elddis XPLORE, Xplore 2015 Owner's Handbook Manual
Touring Caravan
OWNERS
HANDBOOK
Issue 1
CONTENTS
WELCOME AND INTRODUCTION ........ 1-1
Model Year Designation .......................... 1-1
Xplore Technical Approvals ..................... 1-1
GENERAL SAFETY ............................... 2-1
Please read before using your new
caravan. .................................................. 2-1
Ventilation ............................................... 2-2
High-Level Ventilation ............................. 2-2
Low-Level Ventilation .............................. 2-2
Ventilation in Separate Bedrooms........... 2-2
Gas Dispersal Holes ............................... 2-2
Petrol/Diesel Fumes ................................ 2-2
Fire Safety ............................................... 2-2
Fire Extinguishers ................................... 2-2
In Case Of Fire ........................................ 2-2
Fire Retardant Foams ............................. 2-2
Escape Paths .......................................... 2-2
Your Caravan Payload Explained ........... 2-3
PREPARING FOR THE ROAD............... 3-1
Caravan Towing Vehicle Weight Ratio .... 3-1
Loading ................................................... 3-1
Internal Loading & Checks ...................... 3-1
External Loading & Checks ..................... 3-2
Pre-Tow Checklist & Hitch-Up ................. 3-2
TOWING AND DRIVING ......................... 4-1
Reversing ................................................ 4-1
Speed Limits ........................................... 4-1
Setting Off ............................................... 4-1
Caravan Handling ................................... 4-1
Motorway Driving .................................... 4-2
Towing Covers ........................................ 4-2
Tyre and Wheel Checks .......................... 4-2
ARRIVING ON SITE ............................... 5-1
Check Site Regulations ........................... 5-1
Selecting a Pitch ..................................... 5-1
Side-To-Side Levelling ............................ 5-1
Leveller Jack ........................................... 5-1
Ramp ...................................................... 5-1
Front & Back Levelling ............................ 5-1
Parking on a Reverse-Sloping Site
or Steep Hill ............................................ 5-2
Entering and Exiting the Caravan ........... 5-2
GETTING STARTED .............................. 6-1
Electricity ................................................. 6-1
Power Supply Charger ............................ 6-1
12v Systems: .......................................... 6-1
Generator/Charger .................................. 6-1
Electricity Mains Supply .......................... 6-1
Connecting To Mains Supply On
Arrival at Site ........................................... 6-1
Disconnecting Mains Supply When
Leaving Site ............................................ 6-2
Overseas Electrical Connection .............. 6-2
Gas Safety Advice................................... 6-3
Facts about LPG ..................................... 6-3
Awning Spaces, LPG and Appliance
Exhaust ................................................... 6-3
LPG Gas System .................................... 6-3
Gas Supply ............................................. 6-4
Connection .............................................. 6-4
Changing a Gas Cylinder ........................ 6-4
Gas Regulator ......................................... 6-4
High Pressure Gas Hoses ...................... 6-4
Water System .......................................... 6-5
High Flow Watermaster Pump with
Intelligent Control (IC) ............................. 6-5
To Calibrate the Water System ............... 6-5
To Prime the Water System .................... 6-5
Maintenance ........................................... 6-6
Helpful Hints ............................................ 6-6
Troubleshooting ...................................... 6-7
Diagnostic Codes .................................... 6-7
Winterising .............................................. 6-7
ELECTRICAL SYSTEM .......................... 7-1
12v Power Supply ................................... 7-1
Battery Installation .................................. 7-1
Battery Maintenance ............................... 7-1
Generators / Charger .............................. 7-1
230v Power Supply ................................. 7-1
Mains Unit ............................................... 7-1
Resetting the RCD .................................. 7-2
Automatic Charging System ................... 7-2
Maximum Bulb Ratings for Internal Lights7-2
Maximum Bulb Ratings for
Road Lights ............................................. 7-2
HOW TO USE YOUR CARAVAN’S
EQUIPMENT ........................................... 8-1
Electrical Control Panels ......................... 8-1
Thetford Duplex Combi Oven ................. 8-2
3 Burner Hob ........................................... 8-4
Refrigerator ............................................. 8-6
Defrosting .............................................. 8-10
Switching off refrigerator ....................... 8-10
Winter operation .....................................8-11
Whale Underfloor Space Heater ........... 8-12
Whale Water Heater.............................. 8-15
Whale Watermaster® Exterior Water
Pump with Intelligent Control® .............. 8-18
Battery Charger ..................................... 8-26
CONTENTS-1
MY2016/Xplore
CONTENTS
Smoke Alarm ......................................... 8-26
Nuisance Alarms ................................... 8-27
Battery Replacement ............................ 8-27
Cleaning your alarm .............................. 8-27
Carbon Monoxide Alarm ....................... 8-28
Recognising Alarm Signals and
Warnings ............................................... 8-28
Using your Alarm................................... 8-28
Switching on your CO Alarm ................. 8-28
Re-setting the Alarm ............................. 8-28
Replacement of Batteries ...................... 8-28
Carbon Monoxide Alarm Procedure ...... 8-29
Maintenance of your alarm ................... 8-29
Thetford C260 Toilet.............................. 8-30
Introduction ........................................... 8-30
Preparing for Use (Standard) ................ 8-30
Using the Toilet (Standard).................... 8-32
Emptying ............................................... 8-32
Emptying with Optional Features .......... 8-32
Cleaning and Maintenance ................... 8-33
To ilet Bowl ............................................. 8-33
Waste Holding Tank .............................. 8-33
Cleaning and Maintenance for
Optional Features ................................. 8-34
Winter operation .................................... 8-34
Storage ................................................. 8-34
To ilet unit malfunctions.......................... 8-34
Midi Heki Rooflight ................................ 8-37
Windows ............................................... 8-37
Polyplastic Window Opening ................ 8-37
Rooflights .............................................. 8-37
Blinds & Flyscreens .............................. 8-37
Flyscreens ............................................. 8-37
Door Flyscreen (If Fitted) ...................... 8-37
Shower .................................................. 8-38
Taps ...................................................... 8-38
Gas Locker Door ................................... 8-39
Internal Doors ....................................... 8-39
Paddle Latch ......................................... 8-39
Magnetic Catches ................................. 8-40
Sprung Hinges ...................................... 8-40
Sliding Doors ......................................... 8-40
Bed Make-up ......................................... 8-40
L-Shape Lounge Double Bed ................ 8-41
Front Wrap Round Seating (Option) ..... 8-41
Removable Drawer Locker ................... 8-44
Entertainment System ........................... 8-44
Radio/CD with MP3 Connectivity (Option
Only) ..................................................... 8-44
Te leco TV Aerial .................................... 8-44
How to use your TV Aerial..................... 8-46
