xplore touring caravan 2009 handbook

CONTENTS-1

CONTENTS

WELCOME AND INTRODUCTION ... 1-1Model Year .............................................................. 1-1The Explorer Group Limited Technical

Approvals ....................................................... 1-1

GENERAL SAFETY ................................ 2-1Please read before using your new caravan. .. 2-1Ventilation .............................................................. 2-2High-Level Ventilation .......................................... 2-2Low-Level Ventilation ........................................... 2-2Ventilation in Separate Bedrooms ..................... 2-2Gas Dispersal Holes ............................................ 2-2Petrol/Diesel Fumes .............................................. 2-2Fire Safety ............................................................... 2-2Fire Extinguishers .................................................. 2-2In Case Of Fire ...................................................... 2-2Fire Retardant Foams .......................................... 2-2

PREPARING FOR THE ROAD .............. 3-1Caravan Towing Vehicle Weight Ratio ............... 3-1Loading .................................................................... 3-1Internal Loading & Checks ................................. 3-1External Loading & Checks ................................ 3-1Pre-Tow Checklist & Hitch-Up ......................... 3-2Coupling & Uncoupling ....................................... 3-2Use of Your Caravans Breakaway Cable ......... 3-2Correct Procedure For Use .............................. 3-3Where a Designated Attachment Point Is

Provided On The Tow Bar .......................... 3-3Where No Designated Attachment Point Is

Provided On The Tow Bar .......................... 3-3Other Means of Attachment .............................. 3-3When The Breakaway Cable Is AttachedCheck To Ensure ................................................... 3-3Before Setting Off .................................................. 3-4Handbrake .............................................................. 3-4Cables ...................................................................... 3-4

TOWING AND DRIVING ..................... 4-1Reversing ................................................................ 4-1Speed Limits ........................................................... 4-1Setting Off .............................................................. 4-1Caravan Handling ................................................... 4-1

ARRIVING ON SITE .............................. 5-1Check Site Regulations ........................................ 5-1Selecting a Pitch .................................................... 5-1Side-To-Side Levelling .......................................... 5-1Leveller Jack ........................................................... 5-1Ramp ........................................................................ 5-1Front & Back Levelling ......................................... 5-1Parking on a Reverse-Sloping Site or

Steep Hill ........................................................ 5-1

GETTING STARTED ............................. 6-1Electricity ................................................................ 6-1Power Supply Charger ........................................ 6-112v Systems: .......................................................... 6-1Generator/Charger ............................................... 6-1Electricity Mains Supply ....................................... 6-1Connecting To Mains Supply On Arrival at

Site ................................................................... 6-1Disconnecting Mains Supply When Leaving

Site ................................................................... 6-2Overseas Electrical Connection ......................... 6-2Gas Supply .............................................................. 6-3Connection ............................................................ 6-3Changing a Gas Cylinder .................................... 6-3Gas Regulator ........................................................ 6-3High Pressure Gas Hoses ................................... 6-3Water System ........................................................ 6-4Setting Your Water System On Your New

Xplore Caravan .............................................. 6-4Draining Down Your Water System ................. 6-4

GAS SAFETY ADVICE ........................... 7-1Facts about LPG.................................................... 7-1Awning Spaces, LPG and Appliance Exhaust ... 7-1LPG Gas System ................................................... 7-1

ELECTRICAL SYSTEM .......................... 8-112v Power Supply .................................................. 8-1Battery Installation ................................................ 8-1Battery Maintenance ............................................ 8-1Generators / Charger ......................................... 8-1230v Power Supply ................................................ 8-1Mains Unit .............................................................. 8-1Resetting the RCD ................................................ 8-1Automatic Charging System............................... 8-2Maximum Bulb Ratings for Internal Lights ...... 8-2Maximum Bulb Ratings for

Road Lights .................................................... 8-212V Fuses - All Models ........................................ 8-3

HOW TO USE YOUR CARAVAN’SEQUIPMENT .................................... 9-1

Electrical Control Panels .................................... 9-1Cooking equipment .............................................. 9-2Gas Hob ................................................................. 9-2Gas Grill ................................................................. 9-2Refrigerator Model Thetford N108P ............... 9-4Operating instructions ........................................ 9-4Deluxe Refrigerators ........................................... 9-4Electric power operation .................................... 9-4Maintenance (all fridge variants) ........................ 9-5Securing products for driving ............................ 9-5Door locking mechanism .................................... 9-5

CONTENTS-2

CONTENTS

Water heater operation ..................................... 9-6Gas operation ........................................................ 9-6230V Operation .................................................... 9-6Space Heater Operation ..................................... 9-6Gas Operation ...................................................... 9-6230V Operation .................................................... 9-6Fan Operation ....................................................... 9-7Battery Charger .................................................... 9-7Smoke Detector ................................................... 9-7Thetford Cassette C-200 CW Toilet ............... 9-8Introduction ........................................................... 9-8Features: ................................................................. 9-8Preparing for use ................................................... 9-8Emptying the waste holding tank ....................... 9-8Winterising/Storage ........................................... 9-11Cold weather use ............................................... 9-11High Altitude and hot weather use ................ 9-11Cleaning and maintenance ................................ 9-11Rooflights ............................................................. 9-12Standard MPK Rooflight .................................... 9-12Toilet unit malfunctions ..................................... 9-12Windows .............................................................. 9-12Polyplastic Window Opening ........................... 9-12Midi Heki Rooflight ............................................ 9-12Blinds & Flyscreens ............................................. 9-13Flyscreens ............................................................. 9-13Door Flyscreen (If Fitted) ................................. 9-13Taps ........................................................................ 9-13Exterior Door Retainers .................................. 9-14Gas Locker Door ............................................... 9-14Internal Doors .................................................... 9-14Magnetic Catches ............................................... 9-15Bed Make-up ........................................................ 9-15Bunk Beds ............................................................ 9-16Removable Drawer Locker .............................. 9-16TV Aerial ............................................................... 9-16FM Radio Connection ....................................... 9-17

SECURITY ............................................. 10-1Caravan Theft ...................................................... 10-1Anti-Wind Corner Steadies ............................. 10-1CRIS - The Caravan Registration and

Identification Scheme - VIN ...................... 10-2Window Etching & Chassis Marking .............. 10-2Electronic Tagging ............................................... 10-2

CARE OF YOUR CARAVAN ............... 11-1Exterior Cleaning ............................................... 11-1Glass Fibre Reinforced Plastic (GRP) ............. 11-1Acrylic Windows ................................................ 11-1Care Instructions for Seitz Rooflights ........... 11-1Window Blinds & Flyscreens ........................... 11-1

Winterisation/Storage ....................................... 11-1ABS - A Frame Cover, Wheel Spats & Panels 11-1Interior Walls ....................................................... 11-1Furniture ............................................................... 11-2Cooking Equipment ........................................... 11-2Carpets, Upholstery and Curtains .................. 11-2Shower Trays, Shower Room and Wash

Basin Fittings ................................................ 11-2Cleaning of all Taps ............................................. 11-2Water Containers .............................................. 11-2Water Systems - Sterilization .......................... 11-3Truma Space Heater .......................................... 11-3Thetford Toilet ..................................................... 11-3Chassis Mounted Spare Wheel Carrier ......... 11-4Tyres ...................................................................... 11-4Pressures .............................................................. 11-4Tyre Wear and Damage ..................................... 11-4Changing a Wheel ............................................... 11-4Jacking ................................................................... 11-5Lubrication ........................................................... 11-5Maintenance of your BPW Chassis ................ 11-6

STORAGE .............................................. 12-1Long Term & Winter Storage ........................... 12-1Caravan Covers .................................................. 12-1Power Drain ........................................................ 12-1

WARRANTY ......................................... 13-13-Year Manufacturer’s Warranty ..................... 13-1Parts Covered By This Warranty for

Years 1 - 3 .................................................... 13-1Specific Exclusions for Years

2 & 3 .............................................................. 13-1Conditions Attached to the Warranty: .......... 13-1

CODE OF PRACTICE - WATERINGRESS ......................................... 14-1

The Code ............................................................. 14-1Conditions Attached To the Code .................. 14-1Customer Obligation - Servicing .................... 14-1Mains Electrics ..................................................... 14-1Spare Parts ........................................................... 14-1Remedial Work ................................................... 14-2

CARAVAN CONSTRUCTION - MAINCOMPONENTS ............................. 15-1

BPW Chassis ....................................................... 15-1Braking System .................................................... 15-1Body Shell ............................................................. 15-1Windows .............................................................. 15-1Insulation .............................................................. 15-1Front Panel and Gas Bottle Locker Lid ......... 15-1Awning Channel .................................................. 15-1Additional Fixings to Your Caravan Shell ....... 15-1

CONTENTS-3

CONTENTS

EQUIPMENT LIST ............................... 16-1Entry Level ........................................................... 16-1

ELECTRICAL DRAWINGS ................. 17-113 Pin Drawing .................................................... 17-1Wiring Diagram .................................................. 17-2Road Lights .......................................................... 17-3

TECHNICAL SPECIFICATIONS........ 18-1

TECHNICAL SPECIFICATIONS........ 18-2

GENERAL QUESTIONS ..................... 19-1

GLOSSARY ........................................... 20-1

SERVICE DOCUMENTS ..................... 21-1

INDEX ................................................... 22-1

CONTENTS-4

CONTENTS

1-1

INTRODUCTION

WELCOME ANDINTRODUCTIONCongratulations on choosing an Xplore touringcaravan manufactured by The Explorer GroupLimited.

This Owner’s Handbook has been prepared foryour guidance to help you derive the greatestamount of pleasure from the use of your caravanand your leisure time. We strongly recommendthat you read this guide thoroughly so that youare fully aware of all the caravan’s features,equipment and systems.

Additional information and detailed applianceinstruction manuals are also contained in yourOwner’s Information Pack.

Your new Xplore touring caravan has beendesigned as a recreational vehicle and is intendedfor recreational use only. It is not intended forbusiness use or for permanent habitation. TheExplorer Group Limited accepts no liability if thecaravan is used for any purpose other thanrecreational/holiday use.

Your caravan has been designed for towingbehind a normal motor car. Additional careshould be exercised when towing with a 4x4because of the ‘off-road’ nature of the suspension.Owners should not tow their touring caravanswith commercial vehicles (including light andheavy goods vehicles). When selecting a towingvehicle it is recommended that you consult theCaravan Towing Code, which is published by theNational Caravan Council.

By following the instructions provided in thishandbook and maintaining your caravan in a firstclass roadworthy condition, you are sure to havemany years of carefree use.

To ensure the very best quality and reliability alltouring caravan designs and new developmentsare rigorously tested. Therefore the ExplorerGroup Ltd will accept no liability or uphold thewarranty if the caravan is altered or modified insuch a way that would adversely affect thereliability.

Please Note: It is a condition of your warrantythat the caravan must have an “annual service”done by an Approved Retailer or Service Centre,and a record is kept. Pages are provided in theback of this guide, for your assistance.

Approved Retailers or Service Centres will beable to supply any replacement parts for yourcaravan, should the need arise, and in most casesany accessories you may require.

Please note: It is not possible to purchasereplacement parts direct from The ExplorerGroup Limited.

Changing market and supply situations mayprevent us from maintaining the exactspecification details in this guide and we thereforereserve the right to alter specifications asmaterials and conditions demand.

Enjoy your new caravan

Model Year

All Touring caravans manufactured by theExplorer Group Limited are designated by theirmodel year. The model year runs from 1stSeptember to 31st August.

The Explorer Group Limited TechnicalApprovals

In order to ensure your new Caravan is safe touse the The Explorer Group Limited aremembers of and have been inspected by thefollowing bodies.

National Caravan Council (NCC) who operateda certification scheme to ensure compliance withthe European safety standards for caravans.

National Inspection Council for ElectricalInstallation and Contracting (NICEIC) who carryout an annual inspection of the electricalinstallations within caravans.

Confederation of Gas Installers (CORGI) whocarries out an annual inspection to ensure thatthe gas installation installed in our caravans fullycomply with all relevant regulations andstandards.

The Explorer Group Limited has also obtainedISO9001:2000 accreditation and this is audited bySGS UK Limited

1-2

INTRODUCTION

2-1

GENERAL SAFETY

GENERAL SAFETY

Please read before using your new caravan.

In order for you to get the most out of your newXplore touring caravan it is necessary for you tobe aware of the following:

(i) Do not obstruct ventilators and cleanthem regularly, it is advisable to clean andcheck all the ventilators annually forblockages and where necessary rectify anyblockages found.

(ii) Inspect the high pressure flexible gas hose(available from your retailer) regularly fordeterioration and renew as necessary, withapproved type, in any case no later thanthe expiry date stated on the hose.

(iii) Turn off all gas appliances and turn off thegas supply before towing your caravan.

(iv) If your caravan is fitted with a gasbarbecue point it is not designed to allowgas flow into your caravan and shouldnever be used for this purpose.

(v) Never use portable cooking or heatingequipment inside your caravan. Do not useyour fitted cooking equipment as heatingat any time.

(vi) Never allow modification to your gas orelectrical system unless qualified personscarry them out. All modification to the gassystem should be carried out by a CORGIregistered gas fitter. Any modificationscarried out on the electrical systemshould be carried out by an electrician onthe roll of the NICEIC or be a member ofthe ECA.

(vii) In the interest of safety, replacement partsfor an appliance shall conform to theappliance manufacturer’s specifications andshould be fitted by him or his authorisedagent.

(viii) It is recommended that you provide a drypowder fire extinguisher complying withISO 7165 of at least 1KG capacity by theexit door and a fire blanket next to thecooker. Ensure you read the ‘advice tooccupier label’ fitted to your caravanusually found on the inside of thewardrobe door.

(ix) Never exceed your caravans MaximumTechnical Permissible Laden Mass. (seeCaravan Towing Vehicle Weight Ratio)

(x) The laden nose weight for your caravanshould not exceed the lower of thefollowing:

• Towing vehicles maximum nose weight

• Tow bar maximum nose weight

• The caravan’s maximum nose weightwhich is 100kgs

(xi) Ensure heavy and large items are securedbefore towing your new caravan to reducethe risk of damage being caused while thecaravan is in motion.

(xii) When your caravan is connected to yourtowing vehicle it should be level or slightlynose down. An excessive nose downattitude or a nose up attitude could leadto instability when towing.

(xiii) When your caravan is loaded to itsMTPLM and the weight distributed inaccordance with the towing code, yourcaravan is designed to be towed at amaximum speed of 130kmh/80mph.However, your attention is drawn to thefact that in the UK the maximum speedallowed for towing a caravan is 100kmh/60mph.

(xiv) It is illegal to tow your caravan whilstit is occupied.

(xv) If your caravan is fitted with a lift up bunkit is designed for a maximum weight of 11stone and is not suitable for childrenunder 3 years old without supervision.

(xvi) Do not leave children under 14 years ofage unattended in your caravan.

(xvii) The coupling head operating handle MUSTNOT be used to manually manoeuvre thecaravan at any time.

(xviii) In order to manually manoeuvre yourcaravan please use the front and rear grabhandles fitted to the caravan.

IMPORTANT

Your attention is drawn to the noticeaffixed in the caravan’s wardrobe advisingon fire prevention, ventilation and what todo in case of fire.

2-2

GENERAL SAFETY

VENTILATION

All caravans manufactured by The ExplorerGroup Limited are ventilated at both high andlow level in accordance with BSEN 721 SafetyVentilation. The fixed ventilation points fitted inyour caravan must not be blocked under anycircumstances as your safety may depend uponthem. It is advisable that the fixed ventilationpoints are checked and cleaned (wherenecessary) on a regular basis.

High-Level Ventilation

This is always provided by fixed ventilation withinthe fitted roof skylight. All roof skylights fitted byThe Explorer Group Limited provide fixed freearea ventilation. These roof skylights should becleaned annually by use of a small brush toremove any dust that may have accumulatedaround the mesh fitted. On some roof skylightsthe mesh can be easily removed to aid cleaning.On fan-assisted roof skylights it is essential thatthe fan is switched off prior to cleaning.

