can mark the surface ofstainless steel but will become lessnoticeable with time.57

Fitted EquipmentCARVER SPACE HEATERSPlease read these cautions before usingyour heater.In the event of a gas leak, immediatelyturn off all appliances and the gas supplyat the cylinder. Contact your nearestapproved service agent without delay.• The gas supply to the heater must befrom an approved pressure regulator ofadequate capacity. Under NOcircumstances should an industrial oradjustable regulator be used on caravans.• The heater must not be operated whilerefuelling or when the vehicle is in aconfined space such as a garage. The58heater MUST NOT be used if the flue hasbeen damaged.• The Carver 2000 and 5500 range ofheaters MUST NOT be used while thevehicle is in motion.• The products of combustion pass throughthe vehicle floor and requires unrestrictedair entry beneath the vehicle into which itis fitted. A minimum of 3 sides of thevehicle MUST be exposed at all times.This is to allow for dispersal of theunderfloor combustion products. If thereis a possibility of the sides becomingblocked by snow or mud, then the heaterMUST NOT be used. Every effort must bemade to clear obstructions before use.• There MUST NOT be a mantelpiece orshelving sited above the heater.• Curtains MUST NOT hang within 150mmof the sides of the heater, or within300mm above the top of the appliance.• DO NOT place furniture or upholsterycloser than 5mm to the sides of theheater.• Where children, the elderly or infirm arepresent, we recommend that a guard befitted around the heater when in use.• Always wait three minutes beforeattempting to relight the heater afterswitching off or the heater going in to failsafe shut down.• DO NOT obstruct the gap at the bottomof the heater or the outlet grille slots.• This heater does not contain anyasbestos or asbestos related products.• Aerosols and highly inflammable materialsMUST NOT be stored in compartmentsbehind or adjacent to the heater.• These heaters must be switched off andthe gas supply turned off while thevehicle is in motion.• When the heater is first used, it isrecommended that you open a window ordoor and turn the temperature setting tomaximum for one hour. This will allow anyodours when first using the appliance toescape. Note: If odours persist, contactyour local distributor.CARVER 2000P, 2000A and FANMASTERTo Light and Adjust the Heater - GasOperation1. Ensure the gas is turned on at thecylinder.2. Lighting the Heater:2000P, and 2000 FanmasterPress the control knob (3) down and turnto the ‘LOW/ ’ position (4) and thenpress firmly downwards. A click will beheard as the igniter operates, to light theheater. If a gas cylinder has beenreplaced, it may require severaloperations of the igniter to light the flame.

Fitted Equipment21 OFF2 INDICATOR LIGHT3 GAS CONTROL KNOB4 LOW/IGNITION5 HIGH3Observe through the viewing windows onthe lower half of the front case, that theburner lights.2000A and 2000 Fanmaster(12V ‘Auto’ Ignition)As above turn to the ‘ ’ position andpress firmly down. A continuous tickingwill be heard, as the spark generator isactuated. An indicator light (2) built intothe control knob will light up when theflame is lit.3. Continue to hold the knob down for 20seconds and release. The flamesupervision device will now have beenactuated. The knob can now be releasedand adjusted to the desired setting asmarked on the heater top panel.4. If the burner is extinguished for anyreason, or fails to remain alight, the heaterwill shut down to a safe condition. In thecase of the 12V ‘Auto’ ignition models415(2000A and Fanmasters with this ignitiondevice), the continuous ticking of thespark generator will be heard until turnedoff.5. To turn off the heater at any time, turn theknob to the ‘O’ (1) position.6. Wait for at least 3 minutes, after shutdown, before attempting to relight theseheaters.Electric Heating - Fanmaster models onlyCautions:• Read the operating instructions beforeusing the Fanmaster.• Read the operating instructions for theCarver gas heater before using it inconjunction with the Fanmaster.• One or more duct outlets must be openwhilst the Fanmaster is in use.• The 230V external supply to the vehiclemust be disconnected before the caravanis towed.General DescriptionThe Fanmaster is an automatically controlledfan designed to distribute warm air aroundthe caravan via ducting.All of the functions of the 2000 Fanmasterare controlled independently of the gascontrol - by front case slide switches whenright-hand build is installed (Fig. 1), or bywall-mounted control panel for a left-handinstallation (Fig. 2) .Fig. 1Fig. 2The air is heated either by the Fanmaster’sown electric element or by the Carver gasfired heater. Both the Carver gas heater andthe Fanmaster can be used at the same timeproviding the fan is in operation.The built-in elements are automatically ormanually switchable between 0, 1kW and2kW and require a 230V AC mains supplydrawing a maximum of 8 amps at 2kW. Thefan requires a 12V DC supply and will take1.5A at maximum speed.59

Fitted EquipmentWhen using electric heating the caravantemperature is regulated by the thermostatmounted at the top of the installation box butwhen using the gas heating the temperatureis controlled by the gas heater thermostat.The night setting is a 1kW convector heatersetting. In the summer the fan may beoperated without any heat input to distributecool air.The Fanmaster has an air deflector allowingthe majority of air to be directed down onefan outlet. For example, down the longestducting run. This may have been preset oninstallation.The duct outlets are generally of the butterflytype and may be opened or closed byadjusting the butterfly valves. Twisting thedisc in its housing directs the flow in thedirection required. One outlet on each leg ofthe duct layout must be kept open.ServicingIn order to ensure that your heater continuesto operate effectively, you will need toarrange for it to be serviced at least once ayear by a competent and trained serviceengineer. By law no one is permitted to dealwith the installation and servicing of gasappliances unless they have provencompetence. Contact your nearestauthorised caravan distributor if service orrepair is required.FANMASTER CONTROLLER OPERATIONS - SLIDE SWITCH ON HEATER TOP(R.H. INSTALLATION)POSITION OPERATION (without gas) OPERATION (with gas)0 Off Gas convectorManual fan speed - Temperature Blown hot air distribution1 slider governs the fan speed.For cool air distribution.1kW electric convector heating,Electric and Gas convection, but a high gas2 no fan. Temperature slider heater output will inhibit the electric heatingselects desired room temperature to maintain safe operating temperatures.1kW electric fan heating,Electric and Gas blown distribution. Fan3 fan remains slow. speed adjusts automatically based onoutlet temperature.42kW electric fan heating. Fanautomatically adjusts speed to suit.Electric and gas blown distribution. Fanspeed adjusts automatically.FANMASTER CONTROLLER OPERATIONS - WALLSWITCH CONTROL(L.H. INSTALLATION)POSITION OPERATION (without gas) OPERATION (with gas)0 Off Gas convectorManual fan speed - Wall switchBlown hot air distribution12knob governs the fan speed.For cool air distribution.Automatic fan speed, temperatureof heater governs fan speed.Blown hot air distribution with automaticfan speed control.1kW electric convector heating, no Electric and Gas blown distribution. Fan3 fan. Wall switch knob selects speed adjusts automatically based ondesired room temperature.outlet temperature.41kW electric fan heating, fanElectric and gas blown distribution. Fanremains slow.speed adjusts automatically.52kW electric fan heating. Fanautomatically adjusts speed to suit.60

CARVER 5500 Turbo FanmasterSpace HeaterRead the cautionary notes for the CarverSpace Heaters before using your heater.Before Lighting the heaterEnsure the gas is turned on at the cylinder.Lighting the Heater (Fig. 3)For the auto ignition press the control knob(4) down and rotate to the ‘ ’ position (2),maintaining downwards pressure. The igniterwill be heard to operate with a continuous‘ticking’ noise. On ignition the control knobindicator (3) will illuminate to show that aflame is present.After the burner has lit, continue to holddown the control knob for a further 10seconds. Release the control knob and theindicator should remain illuminated to showthat the burner has remained alight.For the Piezo ignition, press the control knob(4) down and rotate to the ‘ ’ position (2),maintaining downwards pressure. Press theignition button (7). Check through the viewingwindow on the front case that the pilotburner is alight, if so continue to hold thecontrol knob down for ten seconds.Release the control knob and the pilot burnershould remain alight. It may require severaloperations of the igniter to light the burner.Fig. 36 5431 OFF2 IGNITION POSITION3 INDICATOR LIGHT4 GAS CONTROL KNOB5 HIGH6 LOW7 ‘ ‘To operate the main burner, turn the controlknob further anti-clockwise and set it at thedesired comfort level, between the high flameand low flame positions (5 & 6).The main burner will ‘cycle’ automatically asrequired by the thermostat to maintain theset temperature, but the pilot light will alwaysremain alight.Turning off the heaterTurn the control knob fully clockwise to the‘•’ position (1).127Fitted EquipmentFANMASTERGeneral DescriptionThe Fanmaster is an electric heating andblown air system controlled by the sliderswitches on the front case of the heater (Fig.4).The automatically controlled fan distributeswarm air around the caravan via ducting. Theair is heated either by the Fanmaster’s ownelectric element or by the Carver gas firedheater. The Carver gas fire and theFanmaster can be used at the same timeproviding the fan is in operation.The built-in elements are automatically ormanually switchable between 0, 1kW and2kW and require a 230V AC mains supplydrawing a maximum of 8 amps at 2kW. Thefan requires a 12V DC supply and will take1.5A at maximum speed.When using electric heating the caravantemperature is regulated by the thermostatmounted at the bottom right of theinstallation box but when using the gasheating the temperature is controlled by thegas heater thermostat. The night setting is a1kW convector heater setting. In the summerthe fan may be operated without any heatinput to distribute cool air.The air ducting outlets are generally of thebutterfly type and may be opened or closedby adjusting the butterfly valves. Twisting thedisc in its housing directs the flow in thedirection required.61

Fitted EquipmentOne outlet on each leg of the air ductinglayout must be kept open at all times.Note:Mains hook-up is needed for positions 2, 3and 4, the current consumption will beapproximately 4 amps for positions 2 & 3 andapproximately 8 amps for position 4.If you suspect that your mains hook-up isinadequate to supply the 8 amps required forposition 4 in addition to your existing mainsload, then for initial warm-up, use the Carvergas heater on a high setting and theFanmaster on the position 1 setting.FANMASTER CONTROLLER OPERATIONS (Fig. 2)POSITION OPERATION (without gas) OPERATION (with gas)0 Off Gas convectorManual fan speed - Temperature Blown hot air distribution1 slider governs the fan speed.For cool air distribution.1kW electric convector heating,Electric and Gas convection, but a high gas2 no fan. Temperature slider heater output will inhibit the electricselects desired roomheating to maintain safe operatingtemperature.temperatures.1kW electric fan heating,Electric and Gas blown distribution. Fan3 fan remains slow. speed adjusts automatically based onoutlet temperature.42kW electric fan heating. Fanautomatically adjusts speed to suit.Electric and gas blown distribution. Fanspeed adjusts automatically.Fig. 4When comfortable change to either positions2 or 3 and turn the gas heater off.Typical mains current consumption is:Carver Cascade 2 water heaterTravelling kettleBattery charger623.6A approx.3.2A approx.1.0A approx.Portable colour TV60w light bulbFanmaster on position 4Fanmaster on position 2 or 30.3A approx.0.3A approx.8.3A approx.4.2A approx.The normal mains supply to UK sites arerated at 16A but some sites have only a 10Acapacity.ServicingIn order to ensure that your heater continuesto operate effectively, you will need toarrange for it to be serviced at least once ayear by a competent and trained serviceengineer. By law no-one is permitted to dealwith the installation and servicing of gasappliances unless they have provencompetence. Contact your nearest caravandistributor if service or repair is required.SafetyTo prevent over-heating of the electricelements at least one warm air outlet mustbe open at all times. It is recommended thatone outlet should be of the non-closabletype and not a butterfly.If all the outlets are closed the self-holdthermal trip will switch off the power to theelements. If this happens, open the outlets,switch the heater power off and wait until theunit has cooled down, the unit will then resetitself.Make sure that clothing etc. is kept clear ofthe back of the heater.

