preparing for the road on the road fire ......lunar 2013 handbook 2 introduction lunar caravans...

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CONTENTS

TOWING CODE

PREPARING FOR THE ROAD

ON THE ROAD

FIRE & SAFETY

SERVICES

ELECTRICS

FITTED EQUIPMENT

AL-KO CHASSIS & TYRES

GENERAL DATA

Lunar 2013 Handbook

2

INTRODUCTION

Lunar Caravans welcomes you as you jointhe ranks of owners of Lunar Caravans. Wehope you will enjoy your caravan and thishandbook tells you how to look after it so thatit may give you years of pleasure andenjoyment.

Remember that it is a vehicle and thus callsfor a small amount of regular maintenance.

You are requested to contact your dealeron all enquiries in order to ensuresatisfaction. You will only experiencedelays if you bypass the normal channels.

Your Lunar caravan has been built andapproved to EN1645 which applies to a largenumber of features such as:

• sizes of beds• escape factor i.e. windows and exterior

door• materials• design and construction• insulation is grade 3 classified which is

able to achieve an average temperaturedifference of 35 degrees centigradebetween interior and exterior when theexterior is -15 degrees centigrade

• electrical equipment, both 12 volt and230 volt

• chassis• undergear• drawbar• jockey wheel• wheels and tyres• installation of gas• ventilation• awnings and channel• fire notices• handbook

Touring caravans are designated by theirmodel year which runs from 1 September to31 August. A new year model can only beregistered by CRIS from 1st Septemberonwards.

This caravan has been security marked andrecorded under the Caravan Registrationand Identifications Scheme that is organisedby the Caravan Industry.

Your Touring Caravan Registration Documentwill include a 17 character V.I.N. (VehicleIdentification Number), which is alsochemically etched on eye level windows.

To protect yourself and your touring caravan,never leave the Registration Document in thecaravan. For security reasons keep it in asafe place.

INTRODUCTION

Disclaimer: The contents of this Handbook book are as accurate as possible at the time of going to print. Lunar Caravans reserve the right to altermaterials and specifications without prior notice.

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TOWING CODE

TOWING

CODE

Scope of Code ........................................................ 4

Caravan Terms ........................................................ 4

Weights ................................................................... 4

Towing Vehicle Terms .............................................. 4

Measurement of Noseweight .................................. 6

TOWING CODE

4

User Payload (UP)

The difference between the MIRO andMTPLM (excluding potential MTPLMupgrade). The user payload allows for itemscommon to all occupants, such as food,cutlery, pots, pans, clothing, footwear,bedding, sports equipment etc. The userpayload also includes an allowance for theauxiliary battery.

The UP is calculated by the followingformula:

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 thecaravan, a sample list is given below.

TV ........................................................... 3kg

Kettle .................................................... 0.5kg

Bed linen ................................................. 6kg

Crockery .................................................. 5kg

Saucepans .............................................. 3kg

Wastemaster ........................................... 6kg

Aquaroll (empty) ...................................... 5kg

Waste bin ................................................ 1kg

Cutlery ..................................................... 2kg

Toilet fluid etc ....................................... 2.5kg

Battery ................................................... 16kg

THE CARAVAN TOWING CODE

Industry Payload Standard for UK touringCaravans

This standard has been prepared by theNational Caravan Council and formulatedwith input from Industry Experts. Thestandard applies to UK specification TouringCaravans and will applies for the NCCcertification from 2011 onwards model yearTouring Caravans.

For the 2012 model year the method ofcalculating the Mass in Running Order(MRO) and user payload figures are in linewith European Vehicle Directives andprovides for the requirements for EuropeanWhole Vehicle Type Approval EWVTA, 2007/46/EC (The Framework Directive) and thedirectives referenced therein.

DEFINITIONS

Maximum Technically Permissible LadenMass (MTPLM)

The fully laden mass of the caravan in themanufacturer’s standard specification whichis stated in the manufacturer publications bythe manufacturer for tow car matching. Thismass takes into account the specificoperating conditions including factors suchas the strength of the materials, loadcapacity of the tyres etc, and can be foundon a plate affixed to the caravan, usuallynear the entrance door.

Please note: The MTPLM is the maximumweight that the caravan can be loaded to,this mass must NOT be exceeded. Howevermost models can have the MTPLM upgradedin capacity; this must be approved by LunarCaravans Ltd via the dealership. Pleasecontact your dealership for further details.

Mass In Running Order (MIRO) or (MRO)

This is the weight of the caravan as it leavesour factory (inclusive of the electrical hook-upcable at 6kg and the winding handle at 1kg)plus the following:

8kg gas bottle allowance.

10kg of water in the water heater.

2kg of water in the toilet holding tank as thisis the maximum recommended by Thetford.

The weight of the spare wheel is 17.5kg.

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TOWING CODE

THE CARAVAN AND TOWINGVEHICLE RATIO

This can be determined by calculation and isequal to:

actual laden weight of caravan

kerb weight of towing vehicle

THE LAW REQUIRES THAT CARAVANS &THEIR TOWING VEHICLES & THE LOADSTHEY CARRY MUST BE IN SUCH ACONDITION THAT NO DANGER ORNUISANCE IS CAUSED.(Regulation 100 of the Road and Vehicles[Construction and Use] Regulations 1986).

IMPORTANT NOTICE:The caravan is manufactured for towingbehind road cars and the 4 x 4 “off road” typeof passenger car derivative. THE CARAVANIS NOT SUITABLE FOR TOWING BEHINDCOMMERCIAL VEHICLES.

POWER TO WEIGHT RATIO:

No hard and fast rules can be stated but,here is a general guide.

(a) Conventional petrol engines with acapacity up to approximately 1500 ccshould be adequate for towing a caravanweighing around 85% of the kerb weightof the towing vehicle.

x 100%

Optional Equipment Payload (OEP)

Items made available by the manufacturerover and above the standard specification forthe caravan in addition to the user payload.

Personal Effects Payload (PEP)

A mass specified for the items which a usercan choose to carry in a caravan and whichare not included as an essential habitationequipment or optional equipment.

Optional Item Additional Weight

R/C Alarm/Awning Light ......................... 1 kg

AL-KO Secure wheel locks (per lock) .... 2 kg

AI-KO ATC Trailer Control ...................... 2 kg

Air Conditioning .................................... 30 kg

Auto Switch over 40L Under slungwater tank ............................................ 47 kg

Please note: Any options fitted by retailerwill reduce the overall payload available tothe customer.

REGULATORY AND SAFETYADVICE

WARNING: UNDER NO CIRCUMSTANCESSHOULD THE MAXIMUM TECHNICALLYPERMISSIBLE LADEN MASS (MTPLM) BEEXCEEDED. PLEASE TAKE CARE TOENSURE THAT YOU HAVE ALLOWED FORMASSES OF ALL ITEMS YOU INTEND TOCARRY IN THE CARAVAN e.g. Optionalequipment and personal effects such asclothing, food, pets, bicycles, sailboards,sports equipment etc.

THE MASS OF THE CARAVAN INRUNNING ORDER (MIRO) CONTAINSPROVISION FOR THE MASSES OFLIQUIDS, GAS ETC. PART OF THISPROVISION CAN ALSO BE UTILIZED ASADDITIONAL PAYLOAD IF FOR EXAMPLEYOU WISH TO TRAVEL WITH NO GASCYLINDERS.

TOWING CODE

6

MEASUREMENT OF NOSEWEIGHT

Towing noseweight should be a minimum of50kg and heavier for twin axle models. Thismay be measured using a proprietary brandof noseweight indicator. Such equipment isobtainable at your Lunar Caravan Dealer.

Another simple method is to use bathroomscales under the coupling head with a pieceof wood fitted between the coupling headand the scales, of such length that thecaravan floor is horizontal with the jockeywheel raised.

(b) Above 1500 cc such engines shouldmanage a caravan weighing up to 100%of the kerb weight of the towing vehicleand still give adequate performance.

Note: The towing vehicle manufacturer’slimit is, in some cases, less than the kerbweight.

Vehicles with automatic transmission mayneed an oil cooler to be fitted or the SAErating of the gearbox oil increased whentowing. The advice of the vehiclemanufacturer should be sought.

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PREPARING

FOR THEROAD

Checklist ................................................................. 8

Loading and Distribution ........................................ 8

Stability ................................................................... 9

Pre-Tow Checklist ................................................ 10

Stabiliser .............................................................. 11

Wheel Lock .......................................................... 13

Breakaway Cable ................................................. 17

Tyres .................................................................... 18

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STABILITY

The most common causes of poor stabilityinclude:

(a) Incorrect tyre pressures on car orcaravan.

(b) Worn springs or loose spring fixings onthe towing vehicle.

(c) Towing vehicle shock absorbers too soft.

(d) Insufficient noseweight.

(e) Nose of caravan is towing too high.

(f) Incorrect loading

Stabilisers. There are many proprietarybrands of stabiliser available. Your Lunardealer will be pleased to advise you of themost suitable. They are an aid to stability andshould not be considered as a cure for astability problem.

Note: It is expressly forbidden by thechassis manufacturer for holes to bedrilled into the 'A' frame to accommodatea stabiliser bracket. A clamp must beused. Similarly, holes should not bedrilled into the coupling head.

Towing vehicle’s rear suspension

It is important that the towing vehicle’s rearsuspension is not deflected excessively bythe noseweight on the tow ball. If it isexcessive the steering and stability will beaffected.

The greater the towing vehicle’s tailoverhang (the distance between the rearaxle and the tow ball) the greater the effectthe noseweight will have on the towingvehicle’s rear suspension.

After trying out the caravan it may befound that stiffening of the rearsuspension is necessary — but note that thismay give the towing vehicle a firmer ridewhen not towing.

There are a number of suspension aidsavailable and advice should be sought onwhich to use and how to fit.

It is important to ensure that the caravan istowed either level or slightly nose down.

Illustration of excessive deflection of vehicle’s rear suspension


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PRE-TOW CHECKLIST

1. Check that the hitch is securely coupledonto the towball and connect thebreakaway cable. Your hitch heightshould be around 440mm (17") to thecentre of the towball when the towingvehicle and caravan are coupled andladen.

2. The Jockey wheel should be raised andtightly clamped or removed completely ifdesired.

3. Corner steadies must be wound up fully.

4. Plug in the electrical connection to thecar, keeping the cable clear of the roadand check the operation of lights.

5. Release the handbrake. “Failure toensure that the handbrake is completelyoff, can result in overheating of thebrakes and failure of the bearings”.

6. Check tyre pressure with cold tyres (seespecification). Wheel bolt torque settingsshould be 88Nm (65lbs/ft) for steelwheels. Alloy wheels should be 115Nm(85lbs/ft).

7. Adjust the tyre pressures of your tow carto the manufacturers recommendationsfor full loads.

8. Engage the stabiliser, if fitted.

9. Fit towing mirrors to your car.

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AKS STABILISER(where fitted)

This model of stabiliser has 4 special frictionpads, which suppress both snaking andpitching. It is essential that the tow ball iskept completely clean as contaminated padswill reduce its effectiveness.

Operating instructions

• Using the coupling handle, put the AKSon to the towball. Push the black handledown and check the green indicatorbutton is showing (Fig. 1).

• Press the red stabilising lever down. TheAKS is now ready for the road (Fig. 2).