Low-Level Ventilation

Low-level ventilation is provided under the frontchest of drawers, except in an L shape layout,where it can be found either in the nearside oroffside bed box. The exact position can beidentified via the white or black plastic coverused to prevent the ventilation from beingobstructed. In order to clean the ventilator,remove the cover by undoing the two screws andclean using a small brush. It is essential that thecover is replaced once cleaning is complete.

Ventilation in Separate Bedrooms

In caravans with separated sleeping areas,separate ventilation is required and is providedvia a roof skylight at high level and a ventilator atlow level within a bed box.

Gas Dispersal Holes

All appliances and gas unions have a gas dispersalhole nearby. It is essential that these are notblocked or made ineffective.

Petrol/Diesel Fumes

The fitting of a tail pipe to your exhaust willreduce the possibility of fumes entering yourcaravan through the front fixed ventilation points.

FIRE SAFETY

Fire Extinguishers

It is recommended that a 1 kg (2lb) minimumcapacity dry powder fire extinguisher be carriedinside your caravan at all times. A fat pan firemust not have an extinguisher aimed at it, butmust be smothered with a fire blanket.

In Case Of Fire

(i) Get everyone out of the caravan as quicklyas possible using whichever exit is quickestincluding windows. Do not stop to collectany personal items.

(ii) Raise the alarm. Call the fire brigade.

(iii) Turn off gas container valve if safe to do so.

Fire Retardant Foams

Under the requirements of the ConsumerProtection Act 1987, the manufacturer has aresponsibility to ensure that their product is assafe as possible. With this in mind all caravans areequipped with either Combustion Modified HighResilient (C.M.H.R.) foam cushions or sprungmattresses. These foams are very much saferfrom a fire point of view than those previouslyused. In addition all upholstery is made of fireretardant fabric.

3-1

PREPARING FOR THE ROAD

PREPARING FOR THE ROADBefore venturing out on to the road with yourXplore touring caravan, it is important that youprepare correctly.

CARAVAN TOWING VEHICLE WEIGHTRATIOThis ratio has a major influence on stability. It isrecommended that:(i) The laden nose weight for your caravan

should not exceed the lower of thefollowing:

* Towing vehicles maximum nose weight,* Tow bar maximum nose weight* The caravan’s maximum nose weight,

which is 100kgs(ii) The actual laden weight of the caravan

should always be kept as light as possible.The lighter it is whilst being towed on aroad, the safer the outfit combination willbe.

(iii) The Caravan Club recommends a maximumcaravan/towing vehicle weight ratio of 85%of the towing vehicle’s kerb weight providingboth are properly maintained, fullyserviceable and the other recommendationsin this Handbook are followed.

(iv) Whilst you can legally tow at a higherweight ratio than 85% (subject tomanufacturers’ towing limits and drivinglicense restrictions) towing a heaviercaravan will increase the risk of instability,especially at higher speeds.

(v) The greater the actual laden weight of thecaravan in relation to the kerb weight of thetowing vehicle the more careful andexperienced the driver needs to be and thelower the speed at which instability could occur.

WARNING: It is strongly recommendedthe loaded weight of the caravan does notexceed the kerb weight of the towingvehicle.

LOADING

Always lower and secure the jockey wheel andthe four corner steadies (with the braceprovided) before entering the caravan. This willensure that the caravan does not tip up when youare inside.

Please Note: Corner steadies should not beused as a jacking device.

Internal Loading & Checks

When loading your caravan it is advisable to:

(i) Distribute items evenly over the axle and aslow as possible to optimize road holding andachieve the best possible braking effect.

(ii) Do not overload on one side as this willcause the caravan to lean and affect the roadholding and stability.

(iii) Do not stow tins, bottles or heavy items inoverhead lockers when towing.

(iv) Loose articles should be stowed securely toavoid movement and possible damage.

(v) Ensure that all lockers and cupboard doorsare closed and secured.

(vi) Secure all bunks (if appropriate).

(vii) Store the main dining table in its transitposition.

(viii) Set the refrigerator for 12V operation if anyfresh food is stored in it and ensure thedoor is locked.

(ix) Fully close and lock all windows androoflights. Never tow with windows onnight setting.

(x) Leave all curtains and blinds open to preventdamage in transit. If your caravan has a rearwindow this may aid visibility.

External Loading & Checks

(i) Gas cylinders should only be stored,correctly positioned, and secured in the gasbottle locker. The gas should be turned off.

(ii) The leisure battery is stored and secured inthe battery locker box, set into the trayprovided and secured.

(iii) Any external connections (battery chargers,connecting cables etc), should bedisconnected and stowed.

(iv) Check that all exterior locker doors aresecure and locked.

(v) Secure and lock the main caravan entrancedoor.

(vi) Ensure the water heater flue cowl is inplace.

3-2


PRE-TOW CHECKLIST & HITCH-UP

Having loaded the touring caravan and securedthe lockers and main entrance door:

(i) Check touring caravan wheel bolts aretorquetightened to the required level (SeeIndex - Changing a Wheel).

(ii) Check tyre pressures (Refer to the TechnicalSpecification section) and tyre condition forroadworthiness.

(iii) Ensure the jockey wheel is down, in goodcontact with the ground, clamp tightlysecured, and the caravan handbrake is fullyon.

(iv) Wind up the corner steadies.

(v) Reverse the car close up to the caravan’shitch. It is advisable to seek assistance toguide you so that the car tow ball alignswith the caravan’s hitch. (Use of the caravanhandbrake is advised. Extreme cautionshould be taken if manoeuvring the caravandown hill or on wet, slippery surfaces).

(vi) Make sure the jockey wheel height issufficient for the hitch head to clear thetowing vehicles tow ball.

(v) Manoeuvre the hitch head over the tow balland lower the jockey wheel using thewinding handle, until the hitch head openingsits comfortably over the tow bar ball.

COUPLING & UNCOUPLING

Note: The handle of the ball hitch and thehandbrake lever must not be used as amanoeuvring aid. There is a risk of damage to theinternal components!

The caravan hitch (ball head hitch) on your BPWchassis is design tested. The maximum supportload at the coupling point must not be exceeded.When coupling your caravan to the towingvehicle lower the jockey wheel to the ground.Reverse the car up to the caravan or, in the caseof a small caravan, manoeuvre the caravan up tothe car’s caravan coupling.

Coupling:

Open coupling jaw by pulling lever H vigorouslyupwards in the direction of the arrow until leverlocks open. Lower the opened hitch onto the ballhead vehicle coupling and the lever willautomatically release. Closing and locking are

carried out automatically. Heed the “+” (Fig 3-1)position! Connect the breakaway cable andelectrical plug to the towing vehicle. Raise thejockey wheel up fully and secure by firmlyclamping it. Ensure that you release parking brakebefore setting off.

Visual check: the ball head should no longer bevisible in coupled condition.

Uncoupling:

Lower the jockey wheel down. Disconnectbreakaway cable and electrical plug. Pull lever ‘H’vigorously upwards in the direction of the arrowand hold. Wind down jockey wheel and lift the

caravan off the ball head of the towing vehicle.Secure the caravan by means of a wheel chockand/or by applying the parking brake.

USE OF YOUR CARAVANSBREAKAWAY CABLE

UK LAW requires that all caravans with brakes(e.g. caravans, horse boxes, car transporters etc),built on or after 1st October 1982, are fitted witha safety device to provide protection in theunlikely event of the separation of the maincoupling while in motion. It’s also a legalrequirement to use the breakaway cablewhenever it’s provided.

The purpose of the breakaway cable is to applythe caravan’s brakes if it becomes separated fromits towing vehicle. The cable assembly is designedto part, allowing the caravan to come to a haltaway from the towing vehicle.

Construction - Usually a thin steel cable, possiblyplastic coated, and fitted with a means of

Fig 3-1

Raising not necessary forversions: EM...R or EM...V

3-3


attachment to connect to the towing vehicle.

Operation - The cable should be able to pull tightto engage the caravan’s brakes without anyhindrance to its action, if the main coupling of thecaravan separates from the towing vehicle. Itshould never become taut during normal use.

Correct Procedure For Use

(i) Check cable assembly for damage. If indoubt contact your Retailer or ServiceCentre.

(ii) Make sure the cable runs as straight aspossible, and goes through a cable guideunderneath the caravan coupling.

(iii) Determine whether or not you have adesignated attachment point (a feature ofthe tow bar which has been identified by thetow bar supplier as being for the attachmentof a breakaway cable).

Where a Designated Attachment Point IsProvided On The Tow Bar

(i) Pass the cable through attachment point andclip it back on itself (Fig 3-2, Step 1);

or(ii) Attach the clip directly to the attachment

point (Fig 3-3, Step 2).Note: this must be specifically permitted by thecaravan manufacturer’s guidance, as the clip maynot be sufficiently strong.

Where No Designated Attachment Point IsProvided On The Tow Bar

(i) Fixed Ball - Loop the cable around theneck of the tow ball. If you fit the cable likethis use a single loop only (Fig 3-4, Step 3).

(ii) Detachable Ball - You must contact thetow bar supplier for advice.

Other Means of Attachment

Alternatively, it may be possible to attach thecable assembly to a permanent part of the towbar structure with the approval of the tow barsupplier, or to an accessory sold for the purposesof breakaway cable attachment.

When The Breakaway Cable Is AttachedCheck To Ensure

(i) That the cable cannot snag in use on thecaravan hitch, jockey wheel or anyaccessories e.g. a stabiliser, bumper shield,

cycle carrier etc.

(ii) That there must be sufficient slack in thecable to allow the towing vehicle andcaravan to fully articulate without the cableever becoming taut and applying the brakes.

(iii) That it is not so slack that it can drag on theground. Leave it too loose, and the cablemay scrape along the ground, and beweakened so that it fails before doing itsjob!

STEP 1

Fig 3-2

Fig 3-3

STEP 2

STEP 3

Fig 3-4

3-4


BEFORE SETTING OFF

(i) Connect the 13 pin plug on the caravan A-frame to the towing vehicle.

(ii) Check that all tail-lights, brake lights, roadlights and indicators work correctly.

(iii) Ensure that the correct vehicle license /registration plate is attached to the rear ofthe touring caravan.

(iv) Using the jockey wheel lift the tow ballslightly to check hitch is locked onto the ball

(v) Wind up the jockey wheel until the wheelsupports locate into the cut out sections atthe base of the winding section.

(vi) Raise and secure the jockey wheel using theclamp. The jockey wheel should be parallelto the direction of travel at all times.

(vii) Check condition of and secure thebreakaway cable to the tow vehicle.

HANDBRAKE

Your caravan is fitted with BPW running gear andhandbrake. It is essential that prior to towing youensure that your handbrake is in the fully offposition. This can be confirmed by ensuring thatthe handbrake arm is resting on the blue stopfitted to the side of the A frame as shown in Fig3-5 below.

CABLES

For peace of mind, you may wish to check theability of the cables to be able to cope withtowing the vehicle at extreme angles beforesetting off. To do so position the vehicle atalternate extreme angles and check that thecables do not pull too tight, are liable to stretchor become unplugged. No cables should beallowed to touch the ground as they will wearand become damaged and ineffective.

Please Note: If having followed this advice, youfeel you cannot achieve a satisfactory cablearrangement, consult your caravan or tow barsupplier or service agent.

Fig 3-5

4-1

TOWING AND DRIVING

Fig 4-1

TOWING AND DRIVING

REVERSING

It is advisable to have a second person availablewhen reversing the caravan.

Start practising by choosing a left-hand bend forease. Reverse slowly; turning the wheel, initiallythe opposite way to the direction you want thecaravan to go.

Now the front of the caravan is nudged out andis moving the rear in the intended direction. Takecare not to hit the van with the car!

Midways through the manoeuvre, when thecaravan is correctly angled, reduce speed to acrawl and gradually apply opposite lock. Make thecar follow the caravan round then finallystraighten up.

Please Note: Proficiency at reversing can onlybe achieved with practice.

SPEED LIMITS

• Normal road towing: 50mph

• Motorways (including dual carriageways):60mph

SETTING OFF

(i) Let the clutch in smoothly on the towingvehicle. Allow more engine speed toproduce the power to move the additionalweight of the caravan.

(ii) Avoid wear and tear on the clutch andtransmission by taking extra care not to‘ride’ the clutch.

(iii) Change gears smoothly. Try not to jerk theclutch.

CARAVAN HANDLING

(i) Allow for the caravan being wider than thecar. Ensure you have a clear view to therear. This may require the fitting ofextended mirrors for towing your caravan.

(ii) Do not bump the kerb with the caravanwheels.

(iii) When passing other vehicles, allow morethan the normal clearance for driving solo.

(iv) Allow longer to obtain a fast enough speedto pass other vehicles.

(v) Allow for the vehicle being twice its normallength. Do not suddenly swing out.

(vi) Carry out all manoeuvres as smoothly aspossible.

(vii) Use the nearside wing mirror to check thecaravan has clearly passed other road userswhen overtaking and changing lanes.

(viii) Adverse weather conditions may affect thesteering and braking characteristics of yourcaravan.

4-2

TOWING AND DRIVING

5-1

ARRIVING ON SITE

ARRIVING ON SITE

CHECK SITE REGULATIONS

On arrival at a site, you should always check thesite regulations. This will help avoid anyunnecessary conflict with site management andother site users.

WARNING: Care has to be taken toprevent fouling when traversing ramps orother ground obstacles.

SELECTING A PITCH

Carefully select where you wish to place yourcaravan. The site should be as level as possible,preferably not under or near trees, well drainedand away from possible boggy areas. Consider howyou will move the caravan when it is time to leavethe site. On sloping ground it is better to pitchfacing downhill, especially during wet weather.

SIDE-TO-SIDE LEVELLING

A quick glance at your pitch should tell you if youare likely to need side to side levelling i.e. levellingacross the axle. On uneven ground laterallevelling is accomplished by the use of a levellerjack or ramp and a spirit level placed ‘across’ thecaravan floor (not supplied).

Leveller JackPlace the leveller jack, folded flat, in front of thewheel needed to be raised to level the axle. Towthe caravan onto the leveller jack and adjust theheight until the spirit level shows that the caravanis laterally level.

Ramp(i) Reverse onto your pitch about 30cm (12")

further back than you wish to end up.(ii) Then place the levelling ramp in front of the

wheel that needs to be raised.(iii) Place a spirit level parallel to the axle on the

A-frame or just inside the caravan door.It helps to have two people at this point. Oneshould drive the car very slowly forward movingthe caravan wheel up the ramp, and the othershould indicate when the spirit level bubble is inthe middle.Whichever method you use, and once level:(i) Apply the caravan handbrake and chock the

caravan wheel if necessary.(ii) Lower the jockey wheel to ground level

before unhitching. (See index uncoupling)

You should then park your car, usually next to thecaravan furthest away from the door side.

Please Note: On upward facing pitches whenthe hydraulically damped drawbar of the hitchbecomes fully extended, it will be necessary tocompress the drawbar slightly in order to achievea clean’ unhitching. With the caravan brake on,reverse the towing vehicle about 2.54cm (1") torelease hitch lock tension and using the jockeywheel adjustment, unhitch the caravan aspreviously described.

FRONT & BACK LEVELLINGThis should be done only when the laterallevelling is complete.(i) Place the spirit level pointing front to back

just inside the caravan door or on the Aframe.

(ii) Then raise or lower the jockey wheel untilthe caravan is horizontally level.

Please Note: If there is a significant front toback slope, you may need to place a block underthe jockey wheel.(iii) Next, wind down the corner steadies onto

load spreaders (blocks of wood a minimumof 15.25cm (6") square or ‘Big Foot’ steadyattachments) until they are firmly set againstthe ground.

Please Note: It is possible on very uneven sitesthat when fully extended blocks may be requiredunder the corner steadies to achieve this. It isimportant that the caravan is correctly levelled toensure the correct working of the refrigerator,cooker etc.(iv) Now that your caravan is level, place the

caravan step in front of the door ensuringthat it is stable and safe to use.

