http://assets.swiftg... Hbook 2003.pdf

http://assets.swiftg... Hbook 2003.pdf
Swift
Owner's
Handbook
Wherever you
want to go, we’re
right behind you.
Congratulations. You couldn’t
have made a better choice than
a Swift caravan.
And when it comes to buying
a new caravan or car, Black Horse
are the finance experts.
With a range of finance options
to suit you, and a wealth of experience, you can relax in the knowledge that Swift and
Black Horse are right behind
you wherever you want to go.
Credit is available to persons aged 18 or over. Guarantors may be required. Written quotations available on request from:
Black Horse Caravan Finance, 24 - 26 Newport Road, Cardiff CF24 0SR Tel: 029 2029 6863
Introduction
INTRODUCTION
DEAR OWNER,
THANK YOU FOR DECIDING TO BUY ONE
OF OUR NEW CARAVANS. WE ARE SURE
YOU WILL ENJOY MANY HAPPY HOURS
IN IT AND WE HOPE THE INFORMATION
AND HINTS IN THIS HANDBOOK WILL
HEIGHTEN YOUR ENJOYMENT.
THE HANDBOOK HAS BEEN DESIGNED
TO GIVE YOU A GENERAL GUIDE TO THE
CARE, USE AND MAINTENANCE OF YOUR
CARAVAN. WHETHER YOU ARE A NEW OR
AN EXPERIENCED CARAVANNER THE
HINTS WILL HELP TO PROTECT YOUR
INVESTMENT.
THE INFORMATION CONTAINED WILL
ANSWER MOST OF YOUR QUERIES, BUT
IF THERE ARE ANY ASPECTS WHICH ARE
NOT COVERED PLEASE CONSULT YOUR
APPOINTED DEALER.
HAPPY CARAVANNING!
The Towing Code
Safety and Security
Services
Electrical Equipment
Fitted Equipment
Maintenance
CONTENTS
General Data
THE
TOWING
CODE
The Caravan Towing Code ...................................................... 2
Scope of the Code ................................................................. 2
Caravan Terms .......................................................................... 2
Weights .................................................................................. 2
Towing Vehicle Terms .............................................................. 3
Weights .................................................................................. 3
Measurement of Noseweight .................................................. 4
Type of Driving Licence Held ....................................................4
Glossary & Checklist ................................................................ 4
Preparing for the Road ............................................................ 7
Checklist ................................................................................ 7
Loading & Distribution ........................................................... 7
Stability .................................................................................. 8
Pre-tow Checklist ................................................................. 10
Pulling Off ............................................................................... 13
Reversing ................................................................................ 13
Speed Limits ........................................................................... 13
Caravan Handling ................................................................... 13
Motorway Driving ................................................................... 14
Changing a Wheel .................................................................. 14
Jacking Points ........................................................................ 14
Stopping on a Hill ................................................................... 15
Arrival on Site ......................................................................... 15
The Towing Code
THE CARAVAN TOWING CODE
This Code of Practice contains
recommendations jointly reviewed and
agreed by the following organisations:
The
The
The
The
The
National Caravan Council
Caravan Club
Camping and Caravanning Club
Caravan Writers Guild
Department of Transport
Scope of the Code
The Code applies to all trailer caravans of
maximum laden weight not exceeding
3500 kg (7,700 lbs), overall width not
exceeding 2.3m (7ft 6in approximately) and
overall length not exceeding 7m (23ft
approximately), excluding the drawbar and
coupling.
This is legally the maximum size of trailer
that can be towed by a motor vehicle with a
maximum gross weight of less than 3500 kg.
CARAVAN TERMS
Mass in Running Order:
The mass of the caravan as stated by the
caravan manufacturer, as new with standard
fixtures and fittings.
Note: Because of differences in the weight
of materials supplied for the construction of
caravans, a tolerance of +3% of the weight
has been allowed in the Mass in Running
Order weight.
2
User Payload:
The maximum allowable weight to be put
into the caravan whilst it is being towed. This
is made up of 3 sections:
Personal effects, optional equipment and
essential habitation equipment.
The user payload is the difference between
the Maximum Technically Permissible Laden
Mass and the Mass in Running Order.
Essential Habitation Equipment:
Those items and fluids required for safe and
proper functioning of the equipment for
habitation as defined by manufacturer of the
caravan.
Personal Effects:
Those items which a user can choose to
carry in a caravan and which are not
included as Essential Habitation Equipment
or Optional equipment.
Optional Equipment:
Items made available by the manufacturer
over and above the standard specification of
the caravan.
Maximum Technically Permissible Laden
Mass:
The maximum weight for which the caravan
is designed for normal use when being
towed on a road, laden. Under no
circumstances should the maximum
technically permissible laden mass of this
caravan be exceeded. This mass takes into
account specific operating conditions
including factors such as the strength of
materials, loading capacity of tyres etc.
Nose weight:
That part of the static mass of the caravan
supported by the towing device on the rear
of the towing vehicle.
Notes:
(i) When measuring the noseweight it is
important that the caravan is fully
loaded. Do not place extra items
indiscriminately into the caravan after
this adjustment has been made.
(ii) The caravan is intended to be towed
slightly nose heavy. The nose weight
can be adjusted by distribution of the
load within the caravan. The nose
weight should be approximately 7% of
the actual laden weight (but not greater
than the hitch capacity) and at the same
time suit the towing vehicle. See section
on Measurement of Nose Weight.
(iii) It is not recommended that you tow with
just a battery, spare wheel and gas
bottles as this may exceed the the
permitted nose weight. Additional
payload must be placed behind the axle
to compensate for this or consider
repositioning the wheel to a underfloor
carrier.
The Towing Code
TOWING VEHICLE TERMS
Kerb weight (Mass of Vehicle in Running
Order):
The weight of the towing vehicle as defined
by the vehicle manufacturer. This is normally
with a full tank of fuel, with an adequate
supply of liquids incidental to the vehicles
propulsion, without driver or passengers,
without any load except loose tools and
equipment with which the vehicle is normally
provided and without any towing bracket.
Caravan to Towing Vehicle Weight Ratio:
The towing vehicle to caravan weight ratio
can be determined by calculation and is
equal to:
actual laden weight of caravan
Kerb weight of towing vehicle
x 100%
THE LAW REQUIRES THAT CARAVANS &
THEIR TOWING VEHICLES & THE LOADS
THEY CARRY MUST BE IN SUCH A
CONDITION THAT NO DANGER OR
NUISANCE IS CAUSED.
(Regulation 100 of the Road and Vehicles
[Construction and Use] Regulations 1986).
YES
NO
85%
MAYBE
EQUAL
Fig. A Car/Caravan Weight Ratios
caravan weighing around 85% of the
kerb weight of the towing vehicle.
Note: Weighbridges have varying weight
tolerance levels.
(b) Above 1500 cc such engines should
manage a caravan weighing up to 100%
of the kerb weight of the towing vehicle
and still give adequate performance.
Maximum Permissible Towing Mass:
The weight defined by the vehicle
manufacturer as being the maximum that
the vehicle is designed to tow.
Note: The towing vehicle manufacturer’s limit
is, in some cases, less than the kerb weight.
Train Weight (Combination Weight):
The maximum combined weight of the
towing vehicle and trailer combination as
specified by the towing vehicle manufacturer.
Power to weight ratio:
No hard and fast rules can be stated but,
here is a general guide.
Vehicles with automatic transmission may
need an oil cooler fitting or the SAE rating of
the gearbox oil increasing when towing. The
advice of the vehicle manufacturer should be
sought.
(a) Conventional petrol engines with a
capacity up to approximately 1500 cc
should be adequate for towing a
Mass in Running Order:
Caravanners can use a public weighbridge to
establish the mass in running order.
3
The Towing Code
lower jockey wheel before entering the
caravan and then raise before measuring
again. (See Loading).
Note: The height of the towball on the
towing vehicle, when laden, is also critical.
430mm
+ 35mm
-
Fig. A Measuring Noseweight
MEASUREMENT OF NOSEWEIGHT
Noseweight may be measured using a
propriety brand of noseweight indicator.
Such equipment is obtainable at your
Caravan Dealer.
Note: These indicators have a varying
tolerance level.
Another simple method is to use bathroom
scales under the coupling head with a piece
of wood, fitted between the coupling head
and the scales, of such length that the
caravan floor is horizontal with the jockey
wheel raised clear of the ground. (Fig. A)
Noseweight can be adjusted simply by
distribution of weights in the caravan. Always
4
TYPE OF DRIVING LICENCE
HELD
In order to be able to tow a caravan a driver
must hold a Category B licence. Those car
drivers who passed their tests prior to 1
January 1997 would have automatically
obtained Category B+E. However, anyone
who passed their test after 1 january 1997
will need to take a further test in order to
obtain a Category B+E if they wish to tow a
car and caravan combination whose train
weight exceeds 3,500kg, or up to 4,250 if
the caravan is less than 750kg or if the
caravan’s Maximum Technically Permissible
Laden Mass exceeds the unladen weight of
the car.
Note: The unladen weight of a car is
normally less than the kerbside weight.
GLOSSARY & CHECKLIST
Awnings - Can consist of just a simple top
sheet but may extend to a five sided frame
tent attached to the side of the caravan.
Fire blanket - approved to BS 6575 is ideal
for dealing with ‘fat pan’ fires.
Fire extinguisher - It is strongly
recommended that a fire extinguisher is
carried in the caravan. (For suitable types
see Safety and Security).
Gas bottles - Bottled L.P. gas is the most
convenient portable source of fuel. Two
bottles are required for a constant supply. An
initial deposit is payable on each cylinder.
We recommend the use of 6kg Propane or
7kg Butane bottles. One position for use and
one for storage only. (For detailed
information see Services - Gas).
Jack - A suitable jack is essential (screw,
scissor, side mounted or air jack type). Many
car jacks are unsuitable.
Levellers - Levellers help level the caravan
from side to side before unhitching.
Proprietary products can be purchased from
your caravan dealer and need to be
positioned as indicated by a spirit level.
Spare Wheel - It is always advisable to carry
a spare wheel for your caravan.
Spirit Level -A spirit level is extremely useful
when siting the caravan.
Stabiliser -Stabilisers help to dampen the
side to side movement of the caravan. One
end fits to the car’s towing bracket and the
other end to the caravan. (See Stability)
The Towing Code
Torque Wrench - A torque wrench is the
only way that the exact recommended
torque can be achieved for wheel nuts and
bolts. (See Preparing for the Road).
Towing Bracket - Car manufacturers
recommend that their own bracket is fitted at
a specialist dealer, to ensure that it is fixed
to the correct mounting points. Never use
cheap alternatives, obtain one manufactured
by a reputable company complying with the
relevant standards.
WARNING: Your caravan dealer should
be consulted if additional equipment is
to be fitted as strong points may or may
not be provided in the design.
Note: Fitting additional equipment will
reduce the caravan allowable payload.
Wooden Blocks - Wooden blocks typically
25cm. square and 2cm. thick are ideal for
placing under corner steadies and jockey
wheel when the ground is uneven or soft.
Water Containers - Two containers are
required, one to carry fresh water to the
caravan and one for waste water, which
needs to be disposed of properly. Several
types are available including jerry cans,
folding cans and wheeled containers.
12N & 12S Sockets - Two sockets
designated 12N and 12S are fitted to your
car to accept corresponding plugs from the
caravan. These are necessary to energise
the road lights and caravan auxiliary circuits
respectively.
12 Volt Battery - A deep cycling, heavy duty
leisure type battery should be purchased to
provide back-up power for lights and other
electrical appliances. (See Battery).
5
The Towing Code
Useful memory aid for other items.
Car
Distilled water
External mirrors
Fan belt
Fire extinguisher
Jack
Jump leads
Petrol can
Socket set
Spare bulbs
Spare keys
Spare wheel
Tool kit
Towball cover
Tow rope
Tyre pressure gauge
Warning triangle
Tyre Pump
Caravan
Awning pegs and poles
Awning ground sheet
Battery 12 volt charger
Bucket
Corner steady brace
Corner steady pads
Coupling lock
Door mat
Fire blanket
Fire extinguisher
Fresh water container
Gas cylinder
6
Gas regulator
Jack
Levelling boards
Mallet
Site/caravan mains lead
Spare bulbs
(Mandatory in E.C.)
Spare 12v fuses
Spare gas hose
Spare wheel
Spirit level
Toilet fluid
Waste water container
Wheel brace
Personal
After sun cream
First Aid Kit
Flannels
Hairbrush and comb
Make up. etc.
Raincoats
Toothbrush
Toothpaste
Scissors
Shampoo
Shaving kit
Shoe cleaning kit
Soap
Sun tan oil
Wellington boots
Domestic
Adhesive tape
Air freshener
Aluminium foil
Ashtrays
Bin liners
Binoculars
Bottle opener
Breadboard
Breadbin
Brush and dustpan
Butter dish
Camera and films
Carving knife
Cassette recorder
Chairs
Clock
Clothes brush
Clothes line
Coat hangers
Coffee percolator
Coolbox
Colander
Crockery
Cruet
Corkscrew
Cutlery
Dish cloth and brush
Dusters and polish
Disposable cloths
Egg cups
Electrical extension lead
Floor cloth
Fly spray
Food
Food mixer
Frying pan
Glasses
Grill pan
Jugs
Kettle
Kitchen roll
Kitchen tools
Litter bin
Matches
Measuring jug
Milk jug
Mixing bowl
Needles and thread
Oven gloves
Pegs
Piezo Gas lighter
Potato peeler
Pressure cooker
Radio
Rubbish bin
Salad shaker
Saucepans
Scissors
Sieve
Sugar bowl
Shopping bags
Sleeping bags
Tea pot
Tea strainer
Tea towels
Table cloths
Table mats
Television
Tin opener
Tissues
Toilet paper
Torch
Towels
Toys & Games
Vacuum cleaner
Washing up bowl
Documents
Bail Bonds
(some Euro countries)
Bank and credit cards
Caravan Certificate
Cheque book
CRIS document
Driving licence
Green Card Insurance
(some Euro countries)
Maps and guides
Money
MOT Certificate
Vehicle Registration
Documents
The Towing Code
PREPARING FOR THE ROAD
PRE-LOAD CHECKLIST
Caution: Never enter the caravan without
first lowering the four corner steadies with
the brace provided.
BEFORE LOADING CHECK:
-
loose articles are stowed securely. Do not
stow tins, bottles or heavy items in
overhead lockers prior to towing.
-
all lockers and cupboard doors are
closed 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 lock
is set.
-
all windows are fully closed and latched.
Never tow with windows on night setting.
Leave all curtains and blinds open to aid
rear visibility.
-
gas cylinders are correctly positioned,
secured and turned off.
-
battery is secure and mains connecting
cable is disconnected and stowed.
-
12v distribution panel selector switch is
set to centre position.
WARNING: Isolate all gas appliances
before setting off.
(a)
(b)
(c)
(d)
Fig. A Loading your caravan
WARNING: Do not travel with televisions
or microwaves in overhead lockers
unless the appliance was supplied fitted
to your caravan by the manufacturer.
rear since this can lead to instability due
to the ‘pendulum effect’.
4. Load remainder to give a suitable
noseweight at the towing coupling.
Check noseweight.
LOADING AND DISTRIBUTION OF
WEIGHT IN THE CARAVAN
Do not exceed recommended maximum
loading for your caravan.
1. Load heavy items low down near the
floor and mainly over or just in front of
the axle(s) (Fig. A).
Note: Do not overload car boot.
Note: Please take care to ensure that you
have allowed for the masses of all items you
intend to carry in the caravan
2. Load evenly right to left so that each
caravan wheel carries approximately the
same weight.
3. Do not load items at the extreme front or
7
The Towing Code
Sensible Loading:
How to apportion it
LIGHT
Fig. A ITEMS
MEDIUM
ITEMS
HEAVY
ITEMS
Towing vehicle’s rear suspension
It is important that the towing vehicle’s rear
suspension is not deflected excessively by
the noseweight on the tow ball. If it is
excessive the steering and stability will be
affected. (Fig. B)
The greater the towing vehicle’s tail overhang
(the distance between the rear axle and the
tow ball) the greater the effect the
noseweight will have on the towing vehicle’s
rear suspension.
After trying out the caravan it may be found
that stiffening of the rear suspension is
necessary - but note that this may give the
towing vehicle a firmer ride when not towing.
Fig. B Illustration of excessive deflection of vehicle’s rear suspension
There are a number of suspension aids
available and advice should be sought on
which to use and how to fit. It is important to
ensure that the caravan is towed either level
or slightly nose down.
STABILITY
All our models are of a well balanced design
and should be exceptionally good towers.
The most common causes of poor stability
include:
If you have any doubts about the suitability
of your towbar for towing a twin axle caravan
consult the towing bracket manufacturer.
(a) Worn springs or loose spring fixings on
the towing vehicle.
DO NOT exceed the:
• Gross Vehicle Mass (G.V.M. on car plate).
• Maximum Technically Permissible Laden
Mass (M.T.P.L.M.).
• Gross Vehicle Combination Mass
(Train Weight) (G.V.C.M. on car plate).
• Maximum Permissible Towing Mass.
8
(b) Towing vehicle springs too soft.
(c) Insufficient noseweight.
(d) Nose of caravan is towing too high.
Galvanised steel chassis
Drilling of the galvanised steel chassis will
invalidate the warranty. If fixing a towing aid,
in the first instance consult your dealer as
regards suitability.
The Towing Code
Never drill the coupling head to aid the fitting
of a stabiliser.
Note: Some stabilisers may require the
towing vehicle to be fitted with an ungreased
or swan neck tow ball. Please refer to
manufacturer's fitting instructions.
Suitable towing vehicles
The caravan is manufactured for towing
behind normal road cars and is not suitable
for towing behind commercial vehicles. It is
strongly recommended that whenever a
caravan is to be towed over rough terrain,
e.g. a farmer’s field or track, great care
should be taken to ensure that no undue
stress is placed upon the caravan via the
hitch mounting, i.e. reduce speed. If in
doubt, please consult the chassis manufacturer and the towing vehicle manufacturer
who will advise. Touring caravans based on
standard Al-Ko chassis can be towed by
four wheel drive off road leisure vehicles
providing the unit is used to tow in a like
manner to a conventional road-going car and
driven in the same considered manner.
Snaking
This is a term used to denote an unstable
car and caravan combination where the
caravan ‘weaves’ from side to side often
causing a similar swaying movement in the
car 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 moving
vehicle.
vii) Erratic driving.
viii) Insufficient tyre pressures.
ix) Mixing radial and cross ply tyres.
Cures:
Cases of persistent snaking can be
alleviated by the use of a stabiliser, about
which your dealer will advise you.
On the road
If you do find your outfit snaking, try to keep
the steering wheel in a central position as far
as possible, decelerate and avoid braking if
possible.
OTHER IMPORTANT TOWING
CONSIDERATIONS THAT COULD AFFECT
STABILITY
Types of tyres fitted
The tyres fitted by the manufacturer are
suitable for towing at sustained speeds of up
to 81 mph (130 kph).
Radial and cross ply tyres should never be
mixed. It is dangerous and can cause
snaking.
Periodically tyres should be rotated to
equalise wear in the same manner as car
tyres.
Do not mix four ply/six ply/eight ply tyres on
the same axle.
Tyre tread
The law requires that tyres and pressures
must be suitable for the use to which they
are being put. The minimum tread depth of
both car and caravan tyres must be 1.6mm
throughout a continuous band comprising
the central three quarters of the breadth of
tread and around the entire circumference of
the tyre.
Tyre pressures
Towing vehicle's tyres must be at the
pressures recommended for towing or heavy
loading as stated in handbook not on tyre
wall. Towing stability may otherwise be
affected. The pressures can be found in the
towing vehicle handbook. The caravan tyre
pressures should be as recommended in the
specification details in your handbook.
Note: Although the caravan may be fitted
with the same type of tyre as the towing
vehicle, the pressures specified are different.
All charts show values for cars and are
therefore not applicable for caravans.
Pressures displayed on tyre walls apply
ONLY in North America and Canada.
9
The Towing Code
Wheels
Caravan wheel nuts should be tightened to a
torque of 88Nm (65lb/ft) on steel wheels or
115Nm (85lb/ft) on alloy wheels and should
be checked with the use of a torque wrench
regularly. Only use a spare wheel and tyre
recommended by the manufacturer.
Wheel Rims
The majority of caravans manufactured since
1993 have been fitted with steel wheel rims
which are the wider 5J size incorporating a
double safety hump rim which conforms to
European standards of safety. The alternative
to steel wheel rims are alloy wheel rims.
If you are in any doubt, have your wheels
checked by a competent tyre supplier.
Fig. A Winding Corner Steady
Fig. B Safety Catch and Handle
Pick up any levelling pads or levelling boards.
Release caravan handbrake.
Hitch head load capacity
The maximum vertical static load which can
be put upon the hitch head when connected
is 100kg. Please refer to the technical data in
your handbook.
Check rooflights/vents are securely closed.
(But see also vehicle manufacturer’s weight
limits on towball loading.)
An assistant can help in the hitching
operation by standing on the left hand side
of the drawbar (facing rear of car) and
extending an arm horizontally to indicate
position of the coupling. When reversing aim
the towball of the car directly at the caravan
drawbar. Remove towball cover and keep in
car.
Position cup over greased towball, release
safety catch and lift handle (Fig. B). The hitch
head is fitted with a visual indicator to show
whether or not it is properly connected to the
towball. A green band will show immediately
below the red indicator button on the hitch
head when a proper connection has been
made. (See Fig. D, Page 11)
PRE-TOW CHECKLIST AND HITCH-UP
Check Gas Locker, Battery Locker (if fitted)
and Cassette Toilet (if fitted) door/s are
secure.
Check wheelnuts, tyre pressures and tyre
conditions.
Fully raise all four corner steadies. (Fig. A).
10
Switch off gas supply and change over to
electricity if required.
Lock the caravan exterior door.
Adjust the jockey wheel to ensure the cup is
high enough to slide over the towball.
WARNING: Serious damage will occur
unless the locking button is depressed
first and the handle lifted forward before
the caravan is lowered manually. This
prevents the noseweight being
transmitted through the locking button.
The Towing Code
Fig. A Handbrake
WARNING: If the green band is showing
when the hitch head is not connected
to the towball there is a fault - contact
your Dealer.
Adjust jockey wheel to lower cup on to the
ball. A click indicates it is fully engaged. Ensure
locking button has returned to its free position.
Secure caravan handbrake. (Fig. A)
Fig. B Checking Secure Attachment
Fig. C Connections - 7 pin Plug
as high as possible and retighten the clamp
handle.
Note: Ensure jockey wheel locates in recess
provided.
Take hold of the caravan under the rubber
gaiter behind the coupling and lift to
ascertain whether the caravan is properly
attached. (Figs. B & D.)
Lock hitch if possible (see Safety and
Security, page 20).
Connect breakaway cable (emergency
braking device) in the form of a noose to
suitable anchorage point on towbar. DO NOT
attach to towball.
Connect 7 pin plugs to car sockets ensuring
there is enough loose cable for cornering.
(Fig. C)
Ensure that the jockey wheel is fully wound
up and properly located in the slots, then
release the clamp handle, lift the whole unit
Check all car and caravan roadlights are
working. Check round the caravan for
anything left behind.
Fig. D Hitch Head Visual Indicator
Release caravan handbrake, adjust all
mirrors from driving seat and proceed.
11
The Towing Code
12N AND 12S VIEWED FROM REAR OF PLUG
TUBES
PINS
PINS
STRIPS
12N (BLACK)
TERMINAL
1
2
3
4
5
6
7
COLOUR
YELLOW
BLUE
WHITE
GREEN
BROWN
RED
BLACK
12S (GREY)
12N PLUG
L/H INDICATOR
REAR FOG LAMP
COMMON RETURN (1-7)
R/H INDICATOR
R/H SIDE TAIL & No PLATE LIGHT
STOP LAMP
L/H SIDE TAIL & No PLATE LIGHT
TERMINAL
1
2
3
4
5
6
7
COLOUR
YELLOW
BLUE
WHITE
GREEN
BROWN
RED
BLACK
12S PLUG
REVERSING LIGHT
NO ALLOCATION
NEGATIVE PIN 4
CONTINUOUS POWER SUPPLY
NO ALLOCATION
FRIDGE
RETURN FOR FRIDGE
VOLTA/JEAGER & MULTICON FEDER 13 PIN PLUGS (viewed from rear)
VOLTA/JEAGER
PIN NO
1
2
3
4
5
6
7
8
9
10
11
12
13
12
COLOUR
YELLOW
BLUE
WHITE
GREEN
BROWN
RED
BLACK
ORANGE
BROWN/BLUE
BROWN/RED
WHITE/BLACK
WHITE/GREEN
WEST
DESCRIPTION
LEFT FLASHER
FOG HAZARD LIGHT
EARTH FOR 1-8
RIGHT FLASHER
RIGHT TAIL LIGHT
STOP LIGHTS
LEFT TAIL LIGHT
REVERSE LIGHTS
CAR +
FRIDGE
EARTH FOR 10
NOT YET ALLOCATED
EARTH FOR 9
PIN NO
1
2
3
4
5
6
7
8
9
10
11
12
13
MULTICON
FEDER 13K
COLOUR
YELLOW
BLUE
WHITE
GREEN
BROWN
RED
BLACK
ORANGE
BROWN/BLUE
BROWN/RED
WHITE/BLACK
WHITE/GREEN
DESCRIPTION
LEFT FLASHER
FOG HAZARD LIGHT
EARTH FOR 1-8
RIGHT FLASHER
RIGHT TAIL LIGHT
STOP LIGHTS
LEFT TAIL LIGHT
REVERSE LIGHTS
CAR +
FRIDGE
EARTH FOR 10
NOT YET ALLOCATED
EARTH FOR 9
ROAD LIGHTING
For your information the wiring diagram of the
12N and 12S connectors is shown opposite.
These should be checked regularly and if in
any doubt a qualified electrician consulted.
Some European cars may be equipped with
Volta, Jeager, West or multi-con sockets, an
adaptor or replacement sockets may be
required. If so consult your dealer or qualified
electrician.
The wiring allocations were changed in 1998
and it is important that you check the car to
caravan connections are compatible prior to
coupling up to the car.
WARNING: Always disconnect the
electrical connector between the towing
vehicle and the caravan before
connecting a low voltage supply to the
caravan (mains) and before charging the
battery (EN 1648-1).
WARNING: Do not cause any road lighting
to be obscured by the addition of any
options or accessories to your caravan.
PASSENGERS
Passengers are forbidden to ride in a caravan
with the exception of authorised test personnel.
BRAKES/BREAKAWAY CABLE
A breakaway cable is required for caravans
and the device must be such that the caravan
stops automatically if the coupling breaks
(Regulation 15 of the Road Vehicles
[Construction and Use] Regulations 1986).
The Towing Code
Always ensure that the breakaway cable is
connected to the towing vehicle, not to the
towball.
MIRRORS
The driver of the towing vehicle must have an
adequate view of the rear.
If there is no rear view through the caravan it
is essential that additional exterior towing
mirrors are fitted. This is mandatory in some
European countries and drivers can face
instant fines if extension mirrors are not fitted.
Caution: Any rear view mirror must not
project more than 200 mm outside:
a) the width of the caravan when being
towed.
b) the width of the towing vehicle when
driven solo.
Note: Any rear view mirror fitted shall be ‘e’
marked and cover the field of view as
stipulated by type approval requirements
(Regulation 33 of the Road Vehicles
[Construction and Use] Regulation 1986).
PULLING OFF
Let the clutch in smoothly.
Fig. A Reversing
REVERSING
Proficiency at reversing can only be achieved
with practice and should be first attempted
in a large open area (Fig. A).
Allow for the outfit being twice its normal
length.
Do not suddenly swing out.
SPEED LIMITS
Carry out all manoeuvres as smoothly as
possible.
Normal road towing: 50mph
Use nearside wing mirror to check caravan
has cleared when overtaking.
Motorways (including dual carriageways):
60mph
Allow more engine speed to produce the
power to move the additional weight of the
caravan.
CARAVAN HANDLING
Reduce wear and tear on clutch and
transmission by taking extra care.
Do not bump kerb with caravan wheels.
Change gears smoothly.
Allow longer to get up speed to pass.
WARNING: Take care not to foul or
ground caravan chassis whilst
traversing ramps or other obstacles.
Allow for caravan being wider than car.
When passing other vehicles allow more than
the normal clearance for driving solo.
Try not to jerk the clutch.
13
The Towing Code
IMPORTANT POINTS ESPECIALLY
FOR MOTORWAY DRIVING
1. Caravans may not be towed in the outside lane of a three or four lane motorway. (Reg. 12(2) of the Motorway Traffic
[England and Wales] Regulations 1982).
2. Reduce Speed:
i) In high or cross winds.
ii) Downhill.
iii) In poor visibility.
3. High sided vehicles cause air buffeting so
extra care must be taken when passing or
being passed. As much space as
possible should be given.
CHANGING A WHEEL
1. Leave caravan hitched to towing vehicle
and ensure handbrake is applied.
2. Lower corner steadies (as safety
measure) on the side that the wheel is
being changed to stabilise the caravan.
3. Use wheel brace to slacken off wheel
nuts on the wheel to be changed.
4. Position jack under the axle at the
appropriate jacking point (see fig. B)
5. Jack up the caravan until the wheel for
removal is just off the ground.
6. Remove the wheel nuts, wheel trims and
remove the wheel.
14
Fig. A Wheel Nut Tightening
7. Fit spare wheel and reverse the above
procedure.
Ensure clean, dry mating surfaces and
clean, dry bolt/nut sealing areas.
8. Tighten all four/five nuts, according to
Fig. A, to 88Nm (65lb/ft) for steel wheels
or 115Nm (85lb/ft) for alloy wheels using
a torque wrench or have checked as soon
as possible.