Safety indicators

If the green indicator is visible then you knowyou have correctly coupled your AKS to yourtowing vehicle (Fig. 3).

Wear Indicator

For Coupling mechanism and front/rearfriction pads. (Fig. 4)

Fig. 1 Fig. 2

Fig. 4Fig. 3


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• Wear of the coupling ball and mechanismcan be easily monitored. If the greensection is visible (when coupled to yourtowball) then the front/rear friction pads,coupling ball and mechanism are inorder.

• If the red lower section obscures thegreen section then you need to checkthese parts immediately.

Fig. 5

Fig 6

Fig. 8

Fig 7

Fig. 9

Friction pads in goodorder

Friction pads worn out andneed replacing

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Friction Pads Replacement

• Unscrew the 2 screws which are underthe soft dock by using the special torxtool (UK version only). (Fig. 7)

• Remove screw from back plate. (Fig. 8)

• Remove friction pads. (Fig. 9)

Loading Capacity

The AKS can be utilised to tow vehicles up toa gross weight of 3000kg and a maximumnose load of 100kg.

AL-KO SECURE WHEEL LOCK

You must register your key, should you fail todo this you will not be able to order a sparekey or obtain lost or stolen keys.

This is how it works:

• On the Al-Ko Secure registration cardyou will find an exclusive securitynumber.

• Please register your key by telephoning0870 7576788 or 0044 1926 818500.

• You will be required to provide thechassis number of the caravan.

• You will need to provide us with apassword and supply answers to threesecurity questions.

• Make a note of your password and keepit in a safe place.

• Also keep your registration card safe.

• Take your registration card with youwhen you are travelling with the caravan.

• Always keep your registration cardseparate from the lock.

Safety Information

• Always secure the caravan againstmovement (chock the wheels, couple totowing vehicle).

• Never leave Secure parts (key, lockingbolt, registration card) in the caravan.

• Always remove Al-Ko Secure beforemoving the caravan.

• After any attempt at theft has been madeon a locked Al-Ko Secure, the caravanmust be inspected in an Al-Ko ApprovedService Workshop.

• Always keep the key in a safe place.

• Keep the lock set and registration cardseparate from the keys.

• The lock parts and key do not have aregistration number, therefore keep theregistration card in a safe place.

• Caravans with twin axles have two locks,keep each lock set in a separate place.The sets are not interchangeable!

Note: Read the operating instructions andact in accordance with them. Keep theoperating instructions for general use.Follow the safety instructions as well asthe warning information.


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ASSEMBLY

We recommend the use of a side-lift jack foreasier fitting of Al-Ko Secure when used on atandem axle caravan. (Order No. Al-Ko JackSet 1389235).

• Align the wheel so that the receiver canbe seen in the centre of the rim opening.DO NOT use the rim opening in whichthe tyre valve is fitted. (Fig. 1)

• Unscrew the plastic cap from the receiverand store in the tool kit box. (When Al-KoSecure is not in use, always screw theplastic cap in place). (Fig. 2)

• Insert the locking bolt into the rim specificinsert. (Fig. 3)

• Insert the locking bolt socket key. (Fig. 4)

• Line up the locking bolts and assemblywith the receiver. (Fig. 5)

• Tighten the locking bolt socket using thewheel spanner provided (or torquewrench as shown) to wheel torque. (Fig.6)

• Remove the locking bolt socket key.(Fig 7)

• Insert barrel lock. (Fig. 8)

• Hold the lock fast and lock. (Fig. 9)

• The Al-Ko Secure is now fitted. (Fig. 10)

Fig. 1 Fig. 2

Fig. 4Fig. 3

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Fig. 5 Fig. 6

Fig. 9Fig. 8

Fig. 7

Fig. 10


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TWIN AXLE CARAVANS

Fit the front lock first by aligning the wheel sothe receiver can be seen in the centre of therim opening. Chock front wheel and oppositewheel. Jack the caravan (preferably usingthe Al-Ko side lift jack) until the rear wheel isclear of the ground. Fit the second lock byaligning the wheel as described previously

Note: Lost components phone 00441215050400.

In the event of attempted theft report topolice and your insurance company.

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SECONDARY BRAKING CABLE(Break away device)

Purpose - To apply a trailer’s brakes if itbecomes separated from its towing vehicle.Having done this, the cable assembly isdesigned to part, allowing the trailer to cometo a halt away from the towing vehicle.

Construction - A thin steel cable, possiblyplastic coated, and fitted with a means ofattachment for connection to the towingvehicle.

Operation - In the event of the main couplingof the trailer separating from the towingvehicle, the cable should be able to pull tight,without any hindrance, engaging the trailer’sbrakes.

NOTE: The breakaway cable should neverbecome taut during normal use.

Correct procedure for use:

● Regularly check the cable and clip fordamage. If in doubt, contact your dealeror service agent.

● Make sure the cable runs as straight aspossible and goes through a cable guideunderneath the trailer coupling.

● Determine whether or not the towbar hasa designated attachment point (i.e. a partspecifically designated by itsmanufacturer for a breakaway cable).

Where a designated attachment point isprovided on the towbar:

Either:

a) Pass the cable through the attachmentpoint and clip it back on itself (Fig 1).

Or:

Where no designated attachment pointhas been provided on the towbar:

Fixed ball - Loop the cable around the neckof the towball. If you fit the cable like this, usea single loop only. (See Figs. 2 and 3).

Detachable ball - You must seek guidanceon procedure from the towbar manufactureror supplier.

Fig 1 Fig 2 Fig 3


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TYRES

All tyres used on Lunar caravans, wheninflated to the pressures recommended, areadequate for speeds up to 130 kph at themaximum specified laden weight of allmodels.

Note: Maximum permitted speed in theU.K. is 60 mph and in the interests of roadsafety speeds above this are notrecommended.

Tyre tread

A caravan is subject to the same criteriaapplied to car tyres, namely; a minimum of1.6 mm tread pattern depth throughout.

Tyre pressures

Caravan and towing vehicle tyres must beat the pressures recommended for towingor heavy loading. The pressures can befound in the towing vehicle handbook andunder the caravan specification in the servicehandbook.

Note: Pressures should only be checkedwhen the tyres are cold, not after ajourney or if the vehicle has beenstanding in the sun.

Other means of attachment:

In some instances it may be possible toattach the cable assembly:

Either:

a) to a permanent part of the towbarstructure, as long as this meets theapproval of the towbar manufacturer/supplier,

Or:

b) to an accessory sold for the specificpurpose of breakaway cable attachment.

When the breakaway cable is attached,check to ensure:

a) that the cable cannot snag in use on thetrailer coupling head, jockey wheel, orany accessory, e.g. a stabiliser, bumpershield, cycle carrier, etc.

b) that there is sufficient slack in the cableto allow the towing vehicle and trailer toarticulate fully without the cable everbecoming taut and applying the brakes.

NOTE: For peace of mind you might wishto check the state of the cable bypositioning the trailer and towing vehicleat extreme angles before setting off.

c) that it is not so slack that it can drag onthe ground. If left loose, the cable may

scrape along the ground and beweakened so that it subsequently fails todo its job. The cable may also be caughton an obstacle when in motion thusengaging the trailer brakes prematurely.

Having followed this advice, should you feelthat a satisfactory coupling arrangementcannot be achieved, consult your trailer ortowbar supplier or service agent.

• It is a legal requirement that thesecondary break away cable is usedwhen towing.

WHEELS

Check wheel nut torques regularly andparticularly before a long trip for extra safety.

This service is available at all tyre servicedepots (inform them of the torque settings)

• The torque settings are:

ALLOY WHEELS 115Nm

STEEL WHEELS 88Nm

• Check wheel/tyres for signs ofdeterioration or damage.

WARNING: After a wheel has beenrefitted, always recheck the torque after20-30 miles use or 20-30 minutestravelling. Even if properly torqued up, itis occasionally possible for fixings toloosen should the wheel "bed in" on thehub.

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To release the handbrake, push it forwardand down using your body weight.

Note: “Failure to ensure that the caravanhandbrake is completely off, can result inoverheating of the brakes and failure ofthe bearings”.

Ground Clearance

Care has to be taken to preventgrounding of the caravan when traversingramps and ground obstacles. If necessaryground clearance can be increased byremoving the jockey wheel whentravelling.

Number Plate

A trailer must carry a rear number platebearing the number of the towing vehicle andbe illuminated at night. The number plateshould conform to the same size and colourregulations as for cars. A reflective black andyellow plate may be used on a trailer towedby a vehicle with non-reflective plates andvice-versa.

Manoeuvring

When pushing or pulling the caravanalways use the grab handles correctly, donot snatch them and never push bodypanels, metal or glass reinforced plastics,as this can cause serious damage to thebodywork or mastic seals.

Mirrors

The driver of the towing vehicle must havean adequate view of the rear.

If there is no rear view through the caravan itis essential that additional exterior towingmirrors are fitted.

Caution: Any rear view mirror must notproject more than 200mm outside:

a) the width of the caravan when beingtowed.

b) the width of the towing vehicle whendriven solo.

Note: Any rear view mirror fitted shall be‘e’ marked and cover the field of view asstipulated by type approved requirements(Regulation 33 of the Road Vehicles[Construction and Use] Regulation 1986).


20

Road lighting

For your information the wiring diagram ofthe 13 pin connector is shown. These shouldbe checked regularly and if in any doubt aqualified electrician consulted.

Passengers

Passengers are forbidden to ride in acaravan with the exception of authorized testpersonnel.

13 pin plug wiring diagram

PIN No COLOUR DESCRIPTION

1 YELLOW LEFT IND

2 BLUE FOG

3 WHITE NEG FOR ROAD LIGHTS

4 GREEN RIGHT IND

5 BROWN RIGHT SIDE LIGHTS

6 RED STOP

7 BLACK LEFT SIDE LIGHTS

8 ORANGE REVERSE

9 BLUE/BROWN CAR +VE

10 RED/BROWN FRIDGE +VE

11 GREEN/WHITE FRIDGE -VE

12 EMPTY

13 BLUE/WHITE CAR -VE

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ON THE ROAD

ON THEROAD

Speed Limits ........................................................ 22

Pulling Off ............................................................. 22

Caravan Handling ................................................ 22

Motorway Driving ................................................. 22

Reversing ............................................................. 22

Changing a Wheel................................................ 23

Jacking Points ...................................................... 23

Stopping on a Hill ................................................. 24

Arrival on Site ....................................................... 24

ON THE ROAD

22

SPEED LIMITS

Normal road towing: 50mph

Motorways (including dual carriageways):60mph

PULLING OFF

Let the clutch in smoothly.

Allow more engine speed to produce thepower to move the additional weight of thecaravan.

Avoid wear and tear on clutch andtransmission by taking extra care.

Change gears smoothly.

Try not to jerk the clutch.

CARAVAN HANDLING

Allow for caravan being wider than car.

Do not bump kerb with caravan wheels.

When passing other vehicles allow morethan the normal clearance for driving solo.

Allow longer to get up speed to pass.

Allow for the vehicle being twice its normallength.

Do not suddenly swing out.

Carry out all manoeuvres as smoothly aspossible.

Use nearside wing mirror to check caravanhas cleared when overtaking.

Never let a ‘tail’ of traffic build up behind you.Always pull in to let others past.

MOTORWAY DRIVING

1. Caravans may not be towed in theoutside lane of a three or four lanemotorway. (Reg. 12(2) of the MotorwayTraffic [England and Wales] Regulations1982).