Warranty ConditionsThe space heaters are covered by a two yearguarantee from the date of purchase of theappliance or the registration date of thevehicle in which it is installed.The guarantee is liable for all manufacturingfaults and defective components.We strongly advise that all repairs on the unitare carried out by authorised ServiceCentres.The guarantee does not cover installationerrors, tampering or damage caused byfrost.PRIMUS AQWE6 (AQUAFLEX)HEATING SYSTEMPlease read through the following operatinginstructions carefully before starting theheater.GeneralThe AQWE6 (Aquaflex) is a modern heaterintended for the supply of central heatingand domestic hot water for caravans/motorhomes. The heater is integrated with a 9-litredomestic water heater and is equipped 1+2= 3 kW electrical heating coils. The gasburner operates in three stages of 2, 5, 6and 7 kW. Regulation is fully automatic, andthe heater drops to a lower stage the closerone approaches the selected temperature.This means that the heater operates veryquietly and with low electrical power and gasconsumption for most of its operating time.Fig. 1 Control PanelFitted EquipmentControl panelThe heater is regulated via the control panel,which is integrated with the PMS2000GPcontrol system (Fig 1). The control panel has4 switches for setting the desired functionsand a knob for setting the desiredtemperature. To reach 20°C set the turningknob accordingly. The control range isapprox.5-30°C.GASIGN = Gas ignition will take place ifheating is required1KW = 1 kW electrical coil connectedif heating is needed.2KW = 2 kW electrical coil connectedif heating is needed.WATER& HEAT = Tap water heating will be givenpriority.HEAT = Heat will be produced whenrequired.GASIGN means that the gas heater will startif heating is required. This switch should bein the On position at all times, except if thegas heater is not required to operate forwhatever reason.1KW and 2KW means that the electricalheating coils will be switched on as heatingis required. Both 1 and 2 kW electricalheating has to be selected when 3 kW isrequired.63

Fitted EquipmentNote. The choice of electrical power isultimately governed by the current availablefrom the site supply. A 5A outlet can allow1000W, a 10A allows 2000W and a 16Aallows 3000W.WATER & HEAT means that heating tapwater takes priority over room heating: Whenlarger amounts of hot water is required forshowering, washing or such the this buttonshould be in the ON position. During coldperiods enough hot water is normallyproduced at the same time as the living areais heated so it can be set in the HEATposition and it should always be in the HEATposition when no water is fed into the waterheater. Heat will still be produced if thethermostat is not turned down.HEAT. Hot water will be produced, asdescribed above, as a function of therequirement to heat the living area exceptwhen the outside temperature is high and noheating of the living area will be required.Then the setting should be WATER & HEATand the thermostat turned down.Both gas and electric can be connected atthe same time if so desired.NB. The programmable timer unit must be inthe ON position to operate the heatingsystem. (see Programmable TimerInstructions)Mode of operation of the heaterControl of the heater takes place fullyautomatically once the basic settingdescribed above has been made. If bothelectrical and gas heating is selected priorityis given to electrical heating.If the setting has been made for automaticwater heating, WATER & HEAT, priority willalways be given to hot water. Except in thecase of a living area which has fully cooleddown, when the heater will prioritise roomheating until the heat in the room hasreached an acceptable level. The heater willthen check the room temperature and watertemperature alternately and will generateroom heating or hot water as required. Thismeans that hot water is always available,and that room heating is provided asrequired. It takes about 15-20 minutes toproduce hot water starting from a fully coldsystem.The temperature of the hot water is limited to70°C. Note that 70°C is a high hot-watertemperature and precautions should betaken during use.If the red lamp lights up, this indicates thatthe heater has gone into safety mode as aconsequence of the gas heater havingattempted to ignite and having failed toignite or that the built in secondary overheatthermostat has acted. This is usuallybecause the gas supply has run out, but itmay also be caused by the presence of air inthe gas line or by a blocked gas supply orthat the heater has been running withoutfluid.Turning the GASIGN Off and On shouldnormally restart a tripped gas heater. Notethat for the secondary overheat thermostatthe heater has to cool down.Starting the heating system1. Make sure that the system has a powersupply (12 V/220 V)2. Open the gas cylinder3. Check that the heating system is filledwith water/glycol (60/40)4. Set the desired temperature.5. Turn on the desired function on theswitches.6. If optional Timer is installed check that itis turned to On. (See Timer instructions)Shutting down the heating system1. Turn GASIGN and 1KW and 2KWswitches Off. (If Timer is installed youonly need to turn it Off )2. Close the gas cylinder3. Empty the water heater if there is a riskof frost4. Switch off the supply voltage64

Filling the water heater1. Ensure that the drain valve of the heateris closed2. Start the fresh water pump3. Open a water tap and leave it open untilwater arrives. If a mixing valve is presentset it to the hot position and allow fillingto take place as described above.Emptying the domestic hot water heater1. Switch off the fresh water pump. When atrisk from frost and heating is turned off,always drain the domestic hot water fromthe boiler2. Open the drain valve on the heater byrotating the red knob by two clicks in ananti-clockwise direction (Fig.2)3. Open all the hot water taps.4. Check that water is running in thedrainage pipe, (The easiest way is to lookunder the vehicle). This is particularlyimportant during the winter, when snowand slush may block the pipe.Maintenance of domestic Hot waterheaterThe heater may be descaled with vinegar orformic acid, or alternatively with a specialdescaling agent.The agent is added to the fresh water that iscirculating through the system. Afterdescaling, the system is flushed with cleanwater. (Do not use agents containingbleach). The domestic hot water heater canbe removed from the main heater withoutaffecting other functions. Depending on theposition of installation the heater may requireremoval to provide access to the domestichot water heater tank.Note. The exhaust outlet in such a casemust be removed and refitted. The small O-ring in the exhaust-connecting piece must bereplaced whenever the exhaust outlet isremoved.The domestic hot water heater can bewashed out and refitted. Check that theO-ring is undamaged before fitting.Note: Only nuts with metal friction lockingFig. 2 may be used. Check that the domestic hot Fig. 3Fitted Equipmentwater heater is leak-proof after fitting bypressurising the system.Electrical coilsThe heater is equipped with 2 electrical coils,with an output of 1000 + 2000W. Regulationis taken care of automatically by setting theswitches as described earlier. The electricalcoils have a mechanical overheatingprotection device capable of tripping if thesystem is operated without water.Pressing the red button on the side of theheater (Fig.3) performs resetting of thetripped overheating protection. Resetting isonly possible after the system has cooleddown, and the button must be pressedfirmly. If the protection trips once more, thecause of the fault must be investigated.Consult a specialist.65

Fitted EquipmentThe heater must only to be connected tothe mains via the integrated 3 wayconnector provided.If the cover to the electrical heater isremoved the mains must be disconnected.Important Note:Any interference with and modification to theheater may lead to serious functionalproblems. Changes to the gas or exhaustcomponents can pose a direct risk to life,and Primus declines all responsibility in theevent of such changes being made.1. The guarantee lapses with immediateeffect if any work is performed other thanby a specialist.2. Use only Primus original spare parts.3. Only a specialist must carry out repairs.4. The small O-ring must be replaced if theexhaust outlet is dismantled.5. The gas installation and any tests mustconform to national requirements.6. Keep the exhaust outlet and the air inletfree from dirt, snow and ice.7. The heater must not be in use whenrefuelling and when in the garage.8. The domestic hot water heater isequipped with a safety valve, whichopens at approx. 3 bar. (Any drainagetakes place via a drainpipe through thefloor.)9. The heater must be run with water/glycol(60/40) in the system at all times. If theheater is operated dry, it will normally bestopped by the operating thermostat. Thethermostat will close after cooling, andthe heater will then function normallyprovided that water is present in thesystem. If the operating thermostat failsto trip for any reason in the event of thesystem overheating, the heater will bestopped by a built-in secondary overheatthermostat. A red LED on the controlpanel indicates this. The electricalcartridge has a separate overheatingprotection.Technical DataAQWE6GasI3BP /I3+Working gas pressure30 mbar/28-30/37mbar IWall exhaustYesVolume Boiler9 litHeating-up time hot water20 minutesMax D: H: W. pressure2,8 barLength x Width x Height 500 x 400 x 300Weight (without water)15,1 kgNumber of steps in gas burner 3Max power2.6/5.0/7.0 kWTechnical DataAQWE6Max gas consumption210/420/580 g/hNumber of steeps electric heater 3Output electrical power1/2/3 kWWorking voltage12 V = /230 V ACElectric power consumption 12 V 300/400/750 mAElectric power consumption 230 V 5/10/16 AExhaust length max.45-mmExhaust diameter54,3-mmAir inlet diameter88,3-mm66

Fig. 1PROGRAMMABLE HEATINGTIMER (USER INSTRUCTIONS)(Fig.1)Features: -• 7 Day / 24 Hour Programmable Timing• 12V DC Operation• Manual and Timed Override OptionUSER INSTRUCTIONSSetting the Clock: -1. Move the Function Select Slider Switchinto the top "Clock set / Clock Adjust"position indicated by a Clock Face symbol.2. Set the day by pressing thecorresponding day button M = Monday,T = Tuesday, etc.3. Set the time by using the + and - arrowkeys to increase or decrease the timeshown until the correct time is reached(Holding the + and - keys in will Scrollquickly to the desired time)Programming the Heating Timer: -1. Move the Red slider switch to thePosition Marked "PROG" (Program).2. Using the + and - Arrow Keys set the firstProgram time, the ON time (note - ON isshown in the top right corner of thedisplay)3. Set the Day or Days this switching timeshould be active, using the Day Selectbuttons.(Note - an active day will appear as markat the bottom of the displaycorresponding to a day select button.)4. Press the Enter Key to store thisinformation. After pressing the Enter keythe display will change, ready to set thenext time. OFF or ON will be shown in thetop right corner indicating which time isnext.5. The next switching time can now beprogrammed by repeating steps 2, 3and 4.6. Run the programmed switching sequenceby moving the Function Select Slider tothe "Auto" position. The module will nowFitted Equipmentcarry out the switching operations asprogrammed, displaying the current timealong with the state of the switch i.e. ONor OFF.Note - the Time display will not be seen if12V DC is not present.Timed / Manual Override.This function gives the ability to Manuallyoverride the Timer switch Program turningthe Heating system ON or OFF, and alsoallows the user to set this override to last fora timed period (set in hours)Manual Override: -1. Move the Function select slider down tothe "Timed / Manual Override" position.The display will read - h with ON or OFFto the Right (depending on the currentswitch state).2. Change the current switch state press the"On / Off Switch Select" button thedisplay will change to read the newswitch state on the right side. This timerwill remain in this state until the SwitchSelect Button is pressed again or theFunction select slider is returned to the"Auto" position and a switching programis run.67