PARKING ON A REVERSE-SLOPINGSITE OR STEEP HILLFor successful parking on a reverse slope orsteep hill, the operator need only apply thehandbrake with one hand while gently butpurposely inching the caravan a small distancebackwards with the other.CAUTIONNever enter the caravan without firstlowering the four corner steadies with thebrace provided. Corner steadies should notbe used as a jack. Take care not to lift thecaravan wheels.

5-2

ARRIVING ON SITE

6-1

GETTING STARTED

GETTING STARTEDYou have arrived at your destination and nowwant to start to enjoy your new Xplore touringcaravan. The following is a step by step guide toconnecting your services and getting everythingin your caravan working.

ELECTRICITY

Power Supply Charger

Your caravan is fitted with a power supply/charger. This will charge the caravan batterywhen fitted and also power the 12V systems inyour caravan.

It is recommended that you always carry a leisurebattery.

The Charger is fully automatic and will notovercharge the leisure battery.

12v Systems:

Your caravan is fitted with an automatic systemfor selection of power.

When connected to the 230V site supply theautomatic Power Supply/Charger will charge theleisure battery and the 12V systems.

When connected to the car (always disconnect230V supply), the system automatically switchesto the car supply.

When the ignition is switched on the 12V systemin the caravan is automatically switched off, carpower is supplied to the refrigerator and batterycharging is in operation.

GENERATOR/CHARGER

When connecting to a generator, always switchoff the RCD, start the generator and allowrunning for a few minutes to stabilize. When thishas happened, switch the RCD to the ONposition.

ELECTRICITY MAINS SUPPLY

Your caravan’s main electrical installation isdesigned to run on 230V at 50 hertz AC supply.

CONNECTING TO MAINS SUPPLY ONARRIVAL AT SITE

Before connecting the caravan installation to themains supply, check that:

(i) The mains supply is suitable for yourinstallation and appliances, i.e. whether it is

AC or DC and whether it is at the correctvoltage and frequency.

(ii) Your caravan is properly earthed. Neveraccept a supply from a socket outlet or plughaving only two pins, or from a lightingoutlet.

(iii) Any residual current device (earth leakagecircuit breaker) in the mains supply to thecaravan has been tested within the lastmonth. In case of doubt, consult the siteowner or their agent.

(iv) Make sure that the switch at the site supplypoint is off and that all electrical equipmentin the caravan is switched off by ensuringyour caravan mains isolating switch on theMCB is in the ‘OFF’ position.

ELECTRICAL WARNING

Attention: Always disconnect the electricalconnector between the towing vehicle andthe caravan before connecting a mainselectric supply to the caravan and beforecharging the caravan battery by any othermeans.

Once the above checks have been made:

(v) Remove any cover to the electricity inletprovided on the caravan, and insert thefemale connector of the flexible orangesupply cable as shown.

(vi) Locate the site supply and remove any coverfrom the socket outlet provided at thesupply point. Insert the male plug at theother end of the flexible orange supplycable. Switch on the main switch at the sitesupply point (if appropriate).

6-2

GETTING STARTED

(vii) Place any surplus cable under the caravan.Ensure that the surplus cable is not coiledup as it could overheat.

(viii) The MCB main electricity supply switchshould be put in the ‘ON’ position.

(ix) Check the RCD is working by pressing thetest button. Once pressed all electrical lightsand appliances should cease to operate.Reset, and then check the electrical systemis operational.

(x) Finally in order to get your 12V systemoperational, ensure the master 12V switch isin the ‘ON’ position. Refer to index forfurther details on the control panel fitted.

DISCONNECTING MAINS SUPPLYWHEN LEAVING SITE(i) Switch ‘OFF’ at the caravan mains isolating

switch.(ii) Remove the male plug from the site supply.(iii) Disconnect the female plug from the

caravan and store the cable in anappropriate locker.

OVERSEAS ELECTRICAL CONNECTION

Please Note: Connection to a mains voltagesupply OVERSEAS requires particular attention.

Care must be taken when connecting suppliesabroad since the supplies can be of REVERSEPOLARITY.

The significance of REVERSE POLARITY is thatwhen equipment is switched off, it may not beelectrically isolated. The only certain way ofmaking equipment safe is to unplug it.

A means of checking the polarity of the mainssupply when overseas is recommended. There areavailable several proprietary makes of equipmentfor the purpose.

If it can be achieved, it is preferable to connectlive to live, and neutral to neutral to maintain fullelectrical protection.

CHECK all caravan equipment is set-up to acceptthe site supply before actually switching on.

WIRING OF CONNECTING CABLE AND CARAVAN MAINS INLET

WARNING: It is essential that connections are made exactly as shown. If terminalmarkings are not in accordance with the above diagram they must be ignored.

6-3

GETTING STARTED

GAS SUPPLYYour caravan is designed to operate using eitherpropane or butane liquefied petroleum gas at30M/bar. Gas can be obtained from your caravandealer. Your caravan is designed to accept amaximum 2 x 6kg BP Light gas bottles.

ConnectionMake sure that heating and cooking appliancesand gas cylinders are switched off.Each gas appliance is connected to its own gasisolation tap under the cooker. These areidentified on the tap via a label. Below is a key toidentify each label.To operate the tap the arrow on the tap showsthe direction of flow for the gas. The arrowshould be pointing towards the appliance for theappliance to operate. There will be a small labelnext to the bank of taps under the cooker, whichis also reproduced below:

Changing a Gas Cylinder

Before commencing to change a gas cylinder ensurethat the valve on the cylinder is turned fully off. Turnoff all gas operated appliances.

Remove the gas hose from gas cylinder.

Before refitting a gas cylinder, ensure that all gasoperated appliances are turned off - particularly afterwinterisation. Ensure all connections are secure.

WARNING: If cylinders other than thoserecommended are used, ensure that thecylinders are adequately supported, do notblock ventilation openings and cannotcause damage to fixtures and fittingslocated in the compartment.

Gas Regulator

Your new Xplore caravan has been fitted with afully approved gas regulator designed to operateat a gas pressure of 30Mbar. Your regulator isfitted with a test point, which is accessed via theinlet at the side of the regulator. This access pointis only for carrying out gas pressure tests andshould not be used for any other purpose.

CAUTION It is strongly recommended thatonly CORGI approved gas fitters carry out anywork on your caravan gas installation.

High Pressure Gas Hoses

You should only connect to this regulator using alength of approved high-pressure hose notexceeding 450mm from the gas cylinder to theregulator. These approved high-pressure hosesare available from your Explorer Group Retailer.These hoses are connected using screw threadfittings, which will make a seal if connected andtightened using a spanner. Once the hose issecurely connected turn on the gas tap above theregulator, then turn on the gas bottle to allow gasto flow into the caravan.

In order to make all your caravan gas appliancesoperational it is necessary to open each appliancegas tap as detailed in previous column. All yourgas appliances should now be operational.Instructions on how to use each appliance aredetailed later in your handbook.

WARNING: Aerosols and highly flammableliquids must not be stored in thecompartment behind, or adjacent to, anygas appliance. Some industrial LPGappliances operate at high pressure andrequire a ‘high pressure’ regulator. Thisoften has an adjusting handle on it. NEVERuse such a regulator on a caravan.

Ventilation holes must be clear at all times.

Water Heater

Space Heater

Refrigerator

Cooking Appliance

Gas On/Off

Hob

6-4

GETTING STARTED

WATER SYSTEM

Your new Xplore caravan is fitted with a Whalepressurized water system using a submersiblewater pump.

To achieve the best performance from yourwater system please follow the setting up yourwater system instructions each time you connectthe submersible pump to your caravan.

Setting Your Water System On Your NewXplore Caravan

1. Ensure all the taps within your caravan arein the closed position.

2. Switch on the master 12V switch withinyour caravan.

3. Insert the submersible pump providedwithin your kit box into your watercontainer (not provided) and connect thepump outlet to the inlet on the caravan(Figure 1) and switch on the pump switch.

4. Using the farthest away tap from the pump,open on HOT (pump LED on control panelshould illuminate) and allow air to expelfrom the tap. Wait for water to flowsmoothly. Close tap, the pump LED shouldgo out.

Repeat step 4 for the 2nd furthest tap.

Repeat step four for all the cold taps.

Your system is now purged and primedready for use.

Draining Down Your Water System

(i) It is essential that you drain down yourcaravan water system when it is not in use.This is most important during wintermonths to protect against frost damage.

(ii) Disconnect the water pump and switch offpower supply.

(iii) Remove the water heater fuse from theswitch spur and store in a safe place.

(iv) Open the safety drain valve on the waterheater located next to the water heater.

(v) Open all taps and remove all plugs fromsinks and showers. Lever operated tapsshould have the lever put into the up andcentral position.

(vi) Open the drain outlets on the outside ofyour caravan.

(vii) If an onboard water tank is fitted ensurethat the drain tap on the tank is open.

(viii) Adjust the level of the caravan to ensurethat the drain outlet is at the lowest pointof the caravan. This will aid the flow of waterto ensure all water is drained off.

(ix) After 30 minutes level the caravan andprepare it for storage if necessary.

Fig 1

7-1

GAS SAFETY ADVICE

GAS SAFETY ADVICEIn the event of a suspected gas leak the gas mustbe turned off using the isolation valve on the gasbottle. A competent gas fitter should then checkthe system before it is used/reused.

Regularly check flexible gas hose, joints andconnections for tightness. Finally, make sure thateach gas appliance is working efficiently to therecommendations of the appliancemanufacturers.

See Index - Ventilation

FACTS ABOUT LPG

• LPG is not poisonous.

• Bi-products are harmless.

• LPG is dangerous if all air and oxygen isexcluded.

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

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

AWNING SPACES, LPG ANDAPPLIANCE EXHAUST

There is no danger of pollution of an enclosedawning space from the LPG exhaust from arefrigerator venting into it. Space heaters mayproduce sufficient exhaust to pollute the awningspace, if it is totally enclosed, from a generalcomfort, smell and hygiene point of view. Inextreme cases there could be a build up ofcarbon dioxide to a dangerous level. Caravanowners are advised to allow some fresh aircirculation in the awning space when suchappliances are in use.

Please Note: Ventilation holes must be clear atall times.

LPG GAS SYSTEM

The Explorer Group Limited does notrecommend the use of any external cylinders. Allcylinders in use should be within the gas lockerprovided. If you wish to utilise a larger cylinderand have this outside the gas locker then theconnecting hose must not exceed 750mm.

It is recommended that no flammable material isstored or placed within 300mm of any openflame. Your attention is also drawn to the fact thatthe surface of the Space Heater in your caravan

will get hot when in use. You are advised not touse any additional gas appliances outside yourcaravan unless it is a Gas Barbecue connected viathe Barbecue point supplied with your caravan.

Please ensure that you have read the operatinginstructions for each gas appliance contained inyour Owners Information Pack. Please ensurethat any gas hose left unconnected is protectedfrom dirt or other foreign bodies entering thehose.

WARNINGS

• Fresh air circulation should be allowedbelow the caravan when appliancesare in use and when flues terminatebelow the floor to allow freeevacuation of the products ofcombustion. At least three sides of theunderfloor space should always bekept open and unobstructed especiallyby snow. Do not make any additionalopenings in the floor.

• Outlet sockets located within thecaravan should only be used with adedicated appliance and not anindependent unit.

• No appliance shall be used outsidewhen connected to an internal outlet.

• Maintain adequate spacing ofcombustible materials from sources ofheat.

• Do not use additional independent gasappliances inside the caravan.

7-2

GAS SAFETY ADVICE

8-1

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

12v POWER SUPPLY

Battery Installation

Your caravan will be fitted with a BCA Leisurecharging and power distribution unit.

If you wish to install a leisure battery pleaseensure that it is placed on the battery traysupplied with your caravan. Then place the tray inthe battery locker fitted to the side of yourcaravan. Connect the battery to the clamp fittingsconnected to the connection leads within thebattery box.

The Explorer Group Limited recommends thatyou use sealed for life leisure batteries of aminimum rating off 40 ampere-hours at 20 hoursdischarge rate.

Battery Maintenance

Your leisure battery should be maintained inaccordance with the manufacturer’s instructions.For information on the automatic chargingsystem in your caravan please refer to ‘AutomaticCharging System’ in the index.

Do not charge your leisure battery with anycharger other than that supplied. Failure tocomply may cause damage to your battery. If youremove your leisure battery, ensure that it is notplaced on a cold surface as the battery willdeteriorate more rapidly than if stored at asuitable temperature

Generators / Charger

All electrical equipment fitted in your newcaravan can be run from either a controlledgenerator or charger whose output is maintainedbetween 11volts and 14volts.

At least once every 3 years, the caravan electricalinstallation should be inspected and tested, and areport on its condition obtained, as prescribed inBritish Standard BS7671.

230v POWER SUPPLY

Mains Unit

The Mains Unit replaces the conventional fusebox. Similar, but larger ones are often fitted innew houses. The unit, normally located in thewardrobe, gives overloads and earth leakageprotection for the 230V electrical supply in yourcaravan.

For normal operation all switches on the unitneed to be in the ON position. The switches onthe left of the unit are known as MCB’s(miniature circuit breakers). These take the placeof the conventional fuse but are more convenient.In the event of a fault the MCB ‘trips’ i.e.automatically moves to the OFF position. Afterelimination of the fault the MCB can be re-set byswitching to the ON position (against the springpressure in an upwards direction). If an earth faultdevelops, or a person was to touch a live piece ofequipment, the leakage of current to earth shouldimmediately operate the RCD (residual currentdevice) and ‘trip’ the main switch, to the OFFposition. This switch can only be re-set afterelimination of the fault.

Please Note: In case of difficulty, consult anapproved electrical installation contractor (whomay be the local electricity board). It is dangerousto attempt modifications and additions yourself.Lamp holder-plugs (bayonet- cap adaptors) shouldnot be used under any circumstances.

Resetting the RCD

To re-set, operate the switch as for MCB’s.Periodically, the RCD should be checked byoperating the test button marked ‘T’. The unitshould immediately switch to the OFF position. Ifthe unit does not switch off then a qualifiedelectrician should be consulted. If the unit doesswitch off, the test is complete and the switch canbe re-set restoring the supply back to normal.

Please Note: Simultaneous operation of all ofthe 230V mains electrical equipment may not bepossible. A typical UK caravan site mains hook-uppoint provides a maximum output of 10 amps andon some continental sites the available outputmay be as low as 5 amps. If your loading exceedsthe site supply it may trip the site circuit breaker.Please check the available mains output with yoursite operator. The following items need to beadded together if used simultaneously.

230V mains equipment typical consumptionfigures:• Refrigerator ............................................ 0.50 amps• Charger .................................................... 0.50 amps• Water heater ............................................ 3.9 amps• Blown air heaters .................................... 8.5 amps• Colour TV ............................................... 2.50 amps• Microwave ............................................... 4.00 amps• Air conditioning ..................................... 4.00 amps

8-2

ELECTRICAL SYSTEM

AUTOMATIC CHARGING SYSTEM

The battery charger will operate automaticallywhen the caravan is connected to the mainsoutlet on a caravan site. The 12V system, with theexception of the 12V refrigerator and batterycharging, will not operate when the caravan isconnected to the towing vehicle.

CHECK all caravan equipment is set-up to acceptthe site supply before actually switching on.

MAXIMUM BULB RATINGS FORINTERNAL LIGHTS

Type of Light Maximum Bulb Rating

Compact Fluorescent ......................................... 9W

Reading Lights .................................................... 10W

Downlighters ...................................................... 10W

MAXIMUM BULB RATINGS FORROAD LIGHTS

Type of Light Maximum Bulb Rating

Front position ....................................................... 5W

Brake/Rear position .................................. 21W/5W

High level marker ................................................ 5W

Indicator .............................................................. 21W

Reversing ............................................................. 21W

Please Note: Ensure that you only replace ablown bulb with one of the same rating. Neverreplace a bulb with one with a higher rating. Youshould ensure that when fitted, no bulb is incontact with the surface of the lamp or shade.