Ensure the correct wheel fixings are used,
as supplied with your caravan
IMPORTANT
When a wheel has been removed and
replaced the torque of the wheel nuts should
be re-checked after approximately 15 miles
of running. (See 8 above).
Fig. B Scissor Jack
JACKING POINTS
WARNING: Only jack up your caravan
when it is coupled up to the car with its
handbrake applied and in 1st gear
(engine off).
Ensure that the jack is located in the correct
position, i.e. on the jacking bracket on the
chassis for the Al-Ko side mounted jack
(Fig.B). Alternatively the reinforced axle
mounting plate can be used as an alternative
but the chassis member itself MUST NEVER
be used as a jacking point.
All caravans are provided with the facility to
fit Al-Ko side jacking points and although a
scissor, trolley or bottle jack may be used,
it is recommended that the side mounted
Al-Ko Jacking System should be used.
The Towing Code
STOPPING ON A HILL
Levelling pads or boards should be used
under the steadies where the ground is soft
or uneven.
Pulling off again can sometimes present a
problem. The easy solution is
In extreme cases where it is necessary to
raise a wheel off the ground for levelling
purposes, further adequate support should
be applied so that the steadies do not take
any undue strain.
(i) Carry a good sized wedge shaped piece
of wood with a rope or light chain
attached.
(ii) Attach the other end of the rope to the
nearside rear grab handle.
(iii) Place the wood behind the nearside
caravan wheel.
(iv) Carefully reverse the car slightly back
down the hill, the caravan will stop
against the wedge and turn.
(v) Drive forward since this attempt to move
up the hill will now not involve pulling the
full weight of the caravan until the car has
gained some traction.
Fig. C levelling Board
1. Selecting a pitch
Do not pitch in such a position that your
outfit will obstruct others coming in.
2. Levelling the caravan
Levelling must be carried out in both
directions in order for the refrigerator and
other equipment to function correctly. This
should be done before unhitching the
caravan. Levelling boards (Fig. C) can be
used to raise one side of the caravan by
driving or reversing the caravan onto the
boards. Apply the handbrake and chock the
wheels.
Try to choose an area which is dry, reasonably level and preferably with a hard base.
The positioning of the jockey wheel can be
used to help level the caravan.
If you have no alternative but to pitch on a
slope ensure that, for when you leave, you
are facing down the slope.
Lower the corner steadies until they are in
firm contact with the ground.
It is good practice to chock the wheels of
the caravan when parked on a slope even
though the caravan brakes are applied.
DO NOT use the steadies as a jack
they are only a means of stabilising
the caravan.
ARRIVAL ON SITE
Note: Check and observe site regulations.
Exterior Door
To prevent distortion of the body, the caravan
must be always correctly sited and levelled.
Failure to site the caravan correctly may
prevent the exterior door from closing
properly.
3. Unhitching
Apply the caravan handbrake.
Lower the jockey wheel to the ground.
Disconnect the breakaway cable and road
lighting plugs.
Operate the handle by depressing the locking
button on the lever mechanism and lift the
handle upwards and forwards, at the same
time winding down the jockey wheel, to
assist in lifting the caravan clear of the
towing vehicle.
When this operation is complete, replace
towball cover.
Park your vehicle alongside the caravan on
the offside.
15
SAFETY
AND
SECURITY
Fire .......................................................................................... 18
Notice ................................................................................... 18
In Case of Fire ...................................................................... 18
Dicon 300AP Smoke Alarm....................................................18
Smoke Alarm......................................................................... 18
Fire Extinguishers.................................................................. 19
Children ................................................................................... 19
Ventilation .............................................................................. 19
Security ................................................................................... 20
Caravan Theft ....................................................................... 20
Chassis Number.................................................................... 20
Additional Security ............................................................... 20
Security Chips....................................................................... 20
Safety & Security
FIRE
Important: Your attention is drawn to the
notice affixed inside the caravan advising on
fire precaution, ventilation and what to do in
case of fire.
IN CASE OF FIRE
1. Get everyone out of the caravan as
quickly as possible using whichever exit is
the quickest, including windows. Do not
stop to collect any personal items.
2. Raise the Alarm. Call the Fire Brigade.
3. Turn off the gas supply valve if it is safe to
do so.
4. Turn off the electricity supply at supply
point.
DICON 300AP SMOKE ALARM
This smoke alarm is approved for use in
caravans and mobile homes. (Fig. A)
The National Caravan Council requires that
all new or used caravans sold by its
members be fitted with a smoke alarm
featuring an alarm silence facility.
Fig. A Smoke Alarm
• Low Battery Warning
Unit “beeps” approximately every 45
seconds for up to 30 days when the
battery needs replacing.
• Sensitivity Test Button
Test sensitivity, circuitry, battery and horn.
• Loud 85 Decibel Piezo Electric Alarm
Automatically resets when hazardous
condition has passed.
the smoke detector should last
approximately one year.
WARNING: Ensure that batteries are
correctly installed. Positive terminal to
positive contact (marked +), negative
terminal to negative contact. Reversing
a battery in its compartment will
immediately drain the battery and
could damage the smoke alarm.
FEATURES
• Precise Sensitivity
HOW TO TEST
• Battery operated. No need for mains
power wiring.
• High Quality Solid State Components
CONNECTING THE BATTERY
Press test button until alarm sounds, then
release. Repeat test weekly.
• Operating Light (LED)
Your alarm requires one 9 volt battery to
power the smoke detector portion of the
unit. Under normal use the battery powering
Note: Always test smoke alarm operation
after vehicle has been in storage, before each
trip and at least once per week during use.
Flashes approximately every 45 seconds
confirming unit is powered.
18
Safety & Security
WARNING: The electronic test button
provides a full test of the unit’s
functionality. DO NOT try to test the
alarm with a naked flame, as this may
present a potential fire hazard.
FALSE ALARMS
Abnormal air conditions may cause the
highly sensitive smoke alarm to give a
“false” alarm. DO NOT DISCONNECT THE
BATTERIES. If no fire is apparent, ventilate
the caravan and/or blow fresh air into the
unit until the alarm stops. Once cleared the
smoke alarm will automatically reset.
MAINTENANCE
Dust can lead to excess sensitivity therefore
it is recommended that the unit be
vacuumed every 6 months to help keep the
unit working efficiently.
Open cover and gently vacuum interior of
detector trying to keep the nozzle from
touching the unit.
WARNING: Never use portable cooking
or heating equipment other than electric
heaters that are not of the direct radiant
type, as it is a fire and asphyxiation
hazard.
FIRE EXTINGUISHER
VENTILATION
It is recommended that a 1kg (2lb) minimum
capacity dry powder fire extinguisher be
carried inside your caravan at all times.
All caravans comply with BS EN 721. The
ventilation points on your caravan are fixed
points of ventilation which are required by
the European Standards.
When using a dry powder extinguisher it is
suggested that the caravan be evacuated
until the powder has settled, to avoid
inhalation.
A fat pan fire should not have a fire
extinguisher aimed at it. It should be
smothered with a fire blanket.
WARNING: Provide one dry powder fire
extinguisher of an approved type or
complying with ISO 7165, of at least 1kg
capacity, by the main exterior door and
a fire blanket next to the cooker.
Familiarise yourself with the instructions
on your fire extinguisher and the local
fire precaution arrangements.
ESCAPE PATHS
It is important that you do not block escape
paths to emergency exits with obstructions
or hazards.
CHILDREN
Do not leave children alone in the caravan in
any event. Keep potentially dangerous items
out of reach, as at home e.g. matches, drugs
etc.
All caravans have ventilation at high level
and low level which have been calculated to
suit the individual needs of your caravan.
High level ventilation is achieved by means
of the roof lights and washroom roof
ventilators. The low level ventilators are
positioned underneath the oven housing.
Some models with sliding doors have two
vents located underneath the sliding doors.
Under no circumstances must these vents
be blocked or obstructed.
It is advised that fixed ventilation points are
checked and cleaned (if necessary) on a
regular basis using a small brush and a
domestic vacuum cleaner.
Additional night time ventilation is obtained
by releasing the window catches and placing
them in the second groove. Note the
windows are not sealed from rain in this
position.
As the ventilation levels are calculated to suit
each models requirements there should be
no modifications made which may result in
reduced ventilation levels.
WARNING: Do not obstruct ventilation.
19
Safety & Security
Petrol/Diesel Fumes
The fitting of a tail pipe to your car exhaust
will reduce the possibility of fumes entering
your caravan through the ventilation points.
SECURITY CHIPS
A special security chip is concealed within
the body of every caravan. This chip contains
the individual identity of your caravan and
can only be read by using a special decoder.
Your local police can obtain the use of a
decoder by contacting C.R.I.S. on telephone
no: 01722 411430
Note: Never allow modification of electrical
or LPG systems and appliances except by
qualified persons at an authorised Swift
Group dealership.
SECURITY
Caravan theft
The theft of a caravan can occur in the most
unlikely circumstances; from a motorway
service area, even from an owner’s driveway.
Secure all windows and doors when your
caravan is unoccupied even if only for a short
length of time.
Chassis number
Record your caravan chassis number which
can be found on the front offside section of
the drawbar (Fig. A) or any of the eye level
windows.
Make a note of this number in the space
provided at the front of this handbook and
make a separate note of the number to keep
safe at home.
Additional security
Consider fitting any device which might deter
or prevent intrusion by thieves.
20
Fig. A Chassis Number
A hitch lock cover prevents towing of the
caravan.
A wheel lock prevents towing of the caravan
and removal of the wheel.
Customers are advised to identify their
caravan with a method for subsequent
identification if other forms of identification
have been altered or removed.
Free crime prevention advice about securing
your caravan, protecting your valuables,
property marking, either at home or whilst on
site, can be obtained from the Crime
Prevention Officer through your local Police
Station.
SERVICES
Connection of Services ......................................................... 22
Water ....................................................................................... 22
Typical Water Schematic Drawing .........................................22
Truma Compact Crystal 2 ......................................................23
Inboard Water Tanks and On-line Water Systems .................24
Truma Waterline......................................................................24
Reich Microswitch Taps .........................................................25
Reich Keramik Twist...............................................................25
Reich Kama ............................................................................26
Whale 'Elegance' Microswitch Mixer Tap ..............................27
Whale 'Elite' Microswitch Taps ..............................................28
Gas ........................................................................................... 30
General Information................................................................30
Typical Gas Schematic Drawing ............................................31
Types of Gas ..........................................................................32
Gas Safety Advice..................................................................32
Electricity ................................................................................ 33
Instructions for Electricity Supply ..........................................33
Overseas Connection.............................................................35
Wiring of Connecting Cable and Caravan Mains Inlet...........36
Services
Connection of services is dealt with under
the separate headings.
Typical water schematic drawing
with water tank (model specific)
In all cases users should become familiar
with the equipment manufacturers’
instructions.
Advice and leaflets, if not supplied with the
caravan, can be obtained from the suppliers
of the equipment.
Before making connections of any
description to the caravan or its equipment,
ensure that ALL equipment is turned off.
WATER
The caravan can use three separate systems
for its water supply.
1. External water carrier.
2. Inboard water tank (for winter use
essential).
3. Watermaster Aqua Source (mains water)
or Truma Water Line.
22
Typical water schematic drawing
without water tank (model specific)
Services
TRUMA COMPACT CRYSTAL 2
Plug the pump connector into the socket.
Turn the top security clip anti-clockwise and
the bottom security clip clockwise to lock
the plug into place.
When using the Winter Kit the blanking plug
provided will be fitted to the housing not
being used.
Clean the water system at the start and
end of the season with sterilising fluid
(see notes under sterilising).
If the pump fails to deliver water the most
likely cause will be air in the system. Switch
off the pump and shake the pump assembly
in the water. Then switch on again.
dust cover
STERILISING
1. When cleaning the water system at the
start or the end of the season it is
advisable to use a sterilising fluid e.g.
Chempo SDP or similar.
Raise the lid, clean both the water socket
and the plug of the pump assembly.
2. Flush the system thoroughly to remove
the effective fluid traces.
Place the pump into the water container,
ensuring that it is fully submerged before
operating the system. A dust cover is
available to stop contaminates falling into
the water container.
3. After sterilising the system at the start of
the season it is recommended that a new
filter cartridge should be fitted.
(Not standard).
To remove the pump assembly from the
Crystal Compact Housing, release the
security clips and pull the hose adaptor by
using the finger grips provided.
pump connection
Do not remove by pulling the hose or
electric cable.
23
Services
INBOARD WATER TANKS AND
ON-LINE WATER SYSTEMS
To fill the inboard tank from an external
container follow these simple instructions:
1. Insert Truma Thames or Maxi submersible
pump into external water container.
2. Lift flap and plug pump connector into
Truma socket on side of caravan.
3. Ensure the inline stem shut off valve is in
the open position. This is located next to
the tank or T-connector feeding the tank.
Ensure that where Ultrastore water heater
is fitted the dump valve adjacent to this is
closed. Ensure that the tank drain valve
(in front of the tank when the bed front
flap is lowered) is in the closed position.
4. Select external pump on the control panel
above the door, and switch the pump on
via the switch adjacent to the mains
fusebox. The inboard tank will now fill
from the external tank.
5. When water starts to flow from the
overflow on the underside of the caravan,
or when the external container is empty,
immediately remove the pump connector
from the socket in the side of the caravan.
Switch off the pump at the control panel
or with the switch adjacent to the mains
fusebox.
6. Turning a cold tap on with the internal
pump now selected at the control panel
will relieve pressure in the tank.
TRUMA WATERLINE
WARNING: It is not recommended to
tow with water in the onboard or
underslung water tank as this could
affect stability.
WARNING: Do not under any
circumstances connect your caravan to
the mains water supply without the
pressure reducer fitted. Damage will
occur to the caravan's water system.
Fig. A
1. Fig. A: Connect the fitted Crystal 2 plug
(1) into the water inlet socket.
2. Fig. B: Uncoil the hose and screw cap
adaptor (4) to the drinking water stand
pipe. Plug in the hose adaptor (5).
3. Turn on the mains water supply and
check for leaks.
4. Open one of the taps and purge any air
that may be trapped in the water system.
5. To remove, make sure that the mains
water supply has been turned off, then
squeeze in the two side clips and pull free
the plug.
Fig. B
24
Services
REICH MICROSWITCH TAPS
The micro switch taps are used when the
water supply is not pressurised.
When the tap is turned on the micro switch
(which is fitted inside the tap) activates the
pump to supply water.
Operation
Swivel the tap spout (a) to the desired
position over the sink, lift the control lever (b)
to activate the pump and allow water to flow
simultaneously. To adjust the temperature
swivel the lever (c) to the left or right as
shown opposite.
Before you Start
1. Ensure pump is isolated.
2. Position lever in central, i.e. mixer, off
location.
REICH TWIST SINGLE LEVER MIXER TAP
Exchange of the ceramic cartridge/
micro switch
1. Detach cover
(1) carefully.
If the cover is
damaged use
spare part
no.: 240-054312
(red cover) and
240-054313
(blue cover).
2. Loosen screw
inside the
handle.
1
2
3. Detach the handle (2).
Note: Before commencing microswitch
replacement ensure instructions are read
through thoroughly. The entire process can
be completed without the need to remove
the tap from the worktop.
5. Detach the plastic
part (3) from the
cartridge lever.
3
6. Loosen screws with
screwdriver
(Tor® TX6).
7. Detach the plastic
ring.
8. Pull out the ceramic
cartridge (4).
9. If the cartridge is
defect:
- Install a new
ceramic cartridge,
part no.:
240-0552M
- Make sure that the
cartridge is in the
right position.
10.If the microswitch (5)
is defect:
- Pull the wire out
of the mixer
- Install a new
microswitch,
part no.: 24006220M.
4
5
4. Detach the housing
carefully.
25
Services
11.Install
cartridge,
plastic parts,
housing and
handle in the
opposite
way.
2
8. If the microswitch is defect:
- Pull the wire out of the mixer
- Install a new microswitch,
part no.: 240-06220M.
9. Install ceramic
cartridge, brass ring,
brass nut, rosette
and handle in the
opposite way.
Maintenance
To prevent your
single mixer tap
TWIST from being
impacted by frost,
always drain the tap
in the middle
position of the
handle.
2. Loosen screw inside the handle.
Maintenance
3. Detach the handle (2).
5. Turn out the
brass nut
with spanner.
To prevent your single
mixer tap KAMA from
being impacted by
frost, always drain the
tap in the middle
position of the handle.
The middle position of the handle is marked
by an arrow!
6. Pull out the
ceramic
cartridge (3).
The middle position of
the handle is marked by
an arrow!
REICH KAMA SINGLE LEVER MIXER TAP
7. If the cartridge is defect:
- Remove the brass ring (4) from the
top of the cartridge
- Install a new
4
ceramic cartridge,
part no.: 2400528M
3
- Make sure that the
cartridge is in the
right position.
4. Turn out the rosette.
Exchange of the ceramic cartridge/
micro switch
1. Detach cover (1)
carefully. If the
cover is
damaged use
spare part no.:
240-059512
(red cover) and
240-059513
(blue cover).
26
1
Services
WHALE ‘ELEGANCE’
MICROSWITCH MIXER TAPS
Microswitch replacement
Dismantling the taps for maintenance
Before you start:
1. Pull off knob(s) and spindle(s).
The microswitch taps are used when the
water supply is not pressurised.
• Ensure the pump is isolated.
2. Unscrew securing screw(s), using a 17mm
(11/16") spanner.
When the tap is turned on, the microswitch
(which is fitted inside the tap), activates the
pump to supply water.
1. Remove the crimp terminals.
• Ensure the taps are in the OFF position.
3. Control unit(s) can now be released for
inspection (see fig. 2).
2. Hold the sides of the microswitch clip with
your thumb and finger and gently pull off
the clip.
3. The microswitch should slide off the two
retaining pins. Be careful not to break the
pins off (see fig. 1).
Knob
4. Replace in the reverse order.
Drive
Spindle
Securing
Screw
Operation
Swivel the tap spout to the required position
over the sink and turn on either the hot or
cold tap to activate the pump and allow
water to flow. To adjust the water
temperature, open both taps to the required
mix.
Cleaning
It is recommended that a non-abrasive damp
cloth is used for cleaning the Elegance tap.
Control
Unit
Fig. 1
Fig. 2
27
Services
WINTERISING
To avoid damage as a result of freezing,
drain the entire water system. To protect
Elegance Tap or Shower units, the tap
control(s) and the shower handset on/off
control should be opened when draining the
system to enable stored water in the outlet
to drain back through the control valves and
out of the system (switch off pump at
isolator). Ensure that both the hot and cold
systems are fully drained, the cold drain plug
is a separate drain plug from the heater drain
plug. Tap spouts and shower heads should
be unscrewed, removed and stored in a dry
place. Please consult your dealer if in
difficulty. If they are unable to solve the
problem, contact Whale Customer Services
on 01247 270531 ext. 211 or 213.
WHALE ‘ELITE’ MICROSWITCH
TAPS
The micro switch taps are used when the
water supply is not pressurised.
When the tap is turned on the micro switch
(which is fitted inside the tap) activates the
pump to supply water.
Operation
Swivel the tap spout (a) to the desired
position over the sink, lift the control lever (b)
to activate the pump and allow water to flow
simultaneously. To adjust the temperature
28
swivel the lever (c) to the left or right as
shown below.
Cleaning
It is recommended that a non-abrasive damp
cloth is used for cleaning the Elite
Tap/Shower.
Microswitch Replacement: A microswitch
replacement kit is available (ref. MT8000).
Note: Before commencing microswitch
replacement ensure instructions are read
through thoroughly. The entire process can
be completed without the need to remove
the tap from the worktop.
Before you Start
1. Ensure pump is isolated.
2. Position lever in central, i.e. mixer, off
location.
Important
Note position of
ACTUATOR before
removing it.
Microswitch Replacement
1. Carefully remove lever cap. A recess at
the back of the lever cap is provided to
assist with this.
2. Remove screw with No. 2 Pozi
screwdriver. Note the position of the lever
at this stage.
3. Lift off the lever.
Services
4. Note the position of actuator before removal. Flange should be facing forward.
9. Attach replacement microswitch and
relocate. Note: Ensure microswitch snaps
fully home.
the outlets to drain back through the control
valves and out of the system. (Switch off
pump at isolator). Ensure that both the hot
and cold systems are fully drained by
draining separately. The cold drain plug is a
separate drain plug from the heater drain
plug. The lever should be up and in the
centre to drain the hot and cold system when
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.
10.Before relocating shroud ensure wires are
neatly located in the front groove as
shown.
GUIDANCE ON CLEANING PORTABLE
WATER TANKS AND THE WATER SYSTEM
IN TOURING AND MOTOR CARAVANS
11.Replace shroud. Note: Ensure shroud
locating rib is aligned with the rear groove
of tap and snap fully home, ensuring clips
are retaining the shroud.
The water systems, and in particular storage
tanks, in caravans are susceptible to
contamination by bacteria if care is not taken
with their use and cleaning. The symptoms
caused by bacterial contamination are not
purely limited to gastro-intestinal diseases,
but may also manifest themselves as ear,
nose, throat, eye or skin infections. It is
therefore important that you carry out the
following procedure prior to using the
caravan each time, even if you boil or filter all
water you use for drinking.
5. Remove actuator.
6. To remove shroud, squeeze clips with one
hand and slide shroud off with other hand.
7. Remove microswitch, using finger and
thumb, pull up and outwards.
8. Slide wire terminals off microswitch.
12.Replace actuator in position noted in 4
above.
13.Replace lever and fix with screw.
Note: Do not overtighten screw.
14.Replace lever cap.
WINTERISING
To avoid damage as a result of freezing, drain
the entire water system. To protect Elite tap
or shower units, the tap control(s) and the
shower control should be opened when
draining the system to enable stored water in
2. The outside of the container should be
thoroughly cleansed and washed down to
remove any dirt, dust or other contaminant.
Water at a suitably hot temperature
containing an appropriate detergent is
recommended for this purpose.
3. Water should be put in the container,
swirled around, then emptied out.
4. The container should then be totally filled
with water containing an appropriate
sterilant solution and allowed to stand for
the recommended contact time (e.g.
Milton for 15 minutes).
5. The solution should be emptied from the
container.
6. The opening of the container should be
cleaned thoroughly with an appropriate
prepared wipe impregnated with a
sterilant.
7. The container should be inverted whilst
stored overnight (if possible).
8. The container must be filled with mains
water only and mains water only should
be used for the above cleaning
procedure.
9. On no account should garden hoses be
used to fill water tanks.
Separate Water Containers
1. All water remaining in the container
should be disposed of so that the
container is empty.
29
Services
For Systems:
1. Drain down the system (open all taps to
allow air in, enabling the system to drain
quickly). (See Maintenance Systems).
2. Remove any water filters fitted, and
replace with a short length of hose or
empty filter cartridge (this will ensure the
filter is not affected by the disinfectant/
sterilant solution).
3. Fill the system by using the pump with a
disinfectant/sterilant solution (check that
the solution at full strength appears at all
taps/showers). Allow to stand for the
recommended period of time.
4. Drain the system completely.
5. Thoroughly clean the outside of all
taps/connectors with a cloth soaked in
the disinfectant/sterilant.
6. Flush the system through with clean
drinking water until no traces of
disinfectant/sterilant can be detected at
any tap.
7. Replace the filter.
Suitable sterilising chemicals are available
from your caravan dealer, accessory shop,
chemist or home-brew shops. It is not,
however, recommended to use bleach or
sodium metabisulphite.
This guidance has been prepared with the
kind co-operation and assistance of The
30
Environmental Health Department of The
Borough Council of King's Lynn and West
Norfolk.
WARRANTY
Products are guaranteed from the date of
purchase against defects in materials and
workmanship. If the unit proves faulty, return
it to your supplier with proof of purchase and
purchase date. Please note that frost
damage is not a valid warranty claim.
The manufacturer retains the right to repair
or replace the unit. The manufacturer cannot
be held responsible for claims arising from
incorrect installation, unauthorised
modification or misuse of the product. The
above does not affect your statutory rights.
Fig. A Gas Bottle Compartment
GAS
GENERAL INFORMATION
Gas Bottles
Bottled Liquified Petroleum Gas (LPG) is the
most convenient portable source of fuel for
your caravan.
Make sure that heating and cooking
appliances and the gas cylinders are
switched off before you move the caravan.
Regularly check flexible gas hose, joints and
connections for tightness. Finally make sure
that each gas appliance is working efficiently
to the recommendations of the appliance
manufacturers.
Fig. B Gas Regulator
Services
Typical gas
schematic drawing
The regulator
The regulator (Fig. B) is a governing device
which adapts the bottle pressure to one that
suits the equipment in the caravan.
Note: Regulator valves should always be in
the ‘OFF’ position when towing.
WARNING: Some industrial LPG
appliances operate at high pressure and
require a ‘high pressure’ regulator. This
often has an adjusting handle on it.
NEVER use such a regulator on a
caravan.
Propane and Butane gas regulators are not
interchangeable.
Cylinders and regulators are also not
interchangable between different makes
of gas cylinder.
31
Services
Hoses
Hoses should be made from Neoprene and
should conform to BS 3212. Rubber hosing
should never be used. It is good practice to
replace hoses annually, and a jubilee clip is a
worthwhile addition to prevent accidental
removal of the hose.
WARNING: Inspect flexible gas hose
regularly for deterioration and renew, as
necessary, with the approved type. In
any case the hose should be renewed
not later than the expiry date marked
on the hose. Flexible gas hose length
should not exceed 400mm.
WARNING: Ensure hoses do not
become entangled in door mechanism.
TYPES OF GAS
Butane
Butane is supplied in the U.K. in green, blue
or aluminium bottles.
All these have a male left hand thread
EXCEPT for Camping Gaz which has a
special female right hand thread and Calor
7kg and 15kg and aluminium bottles which
have a special clip-on connection.
A 7kg bottle is recommended for butane gas.
Continental bottles usually have a male left
hand thread similar to but not identical with
U.K. butane.
Butane is suitable for use at temperatures
down to 2°C but will not work below that.
Propane
Propane is supplied in Red, or partly red
bottles which have a female left hand
threaded connector.
Scandinavian countries use the same
connector.
Germany and Austria supply propane with a
male connection.
Propane will work at temperatures as low as
-40°C and is therefore suitable for all winter
caravanning.
A 6kg bottle is recommended for propane
gas.
GAS SAFETY ADVICE
WARNING: If you smell gas or suspect
a leak and if it is safe to do so, isolate
the gas appliances and turn off the gas
bottles at the regulator. Evacuate the
caravan and ventilate. Seek professional
advice as to the cause of the leak.
Facts about LPG
LPG is not poisonous.
Bi-products are harmless.
32
There is danger if all air and oxygen were
excluded.
(Ventilation holes must be kept clear at all
times).
LPG has been given a smell by the
manufacturers in order to identify leaks.
Awning Spaces LPG Appliance Exhaust
There is no danger of pollution of an
enclosed awning space by the LPG exhaust
from a refrigerator venting into it, as awning
spaces are generally well ventilated.
Space heaters may produce sufficient
exhaust to pollute the awning space, if it is
totally enclosed, from a general comfort,
smell and hygiene point of view. In the
extreme case there could be a build up of
carbon dioxide to a dangerous level.
Caravan owners are advised to allow some
fresh air circulation in the awning space
when such appliances are in use.
PRECAUTIONS
a) Never look for a leak with a match.
Always use a soap solution or its
equivalent when testing connections. Do
not operate any electrical apparatus
whatsoever, especially light switches. If
the leak is not obvious, the caravan
should be evacuated and qualified
personnel consulted.
b) Avoid naked lights when connecting or
changing a cylinder.
Services
c) Check the flexible hose frequently.
d) The gas is heavier than air and therefore
sinks to the lowest point.
e) Keep bottle gas containers outside (and
protected against frost). If they must be
kept inside make sure they are well away
from heat.
Ventilation
All ventilation complies with BSEN 721 and
vents should not be obstructed in any
manner as this could lead to insufficient
fresh air. In this case the confined
atmosphere becomes depleted of oxygen
which leads to the formation of the highly
poisonous gas ‘carbon monoxide’. Carbon
Monoxide is odourless, colourless and
tasteless and will rapidly cause
unconsciousness and death with little or no
warning prior to collapse. THERE IS NO
DANGER WHEN ADEQUATE VENTILATION
IS PROVIDED.
Roof-mounted Flue installations
All flue installations should be inspected
once a year throughout their length for
corrosion. Flues should be replaced if any
sign of perforation is found. Ensure that the
replacement is of an approved type.
CONNECTION
Ensure that the gas regulator is correctly
connected to the gas cylinder in gas bottle
compartment and that the hose is tight.
Before turning on the gas supply, ensure that
all gas operated equipment in the caravan is
turned off.
average temperature difference of at least
20k between inside and outside temperatures when the outside temperature is 0°C.
All gas equipment (except barbecue) is
supplied through a central Gas Manifold
System which has individual isolation taps
for each appliance, as follows:
RED
-
Water Heater
WHITE
-
Space Heater
BLUE
-
Fridge
GRADE 3
A caravan with an average thermal
transmittance (u) that does not exceed
1.2w/(m2k) and which can achieve
an average temperature difference of at
least 35k between inside and outside
temperatures when the outside temperature
is -15°C.
GREEN
-
Hob (Separate)
ELECTRICITY
YELLOW -
Hob & Oven (Combination)
YELLOW -
Barbecue (if fitted)
As with electricity in the home, care must be
exercised when handling mains electricity.
Note: the external barbecue point is fed
from the main feed through an isolation tap.
See schematic layout for details.
Your attention is drawn to the following
notice as laid down by the Institute of
Electrical Engineers.