Fitted EquipmentTimed Override: -1 Move the Function Select Slider down tothe "Timed Manual Override" position.The display will read - h with ON or OFFto the Right (depending on the currentswitch state).2. Set the override duration using the + and- "Up / Down Keys" the time is shown in(h) hours and (d) days and the set timecan be from 1 to 23 hours or 1 to 27days.3. Change the current switch state to theoverride state by pressing the "On /OffSwitch Select" button.4. Return the Function select slider to the"Auto" position. The override will startONLY when the Function Select Slider isreturned to the "Auto" mode, when inauto mode the ON / OFF display will flashto show the override state.Note on Duration: - If X hours areselected, the override timer decrementationwill start on changing mode.If X days are selected, the override timerdecrementation will start at midnight (thepresent day counting for a whole day).Power SupplyThe Programmable Timer Module requires a12v supply to operate fully, without thissupply switching actions will not take placeand the display in "Auto" Mode will notappear. The unit is fitted with internal batterybackup of 25000hrs minimum reserve thiswill retain all programming and allow newprogramming when a 12v supply is notpresent.68

Fitted EquipmentPRIMUS HEATING SYSTEM69

Fitted EquipmentPRIMUS HEATING SYSTEM70

Fitted EquipmentTHETFORD CASSETTEPORTA POTTIINTRODUCTIONThe Cassette Porta Potti is constructed ofhigh quality plastics for durability and has ahigh gloss finish that is easy to clean andmaintain. The unit consists of two sections, apermanently installed toilet system and aslide out waste holding tank — CASSETTE.The toilet section includes a seat and cover,flush and valve blade opener knob, toilettissue compartment and holder, waste levelindicator, built-in toilet fluid storagecompartment, a drip tray — a drain tubeassembly and a fresh water tank.The unique Cassette section is locatedunderneath the toilet and is removed foremptying from outside the caravan throughan access door. A rotating pour-out spout,automatic holding tank vent, air releasevalve, valve blade, carrying handles andhand grips are incorporated into theCassette.PREPARING FOR USE1. Open access door on the side of thecaravan and swing out fresh water fillfunnel.2. Fill fresh water tank using a hose orjerrycan until water funnel level reachesneck. Tank capacity is 15 litres. AquaRinse may be added to improve cleaningof bowl and flushing of unit.3. Replace cap. Swing water fill funnelinward until it touches side of water tank.Note: 150ml of water will remain in fillbottle when fresh water tank is empty.4. Next add Aqua Kem to Cassette for controlling odours. Depress retaining clip.5. Remove cassette by pulling straight out.When Cassette hits stop, tilt downwardslightly and remove (stop for safety whenCassette is full).6. Position tank vertical and swivel pour outspout upward.7. Remove cap. Remove deodorant fromstorage compartment. Add 100ml of AquaKem or 120ml of Aqua Kem Bio throughpour out spout. Add small amount ofwater through spout to cover tankbottom. Replace cap and return pour outspout to its original stored position.Note: As an alternative deodorant can beadded to Cassette through the valve bladeopening. Hotter weather or longer retentiontime may require addition of more Aqua Kem.CAUTION: Do not add Aqua KemConcentrate or Aqua Kem Bio directly intotoilet bowl while Cassette tank valve blade isclosed. Pressure due to heat and altitudechange can build up in the Cassette tankcausing bowl contents to splash upwardupon opening the valve blade, if opened toofast. Before each use, open and shut theCassette valve blade to vent the tank1 23 45 6771

Fitted Equipment8. Slide the Cassette, pour out spout facingoutside into the caravan through accessdoor. Never force insertion or removal ofthe Cassette tank, damage to system canoccur.9. Make sure the Cassette is secured by theretaining clip. Close and lock access door.OPERATIONFlushing (Electric Models)10.Before using the toilet we advise to addsome water to the bowl by pressing downthe flush knob. This avoids marking thebowl. Water will stop flowing when knobis released.11.To flush after use, press the flush knobdown while turning in an anti-clockwisedirection. The turning motion opens thevalve blade, emptying the toilet bowl. Thisprocedure results in the best bowl rinseand most efficient use of water. Afterflushing, turn the knob in a clockwisedirection to close the valve blade. Thetoilet can also be used with valve bladeopen, which allows the waste to godirectly into the holding tank.Flushing (Manual Models)10.Before using the toilet, we advise you toadd some water to the bowl by turningthe flush knob in clockwise direction.When flush knob is released it will turnautomatically back.11.To flush after use, turn the valve knob inanti-clockwise direction and turn the flushknob. This procedure results in the bestbowl rinse and most efficient use of water.TOILET TISSUE12.Toilet tissue is stored in the speciallydesigned storage compartment that helpskeep tissue clean and dry (electric modelsonly). Tissue can also be suspended on atissue holder using the special wall mountbracket, if desired.13.To replace tissue, remove tissue holderfrom compartment by pulling up on tissuecover. Hold bottom of tissue holder in onehand and cover in the other, and turn inopposite directions until you hear a click.Pull apart. Place tissue on holder, insertprongs of cover into holder. Hold coverand holder and twist in opposite directionuntil locked. Aqua Soft toilet tissue isrecommended for best results.Emptying the CassetteThe Cassette capacity is 20 litres and shouldbe emptied when the waste level gaugeindicator goes from green to full red.The gauge does not begin to move fromgreen to red until the tank is over half full.8 910 ELECTRIC 10 MANUAL11 ELECTRIC 11 MANUAL12 ELECTRIC 13 ELECTRIC72

Caution: Do not allow Cassette to becomeoverfilled, see Trouble Shooting section foremergency emptying procedure.The holding tank features a unique slidingcover (1) which guarantees optimal hygiene.The sliding cover moves automatically whenthe holding tank is inserted. When holdingtank is removed, the cover automaticallyassumes its correct position. To clean theholding tank, you may remove the covermanually by sliding it towards the pour-outspout.To empty Cassette be sure that the valveblade is in the closed position.14.Open the access door on side of caravan.Depress the retainer clip, pull Cassetteuntil stop, tilt and remove Cassette.15.Carry the Cassette using the lowercarrying handle, pour out spout up, to anormal household type toilet or otherauthorised disposal point. Set Cassette invertical position on the ground and rotatepour out spout upward.16.Remove spout cap. Grasp unit by uppercarrying handle nearest to pour out spout.Place other hand on upper rear grip sothat the air relief valve button can bedepressed with thumb while emptying, toensure smooth outflow of tank contents.When empty, rinse tank and valve bladewith water.Note: Depress air release valve buttononly when pour out spout is pointeddownwards.17.After preparing for use, slide the Cassetteinto the caravan. Check to make sure thatthe retaining clip secures the tank in alocked position. The pour out spout endof the tank should be visible through theaccess door opening. Add water to thefresh water tank as outlined in “Preparingfor Use” section. Close and lock accessdoor.CLEANING AND MAINTENANCENo routine maintenance is required on theThetford Cassette Porta Potti. The use ofAqua Rinse helps to clean and protect thetoilet bowl, valve blade and seals duringflushing. Do not use strong householddetergents or cleaners with chlorine, solventsor acid contents, as they will damage valveseals.Empty Cassette and rinse tank with clearwater. Use a mild soap to clean toilet bowl,seat and cover, as well as exterior of toiletFitted Equipment14 1516 1718 19 ELECTRICunit and Cassette. Replace tank insidecaravan.Note: Pour-out spout and vent plug can beremoved. Seals should be greased ifnecessary with acid-free vaseline.73

Fitted EquipmentTHETFORD CASSETTEC-200 CW (Manual)and C-200 CE (Electric)FEATURES1. Removable seat and cover.2. Rotatable bowl.3. Valve blade handle: opens and closesvalve blade.4. Flush-handle activates the flush by liftingand pushing down the handle.4a C-200 CE. Flush button: activates flush.4b C-200 CE. Valve blade buttons: openand close valve blade electronically.5. Power-supply for the waste-levelindicator: two batteries, type: Penlite 1,5VAA alkaline.6. Waste-level indicator: indicates whenholding tank requires emptying.7. Rotating pour-out spout: makes emptyingholding tank easy and convenient.8. Upper carrying handle9. Automatic holding tank vent: vents theholding tank when the tank is inserted inthe toilet. This prevents under- oroverpressure in the holding tank.10. Valve blade opener.11. Sliding cover: closes automatically whenholding tank is taken out. Guaranteesoptimal hygiene.12. Valve-blade13. Vent button: vents the holding tank toavoid splashing while emptying.14. Hand grip15. Access door16. Waterfill door7404C-200 CW only C-200 CE only05060304a 06 1604b0102C-200 CWonly08 07 09 14 121015131114

Fitted EquipmentCASSETTE C-200 CW AND C-200 CEThe toilet section of the C-200 includes arotatable bowl, removable seat and cover, aconsole with a flush handle/flush buttons, abuilt in flush-watertank and a waste levelwarning indicator. Underneath the bowl, thevalve blade handle is located.PREPARING FOR USE1. Open access door pull retaining clipupwards (fig. 1).2. Remove holding tank by pulling straightout. When holding tank hits the stop, tiltfront end downwards slightly and remove(fig. 2).3. Position tank vertically and swivel pouroutspout upwards (fig. 3).4. Remove the cap of the pour-out spout.Add required quantity of toilet fluidthrough pour-out spout then add approx.2 litres of water through the spout tocover holding tank bottom. Replace capand return pour-out spout to its originalstored position (fig. 4).Note: Warmer weather or longerintervals between emptying the wastetank may require additional toilet fluid.Use only Thetford toilet fluid to achievethe best results.Caution: Never add toilet fluid directlyinto toilet bowl.5. Slide the holding tank into positionthrough access door (fig. 5).6. Make sure the holding tank is secured bythe retaining clip. (fig. 6).7. Open the waterfill door and add 50 ml ofAqua Rinse. Aqua Rinse results in abetter flush and improves the hygiene ofthe toilet. Then fill the watertank withfresh water using a jerrycan or a hose.Tank capacity is 7 litres (fig. 7).OPERATION8. Turn the bowl in the most comfortableposition (fig. 8)9. C-200 CW only: Before using the toilet itis recommended to flush some waterinto the bowl by lifting and pressing downthe flush handle (fig. 9).9a.C-200 CE only: Before using the toilet itis recommended to flush some water intothe bowl by pressing and releasing theflush button (fig. 9a).1 23 45 67 899a75