8-3

ELECTRICAL SYSTEM

12V FUSES - ALL MODELS

8-4

ELECTRICAL SYSTEM

MAINS UNIT

9-1

HOW TO USE YOUR CARAVAN’S EQUIPMENT

HOW TO USE YOURCARAVAN’S EQUIPMENTWithin this section of your caravan’s handbookwe will give you brief details on how to operateall of the caravan’s equipment from the gascooking equipment to the widow blinds. Forfurther details on the major equipment withinyour caravan please read the individual applianceinstructions contained with your userinformation pack.

Please Note: Before attempting to use any gasequipment please ensure that the gas bottle isconnected securely to the caravan’s regulator viaa high pressure gas hose and the bottle valve is inthe ‘on’ position. Also ensure the applianceisolation valves are in the ‘on’ position as shownin the gas system section.

Please Note: Before attempting to use anyelectrical appliance ensure that you haveconnected the mains connection cable to a mainshook up and that the mains isolation switch is inthe ‘on’ position.

ELECTRICAL CONTROL PANELS

Your new Caravan will be fitted with the controlpanel shown below.

The DC VOLT METER on the control panel will give theapproximate voltage for your auxiliary battery (if fitted) orthe output voltage from the power supply if no auxiliarybattery is fitted.

The switch marked LIGHTS when in the position marked Iwill feed 12V power to all the internal caravan lights. All theinternal lights also have their own switches to enableindividual operation.

The switch marked AWNING will operate the awning lightwhen in the position marked 1 and is the only switch for thislight.

The switch marked PUMP must be in the down position inorder for the water system to work, your caravan is fittedwith a pressured system and the pump will runintermittently and the red LED will illuminate when thepump is running in order to maintain the pressure within thesystem. When the water is switched on for the first time, thepump will run until the working pressure is reached.

The switch marked MASTER is the 12v master switch andunless this is in the position marked 1, i.e. pusheddownwards, no 12v equipment will operate within yourcaravan.

9-2


COOKING EQUIPMENT

WARNINGS

(i) All pans should be mounted centrallyover the burners, even when cooling, toprotect adjacent walls.

(ii) Do not lower the glass cover until hobhas cooled down.

(iii) Glass lids may shatter when heated.Turn off all burners and grill beforeshutting the lid. The glass cover shouldbe raised when operating the grill.

(iv) Accessible parts may be hot when thegrill and oven are in use. Young childrenshould be kept away.

(v) Do not use grill or oven as a spaceheater.

(vi) When you are cooking it is essential toprovide additional ventilation, such asopening windows near grill, cooker andoven.

Gas Hob

(i) Turn the individual control knob for theburner you wish to light.

(ii) If the hob is fitted with electronic ignitionthen depress the ignition button, which canbe found on the front of the oven next tothe oven control, while depressing thecontrol knob. The depressing of the controlknob overrides the flame failure device fittedto the burner. If the burner fails to lightwithin 20 seconds then release the controlknob and wait 30 seconds before tryingagain.

(iii) Once the burner lights it will be necessary tokeep the control knob depressed for about 5to 10 seconds to ensure that the flamefailure device is heated up enough tooperate.

Burner controls

Gas Grill

(i) Turn the grill control knob to the high flameposition and with the knob depressed pressthe electronic ignitor button. If the grill doesnot light within 20 seconds then turn off thegrill control knob for at least 30 secondsbefore trying again.

(ii) Once the grill lights it will be necessary tokeep the grill control knob depressed for 5to 10 seconds to ensure the flame failuredevice is heated enough to operate.

Ignitor button

Grill control knob

9-3


Gas Oven

(i) Turn the gas oven control knob tomaximum then depress the knob whilepressing the electronic ignitor button. If theoven does not light within 20 seconds turnoff the control knob and wait for 30seconds before trying again.

(ii) Once the oven is lit it will be necessary tokeep the control knob depressed for 5 to10 seconds to ensure the flame failuredevice is heated up enough to operate.

Oven control knob

9-4


OPERATING INSTRUCTIONS

When the caravan is on tow, the refrigeratorshould only be operated electrically, i.e. from the12V battery in the towing vehicle and not bymeans of the bottled gas.

The refrigerator can be run on 230V or LP gaswhilst stationary.

CAUTION: Only use one source of energy at atime.

WARNING: The refrigerator should not beoperated on LP gas whilst being towed orwhen on a petrol station forecourt.

Switching on the refrigerator

• Clean the inside of the refrigerator beforeyou switch it on.

• Let the refrigerator run for at least eighthours before you place food in it for the firsttime.

DELUXE REFRIGERATORS

Controls

A = Energy source selector switch. Selects thecorrect energy source at control A as follows:

• direct current

• mains supply

• gas

• OFF

B = Thermostat controls the refrigerationtemperature. Temperature level is indicated by aseries of dots. The larger the dot the colder thetemperature.

C = Flame meter. Indicates if the refrigerator flameis alight.

D = Piezoelectric ignition. Produces a spark, whenpressed, to ignite the burner flame.

ELECTRIC POWER OPERATION

Electric power operation is available from twosources:• Battery operation, 12V.• Mains voltage operation, 230V.

Battery operation must only be selected after therefrigerator has reached optimum temperatureusing either mains voltage or gas supply as thepower source. Battery operation worksindependently of thermostat control.

Mains voltage operation is controlled by thethermostat setting of control B.

GAS POWER OPERATION

WARNINGS:

Ensure correct gas type is used and allrelevant regulations are adhered to.

Do not use gas power while driving or inthe vicinity of fuel sources.

Ensure gas bottle is connected correctlyand then open the bottle valve and gastaps.

Set thermostat control (B) to maximum.

Select at source selector (A).

Ignite the gas flame as follows:

REFRIGERATOR MODEL THETFORD N108P

A = Energy source selector switchB = Thermostat

C = Flame meterD = Manual ignition (piezoelectric ignition)

Control Panel - Manual ignition Model

9-5


Manual ignition:

1. Press and hold in thermostat control (B) fora maximum of 30 seconds.

2. Press manual ignition button (D) severaltimes at intervals of 1-2 seconds.

3. Release thermostat control (B) when theflame meter (C) red needle enters the greenarea of the gauge.

4. Set thermostat control (B) to required value.

Switching off

Set the energy source selector switch (A) to

to switch the refrgierator off.

Use the special storage latch on the door lockmechanism to stop the door closing, preventingunpleasant odours and mould forming in therefrigerator.

Turn off gas taps and gas bottle valve.

Maintenance (all fridge variants)

The maintenance requirements for all types ofThetford fridges are as follows:

• Cleaning: clean the fridge regularly using a softcloth and mild detergent. Dust using a softmoistened cloth and annually remove dustfrom the condenser inside the fridge.

• Defrosting: defrost the fridge regularly as soonas the frost layer is 3mm thick.

• Door lock: check the door lock mechanismregularly and ensure door closes securely.

• Ventilation grilles: check regularly to ensurethe grilles are clean and unblocked.

Securing products for driving

One of the racksin yourrefrigerator has asystem forsecuring productsduring driving.The systemconsists of asimple click-and-slide plastic strip.To secureproducts on therack whiledriving, push theplastic strip as tightly as you can against theproducts on the rack.

In the storage space on the inside of therefrigerator door, there is the unique Thetfordflexible bottle slide. The slide prevents bottlesfrom sliding around during driving. Push the slideagainst the products in the door or place theproducts between the bottle slide.

Door locking mechanism

The refrigerator door has an automatic lockingmechanism. The door locks automatically whenyou press it shut firmly. The lock releasesunnoticed when you open the refrigerator withyour hand. This automatic locking mechanism alsokeeps the refrigerator door shut during driving.For some models an additional security device isfitted below the refrigerator. By pushing thelocking bar over the pin when the door is closed,you can make doubly sure that the door does notcome open during your journey.

9-6


WATER HEATER OPERATION

Gas operation

(i) Ensure that the water heater has been filledwith water and that the outside flue coverhas been removed.

(ii) Using the Ultrastore control knob, turn thedial to the desired temperature setting thenturn the outer ring to the flame position.

(iii) Once the Ultrastore is switched on a greenlight is visible within the switch and the unitwill now try and ignite.

(iv) If within approximately 10 seconds, theUltrastore fails to ignite then a red failurelight will also appear. If this happens wait 30seconds before trying again.

230V Operation

(i) Simply depress the Electrical switch fittednext to the gas control to the 230V position.This will turn on the water heaters electricalelement. It is imperative that there is waterin the heater whenever the Gas or Electric isswitched on.

SPACE HEATER OPERATION

Gas Operation

(i) Turn the gas control on top of the heater tothe desired setting and depress the knob.

(ii) Keeping the control knob depressed lookinto the viewing window and see if the gasignites. If you have an automatic ignitor thenyou should hear it ticking and eventually seethe pilot light. If however you have piezoignition then you will have to manuallydepress the ignitor repeatedly until you seethe pilot light.

(iii) Once the pilot light is lit keep the controlknob depressed for a further 20 seconds toallow the thermocouple to operate.

(iv) If the heater fails to ignite please wait 20seconds before trying again.

230V Operation

(i) Simply depress the main switch on theUltraheat control panel to the 230V position.

(ii) Then set the power rating you require onthe panel at either 500w 1000w or 2000w.

Ultrastore Control Gas Control

Ultrastore Control

9-7


Fan Operation

The blown air function of the space heater iscontrolled by the three position switch on top ofthe heater.

(i) Position 0 is off

(ii) Position A operates the fan in automaticmode. In this position the fan will only runwhen there is sufficient heat to require theair to be circulated.

(iii) The third Position will operate the fan at alltimes.

(iv) The speed of the fan is controlled by thenumber position set with 5 being the fastestspeed and 1 being the lowest.

WARNING: The space heater surfacesbecome hot in use and the guard provideddoes not give full protection to the youngor elderly.

Fan Control

BATTERY CHARGER

The battery charger for the caravan battery willautomatically switch on when the caravan isconnected to a mains supply. The battery chargerwill also provide a 12V supply to the caravanwhen a battery is not connected. Please note thatthe battery charger fitted is designed to keepyour battery charged and is not designed forcharging up a flat battery.

SMOKE DETECTOR

The caravan smoke detector will become activeonce the 9V battery which should be suppliedwith the smoke detector is connected. Thesmoke detector fitted to your caravan has analarm pause mode which will reduce thesensitivity of the alarm for a short period toallow for cooking within the caravan. The alarmpause mode is activated by pressing the buttonmarked HUSH on the smoke detector. While thedetector is in the pause mode the detector willbeep once per minute to alert that the alarmpause mode is activated.

9-8


THETFORD CASSETTE C-200 CWTOILET

Introduction

The Thetford Cassette C-200 CW is functionaland incorporates modern styling with home likefeatures. The unit is an integral part of themotorhome bathroom.

The Thetford Cassette C-200 CW is constructedof high quality plastics for durability and has ahigh gloss finish that is easy to clean and maintain.The unit consists of two sections, a permanentlyinstalled toilet system and a slide out wasteholding tank - the Cassette.

The toilet section includes a rotatable bowl, aremovable seat, and a control unit with a flushbutton and a waste level warning device. Thevalve blade handle is located under the bowl.

The cassette is located underneath the toilet andis removed for emptying from the outside of thevehicle through an access door. A rotating pour-out spout, automatic holding tank vent, air releasevalve, valve blade, carrying handles and hand gripsare incorporated into the cassette. A slidingcover guarantees optimum hygiene.

Features:

• Removable seat and cover.• Rotatable bowl.• Valve blade handle: opens and closes valve

blade manually.• Flush button: activates flush.• Waste level indicator: indicates when

cassette requires emptying.• Rotating pour-out spout: makes emptying

cassette easy and convenient.• Automatic cassette vent: vents the cassette

when inserted in the toilet. This preventsover pressure in the cassette.

• Upper-carrying handles: makes carrying andemptying easy.

• Sliding cover: opens and closes automaticallywhen sliding the cassette in and out.Guarantees optimal hygiene.

• Valve blade and blade seal.• Vent button: vents the cassette to avoid

splashing while emptying.• Handgrip.• Valve blade opener.• Access door. Locks from outside the

motorhome.

Preparing for use

Following is a brief illustrated step by step guide.For more detailed information please refer tomanufacturers literature.

CAUTION (step 4): Warmer weather or longerintervals between emptying the waste tank mayrequire additional toilet fluid. Use only Thetfordtoilet fluid to achieve the best results. Never addtoilet fluid directly into the toilet bowl.

CAUTION (step 14): Do not depress air releasevalve button until pour out spout is facingdownwards.

Emptying the waste holding tank

The cassette capacity is approx. 17 litres and thetank should be emptied when the waste-levelwarning device comes on. This will occur whenthe tank contains more than 15 litres of waste.

Note: After the warning device comes on, thecapacity remaining is equal to approximately 5uses.

CAUTION: Do not allow the waste cassette tobecome overfilled. See trouble shooting sectionfor emergency emptying procedure.

Note: Some vehicles are equipped with waterpumps supplying high water pressure, which canresult in having an over flushing problem. It ispossible to use the flow restrictor supplied withthe toilet (packed together with the instructionmanual) by installing it in the water tube at theconnection level.

Rinse the holding tank with clean water. Preparethe cassette for use again by following steps 1 to6. Replace the holding tank and lock the accessdoor.

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1 - Open access door and pullretaining clips upward.

2 - Remove cassette by pullingstraight out. When cassette hitsstop, tilt downwards

3 - Position tank vertically andswivel pour-out spout upwards.

4 - Remove dosage cap and pour-out spout.Add toilet fluid in the dosage cup. Addapprox. 2L of water through spout to covertank bottom. Replace cap, return pour-outspout to original stored position.

5 - Slide the holding tank into positionthrough access door. Never forceinsertion as this can cause damage tothe toilet.

6 - Make sure the retaining clip securesthe holding tank. Close and lock theaccess door.

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7 - Open water fill door and add 50ml.of Aqua Rinse. Then fill the tank withfresh water using a jerry can or hose.Tank capacity is 7 litres.

8 - Turn the bowl into the mostcomfortable position, when necessary.

9 - Run some water into the bowl bymoving the flush handle up and downonce.

10 - The toilet may be used with bladeopen or closed. To open the valve, pullthe valve handle under the toilet bowltowards you. It is now ready for use.

11 - After use, open the valve blade (if itis still closed) and flush the toilet bymoving the flush handle up and down.Close the valve blade after flushing.

12 - To empty, open access door andremove holding tank. The holding tankcan only be removed when valve bladeis closed.

9-11


Winterising/Storage

The Thetford Cassette C-200 CW is easilywinterised for storage. If the toilet is connectedto a separate water tank, drain the tank. Whenthe motorhome water tank is empty, press theflush button until the water stops flowing. Emptythe cassette. If the toilet is connected to acentral water tank, open the electric valve bypushing the flush button while draining the watersupply system of the motorhome. Empty thecassette. Leave the blade of the cassette open. Donot replace cap on spout, this helps to keep thecassette dry.

Cold weather use

The cassette can be used in cold weather whenthe motorhome is heated. When the vehicle isnot heated for more than a day (or a night),winterise the cassette.

High Altitude and hot weather use

Changes in altitude during driving, and largetemperature variations give no problems as longas the cassette is inserted into the toilet. Theautomatic cassette vent will depressurise thattank when there is over or under pressure. Hightemperatures may require additional Thetfordtoilet fluid.

Cleaning and maintenance

To clean the seal and blade, the use of Thetfordbathroom cleaner and rinse with water isrecommended. Alternatively, use a luke warmsolution of diluted washing up liquid. Do not usehousehold cleaners as they may damage the sealsand other toilet parts.

Dry the seal and blade thoroughly and sprayeconomically with silicone spray, alternatively useolive oil. Do not use Vaseline or other vegetableoil products.

The toilet bowl, seat, cover and the exterior ofthe toilet unit and cassette can be cleaned with amild detergent/water mixture.

13 - Carry the holding tank to a normalhousehold toilet or authorised disposalpoint. Place holding tank in verticalposition and rotate pour-out spoutupwards.

14 - Remove measuring cap. Grasp unitby upper carrying handle nearest pour-out spout. Place other hand on upperrear hand grip so that the vent buttoncan be depressed with thumb whileemptying. This ensures a smooth outflowof tank contents.