2. Reduce Speed:

i) In high or cross winds.ii) Downhill.iii) In poor visibility

3. High sided vehicles cause air buffeting soextra care must be taken when passingor being passed. As much space aspossible should be given.

Reversing

Proficiency at reversing can only be achievedwith practice and should be first attempted ina large open area.

Your caravan is fitted with an automaticreversing mechanism which allows you toreverse without the need to make anyadjustments. After reversing, the caravanshould be drawn forward at least 1 metreto restore the brake shoes to their normalposition before applying the hand brake.

Note: Reversing uphill will be difficult ifeither wheel brake or brake linkage isoveradjusted. You need to ensure that thebrakes have been disengaged beforereversing uphill.

1

2

3

23

ON THE ROAD

CHANGING A WHEEL

1. Leave caravan hitched to towing vehicle andensure handbrake is applied.

2. Lower corner steadies (as safety measure) onthe side that the wheel is being changed tostabilise the caravan.

3. Use wheel brace to slacken off wheel nuts onthe wheel to be changed.

4. Position jack under the axle at the appropriatejacking point (see fig. A).

5. Jack up the caravan until the wheel for removalis just off the ground.

6. Remove the wheel bolts, wheel trims andremove the wheel.

7. Fit spare wheel and reverse the aboveprocedure.

8. When replacing the wheels you should tightenthe nuts in rotation diagonally. Tighten all nutsequally, according to Fig. B, to 88Nm (65 lb/ft)

for steel wheels and 115Nm (85lbs/ft) for alloywheels using a torque wrench or havechecked as soon as possible.

Note: When changing a wheel ensure:

a) that the correct wheel fixings are used.

b) that there are clean, dry mating surfacesand clean, dry bolt/nut area.

NB: Special nuts are supplied with alloywheels and these can be used where asteel wheel is used as a temporary spare.

If replacing an alloy wheel nut, a nut to thefollowing reference should be purchased:M12 x 1.5 pitch, 26mm thread, 10.9 grade,60 degree conical fixing, 19mm hexagon bolthead.

IMPORTANTWhen a wheel has been removed andreplaced the torque of the wheel nuts shouldbe re-checked after approximately 15 milesof running.

JACKING POINTS

It is recommended that the jack is located inthe correct position i.e. on the axle tubeinside the chassis member (Fig. A). The re-inforced axle mounting plate can be used asan alternative but the chassis- member itselfMUST NEVER be used as a jacking point.

Alko Side Jack

The Alko chassis is provided with the facilityto fit an Alko side jack which can be fitted asan optional extra (Fig. C).

AXLE

CHASSIS 50mm”V” HEAD SCISSOR

JACK

Fig. A Jacking Point Fig. B Wheel Nut Tightening Fig. C Alko Side Jack

4 STUD WHEEL 5 STUD WHEEL

ON THE ROAD

24

ARRIVAL ON SITE

Note: Check and observe site regulations.

1. Selecting a pitch.

Do not pitch in such a position that your outfitwill obstruct others coming in.

Try to choose an area which is dry,reasonably level and preferably with a hardbase.

If you have no alternative but to pitch on aslope ensure that, for when you leave, youare facing down the slope.

It is good practice to chock the wheels of thecaravan when parked on a slope eventhough the caravan brakes are applied.

2. Siting/Unhitching

When you arrive at your site and have beenalloted a pitch:

Manoeuvre your caravan onto your pitch (ifyou have reversed read the notes on page20), apply the handbrake, remove the brakesafety cable, unplug the 13-pin plug andstore these in the sockets provided on the ‘A’frame cover.

Unclamp and lower the jockey wheel to theground. Re-clamp the jockey wheel after firstunscrewing slightly.

Free the coupling by winding up the couplinghead until it is clear of the 50mm ball.Replace the tow ball cover and then parkyour car.

3. Levelling the caravan

Levelling must be carried out in bothdirections in order for the refrigerator andother equipment to function correctly.

The positioning of the jockey wheel can beused to help level the caravan.

Lower the corner steadies until they are infirm contact with the ground. DO NOT usethe steadies as a jack they are only a meansof stabilising the caravan.

Levelling pads or boards should be usedunder the steadies where the ground is softor uneven. Stepped levelling boards caneasily be constructed (Fig. D).

In extreme cases where it is necessary toraise a wheel off the ground for levellingpurposes, further adequate support shouldbe applied so that the steadies do not takeany undue strain.

STOPPING ON A HILL

Pulling off again can sometimes present aproblem. The easy solution is:

(i) Carry a good sized wedge shaped pieceof wood with a rope or light chainattached.

(ii) Attach the other end of the rope to thenearside rear grab handle.

(iii) Place the wood behind the nearsidecaravan wheel.

(iv) Carefully reverse the car slightly backdown the hill, the caravan will stopagainst the wedge and turn.

(v) Drive forward since this attempt to moveup the hill will now not involve pulling thefull weight of the caravan until the carhas gained some traction.

Ramps

Take care to prevent fouling when traversingramps or other ground obstacles.

25

ON THE ROAD

Exterior Door

To prevent distortion of the body, the caravanmust be always correctly sited and levelled.Failure to site the caravan correctly mayprevent the exterior door from closingproperly.

Attention: Always disconnect the electricalconnector between the towing vehicle andthe caravan before connecting an LV supplyto the caravan and before charging thecaravan battery by any other means.

Fig. D Levelling Board

ON THE ROAD

26

27

FIRE & SAFETY

FIRE

&

SAFETY

In Case of Fire ....................................................... 28

Smoke Alarm ......................................................... 28

Carbon Monoxide Alarm........................................ 29

Fire Extinguisher ................................................... 29

Children ................................................................. 29

Ventilation.............................................................. 29

Security ................................................................. 30

Theft ...................................................................... 30

Chassis Number.................................................... 30

Additional Security ................................................ 30

Datachip Security Card ......................................... 30

FIRE & SAFETY

28

FIRE ACTION

1. GET EVERYONE OUT2. TURN OFF GAS VALVE3. RAISE THE ALARM AND CALL THE

FIRE BRIGADE4. DISCONNECT THE MAINS

ELECTRICITY SUPPLY5. TACKLE THE FIRE IF SAFE TO DO SO6. MAKE YOURSELF FAMILIAR WITH

THE INSTRUCTIONS ON YOUR FIREEXTINGUISHER AND THE FIREPRECAUTION ARRANGEMENTS ONTHE SITE

7. CHECK FIRE EXTINGUISHERSREGULARLY

8. CHECK GAS PIPING AND MAINSELECTRIC WIRING ANNUALLY

If you suspect a gas leak - never usea naked flame to search - always usesoapy liquid or - better still - call yourcaravan dealer.

Important

With any extinguisher, never use it on a panof fat - this is very dangerous - always use afire blanket.

To tackle a pan fire: First of all, if possible tryto turn off the gas. Make sure you are awareof the position of the gas isolating taps -usually placed in the sink unit cupboard.

Never throw a flaming pan outside, keepyour hands away from the flames andsmother the flame.

Try to remain calm.

Do not throw the blanket on the fire but placeover the pan paying particular attention tothe handle.

Fire Precautions

Make sure you are aware of the operationand location of escape windows and doors.

It is advisable to carry a fire extinguisher (adry powder is recommended) positioned asnear to the exterior door as possible.

A fire blanket approved to BS 6575 is alsoadvisable positioned as near to the cookingarea as possible.

Check the fire regulations on arrival at sites.

Do not leave pans on the stove unattended.

Do not leave matches within easy reach ofsmall children.

Never leave small children alone in thecaravan.

Do not smoke in bed.

Do not block up ventilators.

SMOKE ALARM

The Code of Practice requires that a smokealarm is fitted in your caravan. Every new

manufactured caravan has a smoke alarmfitted as standard equipment.

Connecting the battery

Your alarm requires one 9 volt battery topower the smoke detector portion of the unit.Under normal use, the battery powering thesmoke detector should last approximately oneyear. See label inside smoke alarm lid forsuitable batteries.

With a pencil, write the date of batteryinstallation on the inside of the cover toremind you when to replace the battery.

Lift battery from battery holder and snapbattery connectors to battery. They fit togetheronly one way.

Gently push battery into battery holder.

To close the cover match up snap-in hingesand gently press together until base andcover snap together.

IMPORTANT

When the battery is first connected thealarm may sound for 2–3 seconds.

THIS IS NORMAL.

It means the battery is connectedcorrectly.

Replacing the battery

Test the alarm for correct operation using thetest button whenever the battery is replaced.

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FIRE & SAFETY

When battery power is low and replacementis necessary, the alarm will ‘beep’ about onceper minute for at least 30 days. The batterymust then be replaced. Replace battery if thealarm does not sound when the test button ispressed. For maximum reliability, replacebattery at least once a year.

Testing the Smoke Alarm

It is recommended that you test the smokealarm once a week to be sure the unit isworking. It will also help you and your familyto become familiar with the sound of thealarm.

When you press the test button it simulatesthe effect of smoke during a real fire. So,there is no need to test the alarm withsmoke.

Press and hold the test button until the alarmsounds (it may take up to 10 seconds). Thealarm will stop sounding shortly after thebutton is released.

Cleaning the Smoke Alarm

Clean the smoke alarm regularly. Use a softbristle brush or the brush attachment of yourvacuum cleaner to remove dust from thesides and cover slots where the smokeenters. Keep cover closed while cleaning. Donot vacuum or brush inside the smoke alarm.To clean the cover, remove it completely anduse only mild soap and water. Dry coverthoroughly before replacing it.

Warning: Do not paint the Smoke Alarm.

Other than the maintenance and cleaningdescribed above, no other customerservicing of this product is required.

CARBON MONOXIDE ALARM

Your carbon monoxide alarm is located onthe underside of the offside or nearsidelocker. Under normal operating conditionsthe power pack will last for the lifetime of theproduct (7 years). Batteries for this productare non replaceable.

It is recommended that the alarm is testedweekly by pressing the test/reset button.

LED Indicators

Power. In normal operation the LED willregularly flash green.

Fault. If a fault is found in the sensor andcircuitry or the power pack becomes low thenthe detector will emit a single chirp once perminute and the fault LED will flash yellowonce per minute for 30 days.

Alarm. When sufficient carbon monoxide isdetected a loud audible signal will be emittedand the alarm LED will flash red once everysecond. When alarm is tested the LED willilluminate red.

FIRE EXTINGUISHER

It is recommended that a 1kg (2lb)minimum capacity dry powder fireextinguisher be carried inside yourcaravan at all times. (NCC recommendtypes marked 5A34B).

When using a dry powder extinguisher it issuggested that the caravan beevacuated until the powder has settled, toavoid inhalation.

A fat pan fire should not have a fireextinguisher aimed at it. It should besmothered with a fire blanket.

Children

Do not leave children alone in the caravanin any event. Keep potentially dangerousitems out of reach, as at home e.g. matches,drugs etc.

FIRE & SAFETY

30

Bunks

Where fitted, the foldaway bunk has beentested to 70kg (11 stones) and has arecommended limit of 57kgs (9 stones).Safety features are included but care shouldalways be taken, particularly if the child isunder 3 years of age. Bunks are not suitablefor children under 6 years old withoutsupervision.Solid (fixed) bunks have a recommendedlimit of 75kg (12 stones).