Al-Ko Trailer - Control (Option) ............. 8-48
SECURITY .............................................. 9-1
Caravan Theft ......................................... 9-1
Tracker Retrieve...................................... 9-1
CRIS - The Caravan Registration and
Identification Scheme .............................. 9-1
Al-Ko Secure Wheel Lock (Option) ......... 9-2
Window Etching & Chassis Marking ....... 9-4
Electronic Tagging ................................... 9-4
CARE OF YOUR CARAVAN ................ 10-1
Exterior Cleaning .................................. 10-1
Acrylic Windows .................................... 10-1
Care Instructions for Seitz Rooflights .... 10-1
Window Blinds & Flyscreens ................. 10-1
Winterisation/Storage ............................ 10-1
Interior Walls ......................................... 10-1
Furniture ................................................ 10-2
Cooking Equipment ............................... 10-2
Soft Furnishings .................................... 10-2
Winterisation and Storage ..................... 10-3
Shower Trays, Shower Room and
Wash Basin Fittings .............................. 10-3
Cleaning of all Taps ............................... 10-3
Water Containers .................................. 10-4
Pre-season Water System Preparation. 10-5
Getting Ready for the Winter ................ 10-6
Chassis Mounted Spare Wheel Carrier 10-7
Tyres ..................................................... 10-7
Pressures .............................................. 10-7
Tyre Wear and Damage ........................ 10-7
Changing a Wheel ................................ 10-7
Jacking .................................................. 10-8
Lubrication ............................................ 10-8
The Alko Caravan Chassis.................... 10-9
Chassis Members ................................. 10-9
Drilling or welding of parts or
Accessories ........................................... 10-9
Independent Suspension ...................... 10-9
Coupling Head ...................................... 10-9
Secondary braking (Breakaway Cable) 10-9
Brake Drum/Hub Assembly ................... 10-9
Operating Instructions ......................... 10-10
Braking System Adjustment ................ 10-12
STORAGE ............................................ 11-1
Long Term & Winter Storage ..................11-1
Caravan Covers ..................................... 11-1
Power Drain ........................................... 11-1
CARAVAN WARRANTY COVER ......... 12-1
Non Warranty Repairs........................... 12-3
Remedial Work...................................... 12-3
CONTENTS-2
CONTENTS
CARAVAN CONSTRUCTION -
MAIN COMPONENTS .......................... 13-1
Alko Chassis ......................................... 13-1
Braking System ..................................... 13-1
Solid Construction Body Shell ............... 13-1
Windows ............................................... 13-1
Insulation ............................................... 13-1
Front Panel and Gas Bottle Locker
Door ...................................................... 13-1
Awning Channel .................................... 13-1
EQUIPMENT LIST ................................ 14-1
Xplore Range ........................................ 14-1
WIRING DIAGRAM - XPLORE ............ 15-1
Road Lights - Xplore ............................. 15-2
GENERAL QUESTIONS ...................... 16-1
GLOSSARY .......................................... 17-1
SERVICE DOCUMENTS ...................... 18-1
NOTIFICATION OF CHANGE OF
OWNERSHIP ........................................ 19-1
NOTIFICATION OF CHANGE TO
NAME AND ADDRESS ........................ 20-1
USEFUL ADDRESSES ........................ 21-1
INDEX ................................................... 22-1
CONTENTS-3
CONTENTS
CONTENTS-4
INTRODUCTION
WELCOME AND
INTRODUCTION
Congratulations on choosing an Xplore
Touring Caravan.
This Owner’s Handbook has been prepared
for your guidance to help you derive the
greatest amount of pleasure from the use of
your caravan and your leisure time. We
strongly recommend that you read this guide
thoroughly so that you are fully aware of all
the caravan’s features, equipment and
systems.
Additional information and detailed appliance
instruction manuals are also contained in your
Owner’s Information Pack which can be found
within the kit box supplied with your caravan.
Your new Xplore caravan has been
designed as a recreational vehicle and is
intended for recreational use only. It is not
intended for business, hire use or for
permanent habitation. Xplore accepts no
liability if the caravan is used for any
purpose other than recreational/holiday
use. Any use other than recreational/
holiday use will invalidate your warranty.
Your caravan has been designed for towing
behind a normal motor car. Additional care
should be exercised when towing with a 4x4
because of the ‘off-road’ nature of the
suspension. Owners should not tow their
touring caravans with commercial vehicles.
When selecting a towing vehicle it is
recommended that you consult the Caravan
Towing Code, which is available from the
NCC.
By following the instructions provided in this
handbook and maintaining your caravan in a
first class roadworthy condition, you are sure
to have many years of carefree use.
To ensure the very best quality and reliability
all touring caravan designs and new
developments are rigorously tested. Therefore
Xplore will accept no liability or uphold the
warranty if the caravan is altered or modified
in such a way that would adversely affect the
reliability.
Please note: It is a condition of your warranty
that the caravan must have an “annual
service” carried out by an Xplore approved
Retailer / Service Centre or NCC Approved
workshop or NCC equivalent standard as set
out in this handbook and a record is kept.
Pages are provided in the back of this guide,
for your assistance.
An Xplore Approved Retailer / Service Centre
will be able to supply any replacement parts
for your caravan, should the need arise, and
in most cases any accessories you may
require.
Please note: It is not possible to purchase
replacement parts direct from Xplore.
Changing market and supply situations may
prevent us from maintaining the exact
specification details in this guide and we
therefore reserve the right to alter
specifications as materials and conditions
demand.
Enjoy your new caravan
Model Year Designation
All Touring caravans manufactured by Xplore
are designated by their model year. The 2016
model year runs from 1st September 2015 to
31st August 2016.
Xplore Technical Approvals
All Xplore Caravans have been European
Commission Whole Vehicle Type Approved
via the Vehicle Certification Agency (VCA).
In order to ensure your new caravan is safe
to use, Xplore are members of and have
been inspected by the following bodies.
NCC who operated a certification scheme to
ensure compliance with the European safety
standards for caravans.
National Inspection Council for Electrical
Installation and Contracting (NICEIC) who
carry out an annual inspection of Xplore
electrical installations within caravans.
Gas Safe Register™ approved installers
carry out an annual inspection to ensure that
the gas installations carried out by Xplore
fully comply with all relevant regulations and
standards.
Xplore has also obtained ISO9001:2015
accreditation and this is audited by SGS UK
Limited
1-1
INTRODUCTION
1-2
GENERAL SAFETY
GENERAL SAFETY
Please read before using your new
caravan.
In order for you to get the most out of your
new Xplore touring caravan it is necessary
for you to be aware of the following:
(i) Do not obstruct ventilators and clean
them regularly, it is advisable to clean
and check all the ventilators annually
for blockages and where necessary
rectify any blockages found.
(ii) Inspect the high pressure flexible gas
hose (available from your retailer)
regularly for deterioration and renew
as necessary, with an approved type,
in any case no later than the expiry
date stated on the hose.
(iii) Ensure the gas supply and all
appliances are turned off before towing
your caravan.
(iv) If your caravan has been fitted with a
gas BBQ point it must be only used for
its intended purpose. Do not use a
gas barbeque within an awning.