Thermal insulation heating
Your caravan has been designed to achieve
a thermal insulation and heating level for
specific climatic conditions when tested
according to the procedure in EN1645-1.
The classifications are as follows:
INSTRUCTIONS FOR ELECTRICITY
SUPPLY
GRADE 1
A caravan with an average thermal
transmittance (u) that does not exceed
1.7w/(m2k).
GRADE 2
A caravan with an average thermal
transmittance (u) that does not exceed
1.7w/(m2k) and which can achieve an
On arrival at caravan site
1. Before connecting the caravan installation
to the mains supply, check that
(a) both 12N & 12S plugs and hitch
have been disconnected from the
towing vehicle,
(b) the mains supply is suitable for your
installation and appliances, i.e.
whether it is a.c. or d.c. and whether
it is at the correct voltage and
frequency,
33
Services
(c) your installation will be properly
earthed. Never accept a supply from
a socket outlet or plug having only
two pins, or from a lighting outlet,
and
(d) any residual current device (earth
leakage circuit breaker) in the mains
supply to the caravan has been
tested within the last month.
In case of doubt, consult the site owner or
his agent.
2. MAKE SURE THAT THE SWITCH AT
THE SITE SUPPLY POINT IS OFF.
3. Lift the cover of the electricity inlet
provided on the caravan, and insert the
connector of the supply flexible cable.
4. Remove any cover from the socket outlet
provided at the site supply point, and
connect the plug at the other end of the
supply flexible cable to this. Switch on
the main switch at the site supply point.
Note: Use mains cable fully uncoiled and
protect from traffic.
IT IS IMPORTANT THAT THE MAIN
SWITCH AT THE SITE SUPPLY POINT
SHOULD BE SWITCHED OFF, THE
SUPPLY FLEXIBLE CABLE
DISCONNECTED, AND ANY COVER
REPLACED ON THE SOCKET OUTLET AT
THE SITE SUPPLY POINT BEFORE
34
DISCONNECTING THE FLEXIBLE CABLE
FROM THE CARAVAN. IT IS DANGEROUS
TO LEAVE THE SUPPLY SOCKET OR
SUPPLY FLEXIBLE CABLE LIVE.
*The names and addresses of Approved
Contractors in any locality (there are over
10,500 in the UK) can be obtained from
Electricity Shops, or direct from:
Because touring caravans are generally left
unused for long periods in the open, it is
strongly advised that the mains installation is
inspected periodically to ensure that it is
safe to use. The IEE Wiring Regulations
recommend that mains installations in
touring caravans are re-inspected every 3
years by a qualified person (see list) who
should sign and issue a periodic inspection
report. (The manufacturer recommends
annual inspections).
NICEIC, Vintage House,
37 Albert Embankment, London SE1 7UJ
Suitably qualified persons acceptable to the
NCC to sign and issue inspection and
completion certificates are:
ECA of Scotland, 23 Heriot Row
Edinburgh EH3 6EW
• an approved contractor of the National
Inspection Council for Electrical
Installation 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 the
above (in which event it should be stated
for whom he is acting).
Telephone: 0171 582 7746
The names and addresses of members of
the Electrical Contractors’ Associations can
be obtained direct from:
ECA, Esca House,
Palace Court, London W2 4HY
Telephone: 0171 229 1266
Telephone: 0131 225 7221
WARNING: CURRENT CONSUMPTION
IN THE CARAVAN MUST NOT EXCEED
16 AMPS OR THE PITCH PERMITTED
MAXIMUM IF THIS IS LESS THAN 16
AMPS.
IT IS DANGEROUS TO ATTEMPT
MODIFICATIONS AND ADDITIONS
YOURSELF. LAMPHOLDER—PLUGS
(BAYONET-CAP ADAPTORS) SHOULD
NOT IN ANY CIRCUMSTANCES BE
USED.
Services
CAUTION
The Ultraheat has the potential to draw
8 amps at 2kW. An ALDE heater has a
potential drain of 3kW/13amp. It is,
therefore, advisable to check the supply
rating before switching on two loads
(items) greater than the supply as this may
cause an overload and the circuit breaker
to trip.
WARNING: Never allow modifications
of electrical or LPG systems and
appliances except by qualified persons.
OVERSEAS CONNECTION
Note: Connection to a mains voltage supply
OVERSEAS requires particular attention.
Care must be taken when connecting
supplies abroad since the supplies can be of
REVERSE POLARITY.
The significance of REVERSE POLARITY is
that when equipment is switched off it may
not be electrically isolated.
The only certain way of making equipment
safe is to unplug it.
It is useful to have a means of checking
polarity of the mains supply, especially when
touring overseas. There are available several
proprietary makes of equipment for testing
polarity.
If it can be achieved, it is preferable to
connect live to live, and neutral to neutral to
maintain full electrical protection.
35
Services
WIRING OF CONNECTING CABLE AND CARAVAN MAINS INLET
WARNING
IT IS ESSENTIAL THAT CONNECTIONS ARE MADE EXACTLY AS SHOWN. IF TERMINAL MARKINGS ARE NOT IN ACCORDANCE WITH THE DIAGRAM
THEY 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.
36
ELECTRICAL
EQUIPMENT
Distribution Panels ...................................................................38
Remote Control Instructions...................................................40
ESM 2 - Electrical Supply Module .........................................40
ECM - Electrical Control Module ...........................................41
ESM 2000 - Electrical Supply Module .................................. 42
Battery ......................................................................................44
Habitation Relay ..................................................................... 44
Generator Guidelines ............................................................. 44
SAS 200 Mobile Alarm System................................................45
12V Electrical Supply ............................................................. 47
Wiring of 12S Socket to Towing Vehicle .............................. 48
Electrics
KT92GT2
KT92GB
KT92GM
KT92BT2
ESM2000
KT92GL2
38
Electrics
DISTRIBUTION PANEL
Indicator Module
Switch Module
This module contains all the control switches
for electrical facilities within the caravan.
Battery / Water Level Meter
12V Isolation Switch
This meter indicates the amount of fresh
water remaining in the inboard water tank.
Simply press the test switch to the water
position and the meter will display a level on
the following scale:
This switch will effectively isolate 12 volt
power to all dc circuits by opening a relay.
This switch should be used only when
wishing to isolate power for reasonably short
periods (e.g. when going out for the day).
For isolation during storage the Car/Van
switch on the ESM2000 unit should be used
(place Car/Van switch to the centre 'off'
position)
Empty -
1/4
-
1/2
-
3/4
- Full
To test battery voltage simply press the test
switch to the battery position, readings
should be taken as shown below.
Battery Condition Meter
This battery condition meter indicates the
power 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 charger switch
to re-charge)
Also included in this module is a pump
running indicator. This red indicator will light
up as a warning when the water pump has
been activated.
Pump switch
This switch merely energises the inboard
water pump ready for use. In caravans with
an outboard pump, this switch will be a two
way type for energising whichever pump is
required (i.e. internal or external)
Entry Light switch
DISTRIBUTION PANEL
for specific models
Switch & Indicator Module
Water Level Meter
This meter indicates the amount of fresh
water remaining in the inboard water tank.
Simply press the test switch to the water
position and the meter will display a level on
the following scale:
Empty -
1/4
-
1/2
-
3/4
- Full
Battery Condition Meter
This battery condition meter indicates the
power remaining in your caravan battery. To
test battery voltage simply press the test
switch to the battery position, readings
should then be taken as follows:
Green region - Fully charged
(no charge necessary)
This switch energises an internal entry light.
Yellow region - Adequate charge
(re-charge if desired)
Battery / Water test switch
Red region
This switch should be pressed to the battery
position to test battery voltage or the water
position to test the water remaining in the
inboard tank.
- Low charge
(turn on charger switch
to re-charge)
Pump switch
This switch merely energises the inboard
water pump ready for use. In caravans with
an outboard pump, this switch will be a two
way type for energising whichever pump is
required (i.e. internal or external). The RED
39
Electrics
indicator associated with the pump chosen,
will illuminate when the pump is on.
Entry Light switch
This switch energises an internal entry light.
Battery / Water test switch
This switch should be pressed to the battery
position to test battery voltage or the water
position to test the water remaining in the
inboard tank.
12V Isolation Switch
This switch will effectively isolates 12 volt
power to all dc circuits by opening a relay.
This switch should be used only when
wishing to isolate power for reasonably short
periods (e.g. when going out for the day).
For isolation during storage the Car/Van
switch on the ESM2000 unit should be used
(place Car/Van switch to the centre 'off'
position).
Note: On models with ALDE central heating
the isolation switch excludes the heating
system.
REMOTE CONTROL INSTRUCTIONS
Some models are equipped with a remote
control unit which allows the user to isolate
the caravan outputs from the battery, using
40
button II, whilst still maintaining the charging
of the battery (when connected to a mains
supply). It can also switch on the entry light
inside the caravan, using button I.
1. Button I controls the first light inside the
caravan.
2. Button II controls the isolation of the 12 V
systems.
Overriding the remote control is possible by
using the two switches located on the
control panel above the door. These
switches should be left in the OFF position
when using the remote control during normal
operations.
Important Note: Ensure that the polarity of
the caravan battery is correct, as reverse
connecting the battery may damage the
control unit.
Switching current should be limited to 1.0
Amp DC at 12 V.
On the rear of the control is a UH number,
make a note of this and remove. This
number is to be used when obtaining a
replacement or additional control.
ESM 2 ELECTRICAL SUPPLY
MODULE
The ESM 2 Electrical Supply Module from
Plug-In-Systems Ltd is a 230V mains and
12V DC power supply unit, providing all the
necessary features for supply of electric in
your caravan. The unit provides the following
important features.
Connections
Plug & socket input/outputs
Mains 230V AC
Mains module with
Earth leakage protection (RCD)
Overcurrent protection (MCBs)
12V DC
Fully automatic transformer/charger with
Overcurrent protection
Short circuit protection
Charger on/off switch
UNIT DESCRIPTION
Mains Module
The ESM 2 is designed to operate on a
mains supply of 185-265 volts ac (making it
ideal for use with low continental voltages).
The 40 amp RCD (Residual Current Device)
gives protection against earth faults and also
acts as the main switch.
Electrics
TRANSFORMER/CHARGER
The ESM 2 employs a fully automatic mains
to 12 volt dc transformer and battery charger,
able to operate with a wide range of input
voltages and provide a stable output voltage
even under load.
The unit can provide up to 12 amps
maximum, after which it will begin to shut
down to protect itself.
To use the charger simply place the rocker
switch to the ON position, at which point it
should illuminate and charging will
commence.
ROADS LIGHTS FUSES
The fuses are located on the front bulkhead
of the right hand front locker.
Fuse Ratings
ESM2
The mains module also has three MCBs
(Miniature Circuit Breakers) which are
basically resettable mains fuses, to protect
against overcurrent. Allocation of the MCBs
is as follows:
MBC1MCB2MCB3-
Sockets/Space Heater (if fitted)
Space Heater/Lights (if fitted)
Fridge/Charger
1
LH ROAD
5A
2
RH ROAD
5A
3
LH INDICATOR
7.5A
4
RH INDICATOR
7.5A
5
FOG
7.5A
6
STOP
7.5A
ECM ELECTRICAL CONTROL
MODULE
PUMP SWITCH & INDICATOR
Included on this panel is a pump isolation
switch and pump running indicator. The
pump isolation switch is used to isolate
power to the water pump in the event of a
pump fault or merely as a safeguard against
unwanted pump operation. The red pump
running indicator will light up as a warning
when the water pump has been activated.
AUX SWITCH
This switch may be used to power any
auxiliary dc circuits the user may wish to
have added to the system.
Battery Condition Meter
This meter indicates the power 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 charger switch
to re-charge)
A car/caravan changeover switch is provided
in this module and should be used in the
following way:
41
Electrics
Car position
Note: First of all the towing vehicle should
be electrically connected to the caravan via
the 12S socket.
The switch can be placed in this position
should the caravan battery become
discharged and no mains power is available.
ELECTRICAL SUPPLY MODULE
ESM2000
The ESM2000 Electrical Supply Module is a
230 volt ac and 12 volt dc power control
unit. It provides all the necessary features
for control of the electrics in a caravan. The
unit provides the following features:
Caravan position
When in this position dc power is available
from the caravan battery to power all 12 volt
electric circuits.If the charger is switched ON
the caravan battery will be charged up via
the charger/transformer unit.
Central position
When in this position with the charger switch
ON, power is provided to all 12 volt circuits
via the charger/transformer only.
With the charger OFF all dc circuits are
isolated.
Note: The switch should be placed in this
position when the van is being towed.
42
Mains 230V ac - MAINS MODULE
with EARTH LEAKAGE PROTECTION
OVERCURRENT PROTECTION (RCD)
REVERSE POLARITY INDICATION
12 volt dc - FULLY AUTOMATIC
TRANSFORMER/CHARGER
with OVERCURRENT PROTECTION
SHORT CIRCUIT PROTECTION
SWITCH & FUSE MODULE
with BATTERY CHANGEOVER SWITCH
CHARGER ON/OFF SWITCH
8 FUSED DC OUTPUT CIRCUITS
UNIT DESCRIPTION
Mains Module
The ESM2000 is designed to operate on a
mains supply of 207 - 253 volts ac (making it
ideal for use with low continental voltages).
The 40 amp RCD (Residual Current Device)
gives protection against earth faults and also
acts as the main switch. The mains module
also has three MCB's (Miniature Circuit
Breakers) which are basically resetable
mains fuses, to protect against overcurrent.
Allocation of the MCB's is as follows:For Abbey, Sterling and Swift models
MCB1 - SOCKETS/BLOWN-AIR HEATING
(if fitted)
MCB2 - WATER HEATER/LIGHTS (if fitted)
MCB3 - FRIDGE/CHARGER
For Bessacarr models
MCB1 - HEATING SYSTEM
MCB2 - SOCKETS
MCB3 - LIGHTS/FRIDGE/CHARGER
Using a generator
When using a generator in conjunction with
the ESM2000 the following must be
observed, failure to do so may result in
damage to the unit:
i) Always start the generator with the mains
isolator in the caravan turned off.
ii) Allow the generator to warm up for a few
minutes before energising power in the
caravan, as the output voltage can be
higher when cold.
Electrics
iii) Check the generator output voltage
regularly to ensure it is within the
specification of the ESM2000 system
(i.e. 230 volts +/- 10%)
Transformer/Charger
The ESM2000 employs a fully automatic
mains to 12 volt dc transformer and battery
charger, able to operate with a wide range of
input voltages and provide a stable output
voltage even under load. The unit can
provide upto 12 amps maximum, after which
it will begin to shut down to protect itself.
Switch & Fuse Module
Car/Van Selector Switch
The car/caravan changeover switch provided
in this module should be used in the
following way:
Caravan position When in this position dc power is available
from the caravan battery to power all 12 volt
electric circuits.
If the charger is switched on, the caravan
battery will be charged via the
charger/transformer unit.
Central position When in this position with the charger switch
on, power is provided to all 12 volt circuits
via the charger/transformer only.
Note: The switch should be placed in this
position when the van is being towed.
Car position The switch can be placed in this position
should the caravan battery become
discharged and no mains power is available.
Note: First of all the towing vehicle should
be electrically connected to the caravan via
the 12S socket.
Charger switch
When the caravan battery requires charging,
press this switch to the on position (it should
then illuminate). Also ensure the Selector
Switch is in the van position.
For KT9/2000 BT, GP Distribution Panels
Fuse 1 - Front roof lighting
Fuse 2 - Rear roof lighting
Fuse 3 - Heating System
Fuse 4 - Radio
Fuse 5 - 12v sockets/Hitchlight/TV amp
Fuse 6 - Fan circuits
Fuse 7 - Water system/Thetford toilet
Fuse 8 - Ignitions
Note: For models fitted with Primus central
heating, there is an additional 10 amp fuse
located behind the ESM 2000 distribution
panel.
DC Fuses
Eight fuses are provided in this module to
protect all dc circuits, the fuse allocation is
shown below. Fuses must be replaced only
with the specified values.
Distribution Panels
Fuse 1 - Front roof lighting
Fuse 2 - Rear roof lighting
Fuse 3 - Blown-Air Heating
Fuse 4 - Radio
Fuse 5 - 12v sockets/Hitchlight/TV amp
Fuse 6 - Fan circuits
Fuse 7 - Water pumps/Water sensor/
Thetford toilet
Fuse 8 - Ignitions
With the charger off all dc circuits are
isolated.
43
Electrics
BATTERY
It is recommended that a good quality
leisure battery is always in circuit when the
system is in use.
A deep cycling heavy duty 12v battery
should be purchased to provide power for
lights and other electrical appliances. A
proprietary brand leisure battery with either a
60 or 90amp capacity is recommended.
Note: 90 amp batteries and above should be
checked dimensionally before purchasing, to
ensure fitment within the battery
compartment, as brands vary in size.
It should be remembered that batteries
suitable for the electrical demands of a
caravan differ in design from those for use
with a car, and whilst the system may
operate with a car battery it is strongly
recommended that only a leisure type
battery, maintained in good condition is
used. The battery should be kept topped up
at all times.
The battery should be positioned in a
compartment vented to the outside and
should be properly secured.
WARNING: Do not block battery box
vents.
WARNING: When connecting the battery,
ensure that the correct polarity is
observed (black is negative and red is
positive) and that the terminals are
securely fastened.
44
Under normal circumstances it should not be
necessary to remove the battery other than
for routine inspection of terminals and
“topping up”.
WARNING: Explosive gases may be
present at the battery. Take care to
prevent flames and sparks in the vicinity.
Your caravan has been fitted with an in-line
fuse between the battery terminal and strip
connector. It is recommended that the fuse
rating fitted in this location does not exceed
20 amps.
SUPPORT SERVICE
PLUG-IN SYSTEMS LIMITED PROVIDE AN
ON-CALL SERVICE FOR WARRANTY OR
NON-WARRANTY REPAIRS.
IF YOU WISH TO TAKE ADVANTAGE OF
THIS SERVICE FOR PLUG-IN-SYSTEMS
ONLY
Telephone (01482) 652523 and ask for
PRODUCT SUPPORT SERVICE.
HABITATION RELAY
To conform with European Safety Standards
(EMC) all caravans have been equipped with
a habitation relay.
WARNING: Switch off all appliances
and lamps before disconnecting the
battery.
This relay is actuated when the 12N/12S
plugs are connected to the car’s sockets and
the car ignition is turned on.
Smoking is prohibited around the
battery compartment.
The relay automatically isolates all 12V
equipment within the caravan, excluding the
fridge’s 12V power supply, from the car.
To preserve the life of your leisure battery
and charger please observe the following:
i) Do not leave all 12v lights powered at the
same time as this will drain your leisure
battery 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 and
that the battery charger is turned on.
iii) For optimum performance use the
transformer/charger unit with a leisure
battery attached.
GENERATOR GUIDELINES
• Lack of regular servicing can be the
cause of most generator problems,
gensets under 2kW are mainly dependent
on engine speed for output frequency
and voltage, poor or no servicing may
cause the engine speed governor to run
the genset engine too fast. Therefore
frequency and output voltage can rise
above the specification of the machine
data plate i.e. 230V at 50Hz, this may
Electrics
cause damage to electrical/electronic
equipment (such as battery chargers).
• A generator should always be run for a
few minutes prior to connection with the
caravan or motorhome electrics, to allow
it to warm up and the output to settle to a
steady level.
• The AC output of generators is often
derived from an AC alternator, rectified to
DC then inverted back to AC. In essence
this means the output sinewave may not
be very smooth and may not run
sophisticated electronics efficiently. Some
of the new wave of gensets are more
sophisticated in their production of a
sinewave output and are more suited to
run electronic equipment.
• If in doubt consult your genset dealer or
manufacturer for advice.
SAS 200 MOBILE ALARM
SYSTEM
Using the latest microprocessor technology
the SAS200 provides all year round
protection for your caravan.
Please read all sections of these user
instructions before attempting to operate the
SAS200.
If you are unsure of any of the point, please
contact your local dealer or the manufacturer
direct (see point 5)
1. Operation
1.1 Arm/Disarm
The SAS200 Alarm System is armed
and disarmed by pressing the button
on the key fob remote controller.
The alarm has four modes of
operation:
a) Disarmed
b) Fully armed with internal
movement sensor and tilt sensor
active
c) Partially set with only the tilt sensor
active
d) Partially set with only the
movement sensor active.
The alarm indicates arm/disarm
status by beeping. One beep =
armed, two beeps in quick
succession = disarmed.
To part set the alarm (modes c or d)
hold down the arm button until the
desired mode has been selected:
Hold down and release after 2 long
beeps, mode (c) selected.
Hold down and release after 3 long
beeps, mode (d) selected.
Note: if the arm button is continually
held down the system will disarm and
then repeat the above sequence.
1.2 PIR Movement Sensor
The SAS200 Alarm System comes
complete with a 120° x 360° Passisve
Infra Red movement sensor that
detects body movement within the
vehicle.
If you are leaving pets within the
vehicle the system should be armed
in mode (c) to prevent nuisance
triggering.
1.3 Tilt Sensor
The SAS200 Alarm System has an
inbuilt tilt sensor that detects tilting of
the vehicle during the hitching
process. If the tilt sensor is not set
correctly, the alarm will not arm and
will indicate a fault by beeping 4
times in rapid succession.
During normal (on the flat) operation
there is no need to alter the tilt
sensor.
If the vehicle is parked on a steep
slope it may be necessary to adjust
the tilt sensor. With the alarm
disarmed, while viewing the
movement sensor lens, move the tilt
adjustment lever forward until the
green light illuminates. Note the
position of the lever.
Now move the lever backwards and
again note the position of the lever
when the green light illuminates.
45
Electrics
Set the lever mid way between the
two positions.
Remember to return the lever to the
centre (locked) position when
returning to 'on the flat' use.
1.4 Alarm Siren
When the alarm is triggered the siren
will sound for 2 minutes. Following
the 2 minute period the alarm will
then deactivate for 15 seconds then
rearm.
The alarm siren can be turned off at
any point by pressing the key fob
button. If the movement sensor
caused the alarm trigger, the alarm
will give a standard 'two beeps in
quick succession' disarm indication.
If the tilt sensor caused the alarm
trigger, the alarm will give 'two beeps
in quick succession' followed by a
further 'two beeps in quick
succession'.
1.5 Sleep mode
The SAS200 Alarm System
incorporates a sleep mode that
extends battery life over a long period
of time.
If a charged leisure battery is fitted
and is supplying 12 volts to the alarm
system the alarm will operate in
standard 'quick repsonse' mode.
46
If the alarm is operating from the
internal alarm battery only, the alarm
will operate in 'slow response' battery
saving sleep mode. In this mode you
will need to press and hold the
arm/disarm button for up to 3
seconds to arm or disarm the alarm.
2. Key Fobs
3. Battery
The SAS200 Alarm System incorporates a
3.3Ah sealed lead acid battery that is
charged from the vehicles 12v supply.
This battery has been selected to run the
alarm without any external supply voltage
for up to 9 months depending on ambient
temperature/initial charge.
The SAS200 Alarm System comes
complete with 2 key fob remote
controllers. If an additional controller is
required these can be ordered from your
supplier.
The battery is fully charged when the
alarm system is despatched, but may
need further charging if the vehicle is
stood for a number of months without a
12v supply to the alarm.
2.1 Key Fob Battery Replacement
To charge the alarm battery either fit a
fully charged leisure battery to the vehicle
or connect the vehicle to the mains
supply and switch on the 12v
charger/power supply.
1. Remove the key fob from your key
ring.
2. Prise the casing apart near the key
ring fixing slot.
3. While holding the base part of the
casing, prise out the old Lithium
battery and replace with a new
CR2032 battery. Ensure the [+]
terminal is located towards the
outer case.
4. Relocate the two casing halfs and
snap together.
The internal battery should be replaced
approximately every 3 years to ensure
correct operation. Replacement batteries
can be ordered from your supplier.
Always dispose of old batteries in
accordance with local regulations.
4. Specification
4.1 Control Box
5. Refit the key fob onto your key
ring.
Supply voltage:
10.5 to 15v DC
Supply current:
250mA max
6. Remember to dispose of old
batteries in accordance with local
regulations.
Operating
temperature:
-5 to +30°C
Battery capacity:
3.3Ah at 12v
Electrics
12 VOLT ELECTRICAL SUPPLY
Operating time
(armed) with
no supply:
9 months
at 20°C
Siren output:
110 dB +/- 10%
4.2 Movement Sensor
Range:
120° x 360° x 8M
Current
consumption:
<1mA typical
4.3 Key Fob
Range:
>10M typical
Battery:
CR2032
Lithium Cell
Typical battery life: 1 year
5. Spare Parts/Service
For spare parts, local supplier contact
details or other service information please
contact:
Sargent Electrical Services Ltd.
service desk on 01482 678981 during
normal office hours.
If your car is fitted with the appropriate relay,
please note the following points:
1. The caravan battery will be charged by the
car charging system independently of the
distribution panel.
2. If the caravan battery level is “low”,
power for the caravan 12 volt system can
be obtained from the car battery, by
connecting the 12S (grey) plug to the car,
and setting the distribution panel selector
switch to “car”. This will draw power from
the car battery and care should be taken
not to reduce the level of the car battery
so low that the car engine cannot be
started. (The battery level indicator in the
caravan distribution panel will show the
condition of the car battery in these
circumstances).
4. If an extension lead from the 12S socket
on a towing vehicle to the 7-core
connecting cable is used while a caravan
is parked on a caravan pitch, its length
should be kept to a minimum and not
exceed 5 metres. The minimum cross
sectional area of the supply and return
leads in the extension cable should be
2.5mm2.
3. When the car and caravan are connected
through the 12N and 12S plugs and the
car engine is running, 12 volt power will
be supplied to the refrigerator, provided
the refrigerator selector switch is set to
the 12v position, regardless of the
position of the distribution panel selector
switch.
47
Electrics
WIRING OF 12S SOCKET TO TOWING VEHICLE
Note:
If using a combination relay, ensure the supply fuse is the correct amperage. A lower rating will ‘blow’ causing the fridge, if switched on,
to be connected directly to the caravan battery. While towing, the caravan battery will be discharged instead of being charged.
48
FITTED
EQUIPMENT
Whale Water Pump ................................................................. 50
Shurflo Water Pump ............................................................... 50
Truma Ultra-Store Water Heater............................................ 50
Truma S3002P, S3002 Space Heaters .................................. 53
Truma Ultraheat for S3002 .....................................................55
ALDE Heating System .............................................................56
TP5 Electronic Programmable Room Thermostat ...............63
Refrigerator ............................................................................. 65
Model RM4270 ..................................................................... 65
Model RM4271 ..................................................................... 66
Model RM4501 ..................................................................... 67
Model RM6270, RM6271 & RM6291 .....................................68
Fridge Use and Maintenance .................................................69
Travel Catch ......................................................................... 72
Thetford Absober Refrigerators .............................................72
Stoves Hobs, Grills & Ovens ................................................. 81
The Hob ............................................................................... 81
The Grill ..................................................................................82
The Oven ................................................................................83
Cleaning .................................................................................84
Thetford Cassette Porta Potti ............................................... 85
Thetford Cassette C-200 CW & C-200 CWE........................ 89
TV Inlet ..................................................................................... 92
Exterior Barbeque Point ......................................................... 92
Beds ......................................................................................... 93
Cassette Blinds & Flyscreens ............................................... 96
Doorscreen ............................................................................. 96
Roof Lights, Windows and Air Conditioning .........................97
Ash Framed Doors ................................................................. 98
Shower .................................................................................... 98
Tables ...................................................................................... 99
Fixing of Awnings ................................................................. 100
Fitted Equipment
The instructions covering fitted equipment
to your caravan were correct at the time
of going to print. Owners handbooks are
updated annually and we take great care
to try and ensure their accuracy.
However, the Swift Group Limited cannot
accept responsibility for any changes that
may be made in specification or operating
instructions to the equipment described in
this section after the time of going to
press.
Every care is taken to ensure that the
information provided in this handbook is
correct and easy to understand.
Separate manufacturers’ leaflets on many
of the components are also included in
the Owner’s Pack provided with this
caravan and we recommend that you
compare the instructions in the handbook
with the component manufacturers
literature, to ensure the information
provided is as accurate as possible.
If you are in any doubt as to how to
operate the equipment in your caravan,
please contact the component
manufacturer’s service department on the
telephone number shown on their
component leaflet. If you remain in any
doubt, please contact the Swift Group
Supercare customer care service
department on 01482 875740.
50
Equipment Specification
For details on type of equipment fitted in
your caravan, please refer to the Sales
Brochure or Dealer.
IMPORTANT
To maximise the use and life of all fitted
equipment in your caravan it is essential that
any accompanying manufacturers’ literature
is read fully. All recommended maintenance
and preparation procedures should be
followed. The information provided in this
handbook is only intended as a guide. If in
any doubt consult your manufacturer
appointed dealer, particularly before
attempting to install EXTRA EQUIPMENT.
THE TRUMA ULTRASTORE
WATER HEATER
OPERATING INSTRUCTIONS
Filling the Truma Ultrastore with water
e = Lever
position
"Closed"
f = Lever
position
"Drain"
WHALE WATER PUMP
(Model specific)
The Whale pump is a non self priming
intermittently rated centrifugal pump which
draws approximately two amperes from a 12
volt battery and therefore maximum
continuous operation should not exceed 15
minutes.
The pump should not be run without water
and should not be used to pump water of a
temperature above 60°C.
SHURFLO WATER PUMP
(Model specific)
Fresh water is supplied to the caravan by a
Shurflo pump. This pump is a completely
sealed unit designed for intermittent use and
is self-priming.
Fig. 1
1. Check that the safety/drain valve in the
cold-water intake is closed. Lever should
be in the horizontal position, position (e).