Ventilation

All caravans comply with BritishStandards EN1645. The ventilation points onyour caravan are fixed points of ventilationwhich are stated by the British Standards.

Ventilation is provided at floor and ceilinglevel and care should be taken to ensurethese remain clear of debris by regularcleaning.

Under no circumstances must thesevents be blocked or obstructed.

It is advised that fixed ventilation pointsare checked and cleaned (if necessary) on aregular basis.

Additional night time ventilation isobtained by releasing the window catchesand placing them in the second groove onthe frame catch.

You must maintain adequate spacing ofcombustible materials from sources of heat(eg heater)

Do not use independent gas appliancesinside the caravan.

We advise that the user instructions for thefitted appliances are studied in addition tothe information in this handbook.

Petrol/Diesel Fumes

The fitting of a tail pipe to your car exhaustwill reduce the possibility of fumes enteringyour caravan through the front fixedventilation points.

SECURITY

Caravan theft

The theft of a caravan can occur in themost unlikely circumstances; from amotorway service area, even from anowner’s driveway.

Secure all windows and doors when yourcaravan is unoccupied even if only for a shortlength of time.

Vehicle Identification Number (V.I.N.)

Record your caravan V.I.N. which can befound on any of the eye level windows.

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SERVICES

SERVICES Water ..................................................................... 32

Gas........................................................................ 39

Electricity ............................................................... 44

SERVICES

32

WATER SYSTEM - DELTA MODELS

An underfloor water tank with anapproximate capacity of 40 litres of freshwater is fitted as standard equipment on theDelta models only. Water levels aredisplayed by a series of LED's on thecontrol panel. The tank has its own in-builtpump and filling of the tank via the externalpump supplied, which is operated by aswitch on the control panel.

Full switching operation for the pumps canbe found under Delta control panel.

Due to weight and stability we recommendthat the tank is drained prior to towing.

DO NOT ALLOW ANY OF THE PUMPS TOBE ACTIVATED WHEN NO WATER ISPRESENT AS THIS WILL DAMAGE THEPUMP.

The tank is fitted with an overflow and adrain cock.

Do not use bleach or detergents forcleaning the system but rather a formulationfrom your chemists normally used by homebrewers.

WATER SYSTEM WITH UNDERFLOOR WATER TANK - DELTA MODELS

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SERVICES

Whale Surge Damper

The surge damper prevents water hammerand also reduces switch hunting on and off.

The surge damper is a completely sealedunit and requires no servicing, however, aswith Whale water systems, the completesystem should be drained in the winter.

The Filter

The filter attaches directly to the pump andincorporates a non- return valve designed toprevent dirt and grit from entering the pumpvalves as this will cause pump failure. Thefilter is fitted during installation to protect thepump.

Pressure Switch

The pressure switch is operated by theopening and closing of the taps/shower.When a tap is opened the pressure in thesystem is altered which activates thepressure switch supplying power to theselected pump.

Solenoid

The solenoid is an electrically operated valvecontrolling the water flow from internal andexternal pumps.

Maintenance

Poor pump performance may be anindication that the filter has become blocked

STANDARD WATER SYSTEM

SERVICES

34

WATER PUMP

The separate plug-in pump assemblyconsists of a Crystal Maxi pump, hose andplug. The plug provides connection of bothwater supply to the caravan and 12V dcelectric power to the pump. A dust cover isfitted to the connecting dual hose to preventcontaminants falling into the water container.

The Crystal Maxi pump is a completelysealed unit designed for intermittent use. It isNOT self-priming and therefore to ensureproper performance, the pump MUSTALWAYS be fully submersed in waterBEFORE plugging into the wall socket.

by debris. The filter is easily removed forinspection and cleaning:

• Remove circlip and unscrew filter from

pump.

• Pull two halves of filter apart to expose the

strainer mesh.

• Remove any debris and replace strainer

mesh in position.

• Ensure the rubber seal is correctly seated in

the groove on the outlet side of the strainer

before pushing the two halves firmly

together.

• Attach to the pump and replace the circlip.

• See arrow on pump housing for flow

direction.

Care of your Submersible Pump

Care should be taken to ensure that thepump is not allowed to run dry forappreciable periods. Whilst the design willallow some dry running, such as when thetank requires refilling, the pump life will beappreciably lengthened if care is taken tominimise dry running.

Aquaflow Caravan Filler

There is a special filler fitted for use with theSubmersible Pump which not only provides arecessed, locking filler cap for water input,but also a polarised power take-off pointcomplete with input plug. This is part of theoriginal equipment for Delta models only.

The Water System for Delta Models

A submersible pump is used for pumpingwater from an external container into theinboard tank of the caravan.

To Operate The System

First ensure that the drain tap on the inboardtank is closed. Place the pump inside yourfilled container. Place the hose into the fillercap on the side of the caravan. Plug in the12 volt plug into the socket on the filler cap.When the water container is empty unplugthe 12 volt -do not allow the pump to run dry.

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SERVICES

Initial connection to fresh water supply

1. Fill the fresh water container and place italongside the wall socket located in theoffside external wall of the caravan.

2. Ensure the pump isolator switch at thecontrol panel inside the caravan isswitched off.

3. Open the ‘hot’ kitchen tap. Ensure allother taps are closed.

4. Place the pump into the water containeroutside the caravan, taking care toensure the pump reaches the bottom ofthe container.

5. Lift the lid of the wall socket and fit thepump assembly plug into the socket.Ensure it is pressed in fully.

6. Adjust the dust cover to fit over theopening in the water container to keepcontaminants out.

7. Switch on the pump isolator switch at thecontrol panel inside the caravan.

8. Wait until water flows freely from the ‘hot’kitchen tap. Allow to flow for a few moreseconds to ensure release of any trappedair in the water system, then turn the tapoff.

Repeat the same procedure with the ‘cold’kitchen tap.

If the system has been drained, the aboveprocedure MUST be repeated EVERY timethe water container is filled.

Switch on the pump isolator at the controlpanel.

Once it has been properly connected, and atap is turned on, the pump is activatedautomatically by a pressure switch.

Fault Finding

1. Pump runs very noisy but does not pumpwater. Likely to occur after watercontainer has been refilled. Pump is airlocked. Cure: unplug from socketallowing pump to flood, and reconnect byplugging in again. The correct sequencewhen refilling the container is to unplug,replace pump in container, thenreconnect.

2. Pump fails to deliver water. The mostlikely cause will be air in the system. Toremedy this, switch off the pump andshake the pump assembly in the water.Then switch on again. Alternatively, makesure the assembly is positioned fully intothe housing.

3. Pump does not run at all. If not due toblown fuse or faulty connections, thenmost likely cause is excessive continuousrunning. Cure: replace pump.

Never allow the pump to run dry.

Never allow the pump to run continuouslyfor more than 15 minutes.

Note: When refilling the water container, thepump assembly may be left plugged into thewall socket so that the pump can be kept offthe ground by inserting the hose into thegroove on the underside of the plug. But, thepump assembly MUST be unpluggedBEFORE replacing the pump into the refilledwater container.

STERILISING

When cleaning the water system at the startor the end of the season, it is advisable touse the sterilising fluid, e.g. Milton 2,Chempro SDP or similar. It is recommendedthat for this operation you use any emptyfilter body as the fluid reduces theeffectiveness of a new filter.

Flush the system thoroughly to remove theeffective fluid traces.

After sterilising the system at the start of theseason it is recommended that a new filtercartridge is fitted.

NOTES

• Never allow the pump to run dry. Alwaysensure that the pump is submerged inthe water or the life of the pump will bereduced.

• Before winter storage, the water systemmust be completely drained.

• Clean the water system at the start and

SERVICES

36

end of the season with sterilising fluid(see notes under sterilising).

Water System Winterisation

Caravans may be in use all year round, butwhen not in use, even for short periods, thisprocedure should be followed. One night offreezing temperatures is all that is requiredfor expensive permanent damage to watersystem components.

a. The whole system must be drained.

b. Open kitchen taps. Lever taps should belifted in central position, leave taps openpermanently after system drain down.

c. Open bathroom and shower taps(including shower on/off control rose) andleave open permanently after systemdrain down.

d. Shake the shower head to remove thewater held there and in the hose. At thispoint is is recommended to remove theshower head from the hose. Even thesmallest amount of frozen water canresult in the shower head cracking.

e. Remove cold water drain plug (if fitted),normally located under the caravan nearto the water inlet socket.

f. If possible remove any remaining waterfrom system plumbing at water inletsockets and in between in-line pressureswitch plumbing.

g. Disconnect cartridge or in-line filters fromplumbing.

h. Submersible pumps should be shakenout and stored in a dry place.

i. Drain the external shower bridgeconnection (including models withoutexternal shower) on the Ultraflow housingby inserting the shower connection oropen the valve by means of a tool topush on the black rubber pad of thevalve.

Cleaning the Water System andPortable Water Tanks

The water systems, and in particular storagetanks, in caravans are susceptible tocontamination by bacteria if care is not takenwith their use and cleaning. The symptomscaused by bacterial contamination are notpurely limited to gastro-intestinal diseases,but may also manifest themselves as ear,nose, throat, eye or skin infections. It istherefore important that you carry out thefollowing procedure prior to using thecaravan each time, even if you boil or filter allwater you use for drinking.

Water Containers

1. All water remaining in the containershould be disposed of so that thecontainer is empty.

2. The outside of the container should bethoroughly cleansed and washed down to

remove any dirt, dust or othercontaminants. Water at a suitably hottemperature containing an appropriatedetergent is recommended for thispurpose.

3. Water should be placed in the container,swirled around, then emptied out.

4. The container should then be totally filledwith water containing an appropriatedisinfectant/sterilant solution and allowedto stand for the recommended contacttime (e.g. Milton for 15 minutes).

5. The solution should be emptied from thecontainer.

6. The opening of the container should becleaned thoroughly with an appropriatepre-prepared wipe impregnated with adisinfectant/sterilant.

7. The container should be inverted whilststored overnight (if possible).

8. The container must be filled with mainswater only and mains water only shouldbe used for the above cleaningprocedure.

9. On no account should garden hoses beused to fill water tanks.

Water Systems

1. Drain down the system. (Open all taps toallow air in, enabling the system to drainquickly.)

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SERVICES

2. Remove any water filters fitted, andreplace with a short length of hose orempty filter cartridge (this will ensure thefilter is not affected by the disinfectant/sterilant solution).

3. Fill the system by using the pump with adisinfectant/sterilant solution. (Check thatthe solution at full strength appears at alltaps/showers). Allow to stand for therecommended period of time.

4. Drain the system down using the watersystems internal flip switch located underthe front off-side bed.

5. Thoroughly clean the outside of all taps/connectors with a cloth soaked in thedisinfectant/sterilant.

6. Flush the system through with cleandrinking water until no traces ofdisinfectant/sterilant can be detected atany tap.

7. Replace the filter.

Suitable sterilising chemicals are availablefrom your caravan dealer, accessory shop,chemists or home-brew shops. It is not,however, recommended to use bleach orsodium metabisulphite.

Setting Up the Water System

1. Replace/close all drain valves.

2. Replace shower heads and tap spouts.

3. Close all taps.

4. Refit old filters:

a. Check all plumbing connections.

b. It is recommended at this point tosterilise your water container andflush the system through withsterilising fluid.