(v) Never use portable cooking or heating
equipment inside your caravan. Do not
use your fitted cooking equipment as
heating at any time.
(vi) Never allow modification to your gas or
electrical system unless qualified
persons carry them out. All
modification to the gas system should
be carried out by a Gas Safe
Register™ approved gas fitter. Any
modifications carried out on the
electrical system must be carried out
by an electrician on the roll of the
NICEIC or be a member of the ECA.
(vii) If you suspect there is a gas leak
please open all the windows then
vacate the caravan. Turn off the gas
container if safe to do so, then contact
your nearest Xplore Retailer to arrange
for them to check the gas system.
(viii) In the interest of safety, replacement
parts for an appliance should conform
to the appliance manufacturer’s
specifications and must be fitted by
them or an authorised agent.
(ix) It is recommended that you provide a
dry powder fire extinguisher complying
with ISO 7165 of at least 1KG capacity
by the exit door and a fire blanket next
to the cooker. Ensure you read the
‘advice to occupier label’ fitted to your
caravan usually found on the inside of
the wardrobe door.
(x) Never exceed your caravans Maximum
Technical Permissible Laden Mass.
(see Caravan Towing Vehicle Weight
Ratio)
(xi) The laden nose weight for your
caravan should not exceed the lower
of the following:
•Towing vehicles maximum nose
weight
•Tow bar maximum nose weight
• The caravan’s maximum nose weight
(xii) Ensure heavy and large items are
secured before towing your new
caravan to reduce the risk of damage
being caused while the caravan is in
motion.
(xiii) Pull out worktop extensions, where
fitted, are only designed to take a
maximum weight of 6kgs.
(xiv) Where high level bunks are fitted, care
should be taken when used by
children. The protection against falling
out must be in place when the bunk is
used.
(xv) When your caravan is connected to
your towing vehicle it should be level
or slightly nose down.
(xvi) When your caravan is loaded to its
MTPLM and the weight distributed in
accordance with the handbook, your
caravan is designed to be towed at a
maximum speed of 100kmh/60mph.
(xvii) It is illegal to tow your caravan
whilst it is occupied.
(xviii) If your caravan is fitted with a lift up
bunk it is designed for a maximum
weight of 11 stone and is not suitable
for children under 3 years old without
supervision.
(xix) Do not leave children under 14 years
of age unattended in your caravan.
2-1
GENERAL SAFETY
(xx) The coupling head operating handle
MUST NOT be used to manually
manoeuvre the caravan at any time.
(xxi) In order to manually manoeuvre your
caravan please use the front and rear
grab handles fitted to the caravan.
(xxii) Your vehicles MIRO is calculated with
no water on board. To travel with water
you must take account of the water in
your vehicle payload. 1 litre of water =
1Kg.
VENTILATION
All caravans manufactured by Xplore are
ventilated at both high and low level in
accordance with BSEN 721 Safety
Ventilation.
High-Level Ventilation
This is always provided by fixed ventilation
within the fitted roof skylight. These roof
skylights should be cleaned annually by use
of a small brush to remove any dust that may
have accumulated around the mesh fitted.
On some roof skylights the mesh can be
easily removed to aid cleaning. On fanassisted roof skylights it is essential that the
fan is switched off prior to cleaning.
Low-Level Ventilation
Low level ventilation is provided within the
living area of your new caravan and these
can be identified by the fitting of a black
cover to prevent them from being obstructed.
This cover must not be removed. In order to
clean the ventilator, remove the cover by
undoing the two screws and clean using a
small brush. It is essential that the cover is
replaced once cleaning is complete.
Ventilation in Separate Bedrooms
In caravans with separated sleeping areas,
separate ventilation is required and is
provided via a roof skylight at high level and
a ventilator at low level within a bed box or
under the fixed bed.
Gas Dispersal Holes
All appliances and gas taps have a gas
dispersal hole nearby. It is essential that
these are not blocked or made ineffective.
Petrol/Diesel Fumes
The fitting of a tail pipe to your exhaust will
reduce the possibility of fumes entering your
caravan through the front fixed ventilation
points.
FIRE SAFETY
Fire Extinguishers
It is recommended that a 1 kg (2lb) minimum
capacity dry powder fire extinguisher be
carried inside your caravan at all times. A
pan fire must not have an extinguisher aimed
at it, but must be smothered with a fire
blanket.
In Case Of Fire
(i) Get everyone out of the caravan as
quickly as possible using whichever exit
is quickest including windows. Do not
stop to collect any personal items.
(ii) Raise the alarm. Call the fire brigade.
(iii) Turn off the gas container valve if safe to
do so.
Fire Retardant Foams
All caravans are equipped with either
Combustion Modified High Resilient
(C.M.H.R.) foam cushions or sprung
mattresses and fire retardent fabric. All
furnishings and fabrics used by Xplore
comply with the Furniture and Furnishings
(Fire Safety) Regulations. In addition all
upholstery is made of fire retardant fabric.
Escape Paths
Your new touring caravan has been provided
with escape paths to be used in the event of
an emergency. One of which is always the
main habitation door and others are the large
windows to be used where necessary. Care
must be taken when exiting via a window due
to the potential drop to ground level.
IMPORTANT: Your attention is drawn to
the notice affixed in the caravan’s
wardrobe advising on fire prevention,
ventilation and what to do in case of fire.
2-2
GENERAL SAFETY
YOUR CARAVAN PAYLOAD
EXPLAINED
Definitions
Plated maximum technical
permissible laden mass (PMTPLM)
As specified by Xplore and in compliance
with the European Directive on Masses and
dimensions of vehicles.
Actual MTPLM
Maximum mass of the vehicle, which takes
into account operating conditions including,
factors such as the strength of materials,
loading capacity of the tyres etc.
Mass of the caravan in running
order (MIRO)
This is the weight of your caravan as it
leaves our factory plus the following:
A mass of 10kgs per gas cylinder, the
cylinder number is equal to the number
of connections provided at the regulator.
Personal effects payload (PEP)
This is calculated by the following formula:
10L + 10N + 50
L is the body length of the caravan in
meters.
N is the number of berths.
50 is for normal equipment carried in the
caravan, a sample list is given below.
Kettle ................................... 0.5kgs
Bed linen ................................. 6kgs
Crockery ................................. 5kgs
Saucepans .............................. 3kgs
Wastemaster...........................6kgs
Aquaroll (empty) ..................... 5kgs
Waste bin ................................. 1kg
Cutlery .................................... 2kgs
To ilet fluid etc ....................... 2.5kgs
Battery .................................. 25kgs
Optional equipment payload (OEP)
This is an amount of weight provided by us
for factory fitted options.
Please note: Any options fitted by the retailer
will reduce the overall payload available to
the customer.
User Payload is the sum of the PEP and the
OEP.
Note: It may be possible to upgrade your
Plated MTPLM to the Actual MTPLM up to
the caravan being 3 years old, there is an
administration fee for this service.