2. Open the hot tap in the bathroom or
kitchen with pre-selecting mixing taps or
single lever fittings set to hot.
3. Switch on power for water pump (main
switch or pump switch). Leave the tap
open to let air escape while the water
heater is filling. The heater is filled when
water flows out of the tap.
Residues of frozen water can prevent
filling if there is a frost. The water heater
can be defrosted by switching on the
Fitted Equipment
heater for a short period (max 2 mins).
Frozen pipes can be defrosted by heating
the room.
valve in the gas supply line if the appliance is
not to be used for an extended period of time
and close the gas cylinder.
Gas Operating Instructions
Red Indicator Lamp "Failure"
5
40
The red indicator lamp (c) lights if there is a
failure. The reason for such an indication is,
truma
no gasUltrastore
available or air in the gas supply
system triggering the excess temperature
monitor etc. To reset the red light, switch off
the appliance, wait 5 minutes and switch on
again.
0
60
70
30
Note: In the event of faults always contact
the Truma Service, Tel: 01283 511092.
remove cowl cover before use
2. Open gas cylinder and open quick-acting
valve in the gas supply line.
a = Slide switch On/Off
b = Rotary knob for water temperature
(illuminated by green indicator lamp
"Operation")
c= Red indicator lamp "Failure"
Attention: Never operate the water
heater without water in it!
1. Remove cowl. Carefully remove cowl from
top edge, pulling out then downwards to
disengage lower lugs after top lug. This is
the weather cover which is mounted over
the exhaust on the exterior of the caravan.
3. Select required water temperature at
rotary knob (b) infinitely variable from
approx. 30° to 70°C.
4. Switch on water heater at the side switch
(a) on the control panel, green indicator
lamp "Operational" lights up.
5. If there is air in the gas supply line, it may
take up to a minute before the gas is
available for combustion. If the appliance
switches to failure during this period,
switch off the appliance, wait 5 minutes
and switch on again.
WATER HEATER
d = Switch
On/Off
FUSE
d
Electrical Operating Instructions
Switching Off (Gas Operation)
Switch the switch (d) on the fuse spur to
"On". The indicator lamp indicates the
electrical water-heating element is operative.
Switch off the water heater at the side switch
(a). Mount cowl cover. Drain the water if
there is a risk of frost. Close quick-acting
When using the vehicle switches refer to
operating instructions of the vehicle
manufacturer or see switch labels.
51
Fitted Equipment
Note: The water temperature cannot be
selected, automatic temperature limitation at
approx. 70°C. For a faster heating up period
the appliance can be simultaneously
operated with gas and electrical power.
Draining the Water Heater
e = Lever position "Closed"
f = Lever position "Drain" (see Fig.1 page 52)
1. Disconnect power for water pump (main
switch or pump switch).
2. Open hot water taps in bathroom and
kitchen.
3. Open safety/drain valve in vertical
position, position (f).
4. The water heater is now drained directly
to the outside via the safety/drain valve.
Check that the water contents have been
completely drained (10 litres)
Maintenance
Use wine vinegar for de-scaling the water
heater, this being introduced into the
appliance via the water supply. Allow the
product to react and then thoroughly flush
out the appliance with plenty of fresh water.
To sterilise the water we recommend
"Certsil-Argento". Other products,
particularly those containing chlorine, are
unsuitable.
Note: The water tank in the Truma Ultrastore
is of high quality food-grain stainless steel.
52
The special equipment available, elbow
water hose connections and safety/drain
valve, fulfil the EC guidelines for quality in
plastic parts (90/396/EEC).
In order to prevent the formation of microorganisms, we recommend heating up the
tank at regular intervals to 70°C and not
using the water for drinking.
safety/drain valve. This also applies
when the caravan is in storage.
General Safety Notes
In the event of leaks in the gas system or if
there is a smell of gas:
• Extinguish all naked flames
• Do not smoke
Important Operating Notes
• Switch off the appliance and gas cylinder
1. If the cowl is positioned close to an
opening hatch (window), keep this closed
during operation. See warning plate.
Always mount the cowl cover if the heater
is not being used. Non-observation of
this point can lead to the function of the
appliance being impaired through water,
dirt or insects.
• Open the windows
2. The guarantee will be invalidated if this
point is not observed. Always remove the
cowl cover prior to operating the water
heater!
2. The following would invalidate the
guarantee:
a. Any alteration to the appliance
(including cowl)
b. The use of non-Truma spare
parts/accessories
c. Non observance of the operating
instructions.
3. If there is a defect in the electronics,
return the control Printed Circuit Board
well padded. If you fail to pack it
correctly the guarantee will be
invalidated. Only use original Truma
Ultrastore control P.C.B's as spare parts.
4. If just the cold water system is being
used, without water heating, the header
tank becomes more vulnerable to frost
damage. Accordingly the contents
should be drained by operating the
• Do not operate any electrical switches
• Have the entire system checked by an
expert
1. Repair jobs are only to be carried out by
an expert.
3. The operating pressure for the gas supply
is 30mbar (or 28mbar butane/37mbar
propane) and must correspond to the
operating pressure of the appliance (see
name plate).
4. Do not operate the water heater when
refuelling the vehicle and when in the
garage.
Fitted Equipment
5. During the initial operation of a brand new
appliance (or after it has not been used
for some time, a certain amount of fumes,
and a slight smell, may be noticed for a
short time. Remedial action is to
immediately run the heater at maximum
output and to ensure adequate room
ventilation.
6. If the burner makes an unusual noise or if
the flame lifts off, it is likely that the
regulator is faulty and it is essential to
have it checked.
Technical Data
Water contents:
10 litres
Water pressure:
up to max. 2.8 bar
Type of gas:
Liquid Gas
(propane or butane)
Operating Pressure:
30mbar (or 28mbar
butane, 37mbar
propane)
Rated thermal output:
1500W
Gas consumption:
120g/h
Heating time to approx.
Gas operation:
Electrical operation:
Gas and electrical
operation:
70°C:
approx. 35 mins
approx. 70 mins
approx. 20 mins
Power consumption 12 V
Ignition:
0.17 A
Heating Up:
0.08 A
Standby:
0.04 A
Power consumption 230 V
Heating Up:
(2A) 450 W
Weight (empty):
6.7 Kg
THE TRUMA S 3002 P & S 3002
AUTO SPACE HEATER
INSTRUCTIONS FOR HEATERS FITTED
WITH AUTOMATIC IGNITOR OR PIEZO
IGNITOR
Switching On
1. Open the valve on the gas cylinder. Open
quick-acting valve in gas supply line.
2. Turn control knob to thermostat setting
1-10 and press it down as far as the stop.
At the same time keep operating the
piezo ignitor rapidly until the flame ignites.
3. Keep the control knob depressed for a
further 10 seconds to allow the safety
pilot to operate.
4. (Piezo only) Watch through the flame
window for another 10 seconds to make
sure that the flame does not go out
through air in the supply pipe (caused by
the valve being closed or changing the
cylinder).
Attention: Always wait at least 2 minutes
before attempting to re-ignite, otherwise
there is a risk of blowbacks (misfiring).
This also applies if a working heater
goes out has to be re-lit.
a = Control knob
b = Integrated control panel for
Trumavent fan TEB
c = Piezo ignitor or automatic ignitor
d = Flame observation window
e = Name plate (remove casing)
f = Thermostat probe
In the case of left-handed installation,
the parts are arranged on the other
side.
53
Fitted Equipment
Automatic Ignitor
Prior to first ignition, make sure that the
batteries have been inserted; observe
correct fit battery cassette (see changing
batteries, page 57).
3. Repairs are only to be carried out by a
competent service engineer.
Attention: A new O-ring must always
be installed after dismantling the
exhaust duct.
Thermostat
Set the required room temperature at the
control knob (numbers 1-10). For an
average room temperature of approx. 22°C
we recommend setting:
3-5
Without the Trumavent Fan
(switched on)
4-8
With the Trumavent Fan
Switching Off
Set control knob to "0". If turning off for a
long period of time, close the quick-acting
valve in the gas supply line. Close valve of
gas cylinder.
Important Operating Notes
1. If the gas supply line is filled with air, it
may take up to a minute before the gas
becomes available for combustion.
During this time depress the control knob
and continuously operate the piezo
ignitor until the flame ignites.
2. You will have to find out the exact
thermostat setting yourself, depending on
how much heat you need.
54
4. Any alteration to the appliance (including
exhaust duct and cowl) or the use of
spare parts and accessories, which are
important to the function of the heater
and which are not original Truma parts, as
well as the non-observance of the
installation and operating instructions, will
lead to the cancelling of the guarantee
and exclusion of liability claim.
5. During the initial operation of a brand new
appliance, a certain amount of fumes and
a slight smell may be noticed for a short
while. Remedial action is to immediately
run the heater at maximum output and to
ensure adequate room ventilation.
6. In winter, before switching on the heater,
remove all snow from the cowl.
7. Inspect the exhaust duct and all
connections at regular intervals and
always whenever there is a blowback
(misfire). It is essential that the exhaust
duct is installed so that it slopes upwards
over its whole length and is securely fixed
with several clamps. Never place any
object on the exhaust duct, since this
could result in damage. The exhaust
duct connection to both the heater and
the cowl must be firm and well sealed.
Do not operate heaters with incorrectly
fitted or damaged exhaust ducts.
8. Never allow the warm air outlet on the
heater to be obstructed in any way. For
instance never hang washing on or in
front of the heater to dry. Misusing your
heater in this way could cause serious
damage from overheating. Do not place
flammable objects near the heater.
Please follow these guidelines in the
interest of your own safety.
9. If the burner makes an unusual noise or if
the flame lifts off while burning, it is likely
that the regulator is faulty and it is
essential to have it checked.
10.Cleaning (with switched off appliance): It
is recommended that at least once a year,
before the heating season starts, you
remove any dust that has collected on
the heat exchanger base plate.
Technical Data:
Type of gas:
Liquid gas
(propane/butane)
Operating pressure:
30mbar (28mbar
butane, 37mbar
propane)
Rated thermal output: 3400W
Gas consumption:
30-280 g/h
Fitted Equipment
Product Indent.
No: CE-0085AP0325
Automatic Ignitor
Power consumption:
Operating voltage:
50 MA (ignition)
0.01 MA
(monitoring)
3V
CHANGING OF BATTERIES
Changing the Batteries on the Automatic
Ignitor
Only change the batteries with the heater
switched off.
Always insert new batteries at the beginning
of the heating season.
Only use temperature resistant (+70°C), leakproof Mignon round cells (LR 6, AA, AM 3,
Art. no. 30010-23600). Other batteries could
lead to malfunctions!
TRUMA ULTRAHEAT
ADDITIONAL ELECTRIC HEATING
FOR TRUMATIC S 3002
The electric heater can also be operated
without the Trumavent fans.
If the heater is operated simultaneously with
electricity and gas, the electrical unit will
switch itself off before overheating occurs
as a result of the stronger gas burner.
OPERATING INSTRUCTIONS
Important: Before operating the heater for
the first time it is essential to observe the
operating instructions enclosed with the
heater.
Switching on
Warning: Before switching on, ensure that
the fuse protection for the power supply of
the camp site is sufficient for the selected
power setting (b) (see Technical Data).
Important: The electric feed line for the
caravan must be fully unwound in the cable
drum.
1. Push slide switch (b) to the required
power setting.
2. Push slide switch (a) to the "ON" position.
Unclip front of heater, slide up battery cover
to reveal battery. Change the batteries.
Observe plus/minus.
3. Set rotary control knob (c) to the desired
room temperature.
a = Slide switch: ON - OFF
b = Slide switch
power settings:
500 - 1000 - 2000 W
c = Rotary control knob for room
temperature (illuminated by green
indicator lamp "operation")
Control panel with thermostat
55
Fitted Equipment
Blown air
The air ducting outlets are generally of the
butterfly type and may be opened or closed
by adjusting the butterfly valves. Twisting the
disc in its housing directs the flow in the
direction required.
of the instructions for installation and use
will result in the guarantee becoming
invalid and no liability will be assumed.
Furthermore, the approval for operating
the appliance will become invalid and in
some countries also the approval for
operating the vehicle.
One outlet on each leg of the air ducting
layout must be kept open at all times.
TECHNICAL DATA
Switching off
Power supply: 230 V ~, 50 Hz
Push slide switch (a) to the "OFF" position.
Power consumption at power setting:
500 W: 2,2 A 1000W: 4,5 A 2000 W: 8,5 A
IMPORTANT OPERATING NOTES
1. Repairs may only be carried out by an
expert.
2. Under no circumstances should the hot
air outlet be blocked. Never hang clothes
or similar in front of or on top of the
heater to dry. This could cause serious
damage to the heater as a result of
overheating. Do not place inflammable
materials near the heater! Please observe
these instructions for your own safety.
3. When operating a brand new heater for
the first time (or after it has been idle for a
lengthy period) you may temporarily
notice a slight smoke and smell. We
advise running the heater at full power
and thoroughly ventilating the room
4. Any modifications to the appliance or the
use of spare parts and accessories
important for the operation, which are not
original Truma parts, or non-observance
56
Weight: approx. 2 kg
ALDE HEATING SYSTEM
Please read these instructions carefully
before using the boiler.
These instructions are approved for Alde
Compact 3000 92X, 93X and 94X boilers
fitted in caravans, motor caravans and
buildings in accordance with CE no. 048 AP0013.
A professional may only carry out installation
and repairs. National regulations must be
adhered to.
BOILER DESIGN
The boiler consists of three eccentrically
fitted cylinders (heat exchanger, water jacket
for the heating system and, outermost, water
jacket for hot water). The two outer pipes, as
well as their ends and connections, are made
from stainless steel, while the heat exchanger
is made from aluminium.
The heat exchanger is divided into two semicircles. The burner is located in the upper
half, the combustion chamber, and the
combustion gases are expelled through the
lower half. The burner unit is fitted on the
end of the heat exchanger. It consists of a
combustion fan, burner, solenoid valve and
intake/exhaust connections. One or two
heating cartridges are fitted to the water
jacket of the heating system. Output is 2 or
3 kW, depending on model.
DESCRIPTION OF FUNCTIONS
Using LPG
When the sliding switch on the control panel
is set to LPG, the combustion fan starts. The
fan creates pressure against the pressure
gauge. When the fan pressure is sufficiently
high, the pressure gauge signals the
electronics box that the boiler can be lit. The
electronics box sends ignition sparks to the
spark plug at the same time as it sends
electricity to the solenoid valves, which open
to allow gas in. The burner ignites, and a
sensor transmits a signal back to the
electronics box that the boiler is lit and
ignition spark stops. The burner keeps
burning until the boiler thermostat or the
room thermostat reaches the set temperature
reading. Should the boiler go out for any
Fitted Equipment
reason, the sensor is activated and the
electronics box ensures that a new attempt is
made to start the boiler (in about 10
seconds).
Using the heating cartridge
When the heating cartridge sliding switch is
set to any of the output settings on the
control panel, the 12-volt relays on the circuit
board trip, allowing the 230-volt supply to
reach the cartridge. The heating cartridge is
controlled in the same way as the gas boiler.
IMPORTANT INFORMATION
-
-
The LPG boiler and heating cartridge may
be operated in parallel.
The heating system may be heated up
without the warm water heater being filled
with fresh water.
Always drain the warm water heater of
fresh water if there is a risk of frost.
-
The LPG boiler must not be operated
when filling the vehicle with fuel, in a
garage or elsewhere.
-
The boiler must not be started if there is
no glycol in the system.
Note: If heating is to be operational
whilst unattended, ensure mains hook
up is connected. System can cause
battery to run flat, if battery is the sole
power source.
THE CONTROL PANEL
The boiler is controlled using sliding switches
on the control panel. The desired temperature in the vehicle is set and regulated via
the thermostat on the control panel.
Control panel functions:
A. Heating cartridge switched off.
B. Heating cartridge switched on at 1050 W.
C. Heating cartridge switched on at 2100 W.
thermostat on the control panel controls
the operation of the heating cartridge/LPG
boiler. This setting is used in particular
circumstances, mostly during the winter.
Provides an even flow of heat, but also
reduces the hot water capacity.
K. Knob for setting the desired room
temperature.
L. Index marking for a room temperature of
approx. 22°C.
D. Heating cartridge switched on at 3150W
(if the boiler is fitted with this output
setting).
THE WARM WATER HEATER
E. LPG boiler switched off.
The properties of LPG
F. LPG boiler switched on.
LPG is a petroleum product, formally known
as 'liquid petroleum gas'. It is mainly made
up of propane and butane gas. The
advantage of propane is that it remains
gaseous at temperatures as low as -40∞,
while butane loses effectiveness at +10∞C.
For this reason, propane is used in colder
countries. The cylinders contain LPG both in
liquid and gaseous form. Then the cylinders
are filled, the pressure turns the gas into
liquid. When the cylinder valve is opened,
the LPG becomes a gas again. The risk
involved in using LPG is that any leaking gas
may ignite and explode. Since LPG is
heavier than air, any leaking gas will collect at
the lowest point.
G. LED indicates that the LPG boiler is in
blocking mode (the burner has not
ignited, or has gone out for some reason).
H. Warm water setting. The circulation pump
switched off. The heating cartridge/LPG
boiler is operated by the boiler's built-in
thermostat. Used when only hot water is
wanted.
I. Normal setting. The circulation pump is
switched on and is controlled by the
thermostat on the control panel. The
operation of the heating cartridge/LPG
boiler is controlled by the boiler's built-in
thermostat. Used when both heating and
warm water is wanted.
J. Permanent setting. The circulation pump
is switched on and runs constantly. The
ABOUT LPS
LPG contains no toxic substances but
breathing in concentrated gas may have a
certain anaesthetising effect, and can also
57
Fitted Equipment
result in shortness of breath and symptoms
of suffocation. These symptoms quickly
disappear if the sufferer breathes in ordinary
air or oxygen. Naturally, it is inadvisable to
inhale either LPG or exhaust fumes. To
make it easier to detect gas leaks, a
substance with a distinctly rank smell has
been added.
Combustion
Complete combustion of LPG only generates
carbon dioxide (CO2) and water vapour, just
like the air we exhale. A good supply of air
is essential to ensure complete combustion.
The centre of the flame should be
blue/green. LPG is extremely
environmentally compatible and does not
generate any soot during complete
combustion.
It can be stored in cylinders for an unlimited
time period, without any deterioration of
quality.
Pressure
The LPG burner usually works at a lower
pressure than that in the cylinder. The most
common pressure is a low pressure (0-50
mbar), which is created by allowing the gas
to pass through a reduction valve. There is
also intermediate pressure (50 mbar-2.0 bar)
and, finally, high pressure (over 2.0 bar),
which is unreduced pressure mainly used in
camping equipment. Low pressure and
intermediate pressure are always reduced
pressure.
58
FAULT FINDING
The boiler does not start
1. No LPG?
2. Is the main tap fully open?
3. If the boiler has not been operated for
some time, or if the gas cylinder has been
changed, it may take longer than normal
to light the boiler.
4. Check that the boiler is connected to the
electricity supply (> 11 V).
5. Check that the fuse (T) for the boiler is
intact.
6. Check whether the overheating protection
has been tripped by unscrewing the black
plastic cap (U) and pressing the reset
button (V).
NB! If the overheating protection has
been tripped it cannot be reset until the
boiler has cooled down by 10-20°C.
Before restarting the boiler, check that it
has been properly bled.
7. Check whether the red LED on the
control panel has gone out. If not, switch
off the boiler. Wait 30 seconds and then
try restarting it.
8. Check that the boiler's electrical
connections are properly attached.
9. If none of these help, please contact a
service company.
The heating cartridge is not working
1. Check that there is an electricity supply
(230 V~) to the heating cartridge.
Fitted Equipment
2. Check that the relays fitted to the boiler
come on (a slight click can be heard from
the relays when the heating cartridge is
switched on at the control panel).
3. Check whether the overheating protection
has been tripped by unscrewing the black
plastic cap (U) and pressing the reset
button (V).
4. If none of these work, please contact a
service company.
GUARANTEE
Alde's guarantee is valid for one year from
the date of delivery and only covers
materials or manufacturing faults, provided
that the directions for installation and use
have been followed. The guarantee does
not cover frost damage.
NB! Only Alde original parts should be used
as replacement parts.
The boiler is fitted with a built-in warm water
heater with a volume of approx. 8.5 litres
fresh water. The warm water heater can
produce around 12 litres of 40°C water per
half-hour (at a cold water temperature of
10°C). If the heating cartridge is used instead
of gas for heating the boiler, the capacity is
slightly reduced.
Always rinse out the heater before it is used,
particularly if it has not been in operation for
some time.
NB! The hot water is not intended for
drinking or cooking. When the heater is in
continuous use, it should be emptied
approx. once a month, to ensure that a new
air cushion is formed in the heater. The air
cushion is essential for absorbing pressure
surges in the heater.
For emptying specially adapted boilers, as
well as any other freshwater systems in the
vehicle, please refer to the manufacturer's
instructions.
NB! The warm water heater should always
be drained of fresh water when there is a risk
of frost and when the caravan is not in use.
The guarantee does not cover frost damage.
Draining the heater using the combined
safety/drain valve:
1. Switch off the freshwater pump.
2. Open all water taps.
3. Then open the safety/drain valve by
raising the yellow lever (M) to a vertical
position.
4. The heater will now drain directly below
the vehicle through the safety/drain valve
hose. Check that all the water is emptied
out (about 7-10 litres). Leave the valve in
the open position until the next time the
heater is used.
NB! Check that the automatic check valve
(N) is open and is allowing air to enter the
heater when it is being drained, and that the
hose (O) is not blocked.
THE HEATING CARTRIDGE
All compact boilers are fitted with one or two
230 V heating cartridges with a maximum
output of either 2100 or 3150 W. Select the
heating cartridge output by sliding the switch
on the control panel to the desired output
position. Always check that the input fuse of
the vehicle has the correct amperage in
relation to the selected output.
59
Fitted Equipment
1050 W requires a 6-amp fuse.
2100 W requires a 10-amp fuse.
3150 W requires a 16-amp fuse.
temperature, turn the axle clockwise until it
reaches its maximum position and cannot be
turned any further. The system temperature
is then reset to 80°C.
THE CIRCULATION PUMP
A 12 V circulation pump is fitted in the
expansion tank. It circulates the heated
glycol fluid in the heating system. Use the
sliding switch on the control panel to start
the circulation pump. The room thermostat
on the control panel controls the circulation
pump, i.e. switches it on or off according to
the amount of heat required. The circulation
pump may also be operated continuously.
(See the control panel section.
Please note that continuous operation of
the 12 V circulation pump considerably
reduces the service life of the motor.
SYSTEM TEMPERATURE
The boiler is set to a system temperature of
80°C, i.e. the temperature of the glycol fluid
as it circulates in the heating system. The
system temperature may be reduced when
required, i.e. if the warm water becomes too
hot.
Lowering the system temperature
Turn the spindle (Q) anti-clockwise. A
quarter turn represents a temperature
reduction of 10°C. To increase the system
60
MAINTAINING THE HEATING SYSTEM
Winter camping
While camping during the winter, ensure that
the flue is kept clear of snow and ice since
the inlet air to the LPG boiler enters through
the flue. Do not start the LPG boiler until the
flue is completely free of snow. A flue
extension (part no. 300 320) for fitting on the
roof is recommended for winter camping.
The LPG system
A professional, who will ensure that there are
no leaks from connections or hoses, should
check the LPG system regularly. LPG hoses
should be changed every second year, since
their propensity to dry out and crack will
eventually result in leaks.
AIR CIRCULATION
In order to achieve the best possible result
from the principle of waterborne heat, it is
important to allow air to circulate freely
under bunks, and behind backrests and
wall-mounted cabinets. If the vehicle has a
fitted carpet, ensure that the carpet does not
obstruct the air supply to the radiators. It is
just as important that cushions or blankets
do no interrupt the flow of air behind
backrests and wall cabinets.
To increase safety, we recommend fitting an
Alde leak gauge, type 4071, as close as
possible to the pressure reduction valve.
The heating system
Regularly check the heating system's fluid
level in the expansion tank. The level should
be about 1cm above the minimum indicator
in a cold tank.
The heating system should be filled with a
mixture of water and glycol. For preference,
use high quality ready-mixed glycol (with
inhibitor) intended for use in aluminium
heating systems. If using concentrated
glycol, the mixture should consist of 60%
water and 40% glycol. If the heating system
Fitted Equipment
circulation pump is operating. In newly filled
systems, small air bubbles can form in the
expansion tank, creating a murmuring
sound. If the circulation pump is stopped for
a few seconds, the bubbles will disappear.
will be exposed to temperatures below 25°C, the glycol content must be increased,
but not to more than 50%.
Any vessels used for the liquid must be
spotlessly clean, and the pipes in the heating
system must be free of contamination. This
will prevent the growth of bacterial in the
system.
Bleeding
If a bleeder screw is fitted to the outgoing
pipe on the rear of the boiler, open this
bleeder screw and leave it open until it starts
to discharge water. If the boiler is fitted with
an automatic bleeder, there is no need to
bleed it manually.
The glycol mixture should be checked before
topping up with new liquid. This will ensure
that the concentration of glycol in the
mixture is not too high.
If the fluid level in the expansion tank falls for
reasons other than evaporation, please
check all joints, drain cocks and bleeder
screws to ensure that they are not leaking. If
the glycol-water mixture leaks out, rinse with
water and wipe up. New allow the heating
system to stand empty of glycol.
FILLING THE SYSTEM WITH GLYCOL
FLUID
NB! Any vessels used for the liquid must be
spotlessly clean, and the pipes in the heating
system must be free of contamination. This
will prevent the growth of bacterial in the
system.
The system is filled through the expansion
tank, either manually or using the Alde filling
pump which both tops up and bleeds the
system. For manual filling, unfasten the
circulation pump nut (R) and life the pump
(S) out of the tank. Slowly pour the glycol
mixture into the tank. Bleed the system.
Top up with more liquid if the level has fallen
after bleeding. Bleed a newly filled system
regularly during the first days the heating
system is in operation.
BLEEDING THE SYSTEM
Depending on how the pipes have been
fitted, air pockets may form when the
system is filled with glycol fluid. A sign that
there is air trapped in the system is that the
heat released into the pipes only extends a
metre or so from the boiler even though the
Start the LPG boiler. The circulation pump
should be switched off. Open the remaining
bleeder screws in the system (please refer to
the instruction manual of the vehicle for their
locations). Leave the bleeder screws open
until they start discharging fluid. Start the
circulation pump and let it run for a while.
Check that the pipes and radiators around
the vehicle are heating up. If they still fail to
heat up, try the following:
Single-axle caravans: Stop the circulation
pump. Using the jockey wheel, lower the
front of the caravan as far as possible so
that the rear is tilted upwards. Leave it in
this position for a few minutes to allow the
air to travel upwards in the system. Open
the bleeder screw at the highest point.
Leave it open until it discharges glycol fluid.
Using the jockey wheel, raise the front of the
caravan as far as possible and repeat the
61
Fitted Equipment
procedure in this position. Then position the
caravan horizontally and start the circulation
pump. Check that the pipes and radiators
around the vehicle are heating up.
A
H
E
Motor caravan or twin-axle caravan: The
easiest way to bleed the heating system is to
place the vehicle on a sloping surface or to
raise one end of the vehicle using a jack.
Bleed the system as described above.
SETTINGS FOR OPERATION OF THE
HEATING SYSTEM AND WARM WATER
HEATER
For more information on the settings on the
panel, please refer to the 'Control Panel'
section.
B
WARM WATER ONLY WITH 230 V
HEATING CARTRIDGE
3. Switch the LPG switch to position (F).
1. Switch the circulation pump switch to
position (H).
4. Switch the heating cartridge switch to
position (A).
2. Switch the LPG switch to position (E).
3. Switch the electric cartridge switch to
position (B).
(When the system is being used for warm
water only, the electronics limit output to
1kW, irrespective of the output actually
selected).
WARM WATER ONLY WITH LPG BOILER
1. Open the LPG shut-off valve.
2. Switch the circulation pump switch to
position (H).
62
HEATING AND WARM WATER WITH 230 V
HEATING CARTRIDGE
1. Switch the circulation pump switch to
position (I).
2. Switch the LPG switch to position (E).
3. Switch the heating cartridge switch to the
desired output position (B, C or D).
In the illustration, an output of 2100 W
has been selected.
D
C
G
I
F
4. Adjust the temperature to the desired
level (5-30°C) using the TPS control
thermostat (K).
HEATING AND WARM WATER WITH LPG
BOILER
1. Open the LPG shut-off valve.
2. Switch the circulation pump switch to
position (I).
3. Switch the LPG switch to position (F).
4. Switch the heating cartridge switch to
position (A).
5. Adjust the temperature to the desired
level (5-30°C) using the TPS control
thermostat (K).
Fitted Equipment
HEATING AND WARM WATER WITH BOTH
230 V HEATING CARTRIDGE AND LPG
BOILER
(Use only when electricity or gas alone is not
sufficient)
1. Open the LPG shut-off valve.
2. Switch the circulation pump switch to
position (I).
3. Switch the LPG switch to position (F).
4. Switch the heating cartridge switch to the
desired output position (B, C or D).
In the illustration, an output of 2100 W
has been selected.
If the main switch is not closed, the boiler
will remain in the stand-by position and
use a small amount of electricity.
3. Close the LPG shut-off valve.
IF THE RED LED-LIGHT COMES ON
The boiler is fitted with an ionised flame
sensor. This means that if the flame goes out
for some reason, the electronics will attempt
to re-light it. If the flame is not re-lit within
ten seconds, the solenoid valve switches off
the gas supply, the electronics are blocked
and the red LED (G) on the control panel is
switched on. The electronics must be reset
before the boiler can be started.
5. Adjust the temperature to the desired
level (5-30°C) using the TPS control
thermostat (K).