15 - Once the pump has been cleared ofwater place appropriate size containerunder the drain plug. Empty anyremaining water from the fresh watertank by taking out the drain plug. Cleanthe seals and lubricate them whereappropriate after drying.

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Toilet unit malfunctions

Contact your dealer or a Thetford ServiceCentre.

We advise draining the fresh water tank prior totravelling. Antifreeze should not be required ifthe motor home is heated. If you do wish to useantifreeze, brands containing the followingproperties may be used in the fresh water tank:

• Ethylene glycol

• Mono-Ethylene glycol

• Propane-diol

• Glycerol

• Ethane-diol

• Glycol

Never use alcohol based antifreeze, i.e. Methanol,Ethanol, and Iso-propanol.

WINDOWS

Your new Xplore touring caravan has been fittedwith Polyplastic double glazed windows.

Polyplastic Window Opening

(i) In order to open the Polyplastic window it isonly necessary to move the catch upwardsand release the catch from the backing plate.

(ii) The Polyplastic window should remain in theopen position once opened, however if itdoes not then tighten the friction control onthe window stays to increase the holdingforce.

(iii) The Polyplastic window is also fitted with anight ventilation position where the catch isset to the centre position on the backingplate; in this position it may be possible forrain to enter the caravan in adverseconditions.

ROOFLIGHTS

Your caravan is fitted with at least one type ofthe following roof lights.

Standard MPK Rooflight

To open:

(i) Lower the flyscreen then press the blackcontrol rod in towards the centre of therooflight.

Fig 2

(ii) Then while the rods are depressed, pushupwards to open the rooflight.

Midi Heki Rooflight

(i) To open, push the large central button(Fig 2).

(ii) Whilst depressed, slide the bar to thedesired position and locate into the stopsprovided (Fig 3).

Fig 1

Fig 3

9-13


BLINDS & FLYSCREENS

Blinds

(i) Pull blind down by its centre catch. Do notpull down by one side of the blind. This willinevitably lead to problems.

(ii) Do not allow blinds to spring back freely.Always control them by hand.

Flyscreens

(i) To operate the flyscreen, either pull thescreen fully down, fully up or across,dependant on type of window fitted, and clipinto place on the blind/frame.

(ii) To release, unclip from the blind/frame. If across bar is fitted, gently pull the crossbardownwards towards you and allow thetension of the spring to roll up the flyscreen.

(iii) Where a crossbar is not fitted, disconnectfrom the blind catch and release gently.

(iv) It is recommended that blinds are not in theclosed position whilst the caravan is moving.

Door Flyscreen (If Fitted)

The exterior door flyscreen can be opened orclosed from inside or outside the caravan anddoes not restrict door openings. When openingor closing the door flyscreen use the finger gripprovided.

TAPS

All the taps are operated by lifting the lever andturning the lever right for cold and left for hotwater. In order for the taps to work, the pumpswitch on the control panel needs to be in theON position. For caravans with fixed watertanks the taps need to be in the TAPS position.

WARNING: The water temperature couldbe very high so do not lift the lever withthe tap turned to the full left position.

Kitchen Tap

Shower Mixer Tap

Bathroom Tap

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EXTERIOR DOOR RETAINERS

The door retainer fitted to your Xplore touringcaravan is operated by simply lightly pushing thedoor to the side of the caravan. The retainershould automatically engage and hold the door inplace. To release the door simply pull the leverlocated on the side of the retainer towards thedoor and the retainer will release the doorenabling it to be closed.

GAS LOCKER DOOR

Your new Xplore caravan is fitted with a gaslocker door which is held open via the use of themetal supporting strut which should be located inthe fixing position in the door.

Please Note: It is important when raising yourgas locker door that you do not push the doorpast the vertical position as this could damage thehinges. Also care should be taken when leavingthe door in the open position to ensure that anywind cannot catch the door and push it openbeyond the vertical position.

INTERNAL DOORS

Toilet/Shower Room Doors

Toilet/shower room doors are fitted with a leverlock, which is operated by pushing the leverdown. The lever is spring-loaded and will returnto the closed position upon release. It isrecommend that the lever is always used whenclosing the door.

OTHER INTERNAL DOORS

Other internal doors such as the wardrobe andtable storage locker are fitted with a 2-positionbutton lock. Push the button to lock the doorand the button should remain flush with the door.Push the button again to release and the buttonshould then protrude from the door surface.

Toilet/Shower Room Doors

Other Internal Doors

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MAGNETIC CATCHES

Magnetic catches workon contact with themetal plate on the rearof the door. Simplyclose the door untilthe magnet engagesand holds the metalplate. Pulling the doortowards you with amoderate force will besufficient to disengagethe magnetic catch andopen the door.

SPRUNG HINGES

Overhead lockers will use sprung hinges. Theseare suitably strong enough when closed tosecurely retain the door and prevent it fromopening in transit. Pulling the handle towards youwith moderate force is sufficient to open thelocker door and hold it in the open position.

SLIDING DOORS

The room divider should be held in place duringtransit by the use of the strap with the studfastening. When stationary, the room divider canbe held shut by contact between a metal plateand magnet.

BED MAKE-UP

Parallel Lounge

The two single beds can be easily converted intoa double bed by pulling out the bed slats, storedbeneath the chest of drawers or stored in thebed slat box at the front/end of the caravan.Arrange seat cushions appropriately.

1

2

3

4

5

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Status 315 Directional Antenna

Bunk Beds

All high level beds will take a maximum weight of75kgs / 11 stone. When in use, the high level bedsmust have the bunk safety boards in place asshown in the diagram. Touring caravans aremanufactured with a lightweight construction andtherefore the beds are not designed to be knelt,sat or stood upon without all the bed cushions inplace.

REMOVABLE DRAWER LOCKER

To remove from the caravan, first locate the tworetaining straps at the bottom rear of the unit,the straps are released by pulling away and downthis releases the thumb catches. The locker cannow be removed for storage.

To secure the unit into the caravan, first place thelocker into position, then feed the straps thoughthe thumb locks, holding the strap taut push thethumb lock so that is closes on the strap.

TV AERIAL

Your new Xplore touring caravan will be fittedwith a 315 Status TV aerial

To operate your 315 TV aerial follow theprocedure outlined below:

(i) Switch ON the power pack and the red LEDwill illuminate.

(ii) Check the gain control switch is set to thenormal ‘NML’ position (switch UP). If picturedistortion is caused by too strong a signal,set the switch to ‘LO’

(iii) Turn on your television set and tune in. Thismay be necessary at all new locations.

(iv) The Status 315 aerial is wide band andtherefore digital terrestrial compatible.

1

2

3

4

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FM RADIO CONNECTION

The Status aerial is designed to receive FM radiowhen connected to a car-style radio.

(i) This will require a coaxial car radio plug, acoaxial plug and a length of coaxial cable,which are available from your local caravanretailer.

(ii) Assemble the cable and plugs and route thecable from the power pack to the radio.

(iii) Once the cable has been installed plug intothe ‘TV-FM’ socket of the power pack andinto your radio.

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10-1

SECURITY

SECURITYTheft deterrent, prevention and security of yourtouring caravan is taken very seriously at TheExplorer Group Limited. That is why we haveprovided a combination of standard features andoptional extras designed to deter and preventthieves from stealing your property. And in theunlikely event that they should succeed, aid theidentification, speedy recovery of your propertyand assist in the prosecution of the thief.

Caravan Theft

The theft of a caravan can occur in the mostunlikely circumstances; from a motorway servicearea, even from an owner’s driveway. Secure allwindows and doors when your caravan isunoccupied, even if only for a short length of time.

MICROTAG©

Supplied as standard withevery Xplore touringcaravan, MicroTag© is aninnovative andtechnologically advancedproperty tracing system thatcan be easily applied to allyour valuables. Marking yourproperty with Microdots notonly deters theft, but will also help lead to thesuccessful prosecution of the thief and therecovery of your stolen valuables.

Why Use Microdots? - In order for the Policeto successfully prosecute, it is necessary toidentify the true owner of stolen property.Marking your property with Microdots is theeasiest way to ensure your valuables are quicklyidentified.

You can Microdot all kinds of property againsttheft including your touring caravan, motorvehicles, televisions, bicycles, jewellery, in factanything of value to you, that will also be of valueto a thief.

In the event of theft the police can locate theMicroDot by using an ultra violet light. TheMicroDots are then read using a MicroDotreader, or a conventional microscope. EachMicroDot is laser etched with a free phonehelpline and your own unique number which isregistered on the International Security Registerwhich is manned 24 hours a day, 365 days a year.

Please consult the instructions provided insidethe Microtag box.

ANTI-WIND CORNER STEADIES

The rear corner steadies on all Xplore touringcaravans have a special cowling that allows for theprecise positioning of a security bolt. Once thecorner steadies are down, the bolt is put in placeand padlocked. This prevents the potential thieffrom being able to lift the corner steadies makingit extremely difficult to tow the vehicle away.Owners are advised to purchase good quality,extended loop padlocks in order to secure them.The padlock is not supplied by The ExplorerGroup Limited.

10-2

SECURITY

CRIS - THE CARAVAN REGISTRATIONAND IDENTIFICATION SCHEME - VIN

CriS is the national register of UK manufacturedtouring caravans and was established by theNational Caravan Council (NCC) in conjunctionwith HPI Ltd.

All Xplore touring caravans are recorded on theCriS database by their unique 17 digit VehicleIdentity Number (VIN). This VIN and the caravandescription are recorded on the Touring CaravanRegistration Document, which is sent by CriS tothe caravan’s registered keeper.

Make a separate note of the number to keep safeat home.

CriS issues Touring Caravan RegistrationDocuments which are the equivalent of the logbooks issued by the DVLA for cars - the TouringCaravan Registration Document confirms thename of the registered keeper, the VIN and fullvehicle description.

Shortly after purchasing this caravan you shouldreceive your Touring Caravan RegistrationDocument. It will be sent by post to your homeaddress.

WINDOW ETCHING & CHASSISMARKING

The VIN number is stamped onto the chassis ofthe touring caravan and etched onto all of thewindows acting as a further deterrent. YourTouring Caravan Registration Document willinclude a 17 character VIN (Vehicle IdentificationNumber), shown in the top right -hand corner.This 17 character VIN will be die- stamped intothe caravan drawbar and chemically etched on upto a maximum of 10 eye level windows. Toprotect yourself and your touring caravan, neverleave the Registration Document in the caravan.For security reasons keep it in a safe place.

If you sell the caravan please follow theinstructions on the Touring Caravan RegistrationDocument.

Please Note: If you do not receive a TouringCaravan Registration Document, lose it, or any ofthe details recorded are incorrect, please contact:CRIS - Dolphin House, New Street, Salisbury,Wiltshire, SP1 2TB. Telephone: 01722 411430

Spare windows stencils can be found in yourowners information pack for use if you ever needto order a replacement window.

ELECTRONIC TAGGING

In conjunction with the CriS registration scheme,all Xplore touring caravans are electronicallytagged during manufacture for added security andease vehicle identification. The security tagcontaining the individual identity of your caravanis concealed within the caravan body and can onlybe read by using a special decoder.

Please Note: Your Local Police Can Obtain TheUse Of A Decoder By Contacting C.R.I.S. onTelephone No. 01722 411430

ADDITIONAL SECURITY

Consider fitting any device which might deter orprevent intrusion by thieves. For example: Awheel lock will prevent towing of the caravan andremoval of the wheel.

FREE CRIME PREVENTION advice aboutsecuring your caravan, protecting your valuables,property marking, either at home or whilst onsite, can be obtained from the Crime PreventionOfficer through your local Police Station.

11-1

CARE OF YOUR CARAVAN

CARE OF YOUR CARAVANThis section of the guide is devoted to the care,cleaning and general preservation of your caravanin order to retain its showroom condition.

EXTERIOR CLEANING

Under no circumstances should an abrasive orharsh cleaner be used. Do not use a pressurewash as this can disturb mastic seals. Exteriorpainted body parts of the caravan (usually theside walls) are acrylic finished aluminium, which isextremely durable and easy to clean. It isrecommended you first wash off any heavy dirtand mud with cold water then use a proprietarybrand wash and wax shampoo and rinse withplenty of cold water.

GLASS FIBRE REINFORCED PLASTIC (GRP)

GRP components need to be washed, waxed andtaken care of like a car. Chemicals and dirt cancollect during storage, and the gel coat can bestained or marked when chemicals combine withrain or dew. Most stains or marks can beremoved with mild dishwashing detergent, butmore stubborn marks may require a (fine grit)rubbing compound such as T-cut.

To help keep your GRP components lookingalmost like new, it is wise to wash the partsmonthly (or more frequently) using milddishwashing detergent, but avoid using strongalkaline (e.g. trisodium phosphate) or acidiccleaners or abrasives. Waxing the componentsonce or twice a year with a good grade pastewax will help to maintain the colour and finish.

ACRYLIC WINDOWS

Your caravan is fitted with shatter resistantacrylic windows. To preserve their clarity andunblemished transparency it is essential that thefollowing cleaning instructions are strictlyadhered to: Road grit, dust, sand, flies, lime treesecretions, bird droppings etc., should be washedoff using plenty of cold water do not use asponge to clean off heavy dirt deposits. Anyremaining dirt should be washed off using a softcloth and warm water.

Please Note: Under NO circumstances shouldany abrasive cleaning agents, householddetergents or proprietary cleaning fluids be used.Wash the window again using only cold waterand dry off with chamois leather.

Please Note: Should scratches appear on theacrylic windows these can often be removed withan acrylic polish, i.e. ICI Perspex polish. Gentlepolishing with a liquid metal polish, i.e. Brasso mayalso have the desired effect - consult your retailerBEFORE attempting to remove any but theslightest scratch.

CARE INSTRUCTIONS FOR SEITZROOFLIGHTS

Clean the acrylic rooflight with soap suds andplenty of water, or use the Seitz special cleaner.Use talcum to care for the rubber seals.

Only use water and mild soap suds to clean theblinds.

Please Note: The 12-month guaranteebecomes null and void if these instructions arenot followed.

WINDOW BLINDS & FLYSCREENS

To clean the blinds and flyscreens, moisten a softcloth or sponge with a small amount of waterand mild soap suds and gently wipe dirt off. Allowto dry before retracting, failure to due this couldresult in mildew forming.

Winterisation/Storage

Please Note: The blind/flyscreen should not beleft in the down position when the caravan is notin use or throughout the winter as the memoryof the mechanism may be lost.

ABS - A FRAME COVER, WHEEL SPATS &PANELS

To preserve the appearance of all ABS panels andfittings road grit, dust, sand, flies, lime treesecretions, bird droppings etc., should be washedoff using plenty of cold water. Any remaining dirtshould be washed off using a soft cloth and warmwater. Under NO circumstances should anyabrasive cleaning agents, household detergents orproprietary cleaning fluids be used. Wash the ABSmaterial again using only cold water and dry off

INTERIOR WALLS

Your caravan interior walls will only require awipe over with a damp cloth, using a milddetergent, to keep them in a ‘showroom’condition.

11-2


FURNITURE

Treat your caravan furniture as you would thefurniture in your home. Polish wood surfacessparingly with a good quality wax or spray polish.Use a damp cloth to clean melanate laminatedsurfaces.

COOKING EQUIPMENT

Caustic pastes, abrasive cleaning powders, coarsewire wool and hard implements will damage thesurface.

CARPETS, UPHOLSTERY ANDCURTAINS

Vacuum clean carpets and upholstery to ensure along life, marks on cushions can be removed usinga mild upholstery shampoo with the minimum ofwater. Curtains should be dry cleaned only.

WARNING: Under no circumstancesshould alcohol, spirit or solvent-basedliquids be used on GRP or ABS plasticpanels as these substances may react withthe material and cause visible damage.

SHOWER TRAYS, SHOWER ROOM ANDWASH BASIN FITTINGS

Only clean your shower tray using soap andwater. Do not use chemical based cleaning agentsas this may attack the material of the tray.

CLEANING OF ALL TAPS

It is recommended that a non-abrasive dampcloth be used for cleaning the Elegance taps andshowers.