Note: Please ensure you never load your
caravan above the plated MTPLM.
Note: Please take care to ensure you have
allowed for the mass of all the items you
intend to take in your caravan.
2-3
GENERAL SAFETY
2-4
PREPARING FOR THE ROAD
PREPARING FOR THE ROAD
Caravan Towing Vehicle Weight
Ratio
This ratio has a major influence on stability. It
is recommended that:
(i) The laden nose weight for your caravan
should not exceed the lower of the
following:
*Towing vehicles maximum nose
weight,
*Tow bar maximum nose weight
* The caravan’s maximum nose weight,
is 100kgs.
(ii) The actual laden weight of the caravan
should always be kept as light as
possible. The lighter it is whilst being
towed on a road, the safer the outfit
combination will be.
(iii) What you are able to tow is dependent
on your driving licence.
(iv) If you are a B licence holder you can
only tow a car/caravan combination of
total weight not exceeding 3500kgs and
the cars kerb weight must be greater
than the caravans plated MTPLM.
Note: It is strongly recommended that
the caravan plated MTPLM should not
exceed the cars kerb weight.
(v) If you hold a B + E licence you can tow
up to a combination weight of 7000kgs.
WARNING: It is strongly recommended
the loaded weight of the caravan does not
exceed the kerb weight of the towing
vehicle.
LOADING
Always lower and secure the jockey wheel
and the four corner steadies (with the brace
provided) before entering the caravan. This
will ensure that the caravan does not tip up
when you are inside.
Please note: Corner steadies should not be
used as a jacking or levelling device.
Internal Loading & Checks
When loading your caravan it is advisable to:
(i) Distribute items evenly over the axle and
as low as possible to optimise road
holding and achieve the best possible
braking effect.
(ii) Do not overload on one side as this will
cause the caravan to lean and affect the
road holding and stability.
(iii) Do not stow tins, bottles or heavy items
in overhead lockers when towing.
(iv) Loose articles should be stowed
securely to avoid movement and
possible damage.
(v) Ensure that all lockers, cupboard doors
and showers doors are closed and room
partitions are secured.
(vi) Secure all bunks (if appropriate).
(vii) Store the main dining table in its transit
position.
(viii) Set the refrigerator for 12V operation if
any fresh food is stored in it and ensure
the door is locked.
(ix) Fully close and lock all windows and
rooflights. Never tow with windows on
night setting.
(x) Leave all curtains and blinds open to
prevent damage in transit. If your
caravan has a rear window this may aid
visibility.
(xi) Ensure you remove all items from the
microwave before towing.
3-1
PREPARING FOR THE ROAD
1 2
External Loading & Checks
(i) Gas cylinders should only be stored,
correctly positioned, and secured in the
gas bottle locker. The gas should be
turned off.
(ii) The leisure battery is stored and secured
in the battery locker box, set into the tray
provided and secured.
(iii) Any external connections (battery
chargers, connecting cables etc), should
be disconnected and stowed.
(iv) Check that all exterior locker doors are
secure and locked.
(v) Secure and lock the main caravan
entrance door.
PRE-TOW CHECKLIST & HITCH-UP
Having loaded the touring caravan and
secured the lockers and main entrance door:
(i) Check touring caravan wheel bolts are
torque tightened to the required level
(See Index - Changing a Wheel).
(ii) Check tyre pressures (Refer to the
Technical Data Sheet) and tyre condition
for roadworthiness.
(iii) Ensure the jockey wheel is down, in
good contact with the ground, clamp
tightly secured, and the caravan
handbrake is fully on.
(iv) Wind up the corner steadies.
(v) Reverse the car close up to the
caravan’s hitch. It is advisable to seek
assistance to guide you so that the car
tow ball aligns with the caravan’s hitch.
(Use of the caravan handbrake is
advised. Extreme caution should be
taken if manoeuvring the caravan down
hill or on wet, slippery surfaces).
(vi) Make sure the jockey wheel height is
sufficient for the hitch head to clear the
towing vehicles tow ball.
(v) Manoeuvre the hitch head over the tow
ball and lower the jockey wheel using the
winding handle, until the hitch head
opening sits comfortably over the tow bar
ball.
CABLES
For peace of mind, you may wish to check
the ability of the cables to be able to cope
with towing the vehicle at extreme angles
before setting off. To do so, position the
vehicle at alternate extreme angles and
check that the cables do not pull too tight, as
they are liable to stretch or become
unplugged. No cables should be allowed to
touch the ground as they will wear and
become damaged and ineffective.
Please note: If having followed this advice,
you feel you cannot achieve a satisfactory
cable arrangement, consult your caravan or
tow bar supplier or service agent.
Stabiliser operating instructions
Fig 1
Coupling handle (Fig. 1/Item 1), Stabiliser
Lever (Fig. 1/Item 2)
The Stabiliser lever (Fig. 2/Item 2) must be in
the uppermost position (open).
Fig 2
Fig 3
Coupling
• Pull the coupling handle (Fig. 3/Item 1)
up in the direction of arrow. The coupling
mechanism has an open position ie. as
3-2
PREPARING FOR THE ROAD
long as the AKS 3004 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.
WARNING: The coupling is correctly
engaged when the green edge of the
safety indicator button is visible (Fig. 4/
Item 3).
WARNING: Always ensure that the jockey
wheel is fully raised and secure before
commencing any journey.
Stabiliser Unit:
•To operate the Stabiliser (once coupled
to the towball), simple press the stabiliser
lever down as far as it will go (Fig. 4/Item
2).
Fig 4
Uncoupling
• Pull the stabiliser lever handle up as far
as it will go, open the coupling handle
and lift the AKS 3004 from the towball.
With larger nose loads, coupling and
uncoupling can be made easier by using
the jockey wheel to assist lifting.
The friction pads 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:
1) Couple up AKS 3004
2) Open Stabiliser lever (Fig. 5/Item1).
Fig 5
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. 5/Item 4) is
before or on the marked area (Fig. 5/Item
2) the friction pads are still as new (See
A)
5) The arrow on the arm should lie between
the marked area on the soft dock (See B)
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).
It is not necessary to adjust the friction pads.
3-3
PREPARING FOR THE ROAD
Manoeuvring operation
For easier manoeuvring (on campsites etc),
pull the stabiliser lever to the ‘up’ position.
Please do not use the stabiliser lever as an
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.
6).
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. 6).
Fig 6
3-4
PREPARING FOR THE ROAD
BREAKAWAY CABLE
The law requires that any trailer with a
MTPLM (GVW) exceeding 750 kg must have
a braking system and it must work. If such a
trailer becomes detached from the tow vehicle
then these brakes must be applied
automatically by way of the breakaway cable.
This breakaway cable is an important part of
the management of the braking system and
when the trailer is built the braking system is
part of the certification process for the safe
use of the trailer - so any replacement parts
must be equivalent to the original parts fitted.