Fitted Equipment10. After use open the blade by turning theblade-handle anti-clockwise (fig. 10).10a.C-200 CE only: After use open the bladeby pressing the ‘open’ button (fig. 10a).11. C-200 CW only: To flush, lift the flushhandle and press it down (fig. 11). Afterflushing, close the blade by turning theblade handle clockwise.11a. C-200 CE only: To flush press the flushbutton (fig. 9a). After flushing, close theblade by pressing the close button onpanel (fig. 11a).The toilet may also be used with thevalve blade open, which allows thewaste to pass directly into the holdingtank.The waste holding tank is located underneaththe toilet and is removed for emptying fromthe outside of the vehicle through an accessdoor. A rotating pour-out spout, automaticholding tank vent, air release valve, valveblade, carrying handles and hand grip areincorporated in the waste holding tank. Asliding cover guarantees you optimalhygiene.EMPTYING THE HOLDING TANKThe holding tank capacity is approx. 17 litresand the tank should be emptied when thewaste-level indicator lights up. The wastelevelindicator lights up when the holdingtank contains more than 15 litres of waste.CAUTION: Do not allow the holding tank tobecome overfilled. See trouble shootingsection for emergency emptyingprocedure.12. Open access door and remove theholding tank. The holding tank can onlybe removed when the valve blade isclosed (fig. 12).13. Carry the holding tank to a normalhousehold type toilet or other authorizeddisposal point. Place the holding tank invertical position and rotate pour-outspout upwards (fig. 13).14. Remove the spout cap. Grasp unit byupper carrying handle nearest to pouroutspout. Place other hand on upperrear hand grip so that vent button canbe depressed with the thumb whileemptying. This ensures a smoothoutflow of the tank contents. (fig. 14).Note: Only depress the vent buttonwhen pour-out spout is pointeddownwards.Rinse the holding tank with clean water.For preparing for use again, see steps 1to 7.CLEANING AND MAINTENANCEThe lipseal and the seal of the automatic ventare made of rubber and therefore these partsneed regular maintenance (depending onfrequency of use, once or twice a month).10 10a11 11a12 1314 1576

Lipseal: Remove the sliding cover. Open thevalve-blade by turning the blade-openerknob anti-clockwise. Clean the seal withwater. Dry the seal and grease with siliconespray/oil or vegetable oil.Seal of automatic vent: Turn the automaticvent 60° anti clockwise and remove gently.Clean the seal with water. Dry the seal andgrease with silicone spray/oil or vegetableoil.To clean the holding tank, empty the tank,and rinse with clean water. Use a mild soapto clean toilet bowl, seat and cover, as wellas exterior of toilet unit and holding tank.NOTE: Do not use strong householddetergents or cleaners that contain chlorine,solvents or acid contents.WINTERING/STORAGEThe Thetford Cassette C-200 CW is easilywinterized for storage.Place appropriate size container under thedrainplug. Empty the fresh water tank bytaking out the drainplug (fig. 15). When thetank is empty lift and press down the flushhandle a few times to empty the pump.Empty the holding tank and clean the unit asdescribed in CLEANING andMAINTENANCE. Clean the seals and greasethem after drying (see CLEANING andMAINTENANCE).Leave the blade of the holding tank open.Do not replace cap on the pour out spout, toventilate the holding tank. (Also grease theseal of the pour out spout cap.)COLD WEATHER USEThe toilet can be used in cold weatherconditions provided that the toilet is inheated surroundings. If this is not the case,you can use a nontoxic antifreeze (propyleneglycol) or an antifreeze such as those used incar radiators. Add the antifreeze to the waterin the tank. Add the quantity specified in theinstructions, paying due regard to the safetyinstructions.HIGH ALTITUDE AND WARMWEATHER USEPressure may build up in the holding tank ifthe tank is not inserted while driving at highaltitudes or in warm weather conditions. Theautomatic holding tank vent will vent thetank when there is over- or under-pressure.High temperatures may require additionalThetford toilet fluid.THETFORD WARRANTY1. The Thetford Cassette is warranted forone year from the date of purchase,please fill in and return the warranty card.2. The warranty covers replacement ofdefective or flawed parts and theinadequate performance of the toilet.3. In case of a defect apply to an originaldealer or Thetford Service Centre withproof of purchase.Fitted Equipment4. Defects, which in our judgement occurredfrom misuse, negligence or accident, arenot covered by the warranty. In addition,the warranty does not apply if theproduct is installed or handled improperlyor if other than the prescribed toilet fluidshave been used or if the product hasbeen altered in any way or has beenrepaired by unqualified persons, or if theserial number and/or date has beenaltered or removed.5. Should the original buyer wish to return tous parts believed to be defective, theparts should be sent prepaid. If we findthe parts defective and covered bywarranty, they will be repaired andreturned. If warranty does not apply orhas expired, a nominal charge will bemade. Any transport costs are for theaccount of the owner.6. Before returning product or parts theyshould be properly cleaned, in order tocarry out inspection and repair.7. No other warranty is given and nopersonal representative is authorised tomake any warranty other than that iscontained herein.77

Fitted EquipmentTHETFORD CASSETTE C-200 SFEATURES1. Removable seat and cover.2. Rotatable bowl.3. Valve blade handle: opens and closesvalve blade manually.4. Flush button: activates flush.5. Valve blade button: opens and closesvalve blade electronically.6. Waste-level warning device: indicateswhen holding tank requires emptying.7. Rotating pour-out spout: makes emptyingholding tank easy and convenient.8. Upper carrying handles.9. Automatic holding tank vent: vents theholding tank when there is over pressureif holding tank is inserted into the toilet.10. Valve blade opener.11. Sliding cover: closes automatically whenholding tank is taken out. Guaranteesoptimum hygiene.12. Valve blade.13. Press button valve: allows air in to avoidsplashing while emptying.14. Hand grip.15. Access door.04 060508 07 09 14 12031311010215141078

Toilet SectionThe toilet section includes a rotatable bowl,a removable seat and a control unit with aflush button and a waste level warningdevice. Under the bowl, the valve bladehandle is located.Preparing for Use1. To remove holding tank, open the accessdoor. Pull retaining clip upwards, (fig. 1)2. Remove holding tank by pulling straightout. When holding tank hits the stop, tiltdownwards slightly and remove. (fig. 2)3. Position tank vertically and swivel pouroutspout upwards. (fig. 3)4. Remove the cap of pour-out spout. Addrequired amount of toilet fluid throughpour-out spout. Add small amount ofwater through spout to cover holdingtank bottom. Replace cap and returnpour-out spout to its original storedposition. (fig. 4)NOTE: Hotter weather or longerretention time may require additionaltoilet fluid. Use only Thetford toiletfluid to achieve the best results.CAUTION: Never add toilet fluiddirectly into toilet bowl.5. Slide the holding tank into the vehiclethrough access door. (fig. 5)6. Make sure the holding tank is secured bythe retaining clip. Close and look accessdoor. (fig. 6)Operation7. Turn the bowl in the most comfortableposition, when necessary. (fig. 7)8. Before using the toilet we recommend toadd some water to the bowl by pressingthe flush button. Flush will stop when thebutton is released. (fig. 8)Fitted Equipment1 23 45 67 879

Fitted Equipment9. To open the blade, push on the left sideof the blade opener button (fig. 9.) Bladecan also be opened by turning the bladehandle anti-clockwise (fig. 10).10. To flush, press the flush button (fig. 8).After flushing, close the blade by pushingthe right side of the blade opener button(fig. 11).The blade can also be closed by turningthe blade handle clockwise (fig. 12).The toilet can also be used with the valveblade open, which allows the waste topass directly into the holding tank.Emptying the CassetteThe holding tank capacity is approx. 17 litresand the tank should be emptied when wastelevelwarning device comes on. The wastelevelwarning device will come on when tankcontains more than 15 litres of waste. Asfrom that moment there is approx. 2 litrescapacity left. This is equal to approx. 5 uses.CAUTION: Do not allow Cassette tobecome overfilled. See trouble shootingsection for emergency emptyingprocedure.11. Open access door and remove holdingtank.Holding tank can only be removedwhen valve-blade is closed. (fig. 13)12. Carry the holding tank, pour out spoutup, to a normal household type toilet orother authorised disposal point. Set theholding tank in vertical position androtate pour-out spout upwards (fig. 14).13. Remove spout cap. Grasp unit by uppercarrying handle nearest to pour-outspout. Place other hand on upper rearhand grip so that air relief valve buttoncan be depressed with the thumb whileemptying. This ensures smooth outflowof tank contents (fig. 15).Note: Depress air relief valve button onlywhen pour-out spout is pointeddownwards.Rinse the holding tank with clear water.For preparing for use again, see steps 1to 6.9 1011 1213 141580

WINTERING/STORAGEThe Thetford Cassette C-200 is easilywinterized for storage.Place appropriate size container under thedrainplug. Empty the fresh water tank bytaking out the drainplug. When the tank isempty lift and press down the flush handle afew times to empty the pump. Empty theholding tank and clean the unit as describedin CLEANING and MAINTENANCE. Cleanthe seals and grease them after drying (seeCLEANING and MAINTENANCE).Leave the blade of the holding tank open.Do not replace cap on the pour out spout, toventilate the holding tank. (Also grease theseal of the pour out spout cap.)COLD WEATHER USEThe toilet can be used in cold weatherconditions provided that the toilet is inheated surroundings. If this is not the case,you can use a nontoxic antifreeze (propyleneglycol) or an antifreeze such as those used incar radiators. Add the antifreeze to the waterin the tank. Add the quantity specified in theinstructions, paying due regard to the safetyinstructions.HIGH ALTITUDE AND WARMWEATHER USEPressure may build up in the holding tank ifthe tank is not inserted while driving at highaltitudes or in warm weather conditions. Theautomatic holding tank vent will vent thetank when there is over-or under-pressure.High temperatures may require additionalThetford toilet fluid.THETFORD WARRANTY1. The Thetford Cassette is warranted forone year from the date of purchase,please fill in and return the warranty card.2. The warranty covers replacement ofdefective or flawed parts and theinadequate performance of the toilet.3. In case of a defect apply to an originaldealer or Thetford Service Centre withproof of purchase.4. Defects, which in our judgement occurredfrom misuse, negligence or accident, arenot covered by the warranty. In addition,the warranty does not apply if theproduct is installed or handled improperlyor if other than the prescribed toilet fluidshave been used or if the product hasbeen altered in any way or has beenrepaired by unqualified persons, or if theserial number and/or date has beenaltered or removed.Fitted Equipment5. Should the original buyer wish to return tous parts believed to be defective, theparts should be sent prepaid. If we findthe parts defective and covered bywarranty, they will be repaired andreturned. If warranty does not apply orhas expired, a nominal charge will bemade. Any transport costs are for theaccount of the owner.6. Before returning product or parts theyshould be properly cleaned, in order tocarry out inspection and repair.7. No other warranty is given and nopersonal representative is authorised tomake any warranty other than that iscontained herein.81