Resetting from the blocked position:
SETTINGS FOR OPERATION OF THE
HEATING SYSTEM AND WARM WATER
HEATER
2. Wait approx. 30 seconds while the
electronics reset the block.
For more information on the settings on the
panel, please refer to the 'Control Panel'
section.
SWITCHING OFF THE LPG BOILER,
HEATING CARTRIDGE AND CIRCULATION
PUMP
1. Switch all three switches on the control
panel to the O-position (H, E, A).
2. Close the main switch to the heating
system if the vehicle will not be used.
1. Switch the LPG switch to position (E).
The LED (G) will go out.
3. Switch the LPG switch to position (F).
The electronics will once again attempt to
start the boiler.
TP5 ELECTRONIC
PROGRAMMABLE ROOM
THERMOSTAT
FEATURES
-
Controls central heating systems to
provide different room temperatures up to
6 times a day
-
The TP5 has one programme for Monday
to Friday, with a different programme for
Saturday and Sunday.
-
Setting the TP5 to the lowest temperature
will effectively switch off the heating,
whilst providing frost protection for the
controlled area*
RESET
The unit may be reset to 12:00PM (MO) and
the factory set programme by pressing and
holding down the four buttons, temperature
▲ and ▼ , time + and - , until the display
goes blank.
SETTING THE CLOCK
Press the PROGRAMME button once; the
colon is no longer flashing. Use the + and button to set the time. Hold down a button to
change the time quickly; press and release a
button to change the time by one minute.
When the time and AM or PM are correct,
press the PROGRAMME button to start the
clock, now only the day and the colon are on
display. Use + or - button to select the
63
Fitted Equipment
correct day. Press PROGRAMME to display
the first setting.
Set time
Set day
12:00 PM
:
MO
Setting 1
1
Setting 2
6:30 AM20
MOTUWETHFR
2
8:30 AM16
MOTUWETHFR
Last Setting
10:30 PM16
12
RUN
LIMITS OF ADJUSTMENT FOR TIME
SETTINGS
Time setting 1 can be at any time of the day
or night, but would normally be in the
morning.
Each of the time settings 2 to 6 can be at
any time between the proceeding setting and
1.59am. Time settings 2 to 5 can be set later
than the next setting, but doing this changes
the next setting as well..... E.g.changing
setting 2 in any of the above to 3.00pm
would also change setting 3 and 4 to
3.00pm.
This feature prevents times being set out of
sequence. If you wish to return to the pre-set
programme reset the unit as described
above.
SASU
EVERYDAY OPERATION
REVIEWING THE EXISTING SETTINGS
AND PROGRAMME YOUR OWN
When all twelve time/temperature settings
have been checked and/or
Now each press of the PROGRAMME button
shows, in, turn, the set times, (twelve with
the TP5), together with their associated
control temperatures. The time and/or
temperature of each setting may be altered
to your own requirements using the + and (time) and ▲ and ▼ (temperature) buttons.
altered, ensure the Programmable Room
Thermostat is in the RUN mode with the
colon blinking before sliding the cover shut.
64
MANUAL OVERRIDE
AM
If you wish to temporarily
19
change the control
MO
temperature from the
automatic setting, there is no need to reprogramme the thermostats; just press the
up or down button until the temperature you
want is displayed. An up or down arrow will
6:30
appear in the display to remind you that you
have over-ridden the programmed
temperature. The unit will revert to
programmed temperature at the start of the
next programmed event.
CONSTANT LOW TEMPERATURE
CONTROL
To set the thermostat to control at its low
setting (5°C to 16°C depending on model) for
24 hours a day press both t and u buttons at
the same time. The display will show the
blinking colon, the low setting and the
snowflake symbol. To return to the automatic
programme press the t and u buttons
together again.
BATTERY REPLACEMENT
AM
16
When the batteries
approach the end of their
MO
life, a battery symbol blinks
in the display. Have the new batteries
unwrapped and ready, slide the battery cover
fully off to the left, remove the old batteries
and insert the new ones WITHIN ONE
MINUTE.
12:00
Fitted Equipment
A
B
C
D
E
5. Check the flame viewer (located bottom
left of refrigerator) to see if the flame is
alight.
6. Keep the safety device control knob
depressed for a further 15-30 seconds.
7. Release the safety device control knob
and again check to see that the flame is
alight.
Fig. A Control Panel - RM4270
8. To terminate gas operation, turn knob (D)
to ‘O’.
ELECTRIC OPERATION
REFRIGERATOR
When using your refrigerator for the first time,
it is advisable to wash the interior and its
accessories.
When the caravan is on tow, the refrigerator
should be operated electrically, i.e. from the
12V battery in the towing vehicle, and not by
means of bottled gas.
CONTROLS
The refrigerator can be run on either 230V,
12V or LP gas. Changing between these
modes of operation is carried out by means
of the controls shown on the relevant control
panel.
MODEL RM4270
230V Operation
Bottled Gas Operation - Lighting the
burner
1. Turn off gas or 12V operation when
applicable.
1. Open the shut-off valve of the gas bottle
(check that there is enough gas). Open
any on-board shut-off valve.
2. Turn the knob (C) of the thermostat to its
highest (coldest) position.
2. Check that the switches for mains and
12V are off.
3. Depress and turn on the gas control
safety device knob (D) to the large flame
symbol.
4. Depress the gas control safety device
knob (D) and hold it down while
depressing the piezo-electric igniter
button (E) rapidly 3 or 4 times in quick
succession.
3. Set switch (B) to position I.
12V Operation
There is no thermostat control on 12V
operation.
Only operate your refrigerator on 12V when
the engine of your vehicle is running.
Note: Before operating the refrigerator on
12V it should be pre-cooled, together with
its contents, by running it on bottled gas
or 230V for a few hours before changing
over to 12V and starting on a journey.
Caution!
Only use one source of energy at a time.
65
Fitted Equipment
1. If applicable, turn off the gas operation.
C
2. Set the 230V rocker switch (B) to ‘O’ and
the 12V rocker switch (A) to I.
D
E
4. Set the thermostat knob (E) to the highest
setting.
Regulating the temperature
5. Turn on switch (F). A light in the switch
should now start to flash, indicating that
sparks are being generated at the burner.
Once the refrigerator has been started it will
take a few hours to become cold.
On 230V operation the refrigerator is
controlled by a thermostat and the
thermostat knob (C) should be set at 3. If a
colder temperature is required, set the
thermostat to a higher number and vice
versa.
On LP gas operation the refrigerator
temperature is regulated by the gas control
knob (D). If the ambient temperature is above
25°C and/or the door of the refrigerator is
frequently opened, the knob should be set in
the ‘max’ position. Below 25°C, the knob
should be set at ‘mid’ and below 10°C at
‘min’ to avoid temperatures below freezing in
the main compartment.
MODEL RM4271
Two rocker switches are used to select the
electric power supply, one for 230V (B) and
one for 12V (A) (See Fig. B).
Refrigerator temperature is controlled by a
thermostat knob (C) when the refrigerator
runs on 230V.
The gas supply is turned ON/OFF by means
of the knob (D). When lighting the gas, the
66
3. Turn on gas supply by pressing knob (D)
and turning it to the flame position.
A B
F
Fig. B Control Panel - RM4271
knob must be pressed as explained in LP
Gas Operation.
Refrigerator temperature is controlled by a
thermostat (E) when the refrigerator runs on
LP gas. Please note that the thermostat has
no ‘OFF’ position.
The gas flame is electronically lit, monitored
and re-lit if necessary. For this, the toggle
switch (F) should be ‘ON’ during gas
operation.
STARTING THE REFRIGERATOR
LP Gas Operation
Before you start gas operation:
1. Open the shut-off valve of the gas bottle
(check that there is enough gas). Open
any on-board shut-off valve.
2. Check that the switches for mains and
12V operation are off.
6. Press button (D). This opens the flame
failure device and allows gas to flow to
the burner.
7. When the flame ignites, the sparking
stops automatically and the switch stops
flashing.
8. Keep the knob (D) pressed for a further 10
to 15 seconds to activate the flame failure
device, then release it.
230V Operation
1. Turn off gas or 12V operation when
applicable.
2. Turn the knob (C) of the thermostat to its
highest (coldest) position.
3. Set switch (B) to position I. The switch will
light up green when the power supply is
connected.
12V Operation
Only operate your refrigerator on 12V when
the engine of your vehicle is running. Install
through a relay, otherwise your battery will
soon be discharged.
Fitted Equipment
Note: Before operating the refrigerator
on12V, it should be pre-cooled, together with
its contents, by running it on bottled gas or
230V for a few hours before changing over
to 12V and starting on a journey.
A
B
C
D
LP Gas operation
1. If applicable turn off the gas operation.
2. Set the 12V rocker switch (A) to I. The
switch will light up red when the power
supply is connected.
REGULATING THE TEMPERATURE
The position numbers refer to Fig. B.
Once the refrigerator has been started it will
take a few hours to become cold.
On 230V operation the refrigerator is
controlled by a thermostat and the
thermostat 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 refrigerator
temperature is regulated by the gas
thermostat knob (E), which should be set at
3-5. If a lower (colder) temperature is
desired, set the thermostat at a higher figure.
On 12V operation the refrigerator works
continuously.
STARTING THE REFRIGERATOR
Fig. C Control Panel - RM4501
Manual Ignition
MODEL RM4501
The refrigerator can be run on 230V, 12 V
or LP gas. Changing between these modes
of operation is carried out by means of the
control buttons positioned as shown in
fig. C.
After initial installation, servicing, or changing
gas cylinders etc., the gas pipes may
contain some air, which should be allowed to
escape by briefly turning on the refrigerator
or other appliances. This will ensure that the
flame lights immediately.
To start gas operation:
1. Open the shut off valve of the gas bottle
(check that there is enough gas). Open
any on-board shut-off valve.
2. Set the thermostat knob (D) to the
highest setting.
The energy selection (A) can be set at either
"AC" (230V), "DC" (12 V), "GAS" (LP gas) or
"OFF".
3. Turn the energy selector (A) to position
"GAS". A ticking sound will be heard and
the lamp (B) will start flashing.
An indicator lamp (B) at the control panel
flashes when the automatic ignitor attempts
to light the burner. Otherwise this lamp is
off.
4. Press the button (C). This opens the
flame failure device and allows gas to
flow to the burner.
The refrigerator is fitted with a safety device,
which automatically shuts off the supply of
gas if the flame goes out. The safety device
can be opened manually be depressing knob
(C).
The refrigerator temperature is controlled by
a thermostat (D) when the refrigerator runs
on 230V and LP gas. Please note that the
thermostat has no "off" position when the
refrigerator runs on LP gas.
5. When the flame lights, the sparking stops
automatically and the lamp stops
flashing.
6. Keep the knob (C) depressed for another
10-15 seconds to activate the flame
failure device, then release it.
If the lamp starts flashing again, repeat steps
4-6.
To terminate gas operation, turn the knob (A)
to "OFF" position.
67
Fitted Equipment
230V operation
Before taking the refrigerator into operation,
check that the voltage stated on the data
plate is the same as the main voltage in use.
MODEL RM6270, RM6271
AND RM6291
A
Off
B
AC
C
• Turn the thermostat knob (D) to its
highest (coldest) position.
-+
-
12V
• Set the energy selector (A) to position "AC"
12 V operation
Only operate your refrigerator on 12 V when
the engine of the vehicle is running - otherwise your battery will soon be discharged.
Gas
Fig. D Control Panel - RM6270
Manual Ignition
A
B
D
• Set the energy selector (A) to position "DC"
REGULATING THE TEMPERATURE
It will take a few hours for the refrigerator to
reach normal operating temperature. We
therefore suggest you start it well in advance
of a trip and if possible store it with precooled foodstuffs.
On 230V operation and LP gas operation the
refrigerator is controlled by a thermostat and
the thermostat knob (D) should be set at 3-5.
If a lower (colder) temperature is desired, set
the thermostat to a higher figure.
On 12 V operation the refrigerator works
continuously.
68
-
Fig. E Control Panel - RM6271 & RM6291
Automatic Ignition
The refrigerator is equipped to operate off
mains power, 12V/24V or liquid gas. The
desired potion is selected by means of
energy selector switch (A). Energy selector
switch (A) has four settings: AC mains
power, DC (12V/24V), gas (liquid gas), O off.
Refrigerator temperature is controlled by a
thermostat (B) when the fridge runs on gas
and mains electric. No thermostat control is
available on 12V/24V operation.
STARTING THE REFRIGERATOR
LP Gas Operation
Open the shut off valve of the gas bottle
(check there is enough gas). Open any on
board shut off valve.
For models with manual ignition
1. Set the energy selector switch (A)
to gas
2. Press and hold rotary thermostat switch (B)
3. Activate Piezo ignition (C) several times at
intervals of 1-2 seconds.
4. Check the inspection glass to see if there
is a flame (the inspection glass is inside
the refrigerator at the bottom left).
5. Keep rotary switch (B) depressed for
another 10-15 seconds, then release.
(C) is the manual ignition button (Piezo
ignition).
6. Check the inspection glass, to see that
the flame is burning.
(D) is the automatic ignition indicator.
7. Repeat the entire procedure if the flame
has gone out.
Fitted Equipment
8. Adjust the temperature in the main
refrigerator compartment using rotary
switch (B)
For models with automatic ignition
1. Set the energy selector switch (A)
to gas
2. Press and hold rotary thermostat switch (B)
3. The ignition process is activated
automatically, accompanied by a ticking
sound; the indicator lamp (D) will flash.
Upon successful ignition, the sound and
flashing will stop.
4. Keep rotary switch (B) depressed for
another 10-15 seconds, then release.
5. If there is an inspection glass, check to
see that the flame is burning.
When using for the first time or after
changing the gas cylinder, the gas pipes
may contain air. By means of brief
operation of the refrigerator and any other
gas appliance (eg cooker) air is removed
from the gas pipes. The gas will then
ignite without delay.
Main 230V Operation
Note:
The operation may only be selected
where the supply voltage of the
connection for the power supply
corresponds to the value specific on the
data plate. Any difference in values may
result in damage to the appliance.
1. Set the energy selector switch (A) to
6. If the flame goes out the ignition system
will repeat the ignition process
automatically.
2. Use rotary switch (B) to regulate the
temperature in the main refrigerator
compartment.
8. Adjust the temperature in the main
refrigerator compartment using rotary
switch (B)
12V/24V Operation
Note:
The fridge must exclusively be operated
using liquid gas (propane and butane)
All refrigerators are equipped with
automatic flame protection, which
automatically cuts off the gas supply 30
seconds after the flame goes out.
Only operate your refrigerator on 12V/24V
when the engine of your vehicle is running.
Install through a relay otherwise your battery
will soon be discharged.
Note:
Before operating the refrigerator on
12V/24V, it should be pre-cooled, together
with its contents, by running it on gas or
230V for a few hours before changing
over to 12V/24V for your journey.
1. Set the energy selector switch (A) to
The refrigerator will run continuously without
thermostatic control.
FRIDGE USE AND MAINTENANCE
WINTER OPERATION
Please check that the ventilation grilles or
the flue outlet are not blocked by snow,
leaves etc.
Some caravans with outside ventilation may
have so called winter covers that protect the
cooling unit against cold air (ask your
dealer). The covers may be fitted when the
outside temperature is below approx. 10°C
and should be fitted when the temperature is
below freezing point.
We suggest that you fit the winter covers
when the vehicle is laid up during winter
months.
FOOD STORAGE
Always keep food in closed containers.
Never put hot food in the refrigerator; allow it
to cool first.
Never keep items in the refrigerator
which might give off flammable gases.
The frozen food compartment is intended for
the storage of frozen food and for making
ice. It is not suitable for freezing items of
food.
69
Fitted Equipment
Never put bottles or cans of fizzy drinks in
the frozen food storage compartment as
they may burst when freezing.
Most kinds of frozen food can be stored in
the frozen food compartment for about a
month. This period of time may vary,
however, it is important to follow the
instructions on the individual packages.
ICE MAKING
It is practical to make ice during the night when the refrigerator is less demanded and
the cooling unit has more reserves. Fill the
ice tray to just below the brim with drinking
water and place it on the freezer shelf.
It is possible to make ice faster by turning
the control knob temporarily to its highest
value but do not forget to turn it back to its
regular setting afterwards as the refrigerator
might otherwise become too cold.
DEFROSTING
Frost will gradually accumulate on the
refrigerator surfaces. It must not be allowed
to grow too thick as it acts as an insulator
and adversely affects refrigerator
performance. Check the formation of frost
regularly every week and when it gets about
3mm thick, defrost the refrigerator.
To defrost the refrigerator, turn it off and
remove the ice trays and all food items.
Leave the cabinet and freezer doors open.
70
Do not try to accelerate defrosting by using
any kind of heating appliance as this might
damage the plastic surfaces of the
refrigerator. Neither should any sharp
objects be used to scrape off the ice.
Never use detergents, scouring powder,
strongly scented products or wax polish to
clean the interior of the refrigerator as they
may damage the surfaces and leave a strong
odour.
The defrost water runs from a collector
channel to a receptacle at the rear of the
refrigerator where it normally evaporates.
The exterior of the refrigerator should be
wiped clean now and then, using a damp
cloth and a small quantity of detergent, but
not the door gasket which should only be
cleaned with soap and water and then
thoroughly dried.
Heavy frost build up on the freezer plate and
the cooling fins, and a lot of defrost water:
Move the plastic drain tube into a watertight
bucket or container. (Access through the
lower ventilation grill on the outside of the
vehicle). As the frost melts, the water will
flow into the container. Replace the drain
tube to its original position after defrosting.
The cooling unit behind the refrigerator
should be cleaned with a brush from time to
time, but make sure that the refrigerator is
switched off when doing this.
TURNING OFF THE REFRIGERATOR
Defrost water in the freezer compartment
should be mopped up with a cloth.
If the refrigerator is not to be used for some
time:
When the ice has melted, wipe the
refrigerator dry and restart it. Place the food
items back inside but wait until the
refrigerator is cold before making ice cubes.
1. Turn all controls "OFF".
CLEANING THE REFRIGERATOR
Clean the inside of the refrigerator regularly
to keep it fresh and hygienic.
Soak a cloth in a solution consisting of a
teaspoon of bicarbonate of soda to half a
litre of warm water. Wring out the cloth and
use it to clean the interior of the refrigerator
and its fittings.
2. Shut off any on-board valve in the gas
line to the refrigerator.
3. Empty the refrigerator. Defrost and clean
it as described earlier. Leave the doors of
the refrigerator and frozen food
compartment ajar.
4. When the vehicle is laid up for a long
period of time (e.g. during the winter
months), we suggest fitting the winter
covers on to the grills.
Fitted Equipment
IF THE REFRIGERATOR FAILS TO WORK
2. The evaporator is frosted up.
• The Instruction Manual is available.
Check the following points before calling a
service technician:
3. Incorrect thermostat settings.
• Check that the burner is clean and free
from combustible material.
1. That the "STARTING THE
REFRIGERATOR" instructions have been
followed.
2. The refrigerator is level.
3. If it is possible to start the refrigerator on
any of the connected sources of energy.
4. If the refrigerator fails to work on gas,
check:
- That the gas bottle is not empty
- That the LP gas valves are open.
5. If the refrigerator fails to work on 12 V,
check:
- That the 12 V supply is connected to
the refrigerator.
- That the fuse on the 12 V supply is
intact.
- That the battery is not run down.
6. If the refrigerator fails to work on
230V, check:
- That the 230V supply is connected to
the refrigerator.
- That the fuse is intact.
If the refrigerator is not cooling
sufficiently, the reason may be:
1. Inadequate ventilation of the cooling unit
due to the intake and/or exhaust air vents
being partly or completely blocked.
4. Incorrect gas pressure - please check the
pressure regulator on the gas container.
SOME USEFUL HINTS
5. The ambient temperature is too high.
Make sure that:
6. Too much food is loaded at one time.
• The refrigerator is not operating on 12 V
when the vehicle is parked, otherwise you
will drain the car battery in a short time.
7. The door is not properly closed or the
magnetic sealing strip is defective.
If the refrigerator still does not work
properly, call a service technician.
The sealed cooling system must not be
opened, since it contains corroding
chemicals under high pressure.
MAINTENANCE
Always turn to a qualified service technician
who is familiar with LP gas systems and
refrigerators.
We recommend that a service technician
check the refrigerator once a year.
• Check all connections in the LP gas
system for gas leaks. Connections can
be tested for leaks using a soap solution.
Do not use a naked flame! If there is any
suspicion of damage, call for a service
technician
• Defrosting is carried out periodically.
• The refrigerator is clean and dry with the
door left open when it is not to be used
for some time.
• Liquids or items with a strong odour are
well packed.
• The ventilation openings are
unobstructed.
• The doors are secured by means of both
travel catches when the caravan is on the
move.
SERVICE AND SPARE PARTS
Service and spare parts are obtainable from
your dealer of Dometic - consult the
telephone directory.
• The ventilation openings are
unobstructed.
71
Fitted Equipment
TRAVEL CATCH
THETFORD ABSORBER
REFRIGERATORS
All models are fitted with a travel catch (type
A or B depending on model) to keep the
refrigerator door securely closed when the
vehicle is on the move.
This user’s information is for all N80 models
of Thetford absorber refrigerators. It explains
how to use your refrigerator correctly and
safely. Read the manual carefully before
using the refrigerator for the first time to
obtain a quick overview of how to operate
and use the refrigerator.
Remember always to push the catch down,
so that its lower end fully engages the plastic
bush in the top of the door, before moving
off.
FURTHER DETAILS
Consult the accompanying literature to obtain
the full benefit of your Dometic Refrigerator.
In the event of failure, contact Dometic
Service. Details of which can be found in
your Yellow Pages Directory.
Travel Catch B
Thetford absorber refrigerators are specially
designed to store fresh and frozen food and
make ice cubes in caravans and campers.
The control panel allows you to select the
preferred energy source. Different energy
sources allow you to use your refrigerator
under different conditions.
Thetford absorber refrigerators belong to
category C11: gas appliances that must be
installed so that they are isolated from the
living space.
To find out more about how your absorber
refrigerator works, visit our website at
www.thetford-europe.com .
PRECAUTIONS AND SAFETY
INSTRUCTIONS
Alerts
Travel Catch A
The following alerts are used in this user’s
manual:
Warning!
72
“Warning” alerts the user to the
danger of damage to the
Fitted Equipment
product or to the user if the user
fails to carry out the described
procedures carefully. Nonobservance of the procedures
may result in serious injury to
the user or damage to the
product.
Caution!
“Caution” alerts the user to the
possibility of damage to the
product if the user fails to carry
out the described procedures
carefully.
Important! “Important” denotes
supplementary information for
the user and alerts the user to
potential problems.
Tip!
“Tip” provides the user with
suggestions and advice for
carrying out certain actions
more easily or handily.
Repairs/maintenance
- open the windows and leave the room;
• Never open or damage the cooling
system. The cooling system is
pressurized and contains substances
harmful to health.
- contact the Customer Service
department of Thetford.
• Never attempt to repair gas, extractor or
electrical parts yourself. They must be
repaired by a qualified service engineer.
Contact the Customer Service
department of Thetford for a list of
qualified parties.
• Always switch off the refrigerator before
you perform any kind of maintenance or
cleaning.
Use
• Never cover the ventilation gratings in the
walls of a caravan. Good ventilation is
essential for the correct working of the
absorber system.
Warnings
• Never expose the refrigerator to rain.
• This refrigerator must be installed
according to the manufacturer’s
instructions and in compliance with local
and national regulations.
• Never operate the refrigerator by gas
while driving. If a road accident results in
fire, there is a risk of explosion.
• Read this manual carefully before you
start to use your refrigerator.
• You smell gas:
• Always consult the warnings before you
perform any maintenance or gas checks.
What to do if...
- close the valve of the gas bottle;
- extinguish any naked flames;
• You suspect a leak in the cooling system:
- switch off the refrigerator;
- extinguish any naked flames;
- provide sufficient ventilation;
- contact the Customer Service
department of Thetford.
ABOUT YOUR REFRIGERATOR
Your refrigerator has a cold space and a
freezer compartment. After starting up the
refrigerator, allow it to cool for at least eight
hours before placing any food in it.
Cold space
The condenser is located on the inside of
your refrigerator. The absorber system uses
the condenser to draw off heat from the
refrigerator. Therefore, never place plastic or
paper over the condenser. Air must be able
to circulate freely through the refrigerator so
that heat can be extracted.
Important! Do not cover the condenser at
the back of the refrigerator with plastic or
paper. The refrigerator cools optimally when
air is allowed to move freely through the
refrigerator.
- do not switch on any electrical devices
or lighting;
73
Fitted Equipment
• To limit frosting on the condenser:
- always cover liquid foods before placing
them in the refrigerator;
- always let hot food cool before placing it
in the refrigerator;
- never keep the refrigerator open longer
than necessary.
Fitting racks
Inside your refrigerator there are two or three
storage racks. You can adjust the racks to a
convenient height by means of a simple click
system:
• click the plastic bracket to the right short
side of the rack;
• turn the bracket into the horizontal
position and insert the rack tipped in a
sloping position into the refrigerator;
• place the short side without bracket into
one of the grooves on the left wall of the
refrigerator;
• place the short side with bracket in the
corresponding groove on the right wall of
the refrigerator;
• turn the bracket downwards to fix it into
the groove.
To move a rack, turn the bracket upwards
and remove the rack. Place the rack at the
required height in the way described above.
74
Securing products for driving
Freezer compartment
One of the racks in your refrigerator has a
system for securing products for driving. The
system consists of a simple click-and-slide
plastic strip. To secure products on the rack
while driving, push the plastic strip as tightly
as you can against the products on the rack.
The two-star freezer compartment (N80) is
suitable for making ice cubes and for storing
frozen foods for a short time.
In the storage space on the inside of the
refrigerator door, there is the unique Thetford
flexible bottle slide. The slide prevents
bottles from sliding around during driving.
Push the slide against the products in the
door or place the products between the
bottle slide.
Important!
- The freezer compartment is unsuitable
as a means of freezing food.
- Use only drinking water to make ice
cubes.
- Do not place any other products in the
freezer compartment when you are
making ice cubes.
- Water freezes fastest with the
thermostat at the highest setting.
Tip!
- Make ice cubes at night when your
refrigerator has more spare capacity.
Door locking mechanism
The refrigerator door has an automatic
locking mechanism. The door locks
automatically when you press it shut firmly.
The lock releases unnoticed when you open
the refrigerator with your hand. This
automatic locking mechanism also keeps the
refrigerator door shut during driving. For
some models an additional security device is
fitted below the refrigerator. By pushing the
locking bar over the closed refrigerator door
Fitted Equipment
you can make doubly sure that the door
does not come open during your journey.
Technical data
Category:
C11
If you are not going to use the refrigerator for
a prolonged period of time, you can use the
special hook of the door locking mechanism
to prevent odours. Turn the hook a quarter of
one rotation to position it at right-angles to
the refrigerator. In this position, the hook
prevents the door from closing.
AC:
230V (50/60 Hz)
DC:
12V
Gas types:
I3+ (28-30/G3: 37
mbar) (Countries: BE,
FR, IE, LU, PT, GB, GR,
IT)
I3B/P (G30/G31: 28-30
mbar) (Countries: DK,
DE, IS, NL, SE, FI, NO)
(G30 = butane,
G31 = propane)
Model:
N80 x Exxx
Dimensions
H x W x D (mm)
Depth incl. door:
821 x 525 x 543
Gross volume
incl. Freezer (L):
80
Net volume
incl. Freezer (L):
75
Volume freezer (L):
9.5
Input * (kWh/24h):
2.5
Input * (gr./24h):
238
Net weight (kg):
23
Ignition:
Electrical
*average energy consumption at ambient
temperature of 25°
SWITCHING ON THE REFRIGERATOR
(N80)
• It is recommendable to clean the inside of
the refrigerator before you switch it on.
• Let the refrigerator cool for at least eight
hours before you place food in it for the
first time.
• The freezer compartment should be cold
one hour after switching on the
refrigerator.
Igniting and starting your refrigerator
Automatic ignition (N80E)
A
B
D C
A = Energy source selector switch
B = Electric thermostat
C = Gas control button
D = Flame meter
A. The refrigerator can be powered by the
mains (230V), direct current (12V) or liquid
gas. Select the energy source that you
want by means of the energy source
selector switch (A). The switch has four
settings:
75
Fitted Equipment
• direct current (DC)
• mains supply
• gas
• switched off
B. The thermostat controls the refrigerator
temperature when the refrigerator is
powered from the mains (230V). Position 5
is the coldest temperature setting.
C. The gas control button controls the
refrigerator temperature when the
refrigerator is powered by gas. Position 5
is the coldest temperature setting.
D. The flame meter shows whether the flame
is burning. The flame is burning when the
meter comes into the green area.
Electrical operation
The refrigerator can be powered by electricity
in two ways:
• 12 V DC: Set the energy source selector
switch (A) to
• the refrigerator will now be powered by
the battery of your car or camper.
Important!
- Always use the gas connection or mains
voltage to start up the refrigerator for the
first time and to cool it. Powering from
the battery of your vehicle is suitable
only for maintaining the temperature of
the refrigerator and its contents once it
76
has been refrigerated.
- When powered by a vehicle battery the
refrigerator works without temperature
control (i.e. constant operation).
• Mains voltage (230 V): set the power
selector switch (A) to
- It is prohibited to use gas to power the
refrigerator while you are driving. If a
road accident results in fire, there is a
danger of explosion.
- It is prohibited to use gas to power the
refrigerator in the vicinity of petrol
stations.
• Set the temperature by means of the
thermostat, rotary switch (B). Position 5 is
the coldest temperature setting.
1. Open the valve of the gas bottle and the
gas taps.