There are two types of breakaway cable in
use in the UK. One uses a spring clip (one of
the Al-Ko versions, the other uses a Karabiner
clip (available from Al-Ko and BPW).
Spring type clip
Karabiner type clip
Looking at the two clips it is easy to see that
there is a difference.
The spring clip type is designed to be hooked
back over the breakaway cable when it is
fitted to the tow vehicle and must always be
used this way.
The Karabiner type is designed to be secured
onto a mounting point on the two vehicle, it
does not need to pass back over the cable to
secure it in place (but can if necessary).
So how should the breakaway cable be
secured to the tow vehicle? In the absence of
specific advice from the manufacturer/supplier
follow these simple guidelines:
Fixed tow ball systems
The cable with spring clip should be passed
behind the towbar assembly (where cable
length is sufficient) and then clipped back on
itself. The cable should be in as straight a
path as possible to ensure correct operation.
Where there is insufficient cable length then
the cable should pass around the base of the
tow ball and then be clipped back on itself.
Detachable tow bar systems
Vehicles with a detachable tow bar system
may have a securing point provided on the
tow bar assembly. This securing point should
be part of the towbar assembly fitted to the
tow vehicle but this securing point may not be
large enough to allow the spring clip type
fastener to pass completely through, do not
be tempted to clip onto the securing point
directly. Where this is the case, or where
there is no hooking point provided, then the
cable should pass around the tow ball
assembly and then clipped back on itself.
Where the towbar provides a securing point
and a Karabiner type fastening is provided,
then this can be secured to the securing
point. Make sure that it is completely closed
to ensure that it operates correctly.
Be careful to check that the cable does not
sag so much that it could drag on the ground
- if it does it may become damaged or catch
on debris on the road surface. Also ensure
that the cable is long enough to allow for any
sharp turns, otherwise the cable may
inadvertently apply the trailer brakes and this
could cause damage to the brake
components.
Remember to check the breakaway cable for
any signs of damage. The cable is designed
to apply the trailer brakes and then snap
once the brakes are applied so any damage
may result in premature failure and the
brakes not being properly applied.
And ... remember ... Many inadvertent
detachments occur at low speed - normally
as a result of the hitch head not being
engaged properly onto the tow ball assembly.
A low speed detachment may not result in the
breakaway cable operating properly - so
ALWAYS check that the head is fully secure
before setting off.
3-5
PREPARING FOR THE ROAD
3-6
TOWING AND DRIVING
TOWING AND DRIVING
REVERSING
It is advisable to have a second person
assisting when reversing the caravan.
Start practising by choosing a left-hand bend
for ease. Reverse slowly; turning the wheel,
initially the opposite way to the direction you
want the caravan to go.
Now the front of the caravan is nudged out
and is moving the rear in the intended
direction. Take care not to hit the caravan
with the car!
Midways through the manoeuvre, when the
caravan is correctly angled, reduce speed to
a crawl and gradually apply opposite lock.
Make the car follow the caravan round then
finally straighten up.
Please note: Proficiency at reversing can
only be achieved with practice.
SPEED LIMITS
•Always adhere to the speed limits in
force.
• When national speed limits apply, when
towing on a single carriageway, the
speed limit is reduced to 50mph. Dual
carriageway and motorways, the speed
limit is reduced to 60mph.
SETTING OFF
(i) Pull away smoothly in the towing
vehicle. Allow more engine speed to
produce the power to move the
additional weight of the caravan.
(ii) Avoid wear and tear on the clutch and
transmission by taking extra care not to
‘ride’ the clutch.
(iii) Change gears smoothly. Try not to jerk
the clutch.
CARAVAN HANDLING
(i) Allow for the caravan being wider than
the car. Ensure you have a clear view
to the rear. This may require the fitting
of extended mirrors for towing your
caravan.
(ii) Give yourself more room when
cornering to ensure your caravan
wheels do not strike the kerb.
(iii) When passing other vehicles, allow
more than the normal clearance for
driving solo.
(iv) Allow longer to obtain a fast enough
speed to pass other vehicles.
(v) Allow for the vehicle being twice its
normal length. Do not suddenly swing
out.
(vi) Carry out all manoeuvres as smoothly
as possible.
(vii) Use the wing mirror to check the
caravan has clearly passed other road
users when overtaking and changing
lanes.
(viii) Adverse weather conditions may affect
the steering and braking characteristics
of your caravan.
Fig 4-1
4-1
TOWING AND DRIVING
MOTORWAY DRIVING
Important Points:
1. Caravans may not be towed in the
outside lane of a three or four lane
motorway.
2. Reduce speed:
a) In high or cross winds
b) Downhill
c) 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 to avoid the
drag created by the high sided vehicle.
4. When going uphill, change gear in good
time. If your car is running short of power
or is behind a slower vehicle, keep well
into the nearside and out of the way of
other vehicles. Remember that some hills
can be ascended with relative ease often
pose an unexpected challenge if you
come to a standstill in traffic and then
have to re-start from scratch.
5. When going downhill, take extra care to
ensure you do not gain speed. This can
be avoided by changing down a gear and
reducing speed as you approach the
slope. Don’t leave this gear change too
late. Using low gears throughout the
descent will reduce the strain on the car’s
brakes. For automatics, you may need to
manually change to a lower gear in
anticipation of the effect caused by the
gradient change.
TOWING COVERS
We do not recommend that you tow with
covers on as it can obscure the road lights
fitted.
Tyre and wheel checks
Tyres are an essential part of the safe use of
your caravan and it is important that they are
properly maintained to make sure that they
do what they are intended to do - carry the
load and grip the road as well as bringing you
and your caravan to a safe stop.
So how do we know we have the correct
tyres for our caravan and how do we know
that they are still safe to use?
When your caravan was first manufactured
the tyres fitted were chosen because they
would carry the load that the caravan was
designed to carry.
Note that it may be possible to increase the
maximum technically permissible laden mass
(MTPLM) of the caravan depending on the
capacity of the chassis but it is essential that
the tyres are checked to verify that they are
suitable for the extra loading if this option is
taken. If their loading capacity is less than the
rating necessary for the increased MTPLM,
they will need to be replaced.
Detailed information on the load and speed
rating is marked on the side of the tyre.
Looking at the tyre not only tells us that they
are the right ones for the leisure vehicle, it
also tells us how old the tyre is. It is strongly
recommended that tyres are renewed when
they are five years old and certainly by seven
years. The tyre data is only shown on one
side, so it may be necessary to check the
information on the hidden side.
It is unlikely that caravan tyres will wear out
before they reach the end of their
recommended life, but all tyres deteriorate
over time due to the effects of ultra-violet
radiation and atmospheric ozone, so whilst
the tyre may still seem to be in good
condition with plenty of tread wear left, there
is an increased risk of sudden failure and
they need to be changed due to ageing.
Where the recommended tyre pressure is 50
psi or more, extra care should be observed
as running at such high pressure can make
them more susceptible to wear and damage.