Fitted EquipmentFig. AFig. BFig. CBEDDINGSleeping bags and continental quilts can becompressed into small spaces and can beready to use in minutes.LOWER SINGLE BEDS ASSEMBLY(Figs. A & B)1. Unroll bed slat bundle and place betweenthe recess in both seats.2. Arrange seat cushions as appropriate.DOUBLE BED ASSEMBLY(Fig. C)1. Grip front of slatted bed and walkbackwards until bed is fully extended.2. Arrange seat cushions as appropriate.Fig. DSINGLE BED (Fig. D)Pull out 4" and allow backrest cushion todrop behind base cushion. This applies tocertain models only.DOUBLE BED (Fig. D)Extend the pull-out section of the single bed,and re-arrange the cushions. This applies tocertain models only.82

Fitted EquipmentPULLMAN BUNKS1. Release catches, one at a time.2. Release press studs on the bed board.3. Grasp the bunk as shown and pullcarefully in direction of arrows.4. The bunk is designed to automaticallymove into the correct position.5. Where a bed board is fitted, unfold andmake sure it is secured by press studswhen lifted into position. (The bed boardis required to protect both the occupantand the window from damage during useof the bunk.)6. Locate safety boards.7. Arrange seat cushions as appropriate.83

Fitted EquipmentDROP DOWN BUNKThe bunks (if any) fitted to your caravan areguaranteed to a weight limit of 11 stones(70 kg).1. Remove bunk from its stored positionbelow lockers, taking care to draw outeach side equally thus avoiding damageto the caravan walls.2. Locate on bunk supports and unfold,ensure open bunk is pressed firmly intoposition and cannot slide out of bunksupports.3. Locate safety boards.4. Arrange seat cushions to suit.On caravans with rear side windows fittedwith cassette blinds, care must be taken toavoid damaging the blind frame. Lower thebunk bed (unopened) onto the rearmostsection of the bunk support rails, slide thefront of the bunk forward whilst at the sametime unfolding it.Ensure that your fingers are clear of the frontupstand whilst opening and closing thebunk.WARNING: Always ensure safety boardsare located before entering the bunk.84

Fitted EquipmentDOUBLE CASSETTE BLINDS(SEITZ)Blinds and FlyscreensFlyscreen and blinds operate in the samemanner. The flyscreen can only be ‘fully up’or ‘fully’ down, but the blind also has anintermediate position.To operate, pull down by holding thefingergrip(s), gently ease towards the windowto locate the catches. To retract, pull downeasing away from the window to release thecatches and guide to the required position.• ONLY OPERATE BY HOLDING THEFINGERGRIP(S) - pulling on one side willcause uneven running and snagging.• DO NOT ALLOW THE BLIND ORFLYSCREEN TO RE-COIL WITHOUTCONTROL.• It is not recommended that blinds and/orflyscreens are left in the down position forlong periods, or when travelling, as thiscan result in fatigue of the spring.• Clean the cassette, side track and fabricswith mild detergent and water.• Lubrication of mechanism or spring is notrequired or recommended. However, ifcomponents should require cleaning, useonly WD40 or similar with fluff-free cloth.Other lubricants may result in damage tofabrics and plastics.Tension AdjustmentRemove plastic cover (if fitted) to locatetension lugs. The tension lugs have a slotand are located in the cassette on a‘bayonet’ principle. Insert screwdriver intoslot (ensure a good fit), turn lug clockwise toallow the spring tension to push the lugs justfree of the cassette. Keep fingers away fromscrewdriver tip to avoid accidental injury.Spring can now have more or less tensionapplied as required.If in doubt of tension to be applied, releaseall tension and re-start. In which case, withblind fully wound on the roller, apply 12revolutions of lug (factory setting).Refitting is a reversal of removal procedure.For more detailed information, seemanufacturer’s instructions.DOORSCREENWhen drawing or releasing the doorscreen,care should be taken not to let it spring backfreely, this may result in damage to thescreen or its fittings.Always pull the doorscreen close to thecentre. It is not advisable to pull close to thetop or bottom as this will cause snaggingand uneven running.CautionWhen opening or releasing thedoorscreen, care must be taken to avoidtrapping fingers.Do not allow the doorscreen to slam open.85

Fitted EquipmentROOF LIGHTSWhen opening the roof lights, care must betaken to release the locking mechanism asthe unit is raised.Roof lights must be fully closed when towing.Roof lights provide 12,500mm 2 of fixedventilation each.WINDOWSAll opening windows have two catchpositions. The first position is for ventilationthe second seals the window from ventilationand rain.HEKI-2 ROOF LIGHT (SEITZ)The lift/tilt roof light can be set in 3 positionsby means of pneumatic springs.Position 1 lifts the pane 12mm withoutallowing rain to enter the caravan.Position 2 sets the pane to a 150mm openingand locks with a bar.Position 3 opens the pane through 55°.A fully adjustable flyscreen and black-outscreen are built into the inner frame. Theflyscreen can be drawn independently andthe black-out screen is variable for partial orfull black-out.Forced ventilation functions via a brush linedduct instead of a ventilated pane.86A cover hood can be fitted for winterprotection.Heki-2 roof lights provide 13,200mm 2 of fixedventilationTHE OMNIVENT (12V) ROOFLIGHTThe Omnivent is a double glazed rooflightconstructed from a synthetic ultra-violetscreened material. Its side operatingmechanism allows a completely free centralopening with built-in fixed ventilation whenclosed.Red Switch = Mode of OperationInduction (IN)Expel (OUT)Black Switch = Speed Control1, 2 and 3INOFFOUTOmnivents give no fixed ventilation when seton induction.

THE BLIZZARD ROOFLIGHTThe Blizzard is an optional alternative to theOmnivent.HAULTZHAUER ROOFLIGHT ANDEXTRACTORThe extractor is operated by a singleON/OFF switch.THE BLIZZARD 1300 AIR CONDITIONERStarting and function selection1. Internal temperature control thermostat2. Two speed fan switch3. Main switch (Red light ON’ Green lightOFF) Push the switch ‘3’: Red light ‘ON’to switch the air conditioning on.To set the required temperature adjust theRED/BLUE selector control knob against theindicator mark on the outer bezel. Airflowdirection can be achieved fore and aft byadjustment of the air outlet louvres.Push the switch ‘3’ (Green light ‘OFF’) tostop the unit.AttentionNever obstruct the air inlets and outletsThe air conditioning compressor runs duringthe refrigerating phase, if switched on and offat once it may get damaged. Therefore, it isvery important to wait at least 3 minutesbefore attempting to switch it on again.WARNING: Never introduce your handsor other object within the air inletopenings.MaintenanceTo ensure trouble free running it isrecommended that the unit be cleaned onceor twice a year.Never attempt the following until the power isdisconnected and the unit is coolDemount the external cover, clean the heatexchangers (evaporator and condenser) witha brush or compressed air. Remove any dirt.Check that water trap holes are not clogged.The Blizzard air conditioning unit provides nofixed ventilation.Fitted EquipmentASH FRAMED DOORSIn order to provide customers with the latestdesigns of door furniture it is possible, due tothe use of natural wood, that warping mayoccur. This should not detract from thecorrect functioning of items fitted in thecaravan.SHOWERWhen using the shower, always ensure thatthe shower curtain is fully drawn thusavoiding water spray on unprotected areas.87

Fitted EquipmentTABLESSlide top of drawers out and fold back toform convenient table. (Fig. A)The pedestal table can be swung round foreasy access to the seating and then repositionedafterwards. (Fig. B)Tables stored in the table storagecompartment must be securely clipped intoplace whilst in transit.CAUTIONWhen erecting the free standing table, becareful to avoid trapping fingers.Fig. ANOT TO SCALEFig. B88

Fitted EquipmentBlock - 5” x 1 7 ⁄8” (125 x 45mm)Inner line ofawning channelBlockDETAIL OFSWEEP25mmAvailable blockon sweep forawning bracketWheel ArchPOSITION OF AWNING BLOCKFIXING OF AWNINGSIn order to avoid puncturing the outer skin ofthe caravan wall, it is recommended thatawning poles are fixed to your caravan usingload spreading eyelet pads or rubber suckerpads.Attaching awning brackets and associatedfixings to your caravan by using mechanicalmethods which pierce the outer skin of thecaravan wall can allow water ingress whichwill invalidate the product warranty.Important:Care must be taken when using an awningas poles and suckers can cause damage toexterior side panels.Note:Awnings should be kept ventilated whendischarging products of conbustion exhaustinto them.89

MAINTENANCECaravan Exterior .................................................................... 92Caravan Interior ...................................................................... 92Winterisation/Storage ............................................................ 93Alko Running Gear ................................................................. 95Operation and Maintenance ................................................ 95General Maintenance ............................................................. 98Brake Drum/Hub Assembly .................................................. 98Couplings ............................................................................. 98Towing Ball ........................................................................... 99Over-running Device ............................................................ 99Jockey Wheel ....................................................................... 99Brake Linkage .......................................................................99Corner Steadies ................................................................... 99Braking System .................................................................... 99Tyre Wear and Damage ......................................................... 99Wheels ..................................................................................... 99Al-Ko and Vario Galvanised Chassis .................................. 100Shock Absorbers .................................................................. 100

MaintenanceCARAVAN EXTERIORAluminium PanelsThe stove enamelled paintwork is verydurable and easy to clean owing to the highgloss properties.Plastic Panels (GRP/ABS)These are used for front and rear panels and,in some cases, for roof and side panels.CleaningFor both aluminium panels and plastic panels.1. Wash the caravan regularly with milddetergent. Rinse with cold water andleather off.2. For better protection a similar colouredgood quality car wax may be applied.When cleaning Sikaflex sealed areas, useDomestos/water.WARNING: Under no circumstances useany abrasive cleaning agents or solventson the exterior panels.Care should be taken as the silicon insome polishes can attack the rubberused on the exterior for seals andgaskets.MouldingsAll mouldings are of anodised aluminium andwill retain their lustre for a long period if noabrasive materials are used to clean them.92Acrylic WindowsThe windows in your caravan are fully doubleglazed and with care will remain sparklingand scratch-free.Cleaning: Wash down as you would yourcar. Do not use a sponge on dirty windows.When all dirt has been removed, dry with aleather or ‘Vyleda’ type cloth, the catchesand stays do not require lubricating.Keeping your acrylic windows sparkling:Removing TarUse ‘Jove Tar Remover’ on our doubleglazed windows, it is obtainable from mostleading car accessory or Do-It-Yourselfshops. Do not use petrol or other chemicals.CondensationAs your caravan is double glazed you mayoccasionally get condensation inside thedouble glazing. This is particularly so insevere weather change (usually spring andautumn) and is easily cured in dry weather.i) Remove the plastic plugs from interiortop of each window.ii) Leave unplugged for approximately 1-4hours until condensation has cleared.WARNING: Do not wash your caravanwith a high pressure washer as thesecan permanently damage the seals ofyour caravan.CARAVAN INTERIORFollow these guidelines to ensure yourinvestment is receiving the very bestattention.Side Walls, Roof LiningA simple wipe over with a damp cloth and avery mild detergent is all that is needed.Soft FurnishingsShould be vacuumed occasionally to removegrit and sand and help to keep its smartappearance and ensure long life. Theupholstery can be cleaned with a mild,reputable upholstery cleaner. It isrecommended that the curtains and pelmetsare specialist cleaned only. The foam used incushions is manufactured to meet fireregulations. It requires time to return to itsnormal position after prolonged use.Work SurfacesYou should not stand very hot items on anyof the work surfaces, especially models withpolycarbonate moulded sinks and drainers.Cupboard CatchesIt is advisable to lightly oil all cupboardcatches, sliding bolts and hinges from timeto time.Bathroom, Shower Room and KitchenEquipmentAll the Thermoplastic parts in these areashave easy clean surfaces. To ensure long lifeand prevent damage you must not use any