Note:Frost damage cannot be claimed underwarranty.

SERVICES

38

2. Leave the power supply turned on.

3. Tighten the adjusting screw (clockwise).The pump should now be running.

4. Partly open one cold tap to allow water toflow at about 1 pint per 15 seconds.

5. Now slowly loosen the adjusting screwuntil the switch starts to click. The switchwill then be properly adjusted.

Helpful Hints

a) If the pump will not run:

• Pump could be faulty or a wiredisconnected.

• Check that the pump isolating switch isturned on.

b) If the pump cycles on/off:

• Battery voltage may be too low (at orbelow 10.5 Volts). Adjust switch (see text)and/or recharge battery.

• Check for air or water leaks in taps andpiping. Re-adjust pressure switch.

• Non-return valve may be held open bygrit.

Study the exploded drawing and remove thethree assembly screws to gain access to thenon-return valve.

c) If a pump motor runs steadily and will notstop:

• Battery voltage may be too low (at orbelow 10.5 volts)

• Check all connections in the pipe-work.

• Remove the adjusting screw, if motor stillruns, pump is probably air locked. Turnoff the isolator switch and reprime thepump (see text).

PRESSURE SWITCH

Operation

The pressure switch detects the opening orclosing of any tap in the system and switchesthe pump on or off accordingly. It is locatednear the water heater.

To prime if fitted with a submersiblepump:

1. Trapped air in the submersible pump willnot allow the pump to prime. Air can bereleased by gently shaking the pumpunder water while the pump is in thewater tank but is switched off.

2. If an external submersible pump is used,place the pump in the water beforeconnecting to the side of thevan.

At normal flow rates the pump shouldoperate continuously — but at low rates thepressure switch will cycle on and off tomaintain back pressure in the pipework.

Adjusting the pressure switch:

If the battery voltage is not constant, cyclingmay occur. This can be minimised byadjusting the switch’s diaphragm sensitivityas follows:

1. With the system properly primed, closeall taps and showers.

Pressure switch

39

SERVICES

GAS

GENERAL INFORMATION

Gas BottlesBottled Liquefied Petroleum Gas (LPG) is themost convenient portable source of fuel foryour caravan.

Make sure that heating and cookingappliances and the gas cylinders areswitched off before you move the caravan.

Regularly check flexible gas hose, joints andconnections for tightness. Finally make surethat each gas appliance is working efficientlyto the recommendations of the appliancemanufacturers.

In all cases the cylinder contents are inliquid form under pressure from the gasabove it, and the pressure is onlydependent on the type of L.P.G. and itstemperature.

When gas is supplied the pressure in thecylinder is slightly reduced and liquid “boils”off to restore the balance. This action coolsthe liquid and the cylinder, and condensationor even frost may sometimes be observed onthe outside of the cylinder. The cylinder,when in use, is always cooler than thesurrounding air so allow plenty of circulationin cool weather and do not cover the cylinderwith a “cozy” in the winter.

Butane works satisfactorily at temperaturesdown to 2° C. Propane should be used fortemperatures below this, therefore for allyear round caravanners, Propane is ofgreater use.

There are different sizes of bottles availableand it is better to consult your dealer foradvice. Gas cannot be supplied from thebottle without an approved regulator.

Hoses connected from regulator to thecaravan supply should be made fromNeoprene and comply with EN1949. Hoseshave a limited life and should be inspectedregularly.

The gas cylinders have a recess in the gasbottle compartment into which the cylindersshould be restrained by means of the strapsprovided.

If cylinders are used outwith thiscompartment you must ensure 1) they areadequately supported b) ventilation is notblocked c) damage will not be caused tofixtures and fittings.

Never use a gas cylinder on its side - alwaysstand cylinders upright - keep them in thegas locker provided (Fig. A).

Please note that the Gas Locker Box is not awatertight compartment.

Fig. A Gas Bottle Compartment Fig. B Gas Regulator - Propane & Butane

SERVICES

40

If you should suspect a gas leak turn off thegas at the bottle and ventilate the caravan byopening the door and windows. Do notoperate anything electrical and removeeveryone from the caravan until the gas hasdispersed. It is part of your annual service toinspect all gas pipes and appliances.

Changing a Gas Cylinder

Before commencing to change a gas cylinderensure that the valve on the cylinder isturned fully off. Turn off all gas operatedappliances.

Remove the gas hose from gas cylinder.

Before refitting a gas cylinder, ensure that allgas operated appliances are turned off –particularly after winterisation. Ensure allconnections are secure.

The regulator

Your caravan is fitted with a regulator(capacity 1.5kg/hr) as standard equipment(Fig. B). This is located in front gas bottlelocker. The gas regulator has a workingpressure of 30mbar and is suitable for bothpropane and butane liquefied petroleum gas.

Note: Regulator valves should always be inthe ‘OFF’ position when towing.

The 30mbar bulkhead mounted regulatorfitted to the caravan requires a 'pigtail'connector for use with UK LPG cylinders,see your dealer for details.

To effect a safe connection with a Europeancylinder, you will need to obtain a 'pigtail'connector appropriate to the cylindersavailable in the country you are visiting.

DO NOT use the conventional cylinder-mounted 28mbar/37mbar regulators as thegas pressure is not compatible with theappliances installed in your new caravan/motorhome.

Hoses

Inspect flexible hose(s) regularly fordeterioration and renew, as necessary, withapproved type. In any case not later than theexpiration date marked on the hose. LPGhoses should be routinely replaced at

intervals not exceeding 5 years or asrecommended in manufacturers' instructions.Any hoses that show signs of splitting, wearor damage should be replaced irrespective ofage.

If the gas supply hose is to be leftdisconnected for an extended period ensurethe open end is protected against the entryof dirt or insects.

Duo Control Regulator (Clubman/Delta)

The DuoControl is a safety gas pressureregulation system with automatic changeoverfor connecting to two gas cylinders forcaravans and motorhomes (Fig C).

Fig C

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SERVICES

Operation

Use the control knob (a) to manually selectwhich cylinder will be operating and whichwill be held in reserve.

The mica window (b) indicates the status ofthe operating cylinder:

green = Gas from the operating cylinder.

red = Gas from the reserve cylinder.

- Open gas remote switch if present.

- For example, turn control knob (a) to theleft until it stops (left connection isoperating cylinder).

- Connect gas cylinders and make sure allhose connections are in good condition.

- Open the valves on both gas cylinders.

- If fitted, press SBS (c) on high pressurehose.

- The display in the mica window will turngreen.

Changeover

As soon as the pressure in the operatingcylinder falls below 0.6 bar, the DuoControlregulator automatically switches over andbegins taking gas from the second gascylinder. The display in the mica windowturns red.

In extreme cold or when a large amount ofgas is consumed from the cylinder over along period of time, the gas pressure may fallbelow 0.6 bar even though there is still somegas left in the cylinder. This may result in gasbeing taken from both gas cylinderssimultaneously.

If needed, you can change the position of thecontrol knob at any time. Always turn controlknob (a) as far to the left or right as it will go(an intermediate position will cause gas to beremoved from both gas cylinderssimultaneously).

Changing the LPG Cylinder

DuoControl enables replacement of anempty cylinder without interrupting theoperation of devices currently consuming thegas. Non-return valves integrated into theinlet connecting piece prevent gas fromescaping when only one gas cylinder isattached for a short time.

Please refer to your manual for moreinformation on the DuoControl regulator.

TYPES OF GAS

ButaneButane is supplied in the U.K. in blue bottles.

Butane is suitable for use at temperaturesdown to 2°C, but will not work below thattemperature.

PropanePropane is supplied in red bottles whichhave a left-hand threaded connector.

Propane will work at temperatures as low as-40°C and is therefore suitable for wintercaravanning.

Make sure that heating and cookingappliances are turned off, and also theregulator at the gas cylinders beforetravelling.

Never allow modification of LPG systemsand appliances except by qualifiedpersons.

SERVICES

42

PRECAUTIONS

a) Never look for a leak with a match.Always use a soap solution or itsequivalent when testing connections.

Do not operate any electrical apparatuswhatsoever, especially light switches. Ifthe leak is not obvious, the caravanshould be evacuated and qualifiedpersonnel consulted.

b) Avoid naked lights when connecting orchanging a cylinder.

c) Check the flexible hose frequently.

d) The gas is heavier than air and thereforesinks to the lowest point.

e) Keep bottle gas containers outside (andprotected against frost). If they must bekept inside make sure they are well awayfrom heat.

Ventilation

Fresh air circulation should be allowed belowthe caravan when appliances are in use andwhen flues terminate below the floor to allowfree evacuation of the products ofcombustion. At least three sides of theunderfloor space should always be keptopen and unobstructed especially by snow.Do not make any additional openings in thefloor.

Fixed ventilation openings are sited undergas appliances in various locations in yourtourer.

WARNINGUnder no circumstances should fixedventilation openings or gas applianceflues be obstructed in any manner as thiscould lead to a build up of dangerouscarbon monoxide. Gas drop holes underappliances should also be kept clear at alltimes. Grilles and flues should be keptclean and free from dust.

All ventilation complies with BS EN1645 andvents should not be obstructed in anymanner as this could lead to insufficient freshair. In this case the confined atmospherebecomes depleted of oxygen which leads tothe formation of the highly poisonous gas‘carbon monoxide’. Carbon Monoxide isodourless, colourless and tasteless and willrapidly cause unconsciousness and deathwith little or no warning prior to collapse.THERE IS NO DANGER WHEN ADEQUATEVENTILATION IS PROVIDED.

GAS SAFETY ADVICE

Facts about LPG

LPG is not poisonous.

Bi-products are harmless.

There is danger if all air and oxygen wereexcluded. (Ventilation holes must be keptclear at all times).

LPG has been given a smell by themanufacturers in order to identify leaks.

Awning Spaces LPG Appliance Exhaust

There is no danger of pollution of anenclosed awning space by the LPG exhaustfrom a refrigerator venting into it.

Space heaters may produce sufficientexhaust to pollute the awning space, if it istotally enclosed, from a generalcomfort, smell and hygiene point of view.In the extreme case there could be a buildup of carbon dioxide to a dangerous level.

Caravan owners are advised to allow somefresh air circulation in the awning spacewhen such appliances are in use.

43

SERVICES

Roof-mounted Flue installations

All flue installations should be inspectedonce a year throughout their length forcorrosion. Flues should be replaced if anysign of perforation is found. Ensure that thereplacement is of an approved type.

CONNECTION

Ensure that the gas regulator is correctlyconnected to the gas cylinder in gas bottlecompartment and that the hose is tight.Before turning on the gas supply, ensure thatall gas operated equipment in the caravan isturned off.

Safety Hints

It is advisable to TURN OFF THE MAINVALVE on the gas container when thecaravan is left unattended for a period oris on tow, except where continuousoperation appliances (such as arefrigerator) are in use. AVOID NAKEDLIGHTS when connecting or changing acontainer. Make sure all appliances areturned off.

Space Heating Appliances

Space heating appliances are to becompletely extinguished before the caravanis moved and are not to be used when thecaravan is in motion. Portable heaters shouldnot be used.

Manifold Locations

Heater and Water Heater manifold locatedunderneath front O/S bed towards bulkhead.

Cooker and Fridge manifold located withincompartment below cooker.