Many of the tyres checked out on the road in
Police checks are in a dangerous condition
and using tyres like this increases the
potential for a tyre failure / blow out or other
incident and could result in a fine and penalty
points being added to your licence.
Check your tyres for cuts / lumps, crazing
and cracks as well as wear (both on the
outside and inside walls) - don’t forget to
check the pressures when the tyres are cold.
For further information about tyres see
www.tyresafe.org/tyre-safety/caravan-tyresafety
4-2
ARRIVING ON SITE
ARRIVING ON SITE
CHECK SITE REGULATIONS
On arrival at a site, you should always check
the site regulations. This will help avoid any
unnecessary conflict with site management
and other site users.
WARNING: Care has to be taken to
prevent grounding when traversing ramps
or other ground obstacles.
SELECTING A PITCH
Carefully select where you wish to place your
caravan. The site should be as level as
possible, preferably not under or near trees,
well drained and away from possible boggy
areas. Consider how you will move the
caravan when it is time to leave the site. On
sloping ground it is better to pitch facing
downhill, especially during wet weather.
SIDE-TO-SIDE LEVELLING
A quick glance at your pitch should tell you if
you are likely to need side to side levelling
i.e. levelling across the axle. On uneven
ground lateral levelling is accomplished by
the use of a leveller jack or ramp and a spirit
level placed ‘across’ the caravan floor (not
supplied).
Leveller Jack
Place the leveller jack, folded flat, in front of
the wheel needed to be raised to level the
axle. Tow the caravan onto the leveller jack
and adjust the height until the spirit level
shows that the caravan is laterally level.
Ramp
(i) Reverse onto your pitch about 30cm
(12") further back than you wish to end
up.
(ii) Then place the levelling ramp in front of
the wheel that needs to be raised.
(iii) Place a spirit level parallel to the axle on
the A-frame or just inside the caravan
door.
It helps to have two people at this point. One
should drive the car very slowly forward
moving the caravan wheel up the ramp, and
the other should indicate when the spirit level
bubble is in the middle.
Whichever method you use, and once level:
(i) Apply the caravan handbrake and chock
the caravan wheel if necessary.
(ii) Lower the jockey wheel to ground level
before unhitching. (See index
uncoupling)
(iii) If necessary use a load spreader, such
as a big foot or alternative suitable
device.
You should then park your car, usually next to
the caravan furthest away from the door side.
Please note: On upward facing pitches when
the hydraulically damped drawbar of the hitch
becomes fully extended, it will be necessary
to compress the drawbar slightly in order to
achieve a clean’ unhitching. With the caravan
brake on, reverse the towing vehicle about
2.54cm (1") to release hitch lock tension and
using the jockey wheel adjustment, unhitch
the caravan as previously described.
FRONT & BACK LEVELLING
This should be done only when the lateral
levelling is complete.
(i) Place the spirit level pointing front to
back just inside the caravan door or on
the A frame.
(ii) Then raise or lower the jockey wheel
until the caravan is horizontally level.
Please note: If there is a significant front to
back slope, you may need to place a block
under the jockey wheel.
(iii) Next, wind down the corner steadies
onto load spreaders (blocks of wood a
minimum of 15.25cm (6") square or ‘Big
Foot’ steady attachments) until they are
firmly set against the ground.
Please note: It is possible on very uneven
sites that when fully extended blocks may be
required under the corner steadies to achieve
this. It is important that the caravan is
correctly levelled to ensure the correct
working of the refrigerator, cooker etc.
(iv) Now that your caravan is level, place the
caravan step in front of the door
ensuring that it is stable and safe to use.
5-1
ARRIVING ON SITE
PARKING ON A REVERSE-SLOPING
SITE OR STEEP HILL
For successful parking on a reverse slope or
steep hill, the operator need only apply the
handbrake with one hand while gently but
purposely inching the caravan a small
distance backwards with the other.
CAUTION:
first
brace provided. Corner steadies should not
be used as a jack. Take care not to lift the
caravan wheels.
ENTERING AND EXITING THE
CARAVAN
Due to the height to the entrance door, it is
strongly recommended that you use a step to
enter and exit your caravan. A suitable step is
provided with your caravan and can be found
within your kit box. Please ensure your step
is placed in front of the entrance door and is
on sound and level ground before use.
Never enter the caravan without
lowering the four corner steadies with the
5-2
GETTING STARTED
GETTING STARTED
You have arrived at your destination and now
want to start to enjoy your new Xplore touring
caravan. The following is a step by step
guide to connecting your services and getting
everything in your caravan working.
ELECTRICITY
Power Supply Charger
Your caravan is fitted with a power supply/
charger. This will charge the caravan battery
“not supplied” when fitted and also power the
12V systems in your caravan.
It is recommended that you always carry a
leisure battery.
The Charger is fully automatic and will not
overcharge the leisure battery.
12v Systems:
Your caravan is fitted with an automatic
system for selection of power.
When connected to the 230V site supply the
automatic Power Supply/Charger will charge
the leisure battery and the 12V systems.
When connected to the car (always
disconnect 230V supply), the system
automatically switches to the car supply.
When the towing vehicle’s engine is running
and the caravan’s 13 pin plug is connected,
the internal 12 volt power supply in the
caravan is turned off and all internal lights will
go out. The only 12 volt power left
operational within the caravan is the fridge
and the battery charger.
GENERATOR/CHARGER
When connecting to a generator, always
switch off the RCD (residual current device),
start the generator and allow running for a
few minutes to stabilise. When this has
happened, switch the RCD to the ON
position.
ELECTRICITY MAINS SUPPLY
Your caravan’s main electrical installation is
designed to run on 230V at 50 hertz AC
supply.
CONNECTING TO MAINS SUPPLY ON
ARRIVAL AT SITE
Before connecting the caravan installation to
the mains supply, check that:
(i) The mains supply is suitable for your
installation and appliances, i.e. whether
it is AC or DC and whether it is at the
correct voltage and frequency.
(ii) Your caravan is properly earthed. Never
accept a supply from a socket outlet or
plug having only two pins, or from a
lighting outlet.
(iii) 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 their agent.
(iv) Make sure that the switch at the site
supply point is off and that all electrical
equipment in the caravan is switched off
by ensuring your caravan mains
isolating switch on the MCB (miniature
circuit breaker) is in the ‘OFF’ position.
ELECTRICAL WARNING
Attention: Always disconnect the
electrical connector between the towing
vehicle and the caravan before
connecting a mains electric supply to the
caravan and before charging the caravan
battery by any other means.
Once the above checks have been made:
(v) Open the battery box on your caravan
and insert the female connector of the
mains connection cable supplied with
your caravan into the inlet within the
battery box as shown below.
(vi) Locate the site supply and remove any
cover from the socket outlet provided at
the supply point. Insert the male plug at
the other end of the flexible orange
supply cable. Switch on the main switch
at the site supply point (if appropriate).