Maintenancecleaning materials at all and ensure watertemperatures do not exceed 70°C, (puttingcold water in first is suggested). After everyuse it is essential that you rinse with cleanwater only and wipe with a soft damp cloth.Failure to follow these simple instructionsmay result in premature failure or crackingwhich will not be covered by any guarantees(including extended warranties).FurnitureA simple wipe over with a damp cloth shouldbe all that is required. Polishing with aproprietary brand of wax polish enhancesand maintains furniture in showroomcondition.It must be remembered that because theframes of the doors are made of ash, whichis a natural product, they can be affected bytemperature and humidity and may bowunder certain conditions. As conditionschange they should revert to their originalpositions.WINTERISATION/STORAGEThis is probably an opportune moment toarrange for the caravan to have its annualservice at your appointed dealer.The following applies wherever your caravanis stored particularly during the wintermonths.Do not park near trees or larch type fences,due to possible wind damage.Keep any grass around the floor of thecaravan short, to maintain air flow and stopany possible damp getting into the caravan.It is advised that the caravan is ventilatedregularly throughout the winterisation/storage period, opening windows, doorsand rooflights when possible.GeneralAll moving parts should be checked for freeoperation.Clean all cooking appliances and refrigerator.Lubrication should be carried out at thepoints illustrated in the general notes onchassis maintenance (page 98).Charge up the on-board battery every 2months.Check alarm battery condition every 2months and charge if necessary.Leave the refrigerator door open.Leave furniture doors and lockers open toallow air to circulate fully.Soft FurnishingsClean and dust the upholstery and ifpossible remove before placing the caravaninto winter storage. Alternatively, stand thecushions on their edges to allow circulationof air. This will reduce the possibility ofdampness from condensation.Keep curtains or blinds closed, to minimisefading of furniture.If the blinds and/or flyscreens remain downfor a prolonged period of time, re-tensioningof the springs will be necessary before re-use.Wheels and TyresDo not store in one position with partiallydeflated tyres. The tyre walls will suffer anddo present a real danger of blow outs,especially when travelling at faster speedsthan are allowed in the UK.The wheels should be turned every couple ofweeks or even better, the wheels removedand the caravan placed on “winter wheels”or axle stands.If you are removing the wheels, follow thejacking procedure for changing a wheel.Water SystemThe water heater MUST be drained toprevent frost damage. The drain plug, whichis on the outside of the flue cowl, should beunscrewed to permit draining and removeduntil the system is to be refilled (see page45).To allow the system and the tank to draineffectively, open ALL hot and cold taps whilethe heater is still warm (see ‘TAPS’ inServices Section).93

MaintenanceRemove shower head.The Thetford Cassette porta potti is easilywinterised for storage. Empty the fresh watertank using the drain tube/fresh water tanklevel indicator (level indicator on electronicmodels only). Pull the lever indicator/draintube down from top plug position andoutward through door opening to drain waterfrom the tank.Empty the water fill funnel by pulling thebottle away from tank. Remove the smallwater cap on the filler bottom, allowing waterto drain from the water funnel. (Not C-200toilet).Do not tighten caps, this helps in keepingunit dry.The pour out spout and vent plug can beremoved. Seals should be greased ifnecessary with acid-free vaseline.Remove the drain stop plugs on the freshwater pipes (see Fig. 1). These are locatedthrough the floor on the underside of thecaravan.Lower and raise the front of the caravan bywinding the jockey wheel handle to allowexcess water left in the water pipes to drainaway. This should not be done if the caravanis stored on blocks or axle stands.Leave the drain plugs and the taps open.Push up collar (A) torelease and pull plug(B) down to remove.Fig. 1The caravan may be left in this condition overwinter or until ready to use. It isrecommended to leave the taps in the openposition during storage.Recommissioning the Water SystemFill the fresh water tank on the ThetfordCassette porta potti using a hose or jerrycanuntil the water in the funnel reaches the neck.Tank capacity is 15 litres. Aqua Rinse may beadded to improve cleaning of bowl andflushing of unit. (Not C-200 CE toilet).Replace cap. Swing back the water fill funneluntil it touches the water tank.Add Aqua Kem (100 ml) into the Cassette (or120 ml if using Aqua Kem Bio) through thepour out spout. Add small amount of waterthrough the pour out spout and replace thecap.Close the cold taps and ensure all the drainplugs are fitted.It is advisable after storage to flush the watersystem initially with a sterilising agent (suchas Milton), and then with water repeating untilthe system is well flushed through.Connect the pump.Fill the system with water until water flowsfreely from the hot taps. About 2 gallons ofwater will be required. Close the hot taps.AppliancesBefore starting caravanning after storagecheck all gas appliances and electricalpoints.Note: Preferably not less than once a year,the electrical installation should be inspectedand tested by a qualified electrician.After storage it is advisable to air the caravanand clean throughout, especially cookingappliances and the refrigerator.Replace the bedding and wheels if they wereremoved for storage.ImportantAlways follow the manufacturersrecommended procedures after use of fittedequipment in the caravan and before storingfor any length of time.94

ALKO RUNNING GEARCoupling HeadThe ball couplings are entirely automatic inoperation and designed for one handoperation to suit the 50mm international ballrecommended by the British StandardsInstitution, National Caravan Council and theSociety of Motor Manufacturers and Traders.Each type has provision for an anti- theftdevice (available as an extra) consisting ofbrass insert, complete with 2 keys. Thelocked button will prevent movement of thehandle, therefore making it possible to lockthe coupling either “on” or “off” the towingball.Operation - Type AK10/2Lift locking trigger, and lift handle upwardand forward. Place the unlocked couplingonto the towing ball and with the slightestdownward pressure it will lock onto the ballautomatically. Ensure locking trigger returnsto its free position before commencing totow.Operation - Type AK 13/2Lift handle upward and forward, thisdisengages the security tooth. Place theunlocked coupling onto the towing ball andwith the slightest downward pressure it willlock onto the ball automatically. The securitytooth should again be fully engaged.UncouplingHaving lowered the jockey wheel to theground, operate the handle as previouslydescribed. Lift the coupling clear of thetowing ball either manually or by operatingthe telescopic jockey wheel.IMPORTANTIf the nose of the caravan is lifted manuallythe locking trigger must be engaged first andthe handle lifted forward. Failure to do thiswill cause the nose-weight to be transmittedthrough the locking button and damage willoccur.Forward BrakingIn the free position, with the handbrake fullyforward in the OFF position, the drawshaft ofthe overrun device is fully extended and theshoes are clear of the drum.As the towing vehicle brakes, or starts todrive downhill, the drawshaft of the overrrundevice is depressed toward the unit beingtowed. This action imparts linear motion tothe main shaft of the overrunning devicewhich is transmitted via the overrun lever,brake rod and Bowden cable to theexpanding clutch. This mechanism forcesthe leading brake shoe and, by reaction, thetrailing shoe outwards into contact with thedrum.Friction between the brake shoes and thedrum creates a tendency for both shoes andMaintenancethe expanding clutch to move in thedirection of forward rotation until they abutagainst the adjuster box. This ensures thatboth remain in the braking position.ReversingWhen the towing vehicle reverses, thedrawshaft is pushed backward, moving theoverruning device through its full travel. Thismovement is transmitted in the normalmanner to the expanding clutch.The clutch forces both shoes into contactwith the drum. Initial friction between thesecreates a tendency for the shoes andexpanding clutch to move in the direction ofwheel rotation i.e. reverse. This movementimparts pressure to the spring- loaded autoreverselever, causing it to collapse. Thus,friction between the shoes and drum isalmost eliminated, allowing the trailer toreverse as one with the towing vehicle.Slight forward movement of the chassis willallow the coil spring to reassert itself,enabling the reverse lever to recover to itsnormal position. Normal braking is thenimmediately available.ParkingThe AL-KO parking brake systemincorporates a patented device for addedsafety when parking on a reverse-slopingsite or steep hill.95

MaintenanceThe AL-KO parking brake system comprisesa handbrake lever mechanism actuating aBowden cable which operates a brake unitassembly contained within the wheel hub.AL-KO provide two types of parking brakesystem on their trailers, with the Bowdencable and the wheel hub brake unit beingcommon to both types.The difference between the systems is thehandbrake mechanism used to actuate theBowden cable.AL-KO’s unique parking brake systemrequires a source of stored energy to lockthe wheel brakes should the trailer start tomove after it has been uncoupled from thetowing unit.This energy source can be provided by eithera spring cylinder charged by hand or by agas filled cylinder acting as an energy store.Each system requires a slightly differentmethod of operation when parking the trailer,though they both operate in the same mannerwhen forward or reverse braking is applied.Spring Cylinder TypeA spring system is attached to the linkbetween the handbrake lever and the centralbrake rod. Full application of the handbrakelever (such that the lever is vertical) to thelast tooth of the ratchet compresses a steelspring inside the steel cylinder and energy isstored.The action of the brake lever imparts motionto the brake rod, the Bowden cable and theexpanding clutch. This mechanism forcesboth shoes into contact with the drum.At this stage, the brake unit is latent, themechanism waiting to see in which directionthe trailer will start to move.If the trailer starts to move backwards, thestored energy in the spring will be released.The trailing brake shoe and by reaction, theleading shoe together with the expandingclutch will tend to move in the direction ofrotation (reverse) and abut against the stop.Thus the trailer is braked.However, if the handbrake is NOT fullyapplied to the last tooth (i.e. vertical) and isset to some lesser position than the fullvertical, then problems will almost certainlyarise after the trailer has been uncoupledfrom the towing unit.If the trailer is parked on a reverse slope or ifit is pushed backwards, then the brakemechanism will act as though the trailer isbeing reversed by the towing unit. The shoesand expanding clutch will tend to move withthe direction of rotation (reverse) whichimparts pressure to the spring-loadedreverse lever, causing it to collapse. Thus,friction between the shoes and the drum isalmost elminated and the trailer will runaway.Operating the HandbrakeSome people may find it difficult to set thehandbrake lever to its full vertical positionwithout a great deal of physical effort.However, AL-KO have designed their systemso that the average user need not do so.For successful parking on a reverse slope orsteep hill, the operator need only apply thehandbrake with one hand while gently butpurposefully inching the caravan trailer asmall distance backwards with the other.The user must supply this small but essentialbackward movement to ensure that thefulcrum of the transmission lever moves pastthe point of reverse, thus preventing thelever from collapsing as it would normally dowhen reversing.Most users will find it easier to stand facingthe towing unit while applying the handbrake and at the same time gently push thecaravan an inch or two backwards with theirposterior.Gas Cylinder TypeA gas cylinder, acting as an accumulator ofstored energy, can be fitted to the handbrakelever to provide the same effect as a springcylinder.96