WATER CONTAINERS

(i) All water remaining in any water containershould be disposed of so that the containeris empty.

(ii) The outside of external water containersshould be thoroughly cleansed and washeddown to remove any dirt, dust or othercontaminant. Water at a suitably hottemperature containing an appropriatedetergent is recommended for this purpose.Water should then be put into thecontainer, swirled round, then emptied out.

(iii) All containers should then be totally filledwith water containing an appropriatedisinfectant / sterilizing solution and allowedto stand for the recommended contact time(e.g. Milton for 15 minutes).

(iv) The solution should be emptied from thecontainer.

(v) The opening of any container should becleaned thoroughly with an appropriate pre-prepared wipe impregnated with adisinfectant / sterilizing solution.

(vi) External containers should be invertedwhilst stored overnight (if possible).

(vii) Containers must be filled with mains wateronly and mains water only should be usedfor the above cleaning procedure.

(viii) On no account should garden hoses be usedto fill water tanks.

11-3


WATER SYSTEMS - STERILIZATION

Clean the water system at the start and end ofthe season with sterilizing fluid. When cleaning itis advisable to use a sterilizing fluid e.g. ChemproSDP or similar.

Please Note: It is recommended that for thisoperation the filter is removed as the fluidreduces the effectiveness of a new filter.

(i) Drain down the system. (Open all taps toallow air in, enabling the system to drainquickly.) See Index - Water System,Draining.

(ii) Remove any water filters fitted, and replacewith a short length of hose or empty filtercartridge (this will ensure the filter is notaffected by the disinfectant / sterilizingsolution).

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

(iv) Drain the system down completely.

(v) Thoroughly clean the outside of all taps/connectors with a cloth soaked in thedisinfectant / sterilizing solution.

(vi) Flush the system through with cleandrinking water until no traces of disinfectant/ sterilizing solution can be detected at anytap.

(vii) After sterilizing the system at the start ofthe season it is recommended that a newUltraflow filter cartridge should be fitted.

Please Note: Suitable sterilizing chemicals areavailable from your Explorer Group Retailer,accessory shop, chemists, or home-brew shops. Itis not, however, recommended to use bleach orsodium met bisulphide.

TRUMA SPACE HEATER

Please note: Your Truma Space Heater front isnow attached using 2 screws. These screws mustbe removed prior to removal of the SpaceHeater front. These screws can be seen whenlooking into the fire through the air vents.

THETFORD TOILET

WARNINGS

• Cold Weather Use - to prevent freezingduring cold weather use, add antifreezeto the toilet system fresh water tank.Use a non-toxic (propylene glycol) typeof antifreeze. Refer to chart oncontainer to obtain level of protection.

• Warmer weather or longer intervalsbetween emptying the waste tank mayrequire additional toilet fluid. Use onlyThetford toilet fluid to achieve the bestresults.

CAUTIONS

• Never add toilet fluid directly intotoilet bowl.

• Do not use strong householddetergents or cleaners that containchlorine, solvents or acid contents.

• High Altitude and Hot Weather Use -with large temperature differences andchanging heights during towing, overpressure can start to build up in thewaste holding tank, causing contents tosplash upward upon opening the valveblade if opened too fast.

11-4


CHASSIS MOUNTED SPARE WHEELCARRIER

Each caravan chassis has a set of punched holesimmediately behind the axle to enable fitting of aspare wheel carrier.

To gain access to your spare wheel lift the sparewheel carrier up and lift up the lockingmechanism. Then move the mechanism to thehorizontal position and the spare wheel carrierwill be free to move over the mechanism andallow the spare wheel to drop to the floor to beremoved.

To replace the spare wheel simply reverse theoperation making sure that the quick releasemechanism has been fully pushed down to createa positive lock. The carrier is of extra strong,lightweight construction and zinc plated for allweather protection. It is easy to fit and accepts allconventional wheel sizes.

TYRES

Please refer to Section 18 Technical Specificationswhich is contained within this handbook forinformation regarding tyre pressures.

Pressures

It is customary for manufacturers to mark tyreswith load and inflation data. This informationrelates to the use of the tyre on cars. It isdangerous to drive with under inflated tyres. Thepressures (cold) recommended by themanufacturers should be regarded as a minimum.Pressure checks, including those on the sparetyre, should be made with the tyres cold andusing an accurate pressure gauge. The checksshould be carried out before each journey and atregular intervals during storage.

Tyre Wear and Damage

The legal requirements for tread depth on motorvehicle tyres apply also to caravans. Similarly, it isnot permitted to mix cross-ply and radial tyreson the same axle. A redundant tyre must bereplaced by one of the same size andconstruction. Wheels should be balanced andchanged round occasionally to equal wear andprolong the life of the tyres. A tyre should berenewed if a blister, rupture or cut exposing thecasing is detected. If the tyre has suffered aviolent impact e.g. against a kerb, it should beexamined by a specialist as soon as possible.

CHANGING A WHEEL

Whenever road wheels are removed and re-fitted, they must be tightened using a calibratedTorque Wrench set to 92 Nm for steel wheels.

Only use the wheel bolts supplied with yourcaravan. If you need to replace these bolts youshould obtain bolts from an approved ExplorerGroup Retailer.

The bolt fixings should be tightened in thesequence shown in the diagram below. Do NOTsimply tighten clockwise or anti clockwise.Remember to over tighten is just as dangerous asto under-tighten, as this can distort the wheelrims. Avoid the use of power wrenches. Wheelbolts should NEVER be lubricated.

11-5


The corner steadies must not be used to jack upthe caravan. They can be lowered to touch theground only as a safety measure to stabilise thecaravan.

(i) Apply the handbrake fully as for parking. Donot forget to give the caravan a slightrearwards push to stop the reversing levercollapsing.

(ii) Slacken off the wheel bolts on the wheel tobe changed.

(iii) With a suitable jack, jack up the caravanunder either the axle tube or the axlemounting plate.

Please Note: Do Not Use The Chassis As AJacking Point. If there is lack of ground clearancebecause of a flat tyre, gently move the caravanonto some ramping boards.

(iv) Support the weight of the caravan with thejack and for added safety lower the frontand rear corner steadies on the side of theflat tyre. Then remove the ramping boards.

(v) Remove the wheel bolts and remove thewheel.

(vi) Before fitting the wheel, examine it fordistortion or other damage. Ensure that allmating surfaces are clean and dry, includingbolt/nut seats.

Please Note: Always Use the Correct Bolts toSecure the Wheel - Check with the dealer ifunsure.

Please Note: A corner steady brace is not tobe used for the next step.

(vii) Insert the wheel locating pins (suppliedwithin your Explorer Group kit box) intoholes 4 and 5 and then slide the wheel ontothe locating pins.

(viii) Insert the wheels bolts into holes 1 then 2and then 3.

(ix) Remove the wheel locating pins from holes4 and 5 and insert the wheel bolts.

(x) After the bolts have been screwed in as faras possible by hand, each bolt should betightened gradually in sequence. Do notover tighten at this point as the finaltightening should be done with a calibratedtorque wrench. The wheels of the caravanwill not rotate during tightening as they areheld rigid by the wheel hub brake unit.

(xi) Raise the corner steadies.

(xii) Lower the caravan to the ground.

(xiii) The wheel bolts should be tightenedensuring that the torque is applied evenlyaround the wheel. Using a suitable torquewrench, sequentially tighten the steel boltsto a torque of 92Nm for steel wheels and115Nm for alloy wheels following thesequence stated above.

IMPORTANT

• The torque settings should be re-checked after 50 km (20 miles) andevery 5000 km (3100 miles) thereafter.

• Do not loosen the wheel bolts to carryout this operation whilst the roadwheel is supporting the weight of thecaravan.

• Wheel bolts should NEVER belubricated.

• NB: If you upgrade from steel to alloywheels you must ensure you use thecorrect bolts for the new wheel.

JACKING

Under no circumstances should the cornersteadies be used to jack up the caravan. When itis necessary to jack up, use a bottle, screw, trolleyor scissor type jack, one with an axle shaped headis recommended.

Place the jack plate under the axle tube as nearas possible to the main longitudinal member. Themaximum mass which the jockey wheel and itsclamping mechanism are capable of withstandingis 150kgs.

LUBRICATION

• Lubricate the Jockey Wheel

• Lightly oil the wheel axle and screw thread.

• Lubricate the Brake Linkage

• Lightly oil all moving parts.

• Lubricate the Corner Steadies

• Lightly oil the screw and pivot pins.

11-6


MAINTENANCE OF YOUR BPW CHASSIS

CATEGORY OF EXPOSURE & DURATION OF PROTECTION

The BPW chassis is protected by a hot dip galvanising process in accordance toDIN EN ISO 1461. The duration of protection is according to a salt spray test toDIN 50021 standard.

WARNING: Holes must not be made without approval of the chassis manufacturer.

The following lubrication instructions relate tothe BPW chassis fitted to your new ExplorerGroup caravan. They are a constituent part ofyour warranty conditions.

11-7


Lubrication and maintenance work Prior to Every 10,000each run to 12,000 kilometers

FUNCTION TEST

1 Check coupling.

2 Apply the handbrake lever and observe the linkage.

LUBRICATE

1 Lubricate the coupling head.

2 Drawbar bearings at the housing of the overrun hitch.

3 Oil or grease brake lever.

4 Oil or grease moving parts such as bolts and joints.

MAINTENANCE WORK

1 Overrun hitch function check.

2 Check drawbar, handbrake lever, spring actuator,reversing lever, linkage and all movable parts forease of movement.

3 Check permitted vertical play.

4 Check safety cable for damage.

11-8


FUNCTION TEST

Check coupling head (prior to each run)

Check coupling head for wear and correctoperation

Check the wear indicator (use within the “+”range only).

Check the coupling head fastenings (see item 1)at regular intervals for firm seating.

LUBRICATION WORK

Lubricate the coupling head every 10,000 -12,000 kilometres or annually

Oil ball hitch at regular intervals at the specifiedlocations and moving parts.

Grease the contact surface of the ball of thetowing vehicle.

Completion of the maintenance work inaccordance with the prescribed intervals isessential in order to maintain the operating safetyand roadworthiness of the vehicle. The correctionof any defects found or the replacement of anyworn parts should be carried out by an ExplorerGroup Retailer or Approved Service Centre.

Note: When installing spare parts, it is stronglyrecommended that only original BPWcomponents are used. Parts approved by BPWfor caravan axles and suspensions regularlyundergo special test procedures and as a resultBPW is able to guarantee their quality. However,BPW cannot assess for every single third partyproduct whether it can be used for BPW caravanaxles and suspensions without any risk to safety.This applies even if the accredited test authorityhas already tested such products. Our warrantybecomes null and void if spare parts other thanoriginal BPW parts are used.

PROCUREMENT OF SPARE PARTS

The code and type numbers of the axle andchassis components enable us to quicklydetermine your exact spares requirements whenordering from an Explorer Group Retailer orApproved Service Centre. It is thereforerecommended always quote the 17 digit caravanVIN number.

Note: For full maintenance details of the BPWchassis and undergear please refer to the BPWhandbook supplied within your user informationpack or access the BPW website atwww.bpw.co.uk.

12-1

STORAGE

STORAGE

LONG TERM & WINTER STORAGE

If the caravan is to be stored for any length oftime, especially over the winter period, thefollowing operations are recommended:

(i) Remove all linens, blankets, cushions, clothes,mattresses, etc, that could be affected bydamp conditions.

(ii) Clean the caravan inside and out as detailedin the previous section.

(iii) Drain the water system (see Water system).

(iv) For winter storage and to prevent frostdamage all taps must be left in openposition. For those caravans with lift up tapsplease ensure the taps are left in the centralposition.

(v) Ensure all windows, roof lights and doorsare correctly fastened. All blinds andflyscreens should be left in the retractedposition. Check fixed ventilation aperturesare not obstructed.

(vi) Ensure that the refrigerator/freezercompartment doors are secured in the ventposition using the door catch.

(vii) Check that the site you have chosen tostore the caravan is open, fairly high and dryand if possible not exposed to gales etc. Ifthis proves impossible it is recommendedthat the caravan chassis is anchored to theground.

(viii) Jack up the caravan (use bottle or screwjack, do NOT use the corner steadies) sothat the wheels are clear of the ground.

(ix) Support the caravan axle with woodenblocks, axle stands or similar so that whenthe jacks are removed the wheels remainclear of the ground. Lower the cornersteadies to ‘just’ site the caravan. Cover thetyres to prevent deterioration. Release thehandbrake.

(x) Security: Lowering and locking the cornersteadies and removing the wheels willreduce the risk of caravan theft.

CARAVAN COVERS

Caravan covers may be used to protect your newXplore touring caravan provided that the coverused is of a breathable type.

Ensure that the point of extending aerials or thestatus aerial (depending on model if fitted) areremoved or retracted, and that the cover is welltied down to avoid the cover being punctured.

Your caravan must be ventilated every 4 to 6weeks if it is to be stored with a cover in place.

POWER DRAIN

In order to reduce any drain on your leisurebattery while your caravan is being stored ensurethat the main control switch on the refrigeratoris set to the ‘0’ position

Please Note: Do not work under the caravanunless the corner steadies are down and the axleis supported.

Should the caravan be stored for a prolongedperiod of time it is strongly recommended thatthe caravan is fully serviced before thecommencement of use. Your retailer will ensurethat your caravan is safe, secure and ready foryour enjoyment.

Please Note: Caravans stored for any length oftime should not have the handbrake or brakesapplied. The wheels should be chocked orwedged and the handbrake released. The hitchhead should be checked to see that it is fullyextended and that there is no load on the brakingsystem.

12-2

STORAGE

13-1

WARRANTY

WARRANTY

3-YEAR MANUFACTURER’SWARRANTY

Subject to the following conditions, your caravanis supplied with a manufacturer’s warranty for 3years from the original date of purchase, at noadditional cost to you the customer. Wesincerely hope you will never have cause tocomplain about your caravan. However, if you dohave a problem then please contact your Retailerso they can report this through our warrantysystem. We are confident they will do theirutmost to resolve any problems to yourcomplete satisfaction. The Retailer from whomthe caravan is purchased is liable for warrantyrepairs. Any other approved Retailer or ServiceCentre may carry out work at his ownconvenience and/or discretion, but is not obligedto do so.

PARTS COVERED BY THIS WARRANTYFOR YEARS 1 - 3

Subject to the specific exclusions in years 2 and 3set out below all original components of thecaravan, including permanently fitted equipment,forming part of the manufacturer’s originalspecification.

SPECIFIC EXCLUSIONS FOR YEARS2 & 3

Tyres, batteries, plastic windows, glass, exteriorpaint work, bright work and all similar trim andfinish, soft furnishings, carpets and floor coverings.Entertainment/communication systems andconnected equipment. Adjustment of blinds,hinges, catches, stays and doors. Replacementbulbs, fluorescent tubes, fuses and electricalconnections; GRP, ABS and PVC productsincluding A-frame covers, wheel spats and showertrays. Natural movement of internal doors andfurniture. Normal wear and tear/servicing itemsand other components subject to routinemaintenance.

CONDITIONS ATTACHED TO THEWARRANTY:

(i) The duration of the warranty is 36 monthsfrom the original date of purchase.

(ii) That the original construction of thecaravan has not been tampered with or

repaired other than by The Explorer GroupLimited or an approved Retailer or ServiceCentre.

(iii) That an “annual” service, damp and safetycheck has been carried out by an approvedRetailer or Service Centre. The first andsecond services are due 60 days either sideof the anniversary of the original date ofpurchase. The interval between servicesmust not exceed 14 months. The thirdservice must be on or before theanniversary date of the original purchase.

(iv) That original VAT service invoices areretained as proof that annual service andinspections have been carried out.

(v) No work should be commenced under theterms of the warranty unless priorauthorization is obtained from The ExplorerGroup Limited.

(vi) The Explorer Group Limited reserves theright to inspect the caravan before any workcommences.