6-1
GETTING STARTED
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 above diagram they must be ignored.
(vii) Place any surplus cable under the
caravan. Ensure that the surplus cable is
not coiled up as it could overheat.
(viii) Now switch on the mains isolating switch
within the caravan, this can be found on
the main consumer board, normally
located within the nearside front bed
box.
(ix) Check the RCD is working by pressing
the test button. Once pressed all
electrical lights and appliances should
cease to operate. Reset, and then check
the electrical system is operational.
(x) Finally in order to get your 12V system
operational, ensure the 12V switch is in
the ‘ON’ position. Refer to index for
further details on the control panel fitted.
DISCONNECTING MAINS SUPPLY
WHEN LEAVING SITE
(i) Switch ‘OFF’ at the caravan mains
isolating switch.
(ii) Remove the male plug from the site
supply.
(iii) Disconnect the female plug from the
caravan and store the cable in an
appropriate locker.
OVERSEAS ELECTRICAL
CONNECTION
Please 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.
A means of checking the polarity of the mains
supply when overseas is recommended.
There are available several proprietary
makes of equipment for the purpose.
If it can be achieved, it is preferable to
connect live to live, and neutral to neutral to
maintain full electrical protection.
CHECK all caravan equipment is set-up to
accept the site supply before actually
switching on.
6-2
GETTING STARTED
GAS SAFETY ADVICE
In the event of a suspected gas leak the gas
must be turned off using the isolation valve
on the gas bottle. A competent gas fitter
should then check the system before it is
used/reused.
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.
See Index - Ventilation
FACTS ABOUT LPG
• LPG is not poisonous.
•Bi-products are harmless.
• LPG is dangerous if all air and oxygen is
excluded.
• LPG has been given a smell by the
manufacturers in order to identify leaks.
• The gas is heavier than air and therefore
sinks to the lowest point.
AWNING SPACES, LPG AND
APPLIANCE EXHAUST
There is no danger of pollution of an
enclosed awning space from the LPG
exhaust from a refrigerator venting into it.
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 extreme
cases 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.
Please note: Ventilation holes must be clear
at all times.
LPG GAS SYSTEM
Xplore do not recommend the use of any
external cylinders. All cylinders in use should
be within the gas locker provided. If you wish
to utilise a larger cylinder and have this
outside the gas locker then the connecting
hose must not exceed 750mm.
It is recommended that no flammable
material is stored or placed within 300mm of
any open flame. You are advised not to use
any additional gas appliances outside your
caravan unless it is a Gas Barbecue
connected via the Barbecue point supplied
with your caravan.
Please ensure that you have read the
operating instructions for each gas appliance
contained in your Owners Information Pack.
Please ensure that any gas hose left
unconnected is protected from dirt or other
foreign bodies entering the hose.
WARNINGS
• Fresh air circulation should be
allowed below the caravan when
appliances are in use and when flues
terminate below the floor to allow free
evacuation of the products of
combustion. At least three sides of
the underfloor space should always
be kept open and unobstructed
especially by snow. Do not make any
additional openings in the floor.
• Outlet sockets located within the
caravan should only be used with a
dedicated appliance and not an
independent unit.
• No appliance shall be used outside
when connected to an internal outlet.
• Maintain adequate spacing of
combustible materials from sources
of heat.
• Do not use additional independent
gas appliances inside the caravan.
6-3
GETTING STARTED
GAS SUPPLY
Your caravan is designed to operate using
either propane or butane liquefied petroleum
gas at 30M/bar. Gas can be obtained from
your caravan dealer. Your caravan is
designed to accept a maximum 2 x 6kg BP
Light gas bottles.
Connection
Make sure that heating and cooking
appliances and gas cylinders are switched
off.
Each gas appliance is connected to its own
gas isolation tap under the cooker. These are
identified on the tap via a label. Below is a
key to identify each label.
To operate the tap the arrow on the tap
shows the direction of flow for the gas. The
arrow should be pointing towards the
appliance for the appliance to operate. There
will be a small label next to the bank of taps
under the cooker, which is also reproduced
below:
Water Heater
Space Heater
Refrigerator
Cooking Appliance
Hob
Gas On/Off
Changing a Gas Cylinder
Before commencing to change a gas cylinder
ensure that the valve on the cylinder is turned
fully off. Turn off all gas operated appliances.
Remove the gas hose from gas cylinder.
Before refitting a gas cylinder, ensure that all
gas operated appliances are turned off particularly after winterisation. Ensure all
connections are secure.
When the cylinder is connected please
ensure that the high pressure hose is not
placed under any strain.
WARNING: If cylinders other than those
recommended are used, ensure that the
cylinders are adequately supported, do
not block ventilation openings and cannot
cause damage to fixtures and fittings
located in the compartment.
Gas Regulator
Your new Xplore caravan has been fitted with
a fully approved gas regulator designed to
operate at a gas pressure of 30Mbar. Your
regulator is fitted with a test point, which is
accessed via the inlet at the side of the
regulator. This access point is only for
carrying out gas pressure tests and should
not be used for any other purpose.
CAUTION: It is strongly recommended
that only Gas Safe Register™ approved
gas fitters carry out any work on your
caravan gas installation.
High Pressure Gas Hoses
You should only connect to this regulator
using a length of approved high-pressure
hose not exceeding 450mm from the gas
cylinder to the regulator. These approved
high-pressure hoses are available from your
Xplore Retailer. These hoses are connected
using screw thread fittings, which will make a
seal if connected and tightened using a
spanner. Once the hose is securely
connected turn on the gas tap above the
regulator, then turn on the gas bottle to allow
gas to flow into the caravan.
In order to make all your caravan gas
appliances operational it is necessary to
open each appliance gas tap as detailed in
previous column. All your gas appliances
should now be operational. Instructions on
how to use each appliance are detailed later
in your handbook.
6-4
GETTING STARTED
WARNING: Aerosols and highly flammable
liquids must not be stored in the
compartment behind, or adjacent to, any
gas appliance. 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.
Ventilation holes must be clear at all
times.
WATER SYSTEM
High Flow Watermaster Pump with
Intelligent Control (IC)
The Watermaster IC unit is a yellow box
located on the back of the Watermaster
socket. It automatically adjusts your pressure
switch so that surges or reductions in battery
voltage between sites do not effect your
water flow. It will also protect the life of your
pump by automatically shutting it off if your
water container runs dry.
Prior to using your water system for the first
time, the Watermaster IC unit will need to be
primed and calibrated by following the steps
outlined below. This procedure should only
need to be carried out once.
To calibrate the Water System
Step 5 - The LED should turn solid green and
the pump will stop after
approximately 10 seconds. The
green LED should turn off and blink
briefly every 5 seconds. The system
is now calibrated.
The Watermaster IC is now installed and your
water system is ready for use. In normal
operation the pump may continue to run for
up to 15 seconds after the tap is closed.