Powering with gas
2. Set the gas control button to the 5th
position.
Warning!
- Flammable material must be kept away
from the refrigerator.
- For selection of gas type, see the
information plate inside your refrigerator.
- For the pressure regulator model, see
the information plate inside your
refrigerator.
- The type of gas container and its
location must be in compliance with the
most recent regulations. Ensure that the
unit is installed in a location with good
ventilation and make sure that the
ventilation openings in the gas container
storage location remain open.
- The changing of the gas container must
be done outside in the open air and out
of reach of any possible sources of
ignition.
3. Set the energy source selector switch (A)
to
4. Ignite the gas flame:
Automatic ignition (N80E)
- Press the gas control button, rotary
switch (C), and keep it depressed.
- Ignition takes place automatically. You
will hear a ticking noise. If ignition was
successful, the noise will stop and the
flame meter will turn green. Release the
gas control button.
- If the flame goes out, ignition will be
repeated automatically.
- Set the desired refrigeration level by
means of the gas control button, rotary
switch (C). Position 5 is the coldest
setting.
Fitted Equipment
Switching off the refrigerator
Cleaning
• Leave the refrigerator door open.
1. Set the energy source selector switch (A)
to
;
Tip!
- A good time to clean your refrigerator is
straight after you have defrosted it.
• Place dry towels in the refrigerator to
absorb the water.
2. Turn the gas control button, rotary switch
(C) to 0 (Off);
3. The refrigerator is now completely
switched off.
Note!
- The refrigerator is only fully switched off
when both the energy source selector
switch and the gas control button are at
zero. In the case of a refrigerator with
electrical ignition, when the gas control
button is not set to 0, the ignition
mechanism will keep sparking. This can
cause a flat battery.
4. Use the door locking mechanism to lock
the open door. This prevents unpleasant
odours and mould in the refrigerator.
Important!
- If you are not going to use the
refrigerator for a prolonged period, close
the valve of the gas bottle and the gas
taps.
MAINTENANCE
Regular maintenance is necessary to ensure
the correct functioning of your refrigerator.
- Clean the refrigerator with a soft cloth
and mild detergent.
- Dust the refrigerator with a soft,
moistened cloth.
- Use a brush or soft cloth to remove
once a year any dust from the
condenser at the inside of the
refrigerator.
Important!
- Do not use soap or aggressive
detergents that are abrasive or sodabased.
- Make sure that the door closing
mechanism does not come into contact
with oil or grease.
Defrosting
Frost will gradually build up on the
condenser of the refrigerator. You should
defrost the refrigerator as soon as the frost
layer is about 3 mm thick. Frost reduces the
refrigerating capacity and life of your
refrigerator.
• Remove the ice cube tray and all food.
• Place trays containing hot water in the
freezer compartment.
• After defrosting (when the freezer
compartment and condenser are frostfree), remove the towels and the water
trays and use a cloth to dry off the
refrigerator.
• Switch the refrigerator on again in the way
described previously.
Important!
- Do not use force or sharp objects to
remove frost.
- Do not try to accelerate defrosting by
using a heat source, such as a hairdryer.
Door locking mechanism
Frost will form in the refrigerator if the door is
not closed properly. To determine whether
the door closes properly, close the door with
a piece of paper between the door and the
refrigerator. Pull at the piece of paper. If you
feel resistance, the refrigerator door closes
properly. If you feel no resistance, the door
does not close properly. Perform this test
regularly on all four sides of the refrigerator
door.
• Switch off the refrigerator in the way
described previously.
77
Fitted Equipment
Take the following action if you find that the
door does not close properly:
• check whether the screws of the hinges of
the refrigerator door are securely in place;
• check whether the door locking
mechanism keeps the door properly shut.
Winter operation
If you use the refrigerator when the outdoor
temperature is below 0°C, install the Thetford
winter cover on the ventilation gratings. The
cover protects your refrigerator from
excessively cold air. The winter cover is a
refrigerator accessory obtainable from your
caravan dealer.
Tip!
- It is advisable to use the winter cover if
you are not going to use the vehicle for
a long period of time.
Ventilation grating with winter cover
Maintenance of gas equipment
A qualified service engineer must maintain
and inspect gas and electrical equipment. It
78
is advisable to have this maintenance work
performed by a customer service centre.
Contact the Customer Service department of
Thetford for a list of qualified parties.
Important!
European laws covering gas appliances and
extractors prescribe observance of the
following rules (which are the user’s
responsibility):
- gas appliances and extractors must be
inspected prior to first usage and
thereafter every two years;
- appliances that run on liquid gas must
be inspected each year. After each
inspection a certificate will be issued;
- the gas burner must be cleaned at least
once a year or more frequently if
necessary.
- If a gas hose is used, it must be
checked annually. This hose has a
limited life and, thus, must be regularly
replaced. Check the hose regularly for
cracks, splits and ageing. If in doubt,
replace the hose. Pay attention to the
maximum life of the hose and replace it
in time, as advised by the manufacturer
or in conformance with local regulations.
- For replacement, a gas hose approved
in accordance with the local regulations
must be used . Position the hose so that
it can rotate, is not kinked, and will
allow no bends to occur.
- Due to the limited life of the gas hose, it
must be installed so that replacement is
possible.
Replacing bulbs
If a bulb in your refrigerator is defective, you
can replace it by clicking in a new one:
• remove the cover by pressing both sides;
• remove the defective bulb;
• fit the new bulb;
• click back the cover.
For details regarding spare bulbs please
contact the Customer Service department of
Thetford.
Maintenance checklist
This refrigerator will give you many years of
trouble-free use if you simply run through the
following checklist regularly:
• keep the refrigerator clean (see section
“Cleaning”);
• defrost the refrigerator as often as is
necessary (see section “Defrosting”);
• check the door closing mechanism
regularly (see section “Door locking
mechanism”);
• make sure that the ventilation gratings are
not blocked.
Fitted Equipment
STORAGE
If you do not expect to use your refrigerator
for a lengthy period, carry out the following
actions:
• Check whether the refrigerator can be
used with an available energy source.
Problem: refrigerator will not work on gas
• Remove all food
Possible cause
Action you can take
• Switch off the refrigerator
a) Gas bottle is empty.
a) Replace the gas bottle.
• Clean the refrigerator as described in
Section ‘Cleaning’
b) Valve of the gas bottle or one of
the shut-off valves is closed.
b) Open the valve of the gas bottle
or shut-off valve(s).
• Shut off the gas tap to the refrigerator
Problem: refrigerator will not work on 12V DC
• Leave the door of the refrigerator ajar
using the special door closure hook
(storage position)
Possible cause
Action you can take
a) 12V fuse is defective.
• Place the winter protection on the
ventilation grating.
a) Fit a new fuse (Camper —> fuse box
of camper. Car —> fuse box of car)
b) Battery is empty.
b) Test the battery and charge it.
TROUBLESHOOTING
Problem: refrigerator will not refrigerate sufficiently
If your refrigerator does not refrigerate
properly or will not start, run through the
following checklist. If this fails to solve the
problem, contact our Customer Service staff
who will be pleased to help you.
Possible cause
Action you can take
a) Insufficient ventilation for the refrigerator.
a) Check whether the ventilation
gratings are covered.
b) Thermostat/gas control button set too low.
b) Increase the setting of the
thermostat/gas control button.
c) Too much ice on the condenser.
c) Check whether the refrigerator door
shuts properly and defrost the
refrigerator.
d) Too much hot food stored simultaneously.
d) Let the food cool off first.
e) Gas burner is dirty.
e) Have the gas burner cleaned.
f) Door does not shut properly.
f) Check the door closing mechanism.
Thetford B.V.
Customer Service
( +31 (0)76-5042312
[email protected]
• Check whether you have followed the
instructions in “Switching on the
refrigerator”.
• Check whether the refrigerator is on a
level surface.
79
Fitted Equipment
GUARANTEE, CUSTOMER SERVICE AND
LIABILITY
Guarantee
Thetford B.V offers the end users of Thetford
refrigerators a three-year guarantee, instead
of the normal guarantee of two years. This
extra year guarantee applies only if it can be
demonstrated that the refrigerator has been
properly maintained (as described in this
manual) and serviced by a qualified party
during the second year following purchase. In
the case of defects within the guarantee
period, Thetford will replace or repair the
product. In this instance, the costs of
replacement, labour costs for the
replacement of defective components and/or
the costs of the parts themselves will be paid
by Thetford.
1. To make a claim under this guarantee, the
user must take the product to a Service
Centre recognised by Thetford. The claim
will be assessed here.
2. If components are replaced during repair
under guarantee, these become the
property of Thetford.
3. This guarantee does not prejudice current
consumer protection law.
4. This guarantee is only applicable if the
product is supplied within the European
Community.
80
5. This guarantee is not valid in the case of
products that are for, or are used for,
commercial purposes.
6. No claim under the guarantee will be
accepted in the following circumstances:
- the product has been improperly used
or the instructions in the manual have
not been followed
- the product has not been installed in
accordance with the instructions
- alterations have been made to the
product
- the product has been repaired by a
Service Centre not recognised by
Thetford
- the serial number or product code has
been changed
- the product has been damaged by
circumstances outside the normal use
of the product
Liability
Thetford is not liable for loss and/or damage
caused directly or indirectly by use of the
refrigerator.
ENVIRONMENT
Refrigerators manufactured by Thetford B.V.
are PCB-free. Most of the refrigerator is
recyclable.
If the refrigerator has reached the end of its
service life, contact your local waste
processing company to dispose of the
refrigerator in an environment-friendly way.
Energy-saving tips
• Install the refrigerator and switch it on
about 12 hours before you put anything in
it.
• Do not expose the refrigerator to direct
sunlight.
• At an ambient temperature of
approximately 25°C you can let the
refrigerator operate at the middle position
of the thermostat (both with gas operation
and mains voltage).
• Store foods that have been pre-cooled.
• Open the door only briefly when you take
things out of the refrigerator.
• Defrost the refrigerator regularly.
Fitted Equipment
PLEASE READ THE MANUFACTURERS
INSTRUCTIONS BEFORE OPERATING THE
APPLIANCE
WARNING: When you are cooking it is
essential to provide additional ventilation
such as opening windows.
WARNING: When using cooking or
heating appliances, surfaces and handles
may become hot. Care should be taken
and if necessary hand protection used.
STOVES HOBS, GRILLS AND
OVENS
BURNER IGNITION
The hotplate lid must be open for the
hotplate, grill or oven burners to ignite.
The ignition should not be operated for more
than 15 seconds. If, after 15 seconds the
burner has not lit, stop operating the ignition,
open the compartment door and wait at least
1 minute before attempting to ignite the
burner.
In the event of the burner flames being
accidentally extinguished, turn off the burner
control and do not attempt to re-light the
burner for at least 1 minute.
SPARE PARTS
When ordering spare parts, please give the
following information so the appliance can be
correctly identified:
1. The name of the appliance from the facia,
and its colour.
2. The model number and the serial number
of the appliance (from the data badge).
BE SAFE - NOT SORRY
Turn pan handles inwards so they are out of
reach of children and cannot be caught
accidentally.
Glass lids may shatter when heated, turn off
all burners before shutting the lid.
Warning: Good ventilation is essential to the
continuing safe operation of all gas
appliances. Do not allow any ventilation
openings to become accidentally or
deliberately blocked.
Models without ignition button: For safety
reasons, we recommend the use of a hand
held spark ignitor or gas lighter to ignite the
burner, rather than a match or taper, which
could allow burning debris to fall behind the
appliance.
Keep all flammable materials (such as
curtains, furnishings, towels and clothing)
away from the appliance.
When you have finished cooking, check
that all controls are in the off position.
Parts of the appliance may be hot during or
immediately after use. Allow sufficient time
for the appliance to cool after switching off.
When opening the appliance door, take care
to avoid skin contact with any steam which
may escape from the cooking.
THE HOB
Caution:
• Do not use foil on the hob, as it creates a
fire hazard
• Glass lids may shatter when heated, turn
off all burners before shutting the lid
Do not use aluminium foil to cover the grill
pan, or put items wrapped in foil under the
grill as this can create a fire hazard.
• Note: When positioning the pan support,
ensure that the fingers are central to the
burners (Fig 1).
Do not use the oven with the door inner glass
panel removed (glass oven doors only).
Always use the most appropriate size of
burner for the pan you wish to use. Use
pans with a flat base of minimum 100mm/4
ins diameter, and maximum 200mm/8 ins
diameter, which are stable in use. Avoid old
or misshapen pans as these may cause
instability.
If the cooker has a storage compartment
below the oven, this should only be used to
store oven furniture. Do not store any
flammable materials in this compartment.
When cooking with fat or oil, never leave
unattended.
81
Fitted Equipment
ELECTRIC HOTPLATES
Before using for the first time, prime the
hotplate - switch it on without a pan to
harden and burn off the coating. Use a
medium-high setting for 3 - 5 minutes. A
non-toxic smoke may occur.
To switch on, turn the hotplate control knob
to the required setting.
Stoves Hob
The high speed hotplate ring (if fitted) is
identified by its central red spot - this ring
has a faster response time.
To light the grill
Push in the control knob and turn
anticlockwise to the large flame symbol.
Keep the knob depressed, and press the
ignition button (if fitted), or use a hand held
spark ignitor or gas lighter. The knob must
be held in for 15-20 seconds before
releasing.
Using the grill
Push in the grill pan until it locates centrally
under the grill burner
Important: Any spillage of liquid should be
cleaned away immediately to reduce the risk
of fluid entering the appliance.
82
• Keep all flammable material away from the
appliance.
Detachable grill handle (if supplied)
Place the handle (shield uppermost) over the
edge of the grill pan at the recess and slide
along to position centrally between the two
locator bumps. To remove the handle, place
the grill pan down, and lift the handle slightly
as you slide it along the recess.
Stoves Hob
Ignition - Push in the control knob and turn
anticlockwise to the large flame symbol.
Keep the knob depressed, and press the
ignition button (if fitted), or use a hand held
spark ignitor or gas lighter. The knob must
be held in for 15-20 seconds before releasing.
children should be kept away.
• Never cover the grill pan or grid with
cooking foil, or allow fat to build up in the
grill pan as this creates a fire hazard.
THE GRILL
There are three different grilling positions as
the trivet can be inverted to give a high or
low position or it may be removed.
• Note: The door must be open when the
grill is used.
1. The high trivet position is suitable for
toasting bread.
• Caution: When the grill is being used,
accessible parts may be hot; young
2. The low trivet position is suitable for
grilling all types of meat.
Fitted Equipment
3. With the trivet removed the food is placed
directly on the base of the grill pan, eg;
when cooking dishes such as whole fish.
Always preheat the grill for 3 minutes for
best results.
When you have finished grilling, check the
control knob is in the off position
THE OVEN
Caution: When you are cooking, keep
children away from the vicinity of the
oven.
• Important: A safety device stops the
ignition being used when the oven door is
closed.
• Do no use foil on the oven shelves as this
creates a fire hazard, and can hinder
circulation of heat.
• Keep all flammable material away from
the appliance.
To light the oven
1. Open the oven door and turn the control
knob anticlockwise to the required gas
mark. Push in and hold in the control
knob, and either press the ignition button
(if fitted) or use a hand held spark ignitor
or gas lighter.
2. Once the burner has lit, close the oven
door and hold the knob in for 15-20
seconds.
3. If the flame goes out, the flame sensing
device cuts off the gas supply to the
burner. To light the oven again, wait for 3
minutes then repeat the above procedure.
To turn off - Push in the control knob and
turn clockwise.
Preheating
The oven must be preheated for 10 minutes
when reheating frozen or chilled food, and
we recommend preheating for all yeast
mixtures, batters, soufflés and whisked
sponges.
Using the oven
The shelf positions in the oven can be
altered. If you prefer darker cooked results,
cook on a higher shelf. For paler results use
a lower shelf.
The cake tray and roasting tin that are
supplied with this appliance are the largest
which can be used for good results and even
baking. Extra shelves, tins or trays can be
ordered from your supplier.
Place food items on the tray and position the
tray on the centre of the shelf, leaving one
clear shelf position between shelves to allow
for circulation of air.
83
Fitted Equipment
CLEANING
Caution: Any cleaning agent used
incorrectly may damage the appliance.
Always let the appliance cool before
cleaning.
Some cooking operations generate a
considerable amount of grease. This
combined with spillage can become a hazard
if allowed to accumulate on the appliance
through lack of cleaning. In extreme cases
this may amount to misuse of the appliance
and could invalidate your guarantee.
Clean with a mild cream cleaner eg; Jif, or
use a moist soapy Brillo pad.
Note: Fixed burners (if fitted): Some versions
incorporate fixed burners. These burners are
secured to the hob with 2 screws. Fixed
burners must be cleaned whilst in position.
Make sure that the gap between the burner
and the hotplate does not become blocked
with grease.
Glass parts (if fitted)
DOOR PANELS, FACIA PANEL,
HOTPLATE LID
Fig. 1 Chrome Plated Parts
Do not use caustic pastes, abrasive cleaning
powders, coarse wire wool or any hard
implements as they will damage the surfaces.
Do not use abrasive cleaners or polishes.
Use a mild cream cleaner, eg; Jif. Rinse
thoroughly and dry with a soft cloth.
Use a mild cream cleaner. Look for one that
has the Vitreous Enamel Council's
recommendation seal, eg; Jif.
All parts of the appliance can be safely
cleaned with a cloth wrung out in hot soapy
water.
The inner door glass panel can be removed
for cleaning; open the door wide, hold the
bottom and top edges and slide out. When
replacing the glass panel, hold it level and
straight with the grooves in the door trims
before sliding back in.
Chrome plated parts (Fig 1)
Burner caps and heads
Important: Allow burners to cool before
cleaning.
Caution: Hotplate burners can be damaged
by soaking, automatic dishwashers (or
dishwater powders/liquids), caustic pastes,
hard implements, coarse wire wool and
abrasive cleaning pastes.
For the burners to work safely, the slots in
the burner head, where the flames burn,
need to be kept clear of deposit. Clean with
a nylon brush, rinse and dry thoroughly.
84
GRILL GRID, SHELVES, SHELF RUNNERS
Painted, plastic and gold coloured parts
Do no use abrasives or polishes. Use a
moist soap pad, eg; Brillo. Shelf runners can
be removed for cleaning. Grasp the runners
and slide out of the hanging holes as shown
in fig 1.
DOOR FRAME & HANDLES, CONTROL
KNOBS
Stainless steel surfaces
(stainless steel models only)
Only use a clean cloth wrung out in hot
soapy water.
Only use a clean cloth wrung out in hop
soapy water, and dry with a soft cloth. Do
not use undiluted bleach or any products
containing chlorides as they can permanently
damage the steel.
Vitreous enamel parts
GRILL PAN, HEATGUARD, OVEN/GRILL
COMPARTMENT(S), HOB SPILLAGE WELL,
PAN SUPPORTS
Some foods are corrosive, eg; vinegar, fruit
Fitted Equipment
juices and salt, and they can mark or
damage stainless steel if they are left on the
surface for any length of time. Wipe any
spillage immediately.
Sharp objects can mark the surface of
stainless steel but will become less
noticeable with time.
Electric hotplates
Important: Ensure that elements are
switched off and cool before cleaning
For normal cleaning use a clean damp cloth.
For heavy cleaning, use a clean damp cloth
or scouring pad with a cream cleaner.
Follow the circular grooved pattern on the
hotplate. Rinse off any cleansing agent
thoroughly, then switch on to a low-medium
setting for few minutes to dry. When cleaning
take care to avoid the red dot on the high
speed hotplate (if fitted).
THETFORD CASSETTE
PORTA POTTI
INTRODUCTION
The Cassette Porta Potti is constructed of
high quality plastics for durability and has a
high gloss finish that is easy to clean and
maintain. The unit consists of two sections, a
permanently installed toilet system and a
slide out waste holding tank — CASSETTE.
The toilet section includes a seat and cover,
flush and valve blade opener knob, toilet
tissue compartment and holder, waste level
indicator, built-in toilet fluid storage
compartment, a drip tray — a drain tube
assembly and a fresh water tank.
The unique Cassette section is located
underneath the toilet and is removed for
emptying from outside the caravan through
an access door. A rotating pour-out spout,
automatic holding tank vent, air release
valve, valve blade, carrying handles and
hand grips are incorporated into the
Cassette.
PREPARING FOR USE
1. Open access door on the side of the
caravan and swing out fresh water fill
funnel.
2. Fill fresh water tank using a hose or
jerrycan until water funnel level reaches
neck. Tank capacity is 15 litres. Aqua
Rinse may be added to improve cleaning
of bowl and flushing of unit.
3. Replace cap. Swing water fill funnel
inward until it touches side of water tank.
Note: 150ml of water will remain in fill
bottle 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 downward
slightly and remove (stop for safety when
Cassette is full).
6. Position tank vertical and swivel pour out
spout upward.
7. Remove cap. Remove deodourant from
storage compartment. Add 100ml of Aqua
Kem or 120ml of Aqua Kem Bio through
pour out spout. Add small amount of
water through spout to cover tank
bottom. Replace cap and return pour out
spout to its original stored position.
Note: As an alternative deodourant can be
added to Cassette through the valve blade
opening. Hotter weather or longer retention
time may require addition of more Aqua Kem.
CAUTION: Do not add Aqua Kem
Concentrate or Aqua Kem Bio directly into
toilet bowl while Cassette tank valve blade is
closed. Pressure due to heat and altitude
change can build up in the Cassette tank
causing bowl contents to splash upward
upon opening the valve blade, if opened too
fast. Before each use, open and shut the
Cassette valve blade to vent the tank
85
Fitted Equipment
1
2
8. Slide the Cassette, pour out spout facing
outside into the caravan through access
door. Never force insertion or removal of
the Cassette tank, damage to system can
occur.
9. Make sure the Cassette is secured by the
retaining clip. Close and lock access door.
OPERATION
3
5
7
4
6
Flushing (Electric Models)
10.Before using the toilet we advise to add
some water to the bowl by pressing down
the flush knob. This avoids marking the
bowl. Water will stop flowing when knob
is released.
11.To flush after use, press the flush knob
down while turning in an anti-clockwise
direction. The turning motion opens the
valve blade, emptying the toilet bowl. This
procedure results in the best bowl rinse
and most efficient use of water. After
flushing, turn the knob in a clockwise
direction to close the valve blade. The
toilet can also be used with valve blade
open, which allows the waste to go
directly into the holding tank.
Flushing (Manual Models)
10.Before using the toilet, we advise you to
add some water to the bowl by turning
the flush knob in clockwise direction.
When flush knob is released it will turn
automatically back.
86
11.To flush after use, turn the valve knob in
anti-clockwise direction and turn the flush
knob. This procedure results in the best
bowl rinse and most efficient use of water.
TOILET TISSUE
12.Toilet tissue is stored in the specially
designed storage compartment that helps
keep tissue clean and dry (electric models
only). Tissue can also be suspended on a
tissue holder using the special wall mount
bracket, if desired.
13.To replace tissue, remove tissue holder
from compartment by pulling up on tissue
cover. Hold bottom of tissue holder in one
hand and cover in the other, and turn in
opposite directions until you hear a click.
Pull apart. Place tissue on holder, insert
prongs of cover into holder. Hold cover
and holder and twist in opposite direction
until locked. Aqua Soft toilet tissue is
recommended for best results.
Emptying the Cassette
The Cassette capacity is 20 litres and should
be emptied when the waste level gauge
indicator goes from green to full red.
The gauge does not begin to move from
green to red until the tank is over half full.
Fitted Equipment
8
10 ELECTRIC
11 ELECTRIC
9
10 MANUAL
Caution: Do not allow Cassette to become
overfilled, see Trouble Shooting section for
emergency emptying procedure.
The holding tank features a unique sliding
cover (1) which guarantees optimal hygiene.
The sliding cover moves automatically when
the holding tank is inserted. When holding
tank is removed, the cover automatically
assumes its correct position. To clean the
holding tank, you may remove the cover
manually by sliding it towards the pour-out
spout.
11 MANUAL
To empty Cassette be sure that the valve
blade is in the closed position.
12 ELECTRIC
13 ELECTRIC
14.Open the access door on side of caravan.
Depress the retainer clip, pull Cassette
until stop, tilt and remove Cassette.
15.Carry the Cassette using the lower
carrying handle, pour out spout up, to a
normal household type toilet or other
authorised disposal point. Set Cassette in
vertical position on the ground and rotate
pour out spout upward.
16.Remove spout cap. Grasp unit by upper
carrying handle nearest to pour out spout.
Place other hand on upper rear grip so
that the air relief valve button can be
depressed with thumb while emptying, to
ensure smooth outflow of tank contents.
When empty, rinse tank and valve blade
with water.
Note: Depress air release valve button
only when pour out spout is pointed
downwards.
17.After preparing for use, slide the Cassette
into the caravan. Check to make sure that
the retaining clip secures the tank in a
locked position. The pour out spout end
of the tank should be visible through the
access door opening. Add water to the
fresh water tank as outlined in “Preparing
for Use” section. Close and lock access
door.
CLEANING AND MAINTENANCE
No routine maintenance is required on the
Thetford Cassette Porta Potti. The use of
Aqua Rinse helps to clean and protect the
toilet bowl, valve blade and seals during
flushing. Do not use strong household
detergents or cleaners with chlorine, solvents
or acid contents, as they will damage valve
seals.
Empty Cassette and rinse tank with clear
water. Use a mild soap to clean toilet bowl,
seat and cover, as well as exterior of toilet
87
Fitted Equipment
14
15
04a
06
06
16
04
04b
16
17
18
19 ELECTRIC
C-200 CW only
C-200 CW
only
C-200 CWE only
05
01
02
15
08 07 09 14 12
03
13
11
unit and Cassette. Replace tank inside
caravan.
Note: Pour-out spout and vent plug can be
removed. Seals should be greased if
necessary with acid-free vaseline.
88
14
10
Fitted Equipment
THETFORD CASSETTE
C-200 CW (Manual)
and C-200 CWE (Electric)
FEATURES
1. Removable seat and cover.
2. Rotatable bowl.
3. Valve blade handle: opens and closes
valve blade.
4. Flush-handle activates the flush by lifting
and pushing down the handle.
4a C-200 CWE. Flush button: activates
flush.
4b C-200 CWE. Valve blade buttons: open
and close valve blade electronically.
5. Power-supply for the waste-level
indicator: two batteries, type: Penlite 1,5V
AA alkaline.
6. Waste-level indicator: indicates when
holding tank requires emptying.
7. Rotating pour-out spout: makes emptying
holding tank easy and convenient.
8. Upper carrying handle
9. Automatic holding tank vent: vents the
holding tank when the tank is inserted in
the toilet. This prevents under- or
overpressure in the holding tank.
10. Valve blade opener.
11. Sliding cover: closes automatically when
holding tank is taken out. Guarantees
optimal hygiene.
12. Valve-blade
13. Vent button: vents the holding tank to
avoid splashing while emptying.
14. Hand grip
15. Access door
16. Waterfill door
CASSETTE C-200 CW AND C-200 CWE
The toilet section of the C-200 includes a
rotatable bowl, removable seat and cover, a
console with a flush handle/flush buttons, a
built in flush-watertank and a waste level
warning indicator. Underneath the bowl, the
valve blade handle is located.
PREPARING FOR USE
1. Open access door pull retaining clip
upwards (fig. 1).
2. Remove holding tank by pulling straight
out. When holding tank hits the stop, tilt
front end downwards slightly and remove
(fig. 2).
3. Position tank vertically and swivel pourout spout upwards (fig. 3).
4. Remove the cap of the pour-out spout.
Add required quantity of toilet fluid
through pour-out spout then add approx.
2 litres of water through the spout to
cover holding tank bottom. Replace cap
and return pour-out spout to its original
stored position (fig. 4).
Note: Warmer weather or longer
intervals between emptying the waste
tank may require additional toilet fluid.
Use only Thetford toilet fluid to achieve
the best results.
5. Slide the holding tank into position
through access door (fig. 5).
6. Make sure the holding tank is secured by
the retaining clip. (fig. 6).
7. Open the waterfill door and add 50 ml of
Aqua Rinse. Aqua Rinse results in a
better flush and improves the hygiene of
the toilet. Then fill the watertank with
fresh water using a jerrycan or a hose.
Tank capacity is 7 litres (fig. 7).
OPERATION
8. Turn the bowl in the most comfortable
position (fig. 8)
9. C-200 CW only: Before using the toilet it
is recommended to flush some water
into the bowl by lifting and pressing down
the flush handle (fig. 9).
9a.C-200 CWE only: Before using the toilet
it is recommended to flush some water
into the bowl by pressing and releasing
the flush button (fig. 9a).
7
8
Caution: Never add toilet fluid directly
into toilet bowl.
89
Fitted Equipment
1
2
10. After use open the blade by turning the
blade-handle anti-clockwise (fig. 10).
10a.C-200 CWE only: After use open the
blade by pressing the ‘open’ button
(fig. 10a).
3
4
11. C-200 CW only: To flush, lift the flush
handle and press it down (fig. 11). After
flushing, close the blade by turning the
blade handle clockwise.
11a. C-200 CWE only: To flush press the
flush button (fig. 9a). After flushing, close
the blade by pressing the close button
on panel (fig. 11a).
5
9
6
9a
The toilet may also be used with the
valve blade open, which allows the
waste to pass directly into the holding
tank.
The waste holding tank is located underneath
the toilet and is removed for emptying from
the outside of the vehicle through an access
door. A rotating pour-out spout, automatic
holding tank vent, air release valve, valve
blade, carrying handles and hand grip are
incorporated in the waste holding tank. A
sliding cover guarantees you optimal
hygiene.
EMPTYING THE HOLDING TANK
The holding tank capacity is approx. 17 litres
and the tank should be emptied when the
waste-level indicator lights up. The wastelevel indicator lights up when the holding
tank contains more than 15 litres of waste.