(vii) No liability will be accepted for damagecaused by fair wear and tear, wilful damage,negligence, abnormal working conditions,intrusion of foreign or harmful matter,overheating, freezing, failure to follow TheExplorer Group Limited instructions, misuseor alteration or repair of the caravanwithout The Explorer Group Limited priorapproval.

(viii) Caravans covered by this warranty shall notbe put out to hire, reward, or any othercommercial use or used in any timed race.

(ix) That the caravan shall be used only for itsordinary and intended purpose and shall notbe subjected to any condition which couldreasonably be foreseen to cause or result indamage or excessive wear and tear.

(x) That only private cars or 4x4 type vehiclessubstituting as private cars, shall have towedthe caravan.

(xi) That no liability arises from this warrantyfor transport costs to and from the place ofremedial work or consequential costrelating to transportation. No liability arisesout of this warranty for any indirect, specialor consequential loss or damage (whetherfor loss of profit, use, contract, goodwill, or

13-2

WARRANTY

otherwise), costs, expenses or other claimsfor compensation howsoever arising.

(xii) No liability will be accepted for anyaccidental or fire damage or any lossincurred by accident or fire.

(xiii) The unexpired period of the 3-yearwarranty or the 5 year water ingress istransferable to second and subsequentowners during the warranty period. Thenew owner should contact The ExplorerGroup Limited within 3 months of theirpurchase, with proof of ownership, servicehistory and their payment of £30 to havetheir details recorded in our database.

Please Note: This warranty does not affect thepurchaser’s statutory rights. This warranty shallbe governed and construed in accordance withthe laws of England and the parties irrevocablysubmit to the exclusive jurisdiction of the courtsof England.

14-1

CODE OF PRACTICE - WATER INGRESS

CODE OF PRACTICE - WATERINGRESSAt The Explorer Group Limited we want ourcustomers to be sure that, in buying one of ourcaravans, you are buying the very best. We wouldlike you to continue to believe this for a longtime after you have made your purchase. We areconfident that our new caravans, built withinnovative manufacturing techniques and testedmaterials, make water ingress concernsunnecessary. We are so confident of our newcaravans that we follow a ‘Code of Practice’which gives certain guarantees to our customers,both consumers and Retailers, of financialreimbursement for remedial work costs shouldproblems occur.

THE CODE

The code applies to all new Explorer GroupLimited products manufactured after 1stSeptember 1998. All owners with documentaryproof of annual services by an approved ExplorerGroup Limited Retailer or Service Centre will bepaid in full for the costs of remedial work due towater ingress. This is valid for up to 5 years fromthe original date of purchase of a new product.Unless the caravan has a full service history, theowner will be required to contribute to the costsof remedial work for water ingress damagedepending upon the age of the caravan and workrequired. Each case will be examined on its ownmerit. Explorer Group Limited will decide theamount of contribution towards the remedialwork costs. Owners exchanging their currentExplorer Group Limited model for a newExplorer Group Limited model will not have thevalue of their part exchange reduced due topotential water ingress issues, providing thatthere is documentary evidence that the caravanhas been annually serviced and that it is less than5 years old.

CONDITIONS ATTACHED TO THECODE

(i) Work may only be undertaken after approvalby The Explorer Group Limited (dependingupon individual circumstances).

(ii) The Explorer Group Limited will pay thecosts of remedial work, only after approvedwork has been carried out.

(iii) The Code is not retrospective. Caravans

traded-in prior to implementation of theCode are not covered.

CUSTOMER OBLIGATION - SERVICING

It is a condition of your warranty that yourcaravan must have an “annual” service, damp andsafety check and this should be carried out by anExplorer Group Limited approved Retailer orService Centre, in accordance with NCCguidelines. Proof of this will be required in theevent of a warranty claim.

Please Note: Failure to do so will invalidateyour warranty.

The first service is due 60 days either side of theanniversary of the original date of purchase. Theinterval from purchase date to the first serviceand the intervals between services must notexceed 14 months. Years 3 and 5 must be on orbefore the anniversary date of the originalpurchase.

Your caravan requires servicing for safety,efficiency and to protect the investment you havemade. Whether the caravan is used for shorttrips or continental long range touring, regularservicing is necessary and will ensure continuedenjoyment of your caravan.

Your Retailer or Service Centre will carry outyour service using the latest techniques andequipment (a list of the items to be inspected,tested and adjusted appears on the ServiceVouchers in this handbook), and should provideyou with the service document as proof ofregular maintenance.

As with motor vehicle service documents, notonly will the proof of regular servicing enhanceyour caravan resale value, but in the unlikelyevent of any defect appearing at some later date -a properly serviced and documented caravanhistory will enable your Retailer to rapidly assessand where appropriate, carry out the necessaryremedial work.

MAINS ELECTRICS

It is recommended that you have your MainsElectrics System inspected by an NICEICapproved contractor every 3 years.

SPARE PARTS

Should you require any replacement parts foryour caravan it is necessary that you contact the

14-2

CODE OF PRACTICE - WATER INGRESS

Retailer from whom you purchased the caravanor any Explorer Group Limited approved Retailerand give the following information, which will helpin identifying the required component:

(i) Model and make of caravan

(ii) VIN number

(iii) Description of required part

(iv) Photograph, size or diagram of required part

Please Note: All parts must be ordered andsupplied through an approved retailer.

REMEDIAL WORK

The Explorer Group Limited together with itssuppliers is continually undertaking extensiveresearch into testing, remedial work proceduresand materials such as sealants, adhesives, gasketsand tapes. Therefore, if for any reason your newcaravan is damaged or requires remedial workthen only an approved Explorer Group LimitedRetailer or Service Centre should undertake suchwork.

All such work should be undertaken using onlyapproved Explorer Group Limited genuine parts,recommended sealant and following ExplorerGroup Limited procedures. The Explorer GroupLimited will also undertake to supply certainspecialist repairers with the necessary spareparts. In this case, your selected repairer mustcontact the PARTS DEPARTMENT with allenquiries.

15-1

CARAVAN CONSTRUCTION

CARAVAN CONSTRUCTION -MAIN COMPONENTSThe following is a brief description of the maincomponents used in your caravan. Morecomprehensive descriptions can be found in theequipment manufacturers literature held in theOwner’s Information Pack.

BPW CHASSIS

BPW are one of the largest producers of caravanchassis in Europe. The chassis is galvanized specialsteel fitted with neidhart axles and suspensionsystem. The Explorer Group Limited utilizes thenew BPW V-TEC Chassis System.

BRAKING SYSTEM

The Braking System comprises a rod operatedoverrunning device with expander mechanismand adjuster box. An automatic reversing systemwith a spring loaded reverse lever is attached tothe adjuster box. The system also incorporates alink device, which gives added safety to thehandbrake operation when parking on a reverseslope or steep hill. Brake adjustment instructionsare given in the maintenance section of this guide.

BODY SHELL

Caravan bodies are constructed from the highestquality materials. The fully insulated floor isconstructed from a timber frame with plywoodand insulation laminated together for strength.The walls comprise an insulated foam sandwichhaving pre-coated aluminium exterior surface andvinyl coated plywood interior finish. Woodenframing is positioned within the sandwich to addstrength. The very latest ‘state of the art’ pressesare employed to produce the extremely wellinsulated, robust, yet lightweight sections.

WINDOWS

Windows are all of a double glazed acrylicconstruction and the door frames are extrudedaluminium.

INSULATION

Xplore touring caravans are built to thermalinsulation Grade 2. This states that an averagetemperature difference of at least 20C betweeninside and outside temperatures should beachieved when the outside temperature is 0ºC.

FRONT PANEL AND GAS BOTTLELOCKER LID

These are constructed from moulded GRP forstrength and lightness.

AWNING CHANNEL

Each caravan is fitted, as standard, with an awningchannel as an integral part of the near- and/or off-side aluminium roof and body side moulding. If itis found necessary to fit additional attachments,care must be taken to ensure that any holeswhich are drilled in the outside of the body arecorrectly sealed. Awnings which employ rubbersucker attachments rather than screw fixings arerecommended.

ADDITIONAL FIXINGS TO YOURCARAVAN SHELL

On NO account should screw threads longerthan 5/8th inch (15mm) be permitted to enterthe shell sandwich (from inside). Ensure that allscrews are of the self tapping type. No screw orany other object should be permitted to enterthe ceiling of your new caravan.

Please Note: Holes must not be drilled into thechassis. When purchasing a stabilizer, consult yourretailer who will advise on the correct type to fit.

15-2

CARAVAN CONSTRUCTION

16-1

EQUIPMENT LIST

EQUIPMENT LIST

ENTRY LEVEL

REFRIGERATOR THETFORD N112

HEATER TRUMA ULTRAHEAT PIEZO

INTERNAL BLOWN AIR TRUMA PUSH FIT RAPID INSTALLATION

WATER HEATER TRUMA ULTRASTORE

SINK AND DRAINER ARGENT STAINLESS STEEL

OVEN SPINFLO MIDI PRIMA

HOB SPINFLO 3 BURNER HOB

TAPS KITCHEN DIMATEC SINGLE LEVER MIXER

SHOWER EQUIPMENT DIMATEC MIXER

TAPS VANITY DIMATEC SINGLE LEVER MIXER

WATER FILTER / PUMP WHALE COMPLETE SYSTEM

LIGHTS 12V FLUORESCENT CROWN MATT ZINC

12V READING DOWN LIGHTS ZOE EYEBALL LIGHT

230V LIGHT N/A

CONTROL PANELS BCA

ELECTRICAL FITTINGS PDL

TOILET THETFORD ROTATABLE MANUAL FLUSH

CASSETTE BLINDS SEITZ SERIES 2000

16-2

EQUIPMENT LIST

17-1

ELECTRICAL DRAWINGS

ELECTRICAL DRAWINGS

13 PIN DRAWING

17-2

ELECTRICAL DRAWINGS

WIRING DIAGRAM

17-3

ELECTRICAL DRAWINGS

ROAD LIGHTS

17-4

ELECTRICAL DRAWINGS

18-1

TECHNICAL SPECIFICATIONS


ENTRY LEVEL MODELS

Model 453 474 495

Number of Berths 2 4 5

Interior Length 4540mm (14’11”) 4740mm (15’6”) 5034mm (16’6”)

Exterior Body Length 5325mm (17’6”) 5561mm (18’4”) 5855mm (19’3”)

Shipping Length 6026mm (19’9”) 6226mm (20’5”) 6520mm (21’5”)

Overall Width 2200mm (7’2”) 2200mm (7’4”) 2200mm (7’2”)

Overall Height 2726mm (8’11”) 2726mm (8’11”) 2726mm (8’11”)

Maximum Headroom 1908mm (6’3”) 1908mm (6’3”) 1908mm (6’3”)

Interior Width 2032mm (6’8”) 2032mm (6’8”) 2032mm (6’8”)

Wheel Rim 5.5J x 14 5.5J x 14 5.5J x 14

Tyre Size 175 R 14 99 175 R 14 99 175 R 14 99

Tyre Pressure at MTPLM in psi 47 50 55

Brake Size 200/50 200/50 200/50

Awning Sizes Ground to Ground 8970mm (29’5”) 9200mm (30’2”) 9450mm (31’0”)

Front Bed Sizes 2 x Single 1 x Double 2 x Single1830mm x 673mm 1980mm x 1135mm 1830mm x 673mm

(6’0” x 2’2.5”) (6’0” x 3’8”) (6’0” x 2’2.5”)or or

1 x Double 1 x Double1980mm x 1375mm 1980mm x 1375mm

(6’6” x 4’6”) (6’6” x 4’6”)

Side Dinette Not Applicable Not Applicable Not Applicable

Rear Bed Sizes Not Applicable Fixed Bed 1 x Double1 x Double 1980mm x 1135mm

1866mm x 1300mm (6’0” x3’8”)(6’2” x 4’4”) and

Lift Up Bunk1860mm x 570mm

(6’2” x 1’10”)

M.T.P.L.M. 1165kgs (22.88cwt) 1235kgs (24.25cwt) 1300kgs (25.53cwt)

Mass in Running Order 988kgs (19.60cwt) 1036kgs (20.35cwt) 1088kgs (21.37cwt)

Essential Habitation Equipment 53kgs (1.04cwt) 53kgs (1.04cwt) 53kgs (1.04cwt)

Maximum User Payload 177kgs (3.47cwt) 199kgs (3.91cwt) 212kgs (4.16cwt)

Maximum Hitch Weight 100kgs (1.96cwt) 100kgs (1.96cwt) 100kgs (1.96cwt)

Optional Equipment Payload 20kgs/0.39cwt 20kgs/0.39cwt 20kgs/0.39cwt

A manufacturing tolerance has been added to Mass in Running Order before calculating the Maximum User Payload.Maximum User Payload includes Essential Habitation Equipment, Personal Effects and Optional Equipment.Note 1: Please take care to ensure that you have allowed for the masses of all items you intend to carry in the caravan.Note 2: Warning under no circumstances must the Technical Permissible Laden Mass of the caravan be exceeded.Note 3: All data is calculated using metric weights and measurements. The imperial figures quoted are conversions thereof.

18-2



ENTRY LEVEL MODELS (continued)

Model 546 596

Number of Berths 6 6

Interior Length 5436mm (17’10”) 5980mm (19’7”)

Exterior Body Length 6257mm (20’6”) 6801mm (22’4”)

Shipping Length 6922mm (22’8”) 7466mm (24’6”)

Overall Width 2200mm (7’2”) 2200mm (7’2”)

Overall Height 2726mm (8’11”) 2726mm (8’11”)

Maximum Headroom 1908mm (6’3”) 1908mm (6’3”)

Interior Width 2032mm (6’8”) 2032mm (6’8”)

Wheel Rim 5.5J x 14 5.5J x 14

Tyre Size 175 R 14 99 175/65 R 14 86

Tyre Pressure at MTPLM in psi 55 31

Brake Size 200/50 200/50

Awning Sizes Ground to Ground 9840mm (32’4”) 10040mm (33’0”)

Front Bed Sizes 2 x Single 2 x Single1830mm x 673mm 1830mm x673mm

(6’0” x 2’2.5”) (6’0” x 2’2.5”)or or

1 x Double 1 x Double1980mm x 1375mm 1980mm x 1375mm

(6’6” x 4’6”) (6’6” x 4’6”)

Side Dinette 1 x Single Not Applicable1800mm x 630mm

(5’11” x 2’1”)and

Lift Up Bunk1650mm x 570mm

(5’4” x 1’10”)

Rear Bed Sizes 2 x Single 2 x Single2030mm x 610mm 1830mm x 673mm

(6’8” x 2’0”) (6’0” x 2’2.5”)or

1 x Double1980mm x 1375mm

(6’6” x 4’6”)and

2 x Lift Up Bunk1860mm x 570mm

(6’2” x 1’10”)

M.T.P.L.M. 1335kgs (26.22cwt) 1530kgs (30.05cwt)

Mass in Running Order 1109kgs (21.78cwt) 1298kgs (25.49cwt)

Essential Habitation Equipment 53kgs (1.04cwt) 53kgs (1.04cwt)

Maximum User Payload 226kgs (4.43cwt) 232kgs (4.55cwt)

Maximum Hitch Weight 100kgs (1.96cwt) 100kgs (1.96cwt)

Optional Equipment Payload 20kgs/0.39cwt 20kgs/0.39cwt

A manufacturing tolerance has been added to Mass in Running Order before calculating the Maximum User Payload.Maximum User Payload includes Essential Habitation Equipment, Personal Effects and Optional Equipment.Note 1: Please take care to ensure that you have allowed for the masses of all items you intend to carry in the caravan.Note 2: Warning under no circumstances must the Technical Permissible Laden Mass of the caravan be exceeded.Note 3: All data is calculated using metric weights and measurements. The imperial figures quoted are conversions thereof.

19-1

GENERAL QUESTIONS

GENERAL QUESTIONS

Q: Where Can I Obtain Your Latest Brochure?

A: Our latest brochures are available from Approved Retailers or can be viewed and printed from thedownload section on our website www.explorer-group.co.uk. A request form can also be completedshould you wish to receive a printed copy of our latest brochures.