To prime the Water System
Step 1 - Place pump into a full water
container (Fig. 1)
Step 2 - Insert plug into wall socket and close
lid to lock plug in place.
Step 3 - Adjust dust cover over opening in
container (please note dust cover
should not be secured to water
container as air must be allowed to
enter container to replace water
being pumped out)
Step 4 - Switch on 12 volt supply at main
panel (isolator switch) - the pump
should start to run
Step 5 - Open one cold tap (eg. kitchen sink)
Step 6 - After trapped air has been expelled
water will flow from the open tap
Step 7 - When air has been expelled turn off
tap, the pump should turn off after
approximately 10 seconds.
Fig 1
Step 1 - Press and hold the calibration button
until the green LED starts to flash
after 1-3 seconds (Fig. 2)
Step 2 - Open the tap and the pump should
start (there maybe a short delay)
Step 3 - After approximately 30 seconds, turn
off the tap
Step 4 - After approximately 10 seconds, (the
pump should still be running), press
the calibration button again
Fig 2
6-5
GETTING STARTED
Instructions for Pump Storage when
not in use
Pump hose can be inserted into groove on
plug to keep pump off ground while refilling
water container (Fig. 3). The plug should
always be removed before moving the
caravan.
When removing plug:
Step 1 - Lift the lid to
unlock the
plug
Step 2 - Pull out plug
from socket
using hand
grip
Step 3 Shut lid
Fig 3
Maintenance
The Watermaster IC control unit (located on
the back of the socket) is designed to be
service free and does not contain serviceable
parts. Please note that the unit is enclosed to
protect the electronics, opening the unit will
result in damage, and will invalidate warranty.
A planned maintenance schedule of regular
inspection is recommended, for the
Watermaster pump kit and socket replacing
components as necessary. Replacement
components are available in service kits from
dealers.
For information on replacement parts and
service kits, please visit
www.whalepumps.com.
Helpful Hints
Note: If at any stage the user experiences
less than optimum performance from the
Whale Watermaster IC, recalibrate the
system as per steps outlined above.
To obtain efficient running and maximum
pump life, ensure the following:
• There is sufficient water in the container.
• Maximum pumping period is not more
than 15 minutes.
• All hose connections are firm and water
tight
• When replenishing the water supply, it is
possible to create an air lock in the
pump. As a result, the pump will run
noisily and give no discharge. To remedy,
unplug from the socket while keeping the
pump submerged to dislodge the air
pocket in the pump. Also shaking the
dual hose gently may dislodge the air
pocket in the pump, or switch off pump at
main panel, open a tap outlet and switch
pump on again at the main panel.
6-6
GETTING STARTED
Troubleshooting
(a) If the pump will not run:
• Check at least one tap is open
• Turn the pump isolation switch off and on again
• Check the battery condition
• Check the mains isolator switch is on
• Check the pump isolator switch is on
• Check the contacts in the plug and socket are clean and making contact
• Check wiring connections
• Check fuse (see fuse box)
(b) If the pump cylces on/off with all taps and shower closed:
• Check for air or water leaks in taps and piping
• Check that non return valve in socket is free from grit by pushing a suitable blunt object,
for example a ballpoint pen into the socket nipple against the non-return valve holding
the valve open to dislodge trapped grit.
• Recalibrate the system (see calibration section of the installation section)
(c) If pump motor runs steadily and does not stop after 30-40 seconds:
• Check all connections in pipework
• Recalibrate the system
Diagnostic Codes
To aid with troubleshooting the LED on the back of the Watermaster IC has a number of different
flash codes as described in the table below:
LED State Description
Green Constant On Tap open, pump running
Green Fast Flash (< 1 sec) In Calibration Mode
Green 200ms blink every 5 sec Calibrated and ready for use
Green 200ms blink every 10 sec Un-calibrated
Green 200ms blink every 15 sec Suspended due to dry run need to turn pump switch on
Green 200ms blink every 20 sec Suspended due to low battery voltage, turn pump switch
Winterising
Watermaster IC does not require any additional winterising. For details of how to drain your
water system for winterising please see www.whalepumps.com/rv.
and off
on/off, need to charge battery
6-7
GETTING STARTED
6-8
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
12v POWER SUPPLY
Battery Installation
Your caravan will be fitted with a BCA Leisure
charging and power distribution unit.
If you wish to install a leisure battery please
ensure that it is placed on the battery tray
supplied with your caravan. Then place the
tray in the battery locker fitted to the side of
your caravan. Connect the battery to the
clamp fittings connected to the connection
leads within the battery box.
The type of leisure battery you should utilise
will depend on how you wish to use your new
caravan. If you are going to only use your
caravan when it is connected to a mains
supply and do not have a motor mover fitted,
then any good standard leisure battery rated
at least 85 ampere-hours at 20 hour
discharge rate is sufficient. However, if you
are going to use your caravan without a
mains connection or have a motor mover
fitted, then an AGM type battery rated at least
85 ampere-hours at 20 hour discharge rate is
recommended.
Battery Maintenance
Winter Storage
During winter storage, please ensure that the
leisure battery is fully charged. Dependent on
the battery’s capacity and age, it will require
recharging at regular intervals.
You must check the charge of your battery
and recharge if necessary on a regular basis.
This will depend on your leisure battery’s
capacity, age and state of charge. Charge at
regular intervals.
Points to remember
• Prolonged discharge causes harmful
sulfation and may damage a battery.
•Discharged (dead) batteries are prone to
freezing in cold temperatures.
• For peak performance never let a battery
sit discharged for long periods of time.
• Over discharged batteries are
permanently damaged and need to be
replaced.
Note: Do not over discharge the battery. One
of the most common causes of battery failure
is when the battery is discharged below the
recommended level of approximately 12.2v ref table. Discharging a battery below this
figure will cause permanent damage.
Overheating and gassing will occur when reconnected to the mains supply.
12 Volt Battery State of Charge
Good
OK
Warning
Damaged
Good: the battery is in good condition and not in
need of charging
OK: nothing to worry about but put the battery on
charge as soon as you can
Warning: get the battery on charge as soon as you
can. Leave it and the battery will be damaged,
possibly beyond repair
Damaged: Replace battery
12.7V 100%
12.5V 90%
12.42V 80%
12.32V 70%
12.20V 60%
12.06V 50%
11. 9V 40%
11.75V 30%
11.58V 20%
11.31V 10%
10.5V 0%
Generators / Charger
All electrical equipment fitted in your new
caravan can be run from either a controlled
generator or charger whose output is
maintained between 11volts and 14volts.
At least once every 3 years, the caravan
electrical installation should be inspected and
tested, and a report on its condition obtained,
as prescribed in British Standard BS7671.
230v POWER SUPPLY
Mains Unit
The Mains Unit replaces the conventional
fuse box. Similar, but larger ones are often
fitted in new houses. The unit, normally
located in the wardrobe, gives overloads and
earth leakage protection for the 230V
electrical supply in your caravan.
7-1
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