SERVICES

44

MAINS ELECTRICS

230V Mains Electric Equipment Usage

For your convenience and pleasure thistouring caravan is fitted with a 230V mainselectrical installation.

Please note: It is possible that all of the230V mains electrical equipment may not beable to be operated simultaneously. A typicalUK caravan park mains hook up pointprovides a maximum output of 16 amps,although 10 amps is more common and onsome continental sites the available outputmay be as low as 5 amps. If your loadingexceeds the site supply it may trip the park’scircuit breaker. Please check the availablemains output with your site operator.

The following items need to be addedtogether if used simultaneously.

230V mains equipment typicalconsumption figures:

Fridge 0.5 ampsCharger 1.0 ampsWater heater (max) 5.7 ampsBlown air heaters 4.8 ampsColour TV 2.5 ampsMicrowave 3.5 ampsAir conditioning 4.0 ampsTruma Ultraheat (max) 8.3 ampsKettle 3.2 ampsAlde central heating 10.0 amps

The mains wiring in Lunar caravansmanufactured in the UK complies with theIEE Wiring Regulations, 17th edition, and issafe for the use in the UK. In the UK the on/off switching is always positioned in the livewire. Therefore when the switch is off thecurrent is dead.

Correct polarity of the site supply shouldalways be obtained by the use of a non-reversible plug and socket for connecting thecable to the caravan inlet.

Reverse polarity on overseas use: A plug inpolarity tester is used to determine if thepolarity is reversed, if so and the siteconnector is of the two pin type with the twometal strips for the earth, then the plug maybe unplugged and inserted the other wayround which will then reverse the polarity.

Unfortunately the overseas practice is notalways to discriminate between live andneutral wires and the plugs are notnecessarily non-reversible. They can beinserted the wrong way round. Consequentlywhen switches are turned off the circuits arenot dead. People may touch connectionsthinking that they are safe and they may stillreceive a shock.

A residual current device is already fitted toyour Lunar Caravan. If a fault occurs andanyone makes indirect contact with a livelead the breaker should trip before a

dangerous voltage is apparent.

It is essential that you understand theworkings of each electrical circuit. Checksupply cable terminals are firm and secure.

Check supply cables for wear and damage.Do not attempt modifications to the caravanelectrical installation to accommodate adouble supply.

INSTRUCTIONS FOR ELECTRICITYSUPPLY

On Arrival at Caravan Site

1. Before connecting the caravaninstallation to the mains supply, checkthat:

(a) the main supply is suitable for yourinstallation and appliances, i.e. 230volts AC, frequency 50 Hertz.

(b) your installation will be properlyearthed. Never accept a supply froma socket outlet or plug having onlytwo pins, or from a lighting outlet.

(c) any residual current device (earthleakage circuit breaker) in the mainssupply to the caravan has beentested within the last month.In case of doubt, consult the siteowner or his agent.

45

SERVICES

Note: Always disconnect the electricalconnector between the towing vehicleand the caravan before connecting an LV(low voltage) supply to the caravan andbefore charging the caravan battery byany other means.

2. Ensure that your caravan mains isolatingswitch (RCD) is in the off position. TheMCB's are the breakers for the individualcircuits.

3. Remove any cover from the electricityinlet provided on the caravan, and insert the connector of the supplyflexible cable.

4. Remove any cover from the socketoutlet provided at the site supplypoint, and connect the plug (at theother end of the supply flexible cable) tothis. Switch on the main switch atthe site supply point.

IN CASE OF DIFFICULTY CONSULT ANAPPROVED ELECTRICALINSTALLATION CONTRACTOR (WHO MAYBE THE LOCAL ELECTRICITY COMPANY).IT IS DANGEROUS TO ATTEMPTMODIFICATIONS AND ADDITIONSYOURSELF, LAMPHOLDER PLUGS(BAYONET-CAP ADAPTORS) SHOULDNOT IN ANY CIRCUMSTANCES BE USED.

On Leaving the Caravan Site

5. Reverse the procedure described inParagraphs 3 and 4 above.

IT IS IMPORTANT THAT THE MAINSWITCH AT THE SITE SUPPLY POINTSHOULD BE SWITCHED OFF, THESUPPLY FLEXIBLE CABLEDISCONNECTED, AND ANY COVERREPLACED ON THE SOCKET OUTLET ATTHE SITE SUPPLY POINT. IT ISDANGEROUS TO LEAVE THE SUPPLYSOCKET OR SUPPLY FLEXIBLE CABLELIVE.

Periodically

6. Preferably not less than once a year,the caravan electrical installationshould be inspected and tested and areport on its condition obtained asprescribed in the Regulations forElectrical Installations published bythe Institute of Electrical Engineers.

Never allow modification of electricalsystems or appliances except by qualifiedpersons.

Outlet sockets located within the tourershould only be used with a dedicatedappliance and not an independent unit.

No appliance shall be used outside whenconnected to an internal socket.

YOUR CARAVAN IS NOW SUPPLIEDWITH 25 METRES OF MAINS CABLE TOCOMPLY WITH BS EN1645.

FLEXIBLE WIRING

LIVE BROWNNEUTRAL BLUEEARTH GREEN & YELLOW

FIXED WIRING

LIVE BROWNNEUTRAL BLUEEARTH GREEN & YELLOW

SERVICES

46

47

ELECTRICS

ELECTRICS

Mains Power Units ............................................... 48

Distribution Panel ................................................. 49

Control Panel ....................................................... 50

Battery .................................................................. 52

Use of Generators ................................................ 52

ELECTRICS

48

POWER DISTRIBUTION UNIT PDU

The PDU contains both the 230v acequipment and the Power Supply to give 12volts dc. This is capable of running the 12volts system on its own or in conjunction witha leisure battery. It is however advisable torun with a battery in circuit.

Contained within the PDU are all the inputand output circuit fuses. These are clearlyidentified and have the size of fuse clearlymarked, this rating should not be exceeded.

230 volts ac

Containing the Earth leakage protection RCD(Residual Current Devise) and theOverprotection current device MCB’s(Miniature Circuit Breakers).

12 volt dc

Fully automatic power supply capable ofrunning the 12 volt system up to 20 amps at13.8 volts.

If a fault condition such as a short circuit oroverload occurs, the power supply willautomatically switch off until the fault isremoved. This system is also capable ofcharging a totally flat lead acid, gel or AGMbattery, however depending on its state thismay take up to 48 hours. It is alsorecommended that you only use the powersupply in the PDU to charge your leisurebattery.

Control system

Within the PDU relays control the systemautomatically when it chooses Car or VanSupply. When the Caravan is plugged intothe Car then it will automatically switch touse the Car. However care should be takenwhen using power from the car battery, asthis could drain the voltage of the car batteryrendering insufficient voltage to start the car.

Continued use of a car battery to supplypower to the caravan will in time causedamage to a car battery, and it isrecommended to fit a leisure battery to thecaravan.

When the Car ignition is switched on and theengine is started the interior supply to theCaravan 12 volt system will switch off(except alarm if fitted), and the supply to thefridge is connected. When the car engine isswitched off the 12 volt power to the caravanis restored, however the 12-volt power to thefridge will be disconnected.

Ensure that the steps on page 43"Instructions for electricity supply" arefollowed.

OPERATION

Disconnect the electrical connector betweenthe towing vehicle and the caravan beforeconnecting an LV (low voltage) supply to thecaravan and before charging the caravanbattery by any other means.

Connect the 230 volt mains lead to themains inlet fitted within the battery box, andthen connect to the supply on the caravansite. Switch on the RCD and MCB’s, at thispoint it is important to check the operation ofthe RCD and check the polarity of the siteconnection using a polarity tester. If thepolarity is incorrect the site operators shouldbe notified and rectified by a qualifiedelectrician.

Specification

Power supply

230 volt ac (+/- 10%)

Output voltage 13.8 volts dc

Output current 20 Amps

Dimensions

H 235mm W 375mm D 80mm

49

ELECTRICS

Power Distribution Unit

l. ON l. ON

T RCD

l. ON l. ON l. ON l. ON

SOCKETS ALDE FRIDGE

6A 10A 16A

ALA

RM

FRID

GE

ING

NIT

ION

VA

N B

ATT

+

CA

R

LIG

HTS

1

LIG

HTS

2

IGN

ITIO

N

PU

MP

AU

X S

OC

KE

T

RA

DIO

/AR

IAL

RO

OF

FAN

FIR

E

CO

MB

I BO

ILE

R

FUSES

Clubman/Delta models, fuse marked fire will be spare

CHARGER LIGHTS FRIDGE COMBI BOILER

FIRE SOCKETS

RCD PUSH TO TEST

MAINS ISOLATOR

ELECTRICS

50

Standard Control Panel

All models feature a control panel governingthe master switch, external water pump,awning light, internal lights and volt meterreadings.

Master switch. Controls all the 12 volt supplyto the caravan which is provided by the car/leisure battery or power supply, with theexception of the alarm, tracker, awning lightand fridge ignition depending on fridgemodel.

Pump switch. Activates external pump. Thelight will illuminate when power is beingprovided to the pump.

Volt switch. When pressed illuminates theVolt Meter dial and shows the voltage beingsupplied by the power supply, leisure batteryand car supply when connected to the carwith the ignition turned off.

Awning switch. Activates/deactivates theexternal awning light situated above theentrance door of the caravan. On modelsfitted with the Lunar Protector CaravanAlarm, if this switch is left in the on positionthen the awning light can be operated via thealarm remote handset.

Light switch. Activates/deactivates theinterior central light closest to the entrancedoor, providing the power switch mounted onthe central light is switched ON.

Delta Control Panel

This has features governing the masterswitch, awning light, internal light, volts andonboard water level external water pump andinternal water pump.

Master switch. Controls all the 12 volt supplyto the caravan which is provided by the car/leisure battery or power supply with theexception of the alarm, tracker and fridgeignition depending on fridge model.

Pump switch. Activates the external pump.An LED will be illuminated when power isbeing provided by the pump.

Int/Ext switch. When in the internal positionthe internal pump fitted in the underfloorwater tank is operational. If the water levelfalls to a pre-determined level it willautomatically switch to the external pump.

When in the external position the externalpump will be operational and willautomatically fill the underfloor water tank.LEDs are situated adjacent to the switchindicating which pump is activated. Forexternal water only have pump switch ONand Int/Ext switch in middle position.

Volt switch. When pressed illuminates thevolt meter and shows the voltage beingsupplied by the power supply, leisure battery,or car supply when connected to the car. ItStandard control panel

101


Reversing

During reversing the shaft of the overrunningdevice is subjected to its full travel which istransmitted in the normal manner to theexpander mechanism inside the wheel brake.

The expander (2) forces both brake shoes (1and 3) into contact with the drum as normalexcept with the backward rotation of thewheel the friction between brake shoes anddrum is relieved.

The initial friction between brake shoes anddrum ensures that both shoes plus theexpander mechanism show a definitetendency to move in the direction of rotationi.e. reverse. The pressure generated by thisaction is applied to the spring loaded reverselever (6) which is attached to the adjusterbox (5) causing it to collapse.

The collapse of the reverse lever virtuallyeliminates the friction between brake shoesand drum thus allowing easy reversing. Withonly slight forward movement, the reverselever returns to its normal position by virtueof the coil spring attached, and normalbraking is immediately available.

Parking — Handbrake Application

The AL-KO automatic reversing brakesystem incorporates a patented device foradded safety when parking on a reversesloping site or a steep hill.