This system is much more user friendly, asthe handbrake lever need only be applieduntil it passes a clearly detectable deadpoint for it to render parking on reverseslopes or steep hills absolutely safe.It takes minimal effort from the operator tomove the handbrake lever past this deadpoint.If the caravan or trailer starts to move whenuncoupled from the towing unit, then theenergy stored in the cylinder is released andthe brakes applied in the normal manner.Important Points to RememberIt is absolutely vital that the slight backwardspush of the caravan or trailer is appliedbefore it is uncoupled from the towing unit.It is also important to check that the brakehas in fact operated correctly as soon as thecaravan has been uncoupled.If the caravan or trailer is to be parked on asteep slope or on loose or slippery surfaces,it is advisable to chock the wheels.Where possible, always ensure that thehandbrake lever is in the fully verticalposition.When the handbrake has been applied, it ispossible for the caravan or trailer to roll backas much as 25cm before the full force of thebrake takes effect.All components of both the overrun deviceand the wheel brakes must be thosemanufactured by AL-KO as the braking andreversing systems must be matched toensure optimum braking performance.Combining parts manufactured by AL-KOwith those produced by other suppliers willinvalidate any guarantee entered into byAL-KO.Recommended Brake AdjustmentProcedureJack up the axle raising the road wheelsclear off the ground. Ensure drawshaft is fullyextended (in the towing position) and thehandbrake is in the “OFF” position (fullyforward).Check that there is some end float in the rodand spring cylinder.Adjust brakes first (Fig. A) and the linkageonly if necessary.IMPORTANT: During Wheel brake adjustment the drum must only be revolved in thedirection of FORWARD rotation. Do not useexcessive force during adjustment.Wheel brake adjustment is effected througha hole in the brake backplate (see Fig. A).With a screwdriver adjust the starwheel inthe direction of the arrow until there isresistance to wheel movement. Slacken untilthe brake drum turns freely in the forwarddirection. A check for correct adjustment canFig. A Brake AdjustmentMaintenanceAdjustAdjustbe made at the chassis end of the bowdencable. When pulled the cable should extendbetween 5 and 8mm.Apply the handbrake two or three times toensure brake shoes are centralised in thedrum. Re-check the shoe clearance at thewheel brake.97

MaintenanceCentre brake rod. Check full threadengagement in the fork end of theoverrunning device. Secure locking nut.At the axle ensure compensator plate isparallel to the axle by setting the adjusternuts on the bowden cables. Secure locknuts.Adjust centre brake rod at the rear nut sothere is no clearance between the overrunlever and the drawshaft and plate. Securelock nuts.Correct adjustment of the linkage can bechecked by engaging handbrake lever on thesecond tooth of the ratchet segment. In thisposition you should feel a slight brakingforce at the wheels.98Finally screw up the self locking nut to give1mm clearance between the nut and thespring cylinder.Note: Reversing will be difficult if eitherwheel brake or brake linkage isoveradjusted.GENERAL NOTES ONMAINTENANCE1. Brake Drum/Hub AssemblyThe EURO AXLE fitted to your caravancomes complete with maintenance-freewheel bearings GREASED AND SERVICEDFOR LIFE. Adjustment is not required duringthe design life of the sealed bearing(100,000 km).WARNING: If replacement of the brakedrum or shoes is required, this must becarried out by authorised AL-KO ServiceCentres.If the warning is not observed:- the warranty is void and- the wheel may become detached.Any attempt to slacken the nuts on the stubaxle will result in the toe-in being adjusted.This will cause:- Loss of guarantee- Bad towing performance- Increased tyre wear2. Couplings1. Clean and grease spherical seat, bearingparts and pivot pins regularly.2. Thoroughly examine all moving parts forwear and correct functioning.3. Couplings should never be drilled.

3. Towing BallThe automobile towing ball should measure50mm maximum and 49.5mm minimum (DIN74058). If the ball is found to be worn itshould be replaced immediately.4. Overrunning DeviceThe device housing is packed with grease onassembly, but will require periodicmaintenance to ensure smooth operation ofthe braking system.1. Regrease the shaft bearings via thegrease nipples provided at 3000 mileintervals, and before storage.2. Ensure correct functioning of all pivotpins and levers and oil regularly.3. Ensure correct functioning of handbrakeratchet and oil regularly.5. Jockey WheelLubricate wheel and screw threadperiodically.6. Brake LinkageAll moving parts should be lubricatedperiodically to ensure their satisfactoryoperation.It is recommended that all brake linkagethreads are liberally smeared with grease forprotection and as an aid to future adjustmentof the system.7. Corner SteadiesThe screw and pivot pins should belubricated periodically to ensure theirsatisfactory operation.8. Braking SystemAt 500 miles then every 3000 miles or 1 yearcheck and adjust brake linkage tocompensate for any stretch of the bowdencables.Check and adjust wheel brakes tocompensate for wear.IMPORTANTWhen replacing the wheels you shouldtighten the nuts in rotation diagonally, takingcare to tighten them equally.The recommended torque for steel wheels is88Nm (65 lb/ft) and for alloy wheels 115Nm(85 lb/ft).CHECK THE WHEEL NUTS BEFORESTARTING EVERY JOURNEY.MaintenanceTYRE WEAR AND DAMAGEThe legal requirement for tread depth onmotor vehicles also apply to caravans.In order to equalise wear it is suggested thatthe wheels be balanced and changed aroundfrom time to time.It is dangerous to neglect tyre damage andshould you detect a blister, a rupture or a cutwhich exposes the casing or if it hassuffered a violent impact (for exampleagainst a kerb) such that there is a risk ofinternal damage, it is advisable to have itexamined by a tyre specialist as soon aspossible (as this can affect tracking).Tyres should be inspected regularly and ifany signs of visible deterioration (sidewallcracking, delamination of tread, etc) areevident, they should be replaced regardlessof there being a legal minimum tread depth.WHEELSThe condition of the wheels should bechecked regularly, particularly for distortionof flanges and the wheel dish. Wheels whichare damaged or distorted, or having wheelstud seatings cracked or deformed, must notbe repaired.99

MaintenanceLubrication points aresame for all chassisAl-Ko ChassisALKO AND VARIO GALVANISEDCHASSISHot dip galvanising offers high corrosionprotection by forming a barrier layer throughreaction with the atmosphere. This will beapparent by the chassis members changingto a light grey colour. During winter periodsor storage where there is insufficient aircirculation or heavy moisture, a soft porous,light grey oxidisation layer may form. This isknown as ‘White Rust’ and should NOT beconfused with rust. As applied to steel thesedeposits should be removed by use of a wireor hard nylon brush.SHOCK ABSORBERS (OPTIONAL)The Euro Axle fitted to the caravan is capableof being equipped with octogon shockabsorbers specially developed by AL-KO toensure optimum roadholding of your caravan.They are designed to reduce even theslightest suspension rebound and maketowing safer and more comfortable.Vario Chassis100

GENERALDATAFault Finding ......................................................................... 102Water .................................................................................. 102Gas ..................................................................................... 104Cassette Toilet .................................................................... 105Useful Information ............................................................... 106Owners Club ...................................................................... 106Spares and After Sales ...................................................... 106Repair Facilities .................................................................. 106Factory Tours ..................................................................... 106Caravan Clubs......................................................................107Motoring Associations .........................................................107Trade Association.................................................................107CRIS .....................................................................................107

Fault FindingWATERProblemWater not flowing fromany tap when operatedbut pump runsPossible CauseFreshwater tank emptyPump wired in reversePump not primedPipe inlet or outlet pipe disconnectedPump pipes restricted by kinkingBlockage in pump inlet or outlet pipeBlocked in-line filter of pump filterAir leak in suction line to pumpRemedyCheckCheck wiring, refer to pump manufacturers instructionsRefer to pump manufacturers instructionsCheck connectionsCheck pipes runCheck, starting inside freshwater tankDismantle and cleanCheck for bubbles & secure with clipPump does not run Pump or tap incorrectly wired Refer to pump/tap manufacturers instructionsPump fuse blownCheck wiring connection and then replace with fuse of correct ratingBattery disconnectedCheck connectionsPump seized or overheatedRefer to pump manufacturers servicing instructionsPressure pump sensing switch may have failedRefer to pump manufacturers servicing instructionsContacts may be faultyCheck contacts in plug and socket are clean and making contactWiring connections may be faultyCheck wiring connectionsOn switched tap version, microswitch could be faulty Disconnect wires from microswitch and join together. If the pumpoperates, microswitch should be replacedWater flows from cold tapbut not from hotFeed pipe to water heater incorrectly connected tothe heater outletBlockage in hot pipelineHeater inlet or outlet pipes kinked preventing flowHot tap not connectedHot tap failed or blockedHeater non-return valve jammedRefer to installation instructionsDisconnect pipes and inspectCheck and re-route if necessary. Ensure that hose is Carverrecommended typeRefer to installation manualDisconnect and inspectSeek service attention102

Fault FindingWATER (continued)Problem Possible Cause RemedyWater flows from hot tapbut has reduced flow fromcoldCold water pipe kinked preventing flowBlockage in cold pipe lineCold tap not connectedCold tap failed or blockedIf a water filter is fitted, the cartridge is exhaustedCheck and re-route if necessaryDisconnect pipes after 1st Y connector and check up to tapRefer to installation instructionsDisconnect and inspectReplace cartridgeReduced flow from bothhot and cold tapsBattery condition low causing pump to run slowlyIf new taps have been fitted they may be restricting flowPump needs servicingPartially blocked pump filter or in-line filter, if fittedPump outlet pipe kinked restricting flowWater leakCheck battery state of charge, refer to electrical supply noteDisconnect and check that they have at least 1/4" (6.3mm) boreRefer to pump servicing instructionsDismantle and clean if necessaryCheck and re-route if necessaryCheck all water connectionsReduced flow fromeither tapY’ connector(s) fitted incorrectly Refer to installation instructionsPipe kinking restricting flowCheck and re-route if necessaryBore size difference in tapsUse taps of equal bore sizeWarm water flows out ofcold tapHot water back-feeding into cold line, usually if mixertap or single outlet hot and cold taps being usedFit non-return valve in cold supply, near tapIf pump motor runssteadily and will not stopBattery voltage may be too low (below 10.5 volts)Check that there is water in the containerAdjust switch and/or re-charge batteryCheck all connections in pipework103