90
CAUTION: Do not allow the holding tank to
become overfilled. See trouble shooting
section for emergency emptying
procedure.
12. Open access door and remove the
holding tank. The holding tank can only
be removed when the valve blade is
closed (fig. 12).
13. Carry the holding tank to a normal
household type toilet or other authorised
disposal point. Place the holding tank in
vertical position and rotate pour-out
spout upwards (fig. 13).
14. Remove the spout cap. Grasp unit by
upper carrying handle nearest to pourout spout. Place other hand on upper
rear hand grip so that vent button can
be depressed with the thumb while
emptying. This ensures a smooth
outflow of the tank contents. (fig. 14).
Note: Only depress the vent button
when pour-out spout is pointed
downwards.
Rinse the holding tank with clean water.
For preparing for use again, see steps 1
to 7.
CLEANING AND MAINTENANCE
The lipseal and the seal of the automatic vent
are made of rubber and therefore these parts
need regular maintenance (depending on
frequency of use, once or twice a month).
Fitted Equipment
10
11
10a
11a
Lipseal: Remove the sliding cover. Open the
valve-blade by turning the blade-opener
knob anti-clockwise. Clean the seal with
water. Dry the seal and grease with silicone
spray/oil or vegetable oil.
Seal of automatic vent: Turn the automatic
vent 60° anti clockwise and remove gently.
Clean the seal with water. Dry the seal and
grease with silicone spray/oil or vegetable
oil.
To clean the holding tank, empty the tank,
and rinse with clean water. Use a mild soap
to clean toilet bowl, seat and cover, as well
as exterior of toilet unit and holding tank.
12
13
NOTE: Do not use strong household
detergents or cleaners that contain chlorine,
solvents or acid contents.
WINTERING/STORAGE
The Thetford Cassette C-200 CW/CWE is
easily winterised for storage.
Empty remaining fresh water into the bowl
by activating the flush handle up and down
(C-200 CW) or by pressing the flush button
(C-200 CWE).
14
15
Once pump has been cleared and water flow
has stopped completely, release into waste
tank. Remove waste tank and empty
contents in normal way.
To evacuate any remaining water from the
fresh water tank. place a container
underneath the drainplug and remove
drainplug.
When procedure has been completed
replace drainplug and waste holding tank
(fig. 15). Clean the seals and grease them
after drying (see cleaning and maintenance).
Leave the blade of the holding tank open. Do
not replace cap on the pour out spout, to
ventilate the holding tank. (Also grease the
seal of the pour out spout cap.)
COLD WEATHER USE
The toilet can be used in cold weather
conditions provided that the toilet is in
heated surroundings. If this is not the case,
you can use a nontoxic antifreeze (propylene
glycol) or an antifreeze such as those used in
car radiators. Add the antifreeze to the water
in the tank. Add the quantity specified in the
instructions, paying due regard to the safety
instructions.
HIGH ALTITUDE AND WARM
WEATHER USE
Pressure may build up in the holding tank if
the tank is not inserted while driving at high
altitudes or in warm weather conditions. The
automatic holding tank vent will vent the
tank when there is over- or under-pressure.
High temperatures may require additional
Thetford toilet fluid.
THETFORD WARRANTY
1. The Thetford Cassette is warranted for
one year from the date of purchase,
please fill in and return the warranty card.
2. The warranty covers replacement of
91
Fitted Equipment
defective or flawed parts and the
inadequate performance of the toilet.
3. In case of a defect apply to an original
dealer or Thetford Service Centre with
proof of purchase.
4. Defects, which in our judgement occurred
from misuse, negligence or accident, are
not covered by the warranty. In addition,
the warranty does not apply if the
product is installed or handled improperly
or if other than the prescribed toilet fluids
have been used or if the product has
been altered in any way or has been
repaired by unqualified persons, or if the
serial number and/or date has been
altered or removed.
5. Should the original buyer wish to return to
us parts believed to be defective, the
parts should be sent prepaid. If we find
the parts defective and covered by
warranty, they will be repaired and
returned. If warranty does not apply or
has expired, a nominal charge will be
made. Any transport costs are for the
account of the owner.
6. Before returning product or parts they
should be properly cleaned, in order to
carry out inspection and repair.
7. No other warranty is given and no
personal representative is authorised to
make any warranty other than that is
contained herein.
92
CARAVANS WITH TV INLET IN
BATTERY BOX
Models equipped with TV points in the
battery box can be attached to a pitch
facility:
1. Connect pitch output to input in battery
box being careful not to trap aerial lead
in battery box door.
2. At aerial booster position disconnect roof
aerial input lead and replace it with the
loose end of the cable from the battery
box. The internal TV point is now
connected to the battery box input.
CARAVANS WITH EXTERNAL
BARBEQUE POINT
Models equipped with an external barbeque
point can be used to power any gas
appliance suitable for the gas and pressure
set by your regulator within the caravan. If
you are in any doubt consult your Dealer for
advice. To use point proceed as follows:
1. Fit male nozzle from despatch kit to your
barbeque or appliance ensuring a gas
tight joint. The work should be carried out
by a competent person; if in any doubt
consult your Dealer.
2. Slide up cover over barbeque point and
remove red protective cover from female
coupling.
3. Insert male nozzle on appliance into
female coupling, push firmly home until
click is felt.
4. Open gas locker door on caravan, ensure
main regulator is on and then turn on
point isolation valve. Gas is now available
at appliance.
5. Light and operate appliance to its
instructions.
6. After use, turn off appliance and turn off
isolation valve.
7. Disconnect appliance by pushing back
outer collar of coupling towards caravan
and pull out male nozzle whilst pushing
back.
8. Replace red protective cover and slide
down cover.
WARNING: Care should be taken when
using the external barbeque point.
Never barbeque next to an awning or
tent.
Fitted Equipment
BEDDING
Sleeping bags and continental quilts can be
compressed into small spaces and can be
ready to use in minutes.
LOWER SINGLE BEDS ASSEMBLY
(Figs. A & B)
1. Unroll bed slat bundle and place between
the recess in both seats.
2. Arrange seat cushions as appropriate.
DOUBLE BED ASSEMBLY
(Fig. C)
Fig. A
Fig. C
1. Grip front of slatted bed and walk
backwards until bed is fully extended.
2. Arrange seat cushions as appropriate.
Fig. B
93
Fitted Equipment
PULLMAN BUNKS
1. Release catches, one at a time.
2. Release press studs on the bed board.
3. Grasp the bunk as shown and pull
carefully in direction of arrows.
4. The bunk is designed to automatically
move into the correct position.
94
5. Where a bed board is fitted, unfold and
make sure it is secured by press studs
when lifted into position. (The bed board
is required to protect both the occupant
and the window from damage during use
of the bunk.)
6. Locate safety boards.
7. Arrange seat cushions as appropriate.
Fitted Equipment
DROP DOWN BUNK
The bunks (if any) fitted to your caravan are
guaranteed to a weight limit of 11 stones
(70 kg).
1. Remove bunk from its stored position
below lockers, taking care to draw out
each side equally thus avoiding damage
to the caravan walls.
2. Locate on bunk supports and unfold,
ensure open bunk is pressed firmly into
position and cannot slide out of bunk
supports.
On caravans with rear side windows fitted
with cassette blinds, care must be taken to
avoid damaging the blind frame. Lower the
bunk bed (unopened) onto the rearmost
section of the bunk support rails, slide the
front of the bunk forward whilst at the same
time unfolding it.
Ensure that your fingers are clear of the front
upstand whilst opening and closing the
bunk.
WARNING: Always ensure safety boards
are located before entering the bunk.
WARNING: Care should be taken
against the risk of falling out when this
bunk is used by children, especially
under 3 years of age.
3. Locate safety boards.
4. Arrange seat cushions to suit.
95
Fitted Equipment
• DO NOT ALLOW THE BLIND OR
FLYSCREEN TO RE-COIL WITHOUT
CONTROL.
• It is not recommended that blinds and/or
flyscreens are left in the down position for
long periods, or when travelling, as this
can result in fatigue of the spring.
• Clean the cassette, side track and fabrics
with mild detergent and water.
• Lubrication of mechanism or spring is not
required or recommended. However, if
components should require cleaning, use
only WD40 or similar with fluff-free cloth.
Other lubricants may result in damage to
fabrics and plastics.
DOUBLE CASSETTE BLINDS
(SEITZ)
Blinds and Flyscreens
Flyscreen and blinds operate in the same
manner. The flyscreen can only be ‘fully up’
or ‘fully’ down, but the blind also has an
intermediate position.
To operate, pull down by holding the
fingergrip(s), gently ease towards the window
to locate the catches. To retract, pull down
easing away from the window to release the
catches and guide to the required position.
• ONLY OPERATE BY HOLDING THE
FINGERGRIP(S) - pulling on one side will
cause uneven running and snagging.
96
Tension Adjustment
Remove plastic cover (if fitted) to locate
tension lugs. The tension lugs have a slot
and are located in the cassette on a
‘bayonet’ principle. Insert screwdriver into
slot (ensure a good fit), turn lug clockwise to
allow the spring tension to push the lugs just
free of the cassette. Keep fingers away from
screwdriver tip to avoid accidental injury.
Spring can now have more or less tension
applied as required.
If in doubt of tension to be applied, release
all tension and re-start. In which case, with
blind fully wound on the roller, apply 12
revolutions of lug (factory setting).
Refitting is a reversal of removal procedure.
For more detailed information, see
manufacturer’s instructions.
DOORSCREEN
When drawing or releasing the doorscreen,
care should be taken not to let it spring back
freely, this may result in damage to the
screen or its fittings.
Always pull the doorscreen close to the
centre. It is not advisable to pull close to the
top or bottom as this will cause snagging
and uneven running.
Caution
When opening or releasing the
doorscreen, care must be taken to avoid
trapping fingers.
Do not allow the doorscreen to slam open.
Fitted Equipment
ROOF LIGHTS
When opening the roof lights, care must be
taken to release the locking mechanism as
the unit is raised.
Roof lights must be fully closed when towing.
Roof lights provide 12,500mm2 of fixed
ventilation each.
WINDOWS
All opening windows have two catch
positions. The first position is for ventilation
the second seals the window from ventilation
and rain.
HEKI-2 ROOF LIGHT (SEITZ)
A cover hood can be fitted for winter
protection.
Omnivents give no fixed ventilation when set
on induction.
The lift/tilt roof light can be set in 3 positions
by means of pneumatic springs.
Heki-2 roof lights provide 13,200mm2 of fixed
ventilation
Position 1 lifts the pane 12mm without
allowing rain to enter the caravan.
THE OMNIVENT (12V) ROOFLIGHT
AIR CONDITIONER (BLIZZARD 1500)
The Electrolux air conditioner is optional and
replaces rooflights or Omnivents.
Position 2 sets the pane to a 150mm opening
and locks with a bar.
Position 3 opens the pane through 55°.
A fully adjustable flyscreen and black-out
screen are built into the inner frame. The
flyscreen can be drawn independently and
the black-out screen is variable for partial or
full black-out.
Forced ventilation functions via a brush lined
duct instead of a ventilated pane.
The Omnivent is a double glazed rooflight
constructed from a synthetic ultra-violet
screened material. Its side operating
mechanism allows a completely free central
opening with built-in fixed ventilation when
closed.
Red Switch = Mode of Operation
Induction (IN)
Expel (OUT)
IN
OFF
OUT
Black Switch = Speed Control
1, 2 and 3
97
Fitted Equipment
THE BLIZZARD 1500 AIR CONDITIONER
WARNING: Never introduce your hands
or other object within the air inlet
openings.
Starting and function selection
Main
Switch
ON-OFF
Position
Position
air conditioner ON
air conditioner OFF
Warm/Cold
Dual Switch
Warm-Cold
Position
Position
fresh air
warm air
Thermostat
Air Temperature
(18°C-40°C)
Fan
Switch
Air Speed
By rotating the knob clockwise, temperature
increases (max 40°C)
By rotating the knob anti-clockwise,
temperature reduces (min 18°C)
Position
Position
high speed
low speed
To set the required temperature adjust the
RED/BLUE selector control knob against the
indicator mark on the outer bezel. Airflow
direction can be achieved fore and aft by
adjustment of the air outlet louvres.
Electrolux
Attention
Never obstruct the air inlets and outlets
The air conditioning compressor runs during
the refrigerating phase, if switched on and off
at once it may get damaged. Therefore, it is
very important to wait at least 3 minutes
before attempting to switch it on again.
98
Maintenance
To ensure trouble free running it is
recommended that the unit be cleaned once
or twice a year.
Never attempt the following until the power is
disconnected and the unit is cool
Remove dust and dirt with a damp cloth (do
not use petrol or solvents).
Check that water trap holes are not clogged.
Periodically open cover and clean filters by
washing with a mild detergent solution and
allow to dry before refitting.
The Blizzard air conditioning unit provides no
fixed ventilation.
ASH FRAMED DOORS
In order to provide customers with the latest
designs of door furniture it is possible, due to
the use of natural wood, that warping may
occur. This should not detract from the
correct functioning of items fitted in the
caravan.
SHOWER
When using the shower, always ensure that
the shower curtain is fully drawn thus
avoiding water spray on unprotected areas.
Fitted Equipment
TABLES
Slide top of drawers out and fold back to
form convenient table. (Fig. A)
The pedestal table can be swung round for
easy access to the seating and then repositioned afterwards. (Fig. B)
Tables stored in the table storage
compartment must be securely clipped into
place whilst in transit.
CAUTION
When erecting the free standing table, be
careful to avoid trapping fingers.
Fig. A
NOT TO SCALE
Fig. B
99
Fitted Equipment
Block - 5” x 17⁄8” (125 x 45mm)
Inner line of
awning channel
DETAIL OF
SWEEP
Block
20mm
Available block
on sweep for
awning bracket
Wheel Arch
POSITION OF AWNING BLOCK
FIXING OF AWNINGS
In order to avoid puncturing the outer skin of
the caravan wall, it is recommended that
awning poles are fixed to your caravan using
load spreading eyelet pads or rubber sucker
pads.
Attaching awning brackets and associated
fixings to your caravan by using mechanical
methods which pierce the outer skin of the
caravan wall can allow water ingress which
will invalidate the product warranty.
Important:
Care must be taken when using an awning
as poles and suckers can cause damage to
exterior side panels.
100
Awnings should be taken down in strong
winds to protect the side panels from
cosmetic damage and dents from the awning
poles.
Note:
Awnings should be kept ventilated when
discharging products of combustion exhaust
into them.
MAINTENANCE
Modifications ........................................................................ 102
Caravan Exterior .................................................................. 102
Caravan Interior .................................................................... 102
Winterisation/Storage .......................................................... 103
Alko Running Gear ............................................................... 105
Assembly and Operation ................................................... 105
Servicing and Cleaning ....................................................... 108
Accessories ........................................................................ 110
General Maintenance ........................................................... 114
Brake Drum/Hub Assembly ................................................ 114
Couplings ........................................................................... 114
Towing Ball ......................................................................... 115
Over-running Device .......................................................... 115
Jockey Wheel ..................................................................... 115
Brake Linkage .....................................................................115
Corner Steadies ................................................................. 115
Braking System .................................................................. 115
Tyre Wear and Damage ....................................................... 115
Wheels ................................................................................... 115
Al-Ko and Vario Galvanised Chassis .................................. 116
Shock Absorbers .................................................................. 116
Maintenance
MODIFICATIONS - DIY WORK
Owners need to be aware that carrying out
DIY modifications to your caravan may in
certain instances, invalidate the warranty
cover and could also affect the safety and
structure of the caravan.
Before carrying out any DIY work within the
warranty period (3/5) years please check with
your nearest Swift Group dealer or contact
Supercare customer services on 01482
875740 for advice.
CARAVAN EXTERIOR
WARNING: Under no circumstances use
any abrasive cleaning agents or solvents
on the exterior panels.
Care should be taken as the silicon in
some polishes can attack the rubber
used on the exterior for seals and
gaskets.
Mouldings
All mouldings are of anodised aluminium and
will retain their lustre for a long period if no
abrasive materials are used to clean them.
Acrylic Windows
The windows in your caravan are fully double
glazed and with care will remain sparkling
and scratch-free.
Aluminium Panels
The stove enamelled paintwork is very
durable and easy to clean owing to the high
gloss properties.
Cleaning: Wash down as you would your
car. Do not use a sponge on dirty windows.
Plastic Panels (GRP/ABS)
These are used for front and rear panels and,
in some cases, for roof and side panels.
When all dirt has been removed, dry with a
leather or ‘Vyleda’ type cloth, the catches
and stays do not require lubricating.
Cleaning
For both aluminium panels and plastic panels.
Keeping your acrylic windows sparkling:
1. Wash the caravan regularly with mild
detergent. Rinse with cold water and
leather off.
Removing Tar
Use ‘Jove Tar Remover’ on our double
glazed windows, it is obtainable from most
leading car accessory or Do-It-Yourself
shops. Do not use petrol or other chemicals.
2. For better protection a similar coloured
good quality car wax may be applied.
When cleaning Sikaflex sealed areas, use
Domestos/water.
102
Condensation
As your caravan is double glazed you may
occasionally get condensation inside the
double glazing. This is particularly so in
severe weather change (usually spring and
autumn) and is easily cured in dry weather.
i) Remove the plastic plugs from interior
top of each window.
ii) Leave unplugged for approximately 1-4
hours until condensation has cleared.
WARNING: Do not wash your caravan
with a high pressure washer as these
can permanently damage the seals of
your caravan.
CARAVAN INTERIOR
Follow these guidelines to ensure your
investment is receiving the very best
attention.
Side Walls, Roof Lining
A simple wipe over with a damp cloth and a
very mild detergent is all that is needed.
Soft Furnishings
Should be vacuumed occasionally to remove
grit and sand and help to keep its smart
appearance and ensure long life. The
upholstery can be cleaned with a mild,
reputable upholstery cleaner. It is
recommended that the curtains and pelmets
are specialist cleaned only. The foam used in
cushions is manufactured to meet fire
regulations. It requires time to return to its
normal position after prolonged use.
Maintenance
Work Surfaces
You should not stand very hot items on any
of the work surfaces, especially models with
polycarbonate moulded sinks and drainers.
change they should revert to their original
positions.
Cupboard Catches
It is advisable to lightly oil all cupboard
catches, sliding bolts and hinges from time
to time.
This is probably an opportune moment to
arrange for the caravan to have its annual
service at your appointed dealer.
Bathroom, Shower Room and Kitchen
Equipment
All the Thermoplastic parts in these areas
have easy clean surfaces. To ensure long life
and prevent damage you must not use any
cleaning materials at all and ensure water
temperatures do not exceed 70°C, (putting
cold water in first is suggested). After every
use it is essential that you rinse with clean
water only and wipe with a soft damp cloth.
Failure to follow these simple instructions
may result in premature failure or cracking
which will not be covered by any guarantees
(including extended warranties).
Furniture
A simple wipe over with a damp cloth should
be all that is required. Polishing with a
proprietary brand of wax polish enhances
and maintains furniture in showroom
condition.
It must be remembered that because the
frames of the doors are made of ash, which
is a natural product, they can be affected by
temperature and humidity and may bow
under certain conditions. As conditions
WINTERISATION/STORAGE
Leave the refrigerator door open.
Leave furniture doors and lockers open to
allow air to circulate fully.
The following applies wherever your caravan
is stored particularly during the winter
months.
Soft Furnishings
Clean and dust the upholstery and if
possible remove before placing the caravan
into winter storage. Alternatively, stand the
cushions on their edges to allow circulation
of air. This will reduce the possibility of
dampness from condensation.
Do not park near trees or larch type fences,
due to possible wind damage.
Keep curtains or blinds closed, to minimise
fading of furniture.
Keep any grass around the floor of the
caravan short, to maintain air flow and stop
any possible damp getting into the caravan.
If the blinds and/or flyscreens remain down
for a prolonged period of time, re-tensioning
of the springs will be necessary before re-use.
It is advised that the caravan is ventilated
regularly throughout the winterisation
/storage period, opening windows, doors
and rooflights when possible.
Wheels and Tyres
Do not store in one position with partially
deflated tyres. The tyre walls will suffer and
do present a real danger of blow outs,
especially when travelling at faster speeds
than are allowed in the UK.
General
All moving parts should be checked for free
operation.
Clean all cooking appliances and refrigerator.
Lubrication should be carried out at the
points illustrated in the general notes on
chassis maintenance (page 98).
Charge up the on-board battery every 2
months.
The wheels should be turned every couple of
weeks or even better, the wheels removed
and the caravan placed on “winter wheels”
or axle stands.
If you are removing the wheels, follow the
jacking procedure for changing a wheel.
Check alarm battery condition every 2
months and charge if necessary.
103
Maintenance
Water System
Ensure water pump is turned off.
Lift kitchen sink unit lid and clip in open
position.
Push up collar (A) to
release and pull plug
(B) down to remove.
B
Add Aqua Kem (100 ml) into the Cassette (or
120 ml if using Aqua Kem Bio) through the
pour out spout. Add small amount of water
through the pour out spout and replace the
cap.
All single lever mixer taps, including the
shower control, should have the lever moved
to the central position and lifted to the open
position for hot and cold.
All conventional taps should be opened.
Remove shower head. Let the shower hose
drain into the shower tray and then return to
holder.
Drain water tanks if fitted:
Internal tanks- open inline valve adjacent to
the tank. Valve is open when handle is inline
with valve.
External underslung tanks - remove drain pipe
from retaining clip and open tap. Allow water
to drain. Clip pipe back in position.
Open system drains. Remove red drain plug
from under the floor of the vehicle (Fig.1) and
place in drawer.
Fig. 1
A
Empty the water fill funnel by pulling the
bottle away from tank. Remove the small
water cap on the filler bottom, allowing water
to drain from the water funnel. (Not C-200
toilet).
Do not tighten caps, this helps in keeping
unit dry.
The pour out spout and vent plug can be
removed. Seals should be greased if
necessary with acid-free vaseline.
Before recommissioning the system reverse all
above actions. (See Taps in Services section)
Recommissioning the Water System
Fill the fresh water tank on the Thetford
Cassette porta potti using a hose or jerrycan
until the water in the funnel reaches the neck.
Tank capacity is 15 litres. Aqua Rinse may be
added to improve cleaning of bowl and
flushing of unit.
104
It is advisable after storage to flush the water
system initially with a sterilising agent (such
as Milton), and then with water repeating until
the system is well flushed through.
Connect the pump.
models only). Pull the lever indicator/drain
tube down from top plug position and
outward through door opening to drain water
from the tank.
Drain water heater. Open yellow handle on
inline valve adjacent to heater. Valve is open
when handle is vertical.
The Thetford Cassette porta potti is easily
winterised for storage. Empty the fresh water
tank using the drain tube/fresh water tank
level indicator (level indicator on electronic
Replace cap. Swing back the water fill funnel
until it touches the water tank.
Fill the system with water until water flows
freely from the hot taps. About 2 gallons of
water will be required. Close the hot taps.
Appliances
Before starting caravanning after storage
check all gas appliances and electrical
points.
Note: Preferably not less than once a year,
the electrical installation should be inspected
and tested by a qualified electrician.
After storage it is advisable to air the caravan
and clean throughout, especially cooking
appliances and the refrigerator.
Replace the bedding and wheels if they were
removed for storage.
Important
Always follow the manufacturers
recommended procedures after use of fitted
equipment in the caravan and before storing
for any length of time.
Maintenance
ALKO RUNNING GEAR
ASSEMBLY AND OPERATING
INSTRUCTIONS FOR AL-KO AKS 2004
STABILISER
PLEASE ENSURE YOU READ THESE
INSTRUCTIONS CAREFULLY, BEFORE
COMMENCING ASSEMBLY OR
OPERATION
Clearances for Stabiliser Handles (Fig 1)
Having lowered the jockey wheel to the
ground, operate the handle as previously
described. Lift the coupling clear of the
towing ball either manually or by
operating the telescopic jockey wheel.
- The area above the towball of the
vehicle must be free from vehicle
components or attachments (A) (eg
spare wheels, platforms etc.)
REGULATIONS
1. The AKS 2004 must be used in
conjunction with 50mm diameter
towballs, which conform to EC Directive
94/20 (DIN 74058 or local equivalent).
- The clearance for the stabiliser handle
must be at least 330mm (B) + the stroke
movement (D) (85mm-100mm), which
equates to 440mm when used in
conjunction with AL-KO overrun.
2. Suitable for attachment to drawbars or
approved overrun braking equipment for
single (and tandem axle) caravan/trailers,
with a minimum weight of 200Kg and a
maximum permissible weight of 2000Kg.
- Max 50mm (C) clearance between the
centre of the towball and top of the
overrun assembly or fairing, to ensure
both coupling handle and stabiliser
handle do not foul on operation.
3. EC design approval has been given to the
AL-KO AKS 2004 coupling under permit
No. e194/20*0930*00.
- Maintain the same clearances for other
manufacturers; overrun assemblies.
RESTRICTIONS OF USE
1. The trailer coupling may only be
connected to towing vehicles where the
clearances for the stabiliser can be
observed, in accordance with EC
Directive 94/20 (DIN 74058). If these
clearances are infringed by special
attachments, then the use must be
checked separately.
Fig. 1
2. Not suitable for use with overrun devices,
which can revolve above 25° (Fig 2).
3. Swan Neck towbars (fixed or detachable)
are suitable for use with the AKS 2004
providing they comply with EC Directive
94/20 and have the required minimum
60mm clearance, measured from the
centre of the towball (Fig 2).
Fig. 2
105
Maintenance
REPLACEMENT PARTS
1. Replacement parts are safety critical and
should parts other than original AL-KO
spares be used, warranty and produce
liability become void.
Fig. 3
Fig. 4
SAFETY WARNINGS
1. In accordance with EC Directive 94/20,
couplings of type A 50-1 cannot be used
(see Fig 3); your warranty will be invalid if
this type of towball is used.
2. For UK use, please use the extended
neck towball (type A50-X) provided with
this kit.
3. A bolted-in type ball coupling (Fig 4) is
only permissible if the thread is locked or
welded.
4. The AKS 2004 cannot be used with a
laterally attached reversing lever, on the
left side, when facing direction of traffic.
5. The towball must be free from grease and
other residue; otherwise the stabilising
effect will be greatly reduced.
6. If friction pads become contaminated
with grease they should be replaced.
106
2. Repairs should only be carried out by
trained and qualified workshop personnel.
A list of AL-KO Approved Service Centres
is available upon request.
3. Always quote the FTI number printed on
this product when enquiring about spare
parts.
Coupling
Pull the coupling handle (Fig 5/Item 1) up in
the direction of arrow. The coupling
mechanism has an open position ie. as long
as the AKS 2004 is not placed on the ball,
the handle will remain open. Put the opened
coupling onto the clean towball. The handle
must now make an audible click and return
to the flat position.
Fig. 5
WARNING: The coupling is correctly
engaged when the green edge of the safety
indicator button is visible (Fig 6/Item 3).
Stabiliser Unit
To operate the Stabiliser (once coupled to
the towball), simply press the stabiliser lever
down as far as it will go (Fig 6/Item 2).
Fig. 6
Maintenance
Uncoupling
Pull the stabiliser lever handle up as far as it
will go, open the coupling handle and lift the
AKS 2004 from the towball. With larger nose
loads, coupling and uncoupling can be made
easier by using the jockey wheel to assist
lifting.
PLEASE NOTE: The friction pads (Fig
7/1,2,3) are pressed against the towball and
hence generate a stabilising/damping force.
These pads are therefore subject to wear
over time, however they will have a long
service life (circa. 30,000 miles) provided
they are well maintained and kept free of
grease/dirt.
Checking the efficiency of the left/right
friction pads
5. The arrow on the arm should lie between
the marked area on the soft dock (See B).
1. Couple up AKS 2004.
6. If the arrow on the plate reaches or
passes the marked area on the soft dock
then the friction pads need replacing (See
C).
2. Open Stabiliser lever (Fig 8/Item 1).
3. Close Stabiliser lever until resistance is
felt (ie friction pads are in contact with the
ball but not yet under pressure).
4. If the arrow on the arm (Fig 8/Item 4) is
before or on the marked area (Fig 15/Item
2) the friction pads are still as new
(See A).
PLEASE NOTE: It is not necessary to adjust
the friction pads.
OPERATION
Manoeuvring
For easier manoeuvring (on campsites etc),
pull the stabiliser lever to the 'up' position.
Please do not use the stabiliser lever as a
manoeuvring handle. Please use the
handles on the caravan or fit the AL-KO
manoeuvring handle to your jockey wheel
(available separately).
1. During opening or closing, the AKS must
only be operated by one person.
2. Press stabiliser lever down by hand force
only, DO NOT use your foot or an
extension bar, this will damage the
components (Fig 9).
3. When opening or closing the stabiliser
lever, please ensure your hand does not
touch the coupling handle - you may
accidentally trap your fingers! (Fig 9).
Fig. 7
Fig. 8
107
Maintenance
b. Lubricate the drawshaft sleeve via the
grease nipples. In addition, push the
gaiter forward and grease (DIN 51 824
KTA 3K) the exposed part of the shaft (Fig
10).
c. Visit a specialist workshop to have the
ball holding area checked for damage
and the locking mechanism for function.
If necessary, change the towball.
SERVICING AND CLEANING
Friction Pad Replacement
(please replace one at a time)
Fig. 10
Noises whilst driving
As a rule, the friction pads of the AKS 2004
do not make a noise during driving. Any
clicking, creaking or squeaking noises that
do arise may be due to the following:
Fig. 9
108
1. Uncouple AKS 2004.
2. Remove protective caps (Fig 11/Item 1)
with the aid of a small screwdriver.