A spring cylinder has been added to the linkbetween handbrake lever and centre brakerod.

Full application of the handbrake lever, i.e.as near vertical as possible, compresses acoil spring inside a steel cylinder and shouldany movement of the caravan occur followinguncoupling the energy stored in the spring isimmediately released to lock the wheelbrakes.

It should be noted that it is good commonpractice to chock the wheels of a caravanwhen parking on steep slopes, or underadverse conditions such as loose or slipperysurfaces.

AL-KO Trailer - Control (featured onClubman and Delta range)

AL-KO Automatic Trailer Control is anelectronic control system that reacts quicklyto maintain the stability of the car andcaravan. The system continually monitors thestability of the caravan during a journey andoperates when an unstable condition isencountered. When AL-KO ATC activates,the driver will feel the vehicle being sloweddown by the soft braking of the caravan.


102

AL-KO ATC LED OPERATION

Flashing Green - Simply the ATC is waitingto detect movement. Drive a few metres andthe light will change to green.

Flashing Red - To provide further explanation if the constant RED light is showing: There are anumber of errors that the ATC logs and some are self repairable by the customer but some willrequire the ATC to be monitored by the diagnostic equipment that is available and the AL-KOservice engineers are trained to use.

Display Colour ATC Condition Diagnosis What to do Outcome Status

Green ATC Active Everything OK

Green Flashing ATC Active Self test Drive forward Green Ready forincomplete to detect (Constant) journey

movement tocomplete selftest andrecheck LED

Red ATC Inactive Possible to Remove 12S Green Ready forcontinue journey or 13 pin plug journey

and wait fiveseconds.

Reconnect Red ATC faultplug detected but

can be driven

Red flashing ATC has Do not continue Remove 12S Green Ready fordetected a fault with ATC or 13 pin plug journey

connected and wait fiveseconds

Reconnect Red (flashing) ATC faultthe plug. detected cannot

be driven.Remove pushrod

103


GENERAL NOTES ONMAINTENANCE

Tyre Wear and DamageThe legal requirements for tread depth onmotor vehicles apply also to caravans. Inorder to equalise wear it is suggested thatwheels be balanced and changed aroundfrom time to time.

It is dangerous to neglect tyre damage andshould you detect a blister, rupture or cutexposing the casing, or if it has suffered aviolent impact (for example against a kerb),such that there is a risk of internal damage, itis advisable to have it examined by a tyrespecialist as soon as possible.

WheelsThe condition of wheels should be checkedregularly particularly for distortion of flangesand the wheel dish. Wheels dam-aged ordistorted, or having wheel bolt seatingscracked or deformed must not be repaired.

Couplings1. 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.

Towing BallThe automobile towing ball should measure

50mm maximum and 49.5mm minimum (DIN74058). If the ball is found to be worn itshould be replaced immediately.

Overrunning DeviceThe device housing is packed with grease onassembly, but will require periodicmaintenance to ensure smooth operation ofthe braking system.

1. Regrease the shaft bearings via thegrease nipples provided at 3000 mileintervals and before storage.

2. Ensure correct functioning of all pivotpins and levers and oil regularly.

Jockey WheelLubricate wheel and screw threadperiodically.

Brake LinkageAll moving parts should be lubricatedperiodically to ensure their satisfactoryoperation.

It is recommended that all brake linkagethreads are liberally smeared with grease forprotection and as an aid to future adjustmentof the system.

Corner SteadiesThe screw and pivot pins should belubricated periodically to ensure theirsatisfactory operation.

Braking SystemAt 500 miles then every 3000 miles or 1 yearcheck and adjust brake linkage tocompensate for any stretch of the bowdencables.

Check and adjust wheel brakes tocompensate for wear.

IMPORTANT When replacing the wheels youshould tighten the nuts in rotation diagonally,taking care to tighten them equally.

The recommended torque is 88Nm(65lbs/ft) for steel wheels. Alloy wheelsshould be 115Nm (85lbs/ft).

CHECK THE WHEEL NUTS BEFORESTARTING EVERY JOURNEY

IMPORTANT NOTICE:

The caravan is manufactured for towingbehind road cars and the 4 x 4 “off road” typeof passenger car derivative. THE CARAVANIS NOT SUITABLE FOR TOWING BEHINDCOMMERCIAL VEHICLES.


104

TYRES

PREPARATION

Tyres & Tyre Pressure

Safe driving and handling when towing acaravan is very important and one majorfactor which is frequently overlooked is thetyres. Look after your tyres properly and youwill improve the safety and behaviour of yourcar and caravan.

Check the Pressures

Whatever tyres are fitted to the towing carand caravan it is essential to the safety andstability of the combination that all tyres arecorrectly inflated. This is a ‘golden rule’ ofmotoring and of caravanning in particular.

Pressures should be checked when the tyresare cold, not warm during or just after a runwhen they will be higher. Never reducepressures when tyres are warm as theycould be too low when they cool down.

The tyres specified by the caravanmanufacturer are satisfactory for towing inthe UK and are rated up to 80mph (130kph)at the maximum design weight of thecaravan. In certain countries overseas it islegal to tow at higher speeds. If it is intendedto visit such countries and tow up to thehigher speed limits then it is important thatthe suitability of the tyres is first checked witha caravan dealer.

Tyres & Pressures

The tyres fitted, and the pressures needed,vary from model to model. Check the ServiceHandbook for specific recommendations foryour model.

The speed limit for towing a caravan in theU.K. is 60mph. If a tyre needs to be replacedyou must ensure that you refit a tyre of thesame specification. The correct pressure foryour car tyres will be found in the carhandbook.

Fit the Right Tyres

As with all road vehicles it is alwaysadvisable to have the same type of tyres onall wheels i.e. both on the towing vehicle andthe caravan but it is recognised thatcaravans and trailers will frequently have adifferent type from the towing vehicle.

If a wheel or tyre has been changed thereplacement has to be of the same type ofconstruction and size as on the other wheels.

General Recommendations

Because caravan tyres and wheels are rarelythe same as those on your car you must notattempt to use the car wheel on your caravanif you should have a puncture.

Check your tyres regularly but particularlywhen the caravan has not been used for along time. Vehicles such as caravans if notused in the winter should be thoroughlyinspected prior to re-use during the summermonths. Look particularly for any signs ofage deterioration in the tyres such assidewall cracking and carcass deformation.Tyres on a stationary vehicle, particularly ifparked in coastal areas, always age andcrack more quickly than those which are runfrequently and, if your caravan is going tostand for a long time it is a good idea tocover the tyres with old sacks, etc. to shieldthem from direct light and, if possible, to jackthe weight off the tyres. If in doubt at allabout your tyres have them checkedimmediately by a tyre distributor.

WARNING: Prior to any journey thecondition of the tyres should beinspected. The NCC recommend thattyres are replaced seven years from dateof manufacture at the very latest.

105

GENERAL DATA

GENERAL

DATA

Wiring Diagrams............................................... 106

Wiring Diagram – Road Lighting ..................... 109

Light Bulb Replacements ................................. 110

Security ............................................................ 110

Owners Club .................................................... 111

Owners Warranty ............................................. 111

Winterization Guide .......................................... 112

GENERAL DATA

106

STANDARD LUNAR PRIMARY CIRCUIT DIAGRAM

107

GENERAL DATA

CLUBMAN LUNAR PRIMARY CIRCUIT DIAGRAM

GENERAL DATA

108

DELTA LUNAR PRIMARY CIRCUIT DIAGRAM

109

GENERAL DATA

ROAD LIGHTING WIRING DIAGRAM

GENERAL DATA

110

SECURITY

Ensure that you lock all windows and doorswhen leaving your caravan. Fit a towbar hitchlock or a wheel clamp -consult your dealer onall safety and security recommendations.Keep your gascylinder locked when leaving yourcaravan.

Many devices are available to alarm yourcaravan. It is a good idea to mark yourcaravan in a secret place -this will helpthe police to identify it should it bestolen.

Caravans can be stolen from storagecompounds, motorway service areas andeven your own premises, so it is always wiseto be vigilant at all times. Ask your dealerabout details on all security aspects.

LIGHT BULB REPLACEMENT

Brake/side light .................................................. Twin 21W/5W, 12V

Front side light ................................................... 5W, 12V

Side light (white/red) .......................................... 5W, 12V

Indicator light ...................................................... 21W, 12V

Reversing light ................................................... 21W, 12V

Fog light ............................................................. 21W, 12V

High level brake light .......................................... 12V LED

Number plate light .............................................. 5W, 12V

Mains Reading Light .......................................... 12V LED (Non replaceable bulb)

Ceiling Light ....................................................... 12V LED (None replaceable bulb)

Toilet ceiling light ................................................ 12V LED (None replaceable bulb)

Awning Light ....................................................... 12V LED Strip (None replaceable bulb)

Cocktail Cabinet ................................................. 12V LED (None replaceable bulb)

Spot light ............................................................ 12V LED (None replaceable bulb)

Mood light 195mm ............................................. 12V LED Strip (None replaceable bulb)

Bunk light ........................................................... 12V LED (None replaceable bulb)

Courtesy light ..................................................... 12V LED (None replaceable bulb)

Reading lamp ..................................................... 12V LED (None replaceable bulb)

Front interior corner light .................................... 12V LED (None replaceable bulb)

111

GENERAL DATA

OWNERS WARRANTY

Lunar Caravans Limited hereby warrants,subject to the terms, conditions andexceptions shown within the separateService handbook, that any failureof parts and components will be repairedor replaced by the approved dealer fromwhom the caravan was purchased.

We expect your new Lunar caravan toprovide long and trouble free service, evenso, it is vital that you understand the contentsand follow the correct procedures, to ensureyou receive the full benefit of this protection.

Your legal rights are neither affected norprejudiced against the supplying dealer and/or the manufacturer.

All Lunar Caravans are supplied with a 6year body shell intregrity warranty and a 3year manufacturers backed warranty fromthe date of purchase which is conditional onannual servicing being carried out within 60days either side of the anniversary of thepurchase date, except the third service whichshould be carried out prior to the 3rdanniversary date of the final year.

Validating your warranty

To validate your warranty, you simply need toregister your caravan purchase with us atwww.lunarcaravans.com. By registering yourdetails we will be able to assist you moreeasily should you make a warranty claim.

LUNAR OWNERS CLUB

Now you are the owner of a Lunar caravanwhy not join the Lunar Owners Club.

This is an independent club run andorganised by owners.

Lots of opportunities exist to make newfriends at social gatherings and Rallies bothRegional and National.

A leaflet regarding the Owners Club is withinthe wallet, if it is not please contact Lunarand a copy will be sent to you.

Alternatively for further information pleasevisit the Lunars Owners Club website at:www.lunarsownersclub.net

Before you register please make a note ofyour caravan's 17 digit VIN Number and your3 digit Registration Security Number.

The VIN number, beginning SGL, can befound on the windows. The RegistrationSecurity Number can be found on theThetford Model Label located inside yourfridge or oven. The Model Label has a SerialNumber or SER. NO. and the last 3 digits ofthis number will form your RegistrationSecurity Number.

Please note that your oven and fridge willhave different Serial Numbers to each other,but you can use the last three digits fromeither one to register your van.

Once your details have been submitted, youwill be sent email confirmation that they havebeen successfully received.