Fault FindingGASProblem Possible Cause RemedyHob does not light No gas Check level of gas in bottleCheck gas bottle valve is onCheck gas taps are onAir in pipePurge systemRefer to hob manufacturers instructionsOven does not light No gas Check level of gas in bottleCheck gas bottle valve is onCheck gas taps are onAir in pipePurge systemRefer to oven manufacturers instructionsSpace heater or centralheatingNo gasOver gassedAir in pipeCheck level of gas in bottleCheck gas bottle valve is onCheck gas taps are onCheck exhaust outlet is clearTurn off appliance, wait 2 minutes and try againPurge systemRefer to space heater or central heating boiler manufacturers instructionsFridge does not light No gas Check level of gas in bottleCheck gas bottle valve is onCheck gas taps are onAir in pipePurge systemRefer to fridge manufacturers instructionsWater heater does notlightNo gasAir in pipeCheck level of gas in bottleCheck gas bottle valve is onCheck gas taps are onPurge systemRefer to water heater manufacturers instructions104

Fault FindingCASSETTE TOILETProblemBowl does not drain whentoilet is flushed.Cassette is overfilledOdoursToilet tissue does not fitinto compartment.Soiled bowl after flushingNo power to add water totoilet bowlCassette cannot beremovedValve blade mechanismsticks or is hard to openRemedyDO NOT REMOVE CASSETTE. While inside the caravan turn flush knob anti-clockwise to open valve blade andleave it in the open position.Open access door on side of caravan. Rotate pour-out spout outward. Place appropriate size container under spout cap.Remove cap carefully. Allow bowl contents to drain into container. This will lower the water level in the bowl.Replace cap and return pour-out spout to stored position. DO NOT REMOVE CASSETTE.Go inside the caravan and turn the flush knob clockwise to close valve blade. Now, the cassette may be removedfollowing the normal removal and emptying procedure.Use proper amount of holding tank deodorant specified on bottle.Since some tissues are supplied on larger rolls, it may be necessary to use some tissue before storing into compartment.Partially fill bowl to cover soiled portion of bowl. Next flush will dissolve waste. Tip: Leave valve blade open during use.Check cassette safety sensor switch and fuse-holder for proper engagement and operation.Note: Cassette has to be removed to reach switch and fuse.Insert cassette and try adding water to toilet bowl.Toilet can be flushed manually. Add water. Add water to bowl from a separate container. Turn flush knob anti-clockwiseto open valve blade. Turn clockwise to close valve blade.Check for obstacles under retaining clip. Depress retaining clip several times to check operation. Remove cassette.Flush knob and valve blade in partial open position. Close valve blade by moving knob clockwise.CAUTION: If valve blade is open during cassette removal, severe damage to system can occur. Never force insertionor removal of the cassette tank.Spray light film of silicone on blade.Major unit malfunctionContact your original Caravan Dealer.105

Useful InformationOWNERS CLUBThe Owners Club is a completelyindependent organisation run for the benefitof the caravan owners. They have numerousrallies during the year in various parts of thecountry and every third year there is a‘Works Rally’ where owners have theopportunity to visit the factory. Apart fromthe friendliness and companionship the Clubgenerates it is also actively engaged incharity work for those less fortunate thanourselves. The address of the Secretary ofthe Owners Club can be obtained fromSupercare (SML Ltd), Tel: 01482 875740.SPARES AND AFTER SALESSUPERCARE (SML LTD)There are numerous items available fromyour dealer ranging from door catchesthrough to spare wheels and touch-uppaints. Please note that all after salesenquiries must be directed through yoursupplying dealer. The after sales service atthe factory is geared to support our dealernetwork as is the service provided byappliance manufacturers.In the interest of safety, replacement partsfor an appliance shall conform to theappliance manufacturers specifications andshould be fitted by them or their authorisedagents.Note: Please remember to quote chassis106number when ordering any items from yourdealer.Spares and After SalesSupercare (SML Ltd)Dunswell RoadCottinghamEast Yorkshire HU16 4JXTel: 01482 875740Fax: 01482 840082Customer CareTel: 01482 875740Fax: 01482 840861NOTE:The times for contacting Customer Care bytelephone are:9am to 4pm Monday to Thursday.9am to 12.45pm Friday.Swift Group Websitewww.swiftleisure.co.ukSwift Group E-Mail Enquiryenquiry@swiftleisure.co.ukREPAIR FACILITIESShould you be unfortunate enough to suffera major accident with your caravan it iscomforting to know that we have acompletely separate repair shop facilitywhere their fully trained experts will undertake all types of major damage repair work.Repairs of a minor nature should be referredfirst to your local dealer.FACTORY TOURSThe ultra modern Northmoor productioncomplex at the heart of the Group’smanufacturing facilities is now open to thepublic, offering you a unique opportunity tosee how the caravans are produced.The tours operate on a Tuesday andThursday between the beginning of April andthe end of September (excluding factoryholidays).A programme of activities has been createdto make the tour an interesting day out. Youwill be met at the Group’s purpose builtLearning Centre and shown a shortcorporate video before being given a slidepresentation covering our completemanufacturing process. Professional TourGuides will then take you and your partyaround the Northmoor complex whichfeatures state of the art technology.Headsets are supplied so that you hearevery word your guide says. The tourfinishes at the Group’s after sales facilitywhich holds parts for caravans up to 20years old.Taking part in the tour is by prior bookingonly and there is a small charge for adultsand children over sixteen.To reserve a place, you can complete thebooking form enclosed with your newcaravan or alternatively, arrangements canbe made through any Dealer.

Useful InformationThe enjoyment of caravanning can begreatly enhanced by membership of one ormore of the various caravanning, motoringand holiday clubs. Here are some usefuladdresses:CARAVAN CLUBSThe Caravan Club,East Grinstead House,East GrinsteadWest Sussex, RH19 IUATel: 01342 326944The Camping and Caravanning Club,Greenfields House,Westwood Way,Coventry,West Midlands.Tel: 01203 694995MOTORING ASSOCIATIONSAutomobile Association (AA)Fanum House,Basingstoke,Hants. RG1 2EATel: 0990 448866www.theaa.co.uke-mail: customer.services@theaa.comRAC Motoring ServicesRAC House,M1 Cross,Brent Terrace,London, NW2 1BXTel: 0990 722722Green Flag National BreakdownPO Box 300,1, Cote Lane,Leeds, LS99 2LZTel: 0345 670345TRADE ASSOCIATIONNational Caravan CouncilCatherine House,Victoria Road,Aldershot,Hampshire, GU11 1SSTel: 01252 318251www.martex.co.uk/ncce-mail: mail@martex.co.ukCRISHPI EquifaxDolphin House,New Street,Salisbury,Wiltshire SP1 2TBTel: 01722 411430/422422Swift Group LimitedDunswell Road, Cottingham,East Yorkshire HU16 4JXTel: (Supercare) 01482 875740e-mail/web site: www.swiftleisure.co.uk© 1999 SWIFT GROUP LTD.107

IndexA Air Conditioning...............................87Alarm Module ..................................42AL-KOBraking .........................................95Chassis.......................................100Coupling/Uncoupling ...................95Lubrication .................................100Parking .........................................95Reversing .....................................95Shock Absorbers .......................100Arrival on Site ..................................15Ash Framed Doors ..........................87Awnings ...........................................89B Battery .............................................39Beds ................................................82Blinds...............................................85Blizzard Air Conditioner...................87Brake Linkage..................................99Braking System ...............................99Breakaway Cable ............................12C Caravan Clubs...............................107Caravan Terms...................................2Carver Space Heaters .....................58Cascade Water Heater ....................48Cassette Toilets ...............................71Central Heating................................63Chassis Number ..............................20Clubs .............................................107Corner Steadies ......................7/15/99CRIS ..............................................107D Doorscreen ......................................85Driving Licence..................................4E Electrical Control Module ................38Electricity Supply.............................30Arrival on Site...............................30Generator .....................................35Mains Inlet Cable .........................32Overseas Connections.................3112V ...............................................46FElectrical Supply Module.................37Escape Paths ..................................19Factory Tours.................................106Fanmaster Warm Air Heater............61Fault Finding..................................102Cassette Toilet............................105Gas.............................................104Water..........................................102Fire ..................................................18Fire Extinguisher..............................19Flyscreens........................................85Fumes..............................................20Fuses (DC) .......................................41Fuses (road lights) ...........................38G Gas Supply ......................................27Butane..........................................28Connection...................................29Fault Finding ..............................104Flue Installations ..........................29Gas Bottles ..................................27Hoses ...........................................28Precautions ..................................28Propane........................................28Regulator......................................27Safety Advice ...............................28Ventilation.....................................29Generators.......................................35Generator Guidelines.......................40Glossary and Checklist .....................4Grill ..................................................55H Habitation Relay ..............................40Handling ..........................................13Heating ............................................58Heki Rooflight ..................................86Hob..................................................54I IDM Alarm System...........................42J Jacking Points .................................14Jockey Wheel ..................................99LLevelling...........................................15Loading and Distribution of Weight...7M Maintenance ....................................91Exterior.........................................92Interior ..........................................92Winterisation/Storage...................93Mirrors .............................................13Motoring Associations...................107Motorway Driving ............................13N Noseweight........................................4O Omnivent Rooflight..........................86Oven ................................................55Overseas Electrical Connections ....31Owners Club..................................106PPassengers......................................12Plugs..................................................5Preparing for the Road......................7Loading & Distribution of Weight ...7Other Considerations .....................9Pre-load Checklist..........................7Pre-tow Checklist andHitch Up....................................10Stability ..........................................8Towing Vehicle - RearSuspension .................................8Power Modular Systems .................35Pulling Off ........................................13R Refrigerator......................................50RM4200/4230...............................50RM4271........................................51RM4291........................................52Travel Catch .................................54Repair Facilities .............................106Reversing.........................................13Road Lighting ..................................12Rooflights ........................................86Reich 'Charisma' Taps.....................25SSafety...............................................17Security............................................20Services ...........................................21Electricity......................................30Gas...............................................27Water............................................22Shock Absorbers...........................100Shower ............................................87Smoke Alarm ...................................18Space Heaters.................................58Spares and After Sales..................106Speed Limits....................................13Stability..............................................8Stopping on a Hill............................14Stoves Hobs, Grills and Ovens .......54T Tables ..............................................88Taps .................................................24Thermal Insulation ...........................29Thetford Cassette Porta Potti .........71Thetford Cassette C-200.................74Towing Code......................................2Towing Vehicle Terms ........................3Trade Associations ........................107Transformer/Charger Unit................40Tyres ................................................99V Ventilation ........................................19W WaterHeater...........................................48Pumps ..........................................48Tanks and Systems......................22Weights..............................................2Whale Aqua Source.........................23Whale ‘Elite’ Microswitch Taps........24Whale 'Elegance' MicroswitchMixer Taps....................................26Whale Supersub Systems ...............23Whale Watermaster System ............22Wheels.............................................99Changing......................................14Rims .............................................10Torque .......................................9/14Windows..........................................86Winter Maintenanceand Storage .................................93110

Quality with StyleSWIFT CARAVANS, DUNSWELL ROAD, COTTINGHAM, EAST YORKSHIRE HU16 4JX.TEL: 01482 847332 FAX: 01482 840082 e-mail/web site: www.swiftleisure.co.ukIssued September 1999 9830006