3. Press worn out pad inwards and remove
(use punch and hammer) (Fig 11/2).
a. Foreign bodies or dirt between the friction
pad and towball.
4. Insert new friction pad from below (after
first re-inserting shim washers if they
were present) and press in as far as it will
go (Fig 11/Item 4 & Fig 11a).
b. Dry operation of the drawshaft inside the
overrun device.
Checking the efficiency of the front/rear
friction pads
c. A detachable towball which has too much
play in the locking mechanism.
1. Couple the AKS 2004 to the towball but
do not activate the stabiliser.
Remedial Action:
2. If a green indicator is visible (on the
handle), then the AKS 2004 is in a new
condition or the pads and towball are
within the permissible limits (Fig 12/Item
2).
a. Clean the towball and friction pads by
lightly rubbing the surface (100-120 grit
emery paper).
Maintenance
3. If only a red indicator is visible (Fig
13/Item 3), then this may have the
following causes:
a. AKS 2004 is okay but the towball has
reached the lowest limit of 49mm
9. Fitment of new linings takes place in
reverse. Tighten screws 3/4 to 5 Nm.
10.Replace rubber soft dock, insert top
section first then bottom.
b. AKS 2004 shows signs of wear
c. Towball is in a new condition (50mm)
but the front/rear friction pads show a
high degree of wear.
Establish the diameter of the towball so that
conclusions may be drawn as to the wear of
the friction pads (ball diameter must not be
less than 49mm).
Friction Pad Replacement
(Front/Rear only)
1. Uncouple the AKS 2004.
Fig. 14
2. Remove the rubber soft dock (pull up and
off - Fig 14/Item 1 & Fig 14a).
3. Press the safety indicator outwards and
secure with SW14 hex. spanner (not
included) (Fig 14/Item 2).
Fig. 11
4. Remove cheese-head screws (Fig 14/Item
3 & Fig 14a), using special torx tool.
5. Press friction lining recess (Fig 14/Item 4)
inwards and pull down and out.
Fig. 14a
6. Open coupling handle (Fig 14/Item 8).
7. Remove countersunk head cap screw
using special torx tool (Fig 14/Item 5).
Fig. 12
Fig. 13
8. Press friction pad inwards with a
screwdriver and remove the ball cup.
Fig. 14b
109
Maintenance
Important Maintenance and Cleaning
Advice
1. The towball should be cleaned regularly
to remove grease or other residue, the
use of Thinners, White Spirit or Brake
Cleaner is recommended - otherwise the
stabilising effect will be severely reduced.
2. If friction pads are contaminated, they
should not be cleaned but replaced.
3. The surface of the towball must be free of
grooves, rust or seizing marks.
4. Towballs coated (with paint or similar)
must have this surface completely
removed (use 100 or 120 grain emery
paper). If this is not done, increased
towball wear will occur and may cause
damage to the AKS 2004 components.
5. In winter, carefully spray only the visual
indicator with de-icer.
Lubrication
Should lubrication of the stabiliser parts
become necessary, then the following must
be observed:
a. Clean all parts thoroughly
b Areas may only be covered with a thin
film of grease (Fig 15)
c. Use multi purpose grease DIN 51825 KTA
3K
110
Fig. 15
Fig. 16
WARNING: When lubricating, ensure none
gets into the friction pad or towball holding
area.
less stressful, allowing you to enjoy your
stop without the need to 'guard' your
caravan.
AVAILABLE ACCESSORIES
Operation of Al-KO Safety Device
AL-KO Safety Device
1. Pull stabiliser lever to the 'up' position
(Fig 17).
The AKS 2004 can be retrofitted with the ALKO Safety Device (Part No: 1385810). This
security device has full TUV & Sold Secure
Product Approval and is designed to provide
protection against theft of the caravan and
stabiliser device (Fig 16).
This device can also remain fitted to the
caravan whilst the caravan and car are
hitched together. This alleviates the need to
stow the device when travelling as it remains
fitted to the stabiliser and it ensures that
stops, eg at motorway service areas, are
2. Place the AL-KO Safety over the coupling
handle and lower into bracket.
3. Place the key into the lock and turn to the
left and push in (Fig 18).
4. Remove key and swing the dust cover
over the lock to protect against dirt.
5. Push stabiliser lever to 'down' position the device is now operational.
6. Removal takes place in reverse order and
by turning the key to the right.
Maintenance
As the towing vehicle brakes, or starts to
drive downhill, the drawshaft of the overrun
device is depressed toward the unit being
towed. This action imparts linear motion to
the main shaft of the overrunning device
which is transmitted via the overrun lever,
brake rod and Bowden cable to the
expanding clutch. This mechanism forces
the leading brake shoe and, by reaction, the
trailing shoe outwards into contact with the
drum.
Fig. 17
Fig. 19
AL-KO Safety Ball
AL-KO also recommends fitment of the ALKO Safety Ball, this simple plastic ball fits
inside the coupling head (whilst unhitched
from the towball). Used in conjunction with
the AL-KO Safety Device, the Safety Ball is
locked into the coupling area, ensuring the
thief cannot hitch your caravan to a smaller
diameter towball or hook (Fig 19).
The combined use of the AL-KO Safety and
Safety Ball also acts as a very visual theft
deterrent.
Fig. 18
Forward Braking
In the free position, with the handbrake fully
forward in the OFF position, the drawshaft of
the overrun device is fully extended and the
shoes are clear of the drum.
Friction between the brake shoes and the
drum creates a tendency for both shoes and
the expanding clutch to move in the
direction of forward rotation until they abut
against the adjuster box. This ensures that
both remain in the braking position.
Reversing
When the towing vehicle reverses, the
drawshaft is pushed backward, moving the
overrunning device through its full travel.
This movement is transmitted in the normal
manner to the expanding clutch.
The clutch forces both shoes into contact
with the drum. Initial friction between these
creates a tendency for the shoes and
expanding clutch to move in the direction of
wheel rotation i.e. reverse. This movement
imparts pressure to the spring- loaded autoreverse lever, causing it to collapse. Thus,
friction between the shoes and drum is
almost eliminated, allowing the trailer to
reverse as one with the towing vehicle.
111
Maintenance
The AL-KO parking brake system comprises
a handbrake lever mechanism actuating a
Bowden cable which operates a brake unit
assembly contained within the wheel hub.
The action of the brake lever imparts motion
to the brake rod, the Bowden cable and the
expanding clutch. This mechanism forces
both shoes into contact with the drum.
Operating the Handbrake
Some people may find it difficult to set the
handbrake lever to its full vertical position
without a great deal of physical effort.
AL-KO provide two types of parking brake
system on their trailers, with the Bowden
cable and the wheel hub brake unit being
common to both types.
At this stage, the brake unit is latent, the
mechanism waiting to see in which direction
the trailer will start to move.
However, AL-KO have designed their system
so that the average user need not do so.
The difference between the systems is the
handbrake mechanism used to actuate the
Bowden cable.
AL-KO’s unique parking brake system
requires a source of stored energy to lock
the wheel brakes should the trailer start to
move after it has been uncoupled from the
towing unit.
This energy source can be provided by either
a spring cylinder charged by hand or by a
gas filled cylinder acting as an energy store.
Each system requires a slightly different
method of operation when parking the trailer,
though they both operate in the same manner
when forward or reverse braking is applied.
Spring Cylinder Type
A spring system is attached to the link
between the handbrake lever and the central
brake rod. Full application of the handbrake
lever (such that the lever is vertical) to the
last tooth of the ratchet compresses a steel
spring inside the steel cylinder and energy is
stored.
112
If the trailer starts to move backwards, the
stored energy in the spring will be released.
The trailing brake shoe and by reaction, the
leading shoe together with the expanding
clutch will tend to move in the direction of
rotation (reverse) and abut against the stop.
Thus the trailer is braked.
However, if the handbrake is NOT fully
applied to the last tooth (i.e. vertical) and is
set to some lesser position than the full
vertical, then problems will almost certainly
arise after the trailer has been uncoupled
from the towing unit.
If the trailer is parked on a reverse slope or if
it is pushed backwards, then the brake
mechanism will act as though the trailer is
being reversed by the towing unit. The shoes
and expanding clutch will tend to move with
the direction of rotation (reverse) which
imparts pressure to the spring-loaded
reverse lever, causing it to collapse. Thus,
friction between the shoes and the drum is
almost eliminated and the trailer will run
away.
For successful parking on a reverse slope or
steep hill, the operator need only apply the
handbrake with one hand while gently but
purposefully inching the caravan trailer a
small distance backwards with the other.
The user must supply this small but essential
backward movement to ensure that the
fulcrum of the transmission lever moves past
the point of reverse, thus preventing the
lever from collapsing as it would normally do
when reversing.
Most users will find it easier to stand facing
the towing unit while applying the hand
brake and at the same time gently push the
caravan an inch or two backwards with their
posterior.
Gas Cylinder Type
A gas cylinder, acting as an accumulator of
stored energy, can be fitted to the handbrake
lever to provide the same effect as a spring
cylinder.
Maintenance
This system is much more user friendly, as
the handbrake lever need only be applied
until it passes a clearly detectable dead
point for it to render parking on reverse
slopes or steep hills absolutely safe.
All components of both the overrun device
and the wheel brakes must be those
manufactured by AL-KO as the braking and
reversing systems must be matched to
ensure optimum braking performance.
It takes minimal effort from the operator to
move the handbrake lever past this dead
point.
Combining parts manufactured by AL-KO
with those produced by other suppliers will
invalidate any guarantee entered into by
AL-KO.
If the caravan or trailer starts to move when
uncoupled from the towing unit, then the
energy stored in the cylinder is released and
the brakes applied in the normal manner.
Important Points to Remember
It is absolutely vital that the slight backwards
push of the caravan or trailer is applied
before it is uncoupled from the towing unit.
It is also important to check that the brake
has in fact operated correctly as soon as the
caravan has been uncoupled.
If the caravan or trailer is to be parked on a
steep slope or on loose or slippery surfaces,
it is advisable to chock the wheels.
Where possible, always ensure that the
handbrake lever is in the fully vertical
position.
When the handbrake has been applied, it is
possible for the caravan or trailer to roll back
as much as 25cm before the full force of the
brake takes effect.
Recommended Brake Adjustment
Procedure
Jack up the axle raising the road wheels
clear off the ground. Ensure drawshaft is fully
extended (in the towing position) and the
handbrake is in the “OFF” position (fully
forward).
Check that there is some end float in the rod
and spring cylinder.
Adjust brakes first (Fig. A) and the linkage
only if necessary.
IMPORTANT: During Wheel brake
adjustment the drum must only be revolved
in the direction of FORWARD rotation. Do
not use excessive force during adjustment.
Adjust
Adjust
Fig. A Brake Adjustment
be made at the chassis end of the bowden
cable. When pulled the cable should extend
between 5 and 8mm.
Apply the handbrake two or three times to
ensure brake shoes are centralised in the
drum. Re-check the shoe clearance at the
wheel brake.
Wheel brake adjustment is effected through
a hole in the brake backplate (see Fig. A).
With a screwdriver adjust the starwheel in
the direction of the arrow until there is
resistance to wheel movement. Slacken until
the brake drum turns freely in the forward
direction. A check for correct adjustment can
113
Maintenance
GENERAL NOTES ON
MAINTENANCE
1. Brake Drum/Hub Assembly
The EURO AXLE fitted to your caravan
comes complete with maintenance-free
wheel bearings GREASED AND SERVICED
FOR LIFE. Adjustment is not required during
the design life of the sealed bearing
(100,000 km).
WARNING: If replacement of the brake
drum or shoes is required, this must be
carried out by authorised AL-KO Service
Centres.
Centre brake rod. Check full thread
engagement in the fork end of the
overrunning device. Secure locking nut.
Finally screw up the self locking nut to give
1mm clearance between the nut and the
spring cylinder.
If the warning is not observed:
At the axle ensure compensator plate is
parallel to the axle by setting the adjuster
nuts on the bowden cables. Secure lock
nuts.
Note: Reversing will be difficult if either
wheel brake or brake linkage is
overadjusted.
Any attempt to slacken the nuts on the stub
axle will result in the toe-in being adjusted.
Adjust centre brake rod at the rear nut so
there is no clearance between the overrun
lever and the drawshaft and plate. Secure
lock nuts.
Correct adjustment of the linkage can be
checked by engaging handbrake lever on the
second tooth of the ratchet segment. In this
position you should feel a slight braking
force at the wheels.
114
-
the warranty is void and
the wheel may become detached.
This will cause:
-
Loss of guarantee
Bad towing performance
Increased tyre wear
2. Couplings
1. Clean and grease spherical seat, bearing
parts and pivot pins regularly.
2. Thoroughly examine all moving parts for
wear and correct functioning.
3. Couplings should never be drilled.
Maintenance
3. Towing Ball
The automobile towing ball should measure
50mm maximum and 49.5mm minimum (DIN
74058). If the ball is found to be worn it
should be replaced immediately.
4. Overrunning Device
The device housing is packed with grease on
assembly, but will require periodic
maintenance to ensure smooth operation of
the braking system.
1. Regrease the shaft bearings via the
grease nipples provided at 3000 mile
intervals, and before storage.
2. Ensure correct functioning of all pivot
pins and levers and oil regularly.
3. Ensure correct functioning of handbrake
ratchet and oil regularly.
5. Jockey Wheel
Lubricate wheel and screw thread
periodically.
6. Brake Linkage
All moving parts should be lubricated
periodically to ensure their satisfactory
operation.
It is recommended that all brake linkage
threads are liberally smeared with grease for
protection and as an aid to future adjustment
of the system.
7. Corner Steadies
The screw and pivot pins should be
lubricated periodically to ensure their
satisfactory operation.
TYRE WEAR AND DAMAGE
8. Braking System
At 500 miles then every 3000 miles or 1 year
check and adjust brake linkage to
compensate for any stretch of the bowden
cables.
In order to equalise wear it is suggested that
the wheels be balanced and changed around
from time to time.
Check and adjust wheel brakes to
compensate for wear.
IMPORTANT
When replacing the wheels you should
tighten the nuts in rotation diagonally, taking
care to tighten them equally.
The recommended torque for steel wheels is
88Nm (65 lb/ft) and for alloy wheels 115Nm
(85 lb/ft).
CHECK THE WHEEL NUTS BEFORE
STARTING EVERY JOURNEY.
The legal requirement for tread depth on
motor vehicles also apply to caravans.
It is dangerous to neglect tyre damage and
should you detect a blister, a rupture or a cut
which exposes the casing or if it has
suffered a violent impact (for example
against a kerb) such that there is a risk of
internal damage, it is advisable to have it
examined by a tyre specialist as soon as
possible (as this can affect tracking).
Tyres should be inspected regularly and if
any signs of visible deterioration (sidewall
cracking, delamination of tread, etc) are
evident, they should be replaced regardless
of there being a legal minimum tread depth.
WHEELS
The condition of the wheels should be
checked regularly, particularly for distortion
of flanges and the wheel dish. Wheels which
are damaged or distorted, or having wheel
stud seatings cracked or deformed, must not
be repaired.
115
Maintenance
ALKO AND VARIO GALVANISED
CHASSIS
Lubrication points are
same for all chassis
Al-Ko Chassis
Hot dip galvanising offers high corrosion
protection by forming a barrier layer through
reaction with the atmosphere. This will be
apparent by the chassis members changing to a
light grey colour. During winter periods or
storage where there is insufficient air circulation
or heavy moisture, a soft porous, light grey
oxidisation layer may form. This is known as
‘White Rust’ and should NOT be confused with
rust. As applied to steel these deposits should
be removed by use of a wire or hard nylon brush.
SHOCK ABSORBERS (OPTIONAL)
The Euro Axle fitted to the caravan is capable of
being equipped with octagon shock absorbers
specially developed by AL-KO to ensure
optimum roadholding of your caravan. They are
designed to reduce even the slightest
suspension rebound and make towing safer and
more comfortable.
Vario Chassis
116
GENERAL
DATA
Fault Finding ......................................................................... 118
Water .................................................................................. 118
Gas ..................................................................................... 120
Cassette Toilet .................................................................... 121
Useful Information ............................................................... 122
Owners Club ...................................................................... 122
Spares and After Sales ...................................................... 122
Repair Facilities .................................................................. 122
Factory Tours ..................................................................... 122
Caravan Clubs......................................................................123
Motoring Associations .........................................................123
Trade Association.................................................................123
CRIS .....................................................................................123
Fault Finding
WATER
Problem
Possible Cause
Remedy
Water not flowing from
any tap when operated
but pump runs
Freshwater tank empty
Pump wired in reverse
Pump not primed
Pipe inlet or outlet pipe disconnected
Pump pipes restricted by kinking
Blockage in pump inlet or outlet pipe
Blocked in-line filter of pump filter
Air leak in suction line to pump
Check
Check wiring, refer to pump manufacturers instructions
Refer to pump manufacturers instructions
Check connections
Check pipes run
Check, starting inside freshwater tank
Dismantle and clean
Check for bubbles & secure with clip
Pump does not run
Pump or tap incorrectly wired
Pump fuse blown
Battery disconnected
Pump seized or overheated
Pressure pump sensing switch may have failed
Contacts may be faulty
Wiring connections may be faulty
On switched tap version, microswitch could be faulty
Refer to pump/tap manufacturers instructions
Check wiring connection and then replace with fuse of correct rating
Check connections
Refer to pump manufacturers servicing instructions
Refer to pump manufacturers servicing instructions
Check contacts in plug and socket are clean and making contact
Check wiring connections
Disconnect wires from microswitch and join together. If the pump
operates, microswitch should be replaced
Water flows from cold tap
but not from hot
Feed pipe to water heater incorrectly connected to
the heater outlet
Blockage in hot pipeline
Heater inlet or outlet pipes kinked preventing flow
Refer to installation instructions
Hot tap not connected
Hot tap failed or blocked
Heater non-return valve jammed
118
Disconnect pipes and inspect
Check and re-route if necessary. Ensure that hose is Carver
recommended type
Refer to installation manual
Disconnect and inspect
Seek service attention
Fault Finding
WATER
(continued)
Problem
Possible Cause
Remedy
Water flows from hot tap
but has reduced flow from
cold
Cold water pipe kinked preventing flow
Blockage in cold pipe line
Cold tap not connected
Cold tap failed or blocked
If a water filter is fitted, the cartridge is exhausted
Check and re-route if necessary
Disconnect pipes after 1st Y connector and check up to tap
Refer to installation instructions
Disconnect and inspect
Replace cartridge
Reduced flow from both
hot and cold taps
Battery condition low causing pump to run slowly
If new taps have been fitted they may be restricting flow
Pump needs servicing
Partially blocked pump filter or in-line filter, if fitted
Pump outlet pipe kinked restricting flow
Water leak
Check battery state of charge, refer to electrical supply note
Disconnect and check that they have at least 1/4" (6.3mm) bore
Refer to pump servicing instructions
Dismantle and clean if necessary
Check and re-route if necessary
Check all water connections
Reduced flow from
either tap
Y’ connector(s) fitted incorrectly
Pipe kinking restricting flow
Bore size difference in taps
Refer to installation instructions
Check and re-route if necessary
Use taps of equal bore size
Warm water flows out of
cold tap
Hot water back-feeding into cold line, usually if mixer
tap or single outlet hot and cold taps being used
Fit non-return valve in cold supply, near tap
If pump motor runs
steadily and will not stop
Battery voltage may be too low (below 10.5 volts)
Check that there is water in the container
Adjust switch and/or re-charge battery
Check all connections in pipework
119
Fault Finding
GAS
Problem
Possible Cause
Remedy
Hob does not light
No gas
Check level of gas in bottle
Check gas bottle valve is on
Check gas taps are on
Purge system
Refer to hob manufacturers instructions
Air in pipe
Oven does not light
No gas
Air in pipe
Space heater or central
heating
No gas
Over gassed
Air in pipe
Fridge does not light
No gas
Air in pipe
Water heater does not
light
No gas
Air in pipe
120
Check level of gas in bottle
Check gas bottle valve is on
Check gas taps are on
Purge system
Refer to oven manufacturers instructions
Check level of gas in bottle
Check gas bottle valve is on
Check gas taps are on
Check exhaust outlet is clear
Turn off appliance, wait 2 minutes and try again
Purge system
Refer to space heater or central heating boiler manufacturers instructions
Check level of gas in bottle
Check gas bottle valve is on
Check gas taps are on
Purge system
Refer to fridge manufacturers instructions
Check level of gas in bottle
Check gas bottle valve is on
Check gas taps are on
Purge system
Refer to water heater manufacturers instructions
Fault Finding
CASSETTE TOILET
Problem
Remedy
Bowl does not drain when
toilet is flushed.
Cassette is overfilled
DO NOT REMOVE CASSETTE. While inside the caravan turn flush knob anti-clockwise to open valve blade and
leave 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 removed
following the normal removal and emptying procedure.
Odours
Use proper amount of holding tank deodourant specified on bottle.
Toilet tissue does not fit
into compartment.
Since some tissues are supplied on larger rolls, it may be necessary to use some tissue before storing into compartment.
Soiled bowl after flushing
Partially fill bowl to cover soiled portion of bowl. Next flush will dissolve waste. Tip: Leave valve blade open during use.
No power to add water to
toilet bowl
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-clockwise
to open valve blade. Turn clockwise to close valve blade.
Cassette cannot be
removed
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 insertion
or removal of the cassette tank.
Valve blade mechanism
sticks or is hard to open
Spray light film of silicone on blade.
Major unit malfunction
Contact your original Caravan Dealer.
121
Useful Information
OWNERS CLUB
The Owners Club is a completely
independent organisation run for the benefit
of the caravan owners. They have numerous
rallies during the year in various parts of the
country and every third year there is a
‘Works Rally’ where owners have the
opportunity to visit the factory. Apart from
the friendliness and companionship the Club
generates it is also actively engaged in
charity work for those less fortunate than
ourselves. The address of the Secretary of
the Owners Club can be obtained from
Supercare (SML Ltd), Tel: 01482 875740.
SPARES AND AFTER SALES
SUPERCARE (SML LTD)
There are numerous items available from
your dealer ranging from door catches
through to spare wheels and touch-up
paints. Please note that all after sales
enquiries must be directed through your
supplying dealer. The after sales service at
the factory is geared to support our dealer
network as is the service provided by
appliance manufacturers.
In the interest of safety, replacement parts
for an appliance shall conform to the
appliance manufacturers specifications and
should be fitted by them or their authorised
agents.
122
Note: Please remember to quote chassis
number when ordering any items from your
dealer.
Customer Care
Tel: 01482 875740
Fax: 01482 840861
NOTE:
The times for contacting Customer Care by
telephone are:
9am to 4pm Monday to Thursday.
9am to 12.45pm Friday.
Swift Group Website
www.swiftleisure.co.uk
Swift Group E-Mail Enquiry
[email protected]
REPAIR FACILITIES
Should you be unfortunate enough to suffer
a major accident with your caravan it is
comforting to know that we have a
completely separate repair shop facility
where their fully trained experts will under
take all types of major damage repair work.
Repairs of a minor nature should be referred
first to your local dealer.
Useful Information
The enjoyment of caravanning can be
greatly enhanced by membership of one or
more of the various caravanning, motoring
and holiday clubs. Here are some useful
addresses:
CARAVAN CLUBS
MOTORING ASSOCIATIONS
TRADE ASSOCIATION
The Caravan Club,
East Grinstead House,
East Grinstead
West Sussex, RH19 IUA
Tel: 01342 326944
Automobile Association (AA)
Fanum House,
Basingstoke,
Hants. RG1 2EA
Tel: 0990 448866
www.theaa.co.uk
e-mail: [email protected]
National Caravan Council
Catherine House,
Victoria Road,
Aldershot,
Hampshire, GU11 1SS
Tel: 01252 318251
www.martex.co.uk/ncc
e-mail: [email protected]
The Camping and Caravanning Club,
Greenfields House,
Westwood Way,
Coventry,
West Midlands.
Tel: 01203 694995
RAC Motoring Services
RAC House,
M1 Cross,
Brent Terrace,
London, NW2 1BX
Tel: 0990 722722
Green Flag National Breakdown
PO Box 300,
1, Cote Lane,
Leeds, LS99 2LZ
Tel: 0345 670345
CRIS
HPI Equifax
Dolphin House,
New Street,
Salisbury,
Wiltshire SP1 2TB
Tel: 01722 411430/422422
Swift Group Limited
Dunswell Road, Cottingham,
East Yorkshire HU16 4JX
Tel: (01482) 875740
e-mail: [email protected]
web site: www.swiftleisure.co.uk
© 2000 SWIFT GROUP LTD
123
Index
A
Air Conditioning...............................97
Alarm System ..................................45
Alde Heating System.......................56
AL-KO Running Gear.....................105
Accessories................................110
Assembly and Operation ...........105
Braking .......................................111
Chassis.......................................116
Coupling/Uncoupling .................104
Maintenance...............................114
Reversing ...................................111
Servicing and Cleaning ..............108
Shock Absorbers .......................116
Arrival on Site ..................................15
Ash Framed Doors ..........................98
Awnings .........................................100
B
Barbeque Point................................92
Battery .............................................44
Beds ................................................93
Blinds...............................................96
Blizzard Air Conditioner...................97
Brake Linkage................................115
Braking System .............................115
Breakaway Cable ............................12
C
Caravan Clubs ...............................123
Caravan Terms...................................2
Cassette Toilets ...............................85
Central Heating................................55
Chassis Number ..............................20
Children ...........................................19
Clubs .............................................123
Corner Steadies ..................10/15/115
CRIS ..............................................123
D
E
126
Modifications/DIY.......................102
Winterisation/Storage.................103
Mirrors .............................................13
Motoring Associations...................123
Motorway Driving ............................14
12V ...............................................47
Electrical Supply Module ...........40/42
Escape Paths ..................................19
F
G
H
Fault Finding..................................118
Cassette Toilet............................121
Gas.............................................120
Water ..........................................118
Fire ..................................................18
Fire Extinguisher ..............................19
Flyscreens........................................96
Fumes..............................................20
Fuses (DC) .......................................43
Fuses (road lights) ...........................41
Gas Supply ......................................30
Butane..........................................32
Connection...................................33
Fault Finding ..............................120
Flue Installations ..........................33
Gas Bottles ..................................30
Hoses ...........................................32
Precautions ..................................32
Propane........................................32
Regulator......................................31
Safety Advice ...............................32
Ventilation.....................................33
Generator Guidelines.......................44
Glossary and Checklist .....................4
Grill ..................................................82
N
O
Distribution Panel ............................39
Doorscreen ......................................96
Driving Licence ..................................4
Drop Down Bunk .............................95
I
J
Inboard Water Tanks........................24
Electrical Control Module ................41
Electricity Supply.............................33
Arrival on Site...............................33
Generator .....................................44
Mains Inlet Cable .........................36
Overseas Connections.................35
L
Levelling...........................................15
Loading and Distribution of Weight...7
M
Maintenance ..................................101
Exterior .......................................102
Interior ........................................102
Noseweight........................................4
Omnivent Rooflight..........................97
Oven ................................................83
Overseas Electrical Connections ....35
Owners Club..................................122
P
Passengers ......................................12
Preparing for the Road ......................7
Loading & Distribution of Weight ...7
Other Considerations .....................9
Pre-load Checklist..........................7
Pre-tow Checklist and
Hitch Up....................................10
Stability ..........................................8
Towing Vehicle - Rear
Suspension .................................8
Power Modular Systems .................38
Pulling Off ........................................13
Pullman Bunks.................................94
R
Refrigerators ....................................65
Absorber.......................................72
RM4270........................................65
RM4271........................................66
RM4501........................................67
RM6270, RM6271 & RM6291 ......68
Use and maintenance ..................69
Travel Catch .................................72
Repair Facilities .............................122
Reversing.........................................13
Road Lighting ..................................12
Rooflights ........................................97
Reich 'Kama' Taps...........................26
Reich 'Twist' Taps............................25
Habitation Relay ..............................44
Handling ..........................................13
Heating ............................................53
Heki Rooflight ..................................97
Hob ..................................................81
Hotplates .........................................82
Jacking Points .................................14
Jockey Wheel ................................115
S
Shock Absorbers...........................116
Shower ............................................98
Smoke Alarm ...................................18
Space Heaters.................................53
Spares and After Sales..................122
Speed Limits....................................13
Stability..............................................8
Stopping on a Hill............................15
Stoves Hobs, Grills and Ovens .......81
Safety and Security .........................17
Security............................................20
Services ...........................................21
Electricity......................................33
Gas...............................................30
Water ............................................22
T
Tables ..............................................99
Taps .................................................25
Thermal Insulation ...........................33
Thermostat ......................................63
Thetford Absorber Refrigerator .......72
Thetford Cassette Porta Potti .........85
Thetford Cassette C-200.................89
Towing Code......................................2
Towing Vehicle Terms ........................3
Trade Associations ........................123
Transformer/Charger Unit ................41
Truma Compact Crystal 2 ...............23
Truma Space Heaters......................53
Truma Ultraheat Heating .................55
Truma Ultrastore Water Heater........50
Truma Waterline...............................24
TV Inlet.............................................92
Tyres ..............................................115
V
W
Ventilation ........................................19
Water
Heater...........................................50
Pumps ..........................................50
Tanks and Systems ......................24
Weights..............................................2
Whale ‘Elite’ Microswitch Taps........28
Whale 'Elegance' Microswitch
Mixer Taps....................................27
Wheels ...........................................115
Changing......................................14
Rims .............................................10
Torque .......................................9/14
Windows..........................................97
Winter Maintenance
and Storage ...............................103
Quality with Style
Swift Caravans, Dunswell Road, Cottingham, East Yorkshire HU16 4JX. Tel: 01482 875740 Fax: 01482 840082
e-mail: [email protected] website: www.swiftcaravans.co.uk
Issued September 2002
1048547
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