Additional equipment

If additional equipment (other than those onthe optional list of Lunar) is to be fitted youshould check with your dealer beforehand.The warranty may be invalidated.

Vermin

Vermin can gain access via the smallest ofholes. Lunar fit grills and grommets toprevent this but the nature of some caravanstorage means it can happen, with upsettingresults. We advise setting a trap and/orpoison and regular inspection.

Vermin damage is not covered by warranty.

GENERAL DATA

112

CARAVAN WINTERIZATION GUIDE

If the caravan is to be stored for any lengthof time, the following procedure is advisable:

1. Location

If possible avoid siting the caravan beneathtrees or near dilapidated buildings, wherestrong winds may dislodge branches orslates that can damage the caravan. Inexposed conditions ground anchors may beadvisable. Be wary of low lying areas thatmay be prone to flooding.

2. Covers

Large polythene or tarpaulin sheets shouldnot, in the opinion of most experts, be usedto ‘seal’ the caravan against the elements.Condensation and mould growth may beencouraged and any flapping material or guyropes could scratch acrylic windows.

If you feel a cover is absolutely necessarybecause of where the caravan is parked,however, purchase one that is made of“breathable” material.

3. Ventilation

Caravan vents should be left uncovered toprovide adequate air circulation inside thecaravan; however if in an exposed or saltylocation the vents on the side of theprevailing wind and/or the ‘fridge vent maybe closed off for the winter. If you have

regular access to the caravan, you couldplace some moisture absorbing crystals incupboard corners to reduce the risk ofcondensation, but these will require fairlyfrequent changing.

4. Interior

To prevent possible mould growth over thewinter, clean and vacuum carpets, curtainsand upholstery and if possible remove thesoft furnishings and store in a warm, dryplace (eg attic). If not possible to remove thecushions, store on edge away from thecaravan walls, allowing air to circulatearound them and cover with an old sheet toprevent fading in the sunlight.

Walls and ceilings should be wiped over witha mild anti-bacterial solution (eg Dettox) andcan be polished afterwards if desired.Cupboards should be emptied, cleaned andvacuumed out. Small doors can be left ajar toassist ventilation, but larger doors should beclosed or they may warp.

The refrigerator should be emptied, cleanedwith a solution of bicarbonate of soda or anti-bacterial solution and the door left ajar.

The hob/oven should be thoroughlydegreased and cleaned. If using one of thestronger oven-cleaners on the market besure to allow plenty of ventilation whilstworking. If necessary burner jets can be

brushed over with a stiff brush, and blockagescleared with a high-pressure air line. Never tryto clear blocked jets with a piece of wirewhich can damage or enlarge jet holes.

Water heaters must be drained and care mustbe taken to remove any lurking pools of wateror frost damage may result. If possible blowair through the heater to push any waterdroplets through. Leave drain taps and inletsopen.

The water pipes can be flushed through witha proprietary sterilising agent and the wastepipes with a stronger disinfectant. Make surethe water pump is drained and remove thewater filter. Fresh and waste water containersshould be cleaned, drained and stored withcaps loose or off. Leave all water inlets andoutlets open, but they may be covered with afine mesh material (eg stocking) to prevententry of insects etc.

The toilet should be cleaned according to themanufacturer’s instructions, using a suitabledisinfectant for the holding tank. Rinse allsections thoroughly and store unsealed. Anyrubber seals or diaphragms can be lubricatedwith olive oil to prolong life.

5. Battery

Unless powering an alarm system, the 12vbattery should be removed, wiped over, theterminals cleaned and smeared with

113

GENERAL DATA

petroleum jelly. The electrolyte level shouldbe checked and topped up with distilledwater if necessary. Trickle charge from themains until you obtain a reading of 12.6v ona voltmeter or 1.27 on a hydrometer. Storethe battery in a cool, dry place and check thestate every 6-8 weeks. Top up the charge asrequired.

Electric clocks, smoke detectors etc, if fitted,should have their internal battery removed.Battery powered burglar alarms may benefitfrom a new set of batteries for the winter.

6. Awning

The awning should be spread out on drygrass or concrete and brushed with a broomto remove any mud. If the canvas is stainedtry removing the marks with a stiff brush andplain water. If this fails pure soap flakes canbe tried, which will mean re-proofing isnecessary afterwards, but never usedetergents. If stains are stubborn there areproprietary cleaners such as Fabsil UniversalCleaner, available from caravan accessoryshops, or contact Grangers International Tel:01773 521521. Any mildew spots can betreated with a weak solution of hydrogenperoxide – scrub into the affected area andallow to dry before re-proofing (spot test ahidden area in case colour is affected). Suchsevere treatment will weaken the awningmaterial so live with stains if you can! Clearwindows can be cleaned with methylated

spirits if water doesn’t work, but nothingstronger. Examine seams and repair anybroken stitching and replace perished rubbertensioners. Give the awning a good shakeand pack it when completely dry, trying not toput too many creases in the window. Store ina dry, vermin free area.

Awning poles need little attention other thana wipe down with a damp cloth. Don’t oil orgrease them as this may get onto thecanvas. Pegs can be cleaned andstraightened and any badly damaged onescan be replaced ready for the next season.

7. Exterior

Look over the rubber window seals andreplace any that look perished. Coatserviceable rubbers with olive oil. If you havea damp meter check around the inside forany trouble spots and re-seal suspect joints.Any major damp penetration problemsshould be resolved before storage. Minorleaks might be cured using Captain Tolley’sCreeping Crack Cure. Major leaks requirecomplete renewal of the sealant; bothproducts should be available from caravanaccessory shops.

The caravan body will benefit from athorough clean using a car shampoo(household detergents are corrosive) and acoating of good quality polish. Take carewhen washing the windows as they scratch

quite easily. Small scratches can be removedusing a liquid metal polish such as Brasso.Duraglit wadding may also prove successful,and Farecla Products make a polishespecially for use on acrylic windows –telephone Farecla Products Ltd on 01920465041 for nearest stockist. Door locks andhinges can be squirted with WD40, wiping offany excess. Fenwick’s OverwinteringCaravan Storage Fluid protects againstalgae, mould, airborne pollutants, acid rainand bird lime, available from selectedcaravan accessory shops or contactFenwicks Tel: 01270 610161.

8. Chassis

The chassis should be brushed off, or ifexposed to corrosive elements, eg road salt,thoroughly washed down. Any surface rustcan be removed with a wire brush orsandpaper and the chassis and axle tubecan be painted with a rust inhibitor, suitablepaint (eg Hammerite) or Finnigan’s Waxoyl.The coupling and all winding mechanismsshould be degreased, examined for wearthen re-greased.

9. LPG cylinders

LPG cylinders should be removed and storedin a cool, ventilated location. Some storagecompounds will insist they are removed tocomply with fire safety regulations. Theregulator and/or pipe end can be covered

GENERAL DATA

114

with a stocking or similar to prevent the entryof debris or insects that can block the gassupply.

10. Electrics

13 pin, 12N and 12S plugs should beinspected and cleaned and the pins coatedwith vaseline. WD40 should not be used as itmay ‘melt’ some plastics on contact. Theplugs should be protected from the weatherbut not fully sealed in polythene which willencourage condensation. Road lights shouldbe checked and any water ingress cured, fullinspection and cleaning can be done now orleft to the springtime service.

11. Axle stands

Ideally the caravan should be jacked up andsupported on axle stands with the wheelsclear of the ground. Wheels can be removedif desired and stored in a cool, dark place atnormal inflation pressure. Inspect tyrescarefully and make a note to renew anysuspect ones before using the caravanagain. The corner steadies should belowered and rested on blocks if they do notreach the ground. The handbrake should beleft off and the wheels rotated from time totime to keep the bearings lubricated.

12. Security

Finally remove any valuables and documentsfrom the caravan to make it secure; thievesdo not hibernate for the winter!

Please note that neither Lunar Caravans Ltdnor The Caravan Club endorse any of thelisted products and you should satisfyyourself as to their suitability. As always,check that the installation of an after-marketaccessory does not invalidate your warranty.

115

AAlarm ...................................................... 95

Arrival on Site ......................................... 24

Levelling the caravan ........................ 24

Siting/Unhitching ............................... 24

ATC (Automatic Trailer Control) ........... 101

Awning Fixing Points .............................. 90

BBattery .................................................... 52

Blinds ..................................................... 93

Boiler

Truma Combi ..................................... 71

Breakaway Cable ................................... 17

Bulb Replacement ................................ 110

CCaravan Handling .................................. 22

Caravan Towing Code .............................. 4

Carbon Monoxide Alarm ........................ 29

Chassis & Undergear ........................... 100

AL-KO Running Gear ...................... 100

General Notes on Maintenance ...... 103

Circuit Diagram

Delta ................................................ 108

Lunar ............................................... 107

Standard .......................................... 106

DDistribution of Weight ............................... 8

EElectrics ................................................. 44

13 pin wiring diagram ........................ 20

230V Mains Electric Equipment

Usage ........................................... 44

Control Panel .................................... 50

Delta Control Panel ........................... 50

Instructions for Electricity Supply ...... 44

Power Distribution Unit ...................... 48

INDEX

FFire Action .............................................. 28

Fire Extinguisher .................................... 29

Fire Precautions ..................................... 28

Flyscreens .............................................. 93

Fridge Freezer RMD8551 ...................... 63

Fuses ................................................... 109

GGas ........................................................ 39

Gas Bottles ........................................ 39

Gas Safety Advice ............................. 42

Precautions ....................................... 42

Types of Gas ..................................... 41

General Data ........................................ 110

Lunar Owner’s Club ......................... 111

Security ........................................... 110

Servicing .......................................... 111

HHeating

Alde Compact 3kW ........................... 74

JJacking Points ........................................ 23

LLighting .................................................. 92

MMains Power Unit ................................... 48

Microwave .............................................. 70

Mirrors .................................................... 19

Motorway Driving ................................... 22

NNoseweight .............................................. 6

Number Plate ......................................... 19

OOven

Grill .................................................... 67

Hotplate burners ................................ 66

PPre-load Checklist .................................... 8

Pre-tow Checklist ................................... 10

RRefrigerators

Model RMS8500, RMS8551 ............. 56

Reversing ............................................... 22

Road lighting .......................................... 20

SSecurity .................................................. 30

Vehicle Identification Number

(V.I.N.) .......................................... 30

Smoke Alarm .......................................... 28

Speed Limits .......................................... 22

Stabiliser, AKS2004 ............................... 11

Stability .................................................... 9

Stabilisers ............................................ 9

Sterilising ............................................... 35

TToilet

Cassette Toilet C-260 CWE .............. 76

Dometic CTW4050 ............................ 84

TV Antenna ............................................ 90

Tyres ............................................. 18, 104

General Recommendations ............ 104

Tyres & Pressures ........................... 104

VVermin ................................................... 111

WWarranty

Extended Warranty ........................... 111

Owner’s Warranty ............................. 111

Validation .......................................... 111

Water System

Helpful Hints ...................................... 38

Pressure Switch ................................ 38

Setting Up the Water System ............ 37

Wheel Changing .................................... 23

Wheel Lock ............................................ 13

Wheels

Torque ............................................... 18

Window Care ......................................... 94

Winterization Guide .............................. 112

Wiring Diagrams .................................. 109

preparing for the road on the road fire ......lunar 2013 handbook 2 introduction lunar caravans...

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