Q. I Require Technical Or Other Information, Who Can Help Me?

A. The majority of information you require is available through your Explorer Group Retailer.

Q - Can You Tell Me The Second Hand Price Of My Caravan?

A - As a manufacturer we are not involved in the second hand market. You should contact a Retailer, TheCamping and Caravanning Club and/or The Caravan Club. They should be able to give some indication ofmarket value.

Q: How Can I Avoid Excessive Caravan Snaking When I Tow And What Should I Do If ItStarts?

A: The Explorer Group Limited has extensively tested our caravans and we are confident of their stability.However, many other factors can influence your towing unit. When loading your caravan put heavy itemslow down and mainly over the axle(s). You should not stow tins, bottles or heavy items in overheadlockers, during towing. Everything else should be distributed evenly around your caravan, front and back,and each side of the centre line should snaking start, if at all possible don’t brake and don’t compensate bysteering into the swings. Just ease up on the accelerator and allow your speed to gradually decrease untilthe snaking subsides.

Q: What Is The Correct Awning Size For My Caravan?

A: Ground to ground awning measurements for Xplore touring caravans can be found by looking in thelatest model section, the Product Archive section on our website, or by referring to the relevant TechnicalSpecification section of this handbook. However, we advise you verify this information by threading apiece of string through the awning channel from ground to ground, and then by measuring the string.Your awning manufacturer will then advise on the nearest size of awning appropriate for yourmeasurement.

Q: Can I Fit A Bicycle Rack/Top Box/Air Conditioning To My Caravan?

A: The Explorer Group Limited do not approve the fitting of bike racks, top boxes or air conditioning tothe Explore range of caravans.

Q: My Interior Lights Are Not Working, What Do I Do?

A: It is possible that all of the 230V mains electrical equipment may not be operated simultaneously.Check fuses, battery connections and power supply (master light switch). Refer to your Retailer forfurther assistance. PLEASE NOTE: The internal lights in your caravan will not operate whilst the caravan’selectrical hitch cables are connected to a towing vehicle with the engine running.

Q: Where Can I Get Spare Parts For My Caravan?

A: Retailers will be able to source most parts you require. For details of your nearest Explorer GroupRetailer please refer to our Find A Retailer section on our website, or call 01207 699 000 for assistance.

19-2

GENERAL QUESTIONS

Q. How Many Years Will Spare Parts Be Available For My Caravan?

A. The Explorer Group Limited will endeavour to supply spare parts for a caravan, for at least 8 yearsfrom new.

Q. What If The Parts Are No Longer Available?

A. Where an original part is no longer available, whenever possible we will suggest a suitable alternative ifit is available.

Q. Who Can Carry Out Warranty Work On My Caravan?

A: Your supplying Retailer is obliged to undertake your warranty work. However, any approved ExplorerGroup Limited Retailer or Service Centre can undertake the work, but this is at their discretion. We willalso accept services completed by a NCC Jones Vening approved company, but they will not be able toundertake warranty work if they are not approved by The Explorer Group Limited.

Q. Why Don’t You Stock Parts At The Explorer Group Factory?

A. Due to the volume of models we produce it is not possible for us to maintain stock levels of everyindividual component used in our manufacturing process. We do stock commonly requested items, butsome items must be made to order.

Q. I Am Having Trouble Booking My Caravan For Its Service, In Line With TheRequirements. What Timescale Is Acceptable?

A. We will allow a delay of 60 days after your service is due, but subsequent annual services should stillbe undertaken as close as possible to the anniversary of the original date of purchase. Except for 3rd and5th services which must be on or before the anniversary of the original date of purchase. We wouldrecommend that you plan these services in advance to ensure you can meet the above requirements.

Q. I Have A Problem With My Caravan, Who Can Help Me?

A. We would always recommend that you contact your supplying Retailer. Your local Explorer GroupRetailer or Explorer Group Approved Service Centre may be able to assist. An inspection can then takeplace and the necessary course of action agreed.

Q. I Am Unhappy With The Service I Have Received From My Retailer/Service Centre,Where Do I Go From Here?

A. We would recommend that you write to your Retailer/Service Centre, detailing your problems andrequirements, requesting a response explaining how they will resolve your complaint. A copy of yourletter can also be forwarded to The Explorer Group Limited Customer Services Department, quoting theserial number of your caravan and the name of the Retailer/Service Centre. Please be assured that we willassist your Retailer/Service Centre in resolving any problems.

20-1

GLOSSARY

GLOSSARY

13 pin plug

The plug used to connect the caravans electricalsystem to your towing vehicle to enable the roadlights, refrigerator and battery charger to operateduring towing.

A Frame

This is the triangular part at the front of thecaravan’s chassis which is between the main bodyand the hitch it is also called the drawbar.

ABS

This is an acronym for anti-lock braking system.

Actual Laden Weight

This is the total weight of the caravan whenloaded ready for use by the end user.

Aquaroll

Brand name used generically for a watercontainer that rolls so you don’t need to lift it.

Awning

This is a tent-like structure of fabric over asupporting framework, which can be attached tothe side of caravan.

Battery Charger

This is required to keep a leisure battery charged.Most caravans include a charging facility whichoperates via the mains hook-up, and also has theability to recharge from the tow car’s alternatorwhile travelling.

Berth(s)

Sleeping place - Refers to the number of people acaravan can accommodate for sleeping.

Blown Air Heating

A method of heating the living quarters of acaravan by use of a fan pushing air out through anumber of outlets.

Breakaway Cable

A thin steel cable linking the caravan handbraketo the vehicles tow bar - In the event of thecaravan becoming detached from the car, thecable will pull the caravan handbrake on beforesnapping.

Bunk Bed

This is a sleeping place, usually higher up than aconventional bed. Often (but not always) this canbe folded or removed to provide additional livingspace.

Butane

Is a form of Liquefied Petroleum Gas (LPG) whichnormally comes in blue cylinders. This type of gasis most commonly used in the UK, although aswitch to propane is advised in severely coldweather conditions.

Campingaz

This is the trade name of Butane gas.

Cassette Blind

This is a roller blind which is fitted as part of thewindow assembly, often along with a flyscreen,thus giving a neat installation.

Cassette Toilet

A form of chemical toilet found in moderncaravans, where the waste holding tank can beaccessed and emptied from, outside.

Chemical Toilet

Most modern caravans have them, with more upmarket models having a fully plumbed-in flushingversion.

Control Panel

Used as the description for the panel of electricalswitches and gauges governing 12V and mainselectricity systems.

Corner Steadies

The winding device built into each corner of acaravan chassis that is used to stabilise the bodyonce set up on a pitch.

Coupling Head - See hitch.

CRiS

This is the Caravan Registration and IdentificationScheme. It is a voluntary scheme which registerscaravans in a similar manner to how motorvehicles are registered. Allows you to check thelegitimate right to ownership of the seller of asecondhand caravan, and helps in the recovery ofstolen caravans.

20-2

GLOSSARY

Dinette

This is a popular style of seating arrangementwhere two seats or settees face each otheracross a table.

Earth Leakage Circuit Breaker

ELCB Earth leakage circuit breaker - see residualcurrent device (RCD)

Essential Habitation Equipment

Those items and fluids required for the safe andproper functioning of the equipment forhabitation as defined by the manufacturer of thecaravan. This includes items such as the leisurebattery and gas cylinders, plus water contained inthe water heater etc.

Flyscreens

Mesh fittings for windows doors and roof vents,to keep out insects etc.

Free-Standing Table

This is a table which, because of its leg design, canbe used inside or outside.

Full Service Pitch

This is a pitch which has individual provision forfresh water supply and waste water disposal, inaddition to mains electricity and in some cases TVaerial connection.

Gas Cylinder

This is a portable, pressurized container for thestorage of LPG.

Gas Cylinder Locker

Is the compartment on the caravan for thestorage of gas cylinders.

Gas Drop out Holes

These are not part of the ventilation. LPG isheavier than air, so holes through the floor belowgas-powered appliances allow any leakage of gasto exit the habitation area.

Grey Water

This is the waste water from sink/shower.

Gross Train Weight

This is also known as Combined Weight. Themaximum permitted weight of an outfit asspecified by the tow car manufacturer.

Gross Vehicle Weight (GVW)

This is the weight of the vehicle laden to itsmaximum, as defined by the manufacturer. Seealso MTPLM.

GRP

Is Glass-reinforced plastic, but more commonlyknown as glass fibre (not fibre glass, which is atrade name).

Handbook

This is a owners manual, a guide to the workingsof your caravan.

Hardstanding

This is a pitch which has a hard surface made ofgravel, asphalt, concrete etc, instead of grass.

Hitch

This is the mechanism which allows a caravan tobe attached to a tow ball.

Hitch Lock

A security device that prevents the caravan hitchbeing used.

Hook-Up

This is a facility on a pitch for connection tomains electricity.

Ingress

Usually meaning water ingress, a possible problemwhere water seeps in at the joins, usually as aresult of worn sealant.

Jack

This is a device for raising the vehicle so that awheel can be changed, for instance. Not to beconfused with corner steadies which althoughthey are sometimes referred to as ‘corner jacks’are steadying, not lifting devices.

Jockey Wheel

The small front wheel attached to the caravan A-frame used to support the forward end of thecaravan, when detached from the towing vehicle.

Kerb Weight

This is the empty weight of a motor vehicle asdefined by the manufacturer.

20-3

GLOSSARY

Layout

This is the interior design and details wherefurniture units are placed in relation to eachother.

Leisure Battery

This supplies the power for the caravan electricalsystems and is sometimes called an auxiliarybattery.

Levelling

The process of ensuring that a caravan is levelwhen sited on a pitch. It is important for comfortand also to ensure the correct functioning of thefridge and water systems.

LPG

Liquid Petroleum Gas, i.e. butane or propane.

Mains Hook-Up

This is a campsite facility where you can plug intoa mains electricity supply.

Maximum Hitch Height

The maximum height at which the hitch shouldbe connected to a towing vehicle

Maximum Permissible Towing Weight

This is the maximum weight that the towingvehicle is allowed to tow.

Maximum User Payload

This is the maximum payload available for theuser including essential habitational equipment.

MIRO - Mass In Running Order

Weight of the caravan equipped to themanufacturer’s standard specification. Thereforethe condition in which it leaves the factory. Notethat this does not include any part of the userpayload, including the essential habitationequipment.

MTPLM - Maximum TechnicallyPermissible Laden Mass

The technical maximum permissible laden weightof the caravan, this must not be exceeded.

National Caravan Council

The only trade association representingmanufacturers, retailers and suppliers within thecaravan industry.

Nose weight

The weight exerted on the tow bar. Special scalesare available from accessory shops for measuringthis weight.

Number Plate

Caravans must display a legal number plateshowing the same registration mark as theirtowing vehicle.

Optional Equipment Payload

The payload required for equipment to enablethe caravan to be used for habitation purposes.

Outfit

The caravan and its towing vehicle considered asa unit.

Owners’ Club

This is a group of people who usually own thesame brand of caravan and enjoy meeting up forrallies.

Payload

The amount you can put into a caravan.Specifically the difference between the MaximumTechnical Permissible Laden Mass (MTPLM) andthe Mass In Running Order (MIRO).

PDI

This is an inspection undertaken by the Retailerprior to handover to the customer.

Pitch

A designated area of a caravan site allocated forthe use of one outfit. Most sites will be arrangedwith defined pitches.

Propane

Gas used in colder conditions and is usuallysupplied in red cylinders.

RCD

This is a residual current device and is part of theelectrical system which will ‘trip’ if there is anelectrical fault.

Gas Regulator

Safety device fitted between the gas cylinder andthe gas system of a caravan, which controls thepressure of gas being released from the cylinder.

20-4

GLOSSARY

Road Lights

The external lights used while the vehicle istravelling.

Roof Lights - See Roof Vent.

Roof Vent

Is an opening unit in the ceiling which lets inventilation and light, these vary in size, but thebest ones will have integral blinds and flyscreensand are also called rooflights.

Semi-Rigid Pipe work

Is water pipes made of a semi rigid plastic.

Single Axle

This is a caravan with a single pair of wheels onone axle. See also twin axle.

Slats

Sometimes used for beds and can improveventilation to mattress cushions.

Space Heater

This is a type of heating equipment for the livingquarters. Modern units fitted offer gas and mains-operation.

Speed Rating

This is the maximum speed at which a tyre maybe used, as marked on its sidewall.

Stabiliser

A safety device which helps to prevent instability,this is done by increasing the friction betweenthe caravan hitch and the tow ball.

Steady Winder

A handle for operating the corner steadies.

Torque WrenchA form of spanner used to set nuts and bolts to aspecified degree of tightness. It is recommendedfor adjustment of wheel fixings on caravans.

Towing LimitSee manufacturer’s braked towing limit andmanufacturer’s unbraked towing limit.

Towing MirrorsAdditional rear vision mirrors added to a towingvehicle to provide a greater width of view to seepast a caravan.

Train WeightThe maximum permissible combined weight oftow car and touring caravan.

Twin AxleIs a caravan with two pairs of wheels, on twoaxles which are located close together. These areusually the larger, heavier caravans, where thesecond axle helps carry the greater weight moreeasily, and also makes a longer caravan morestable to tow. See also single axle.

User PayloadThe weight of all items carried in the caravan.

U-Shaped SetteeUsually a reference to seating that literally is ‘U’shaped.

Vehicle Kerb weightThe weight of the tow car often indicated in themanufacturers specifications..

VIN - Vehicle Identification NumberThis is a unique serial identification number for avehicle. All Cars and motor caravans should carrya VIN. Caravans are not obliged to, but most ofthose sold in recent years in the UK do as aresult of the CRiS voluntary registration scheme.

WarrantyIs the terms and conditions that spell out yourrights with regard to servicing, repair orreplacement of parts as provided by themanufacturer.

Wild Camping

Term used for staying overnight away from acampsite. Illegal in many countries, but permissionmay be granted by individual landowners.

21-1

SERVICE DOCUMENTS

SERVICE DOCUMENTS

TOURING CARAVANS - ANNUAL SERVICE RECORD

In order to take full use of your warranty offered by The Explorer Group Limited it is essential that yourcaravan is serviced within the time scale laid down in the warranty terms and conditions. See Index -Warranty Terms & Conditions. Whether you use your caravan for short journeys or for touring at homeor abroad, regular servicing will help to ensure that you can enjoy it to the full. The Annual Service offeredby your retailer will include the following work and it is our recommendation you have your caravanserviced to this standard annually, in accordance with the National Caravan Council recommendations.

The retailer will complete the record in this guide to show the work has been carried out.

SECTION (A) CHASSIS

1. Brakes

2. Suspension

3. Axles and Hubs

4. Tyres and pressures

5. Wheeled nuts

6. Towing hitch and reverse

7. Jockey wheel

8. Breakaway chain

9. Corner steadies

10. Adjusted and lubricated

11. Fully operational

SECTION (B) EXTERIOR

1. Exterior panels

2. Windows

3, Rooflights

4. Entrance door/Door locks

5. Wheel boxes

6. Mouldings

7. Gas bottle and fairing

8. Ventilators

9. Paintwork

10. All seals, mouldings etc.

11. Damp test

12. Striping etc.

SECTION (C) INTERIOR

1. Wall panels

2. Furniture

3. Curtains/Blinds/Flyscreens

4. Mattresses

5. Carpet

6. Doors and drawers

7. All hinges and catches

8. Ventilators

9. Water pumps

10. Hoses and sink plugs

11. Hot water system

12. Cold water system

13. Window hinges and stays

14. Cassette toilet

15. Shower

16. Shower tray

17. Central heating

18. Damp test

SECTION (D) ELECTRICAL

1. Reflectors

2. All interior lights/Road lights

3. Water pump and switches

4. Refrigerator

5. Distribution unit

6. Charging unit

7. Junction box/Strip

8. Wiring and supports

9. Trailer connecting plug sockets

10. Overall tests etc.

11. Awning lights

12. Electronic ignition (hob)

13. 230V system where applicable

(Continued)

21-2

SERVICE DOCUMENTS

SECTION (E) GAS INSTALLATION

1. Hotplate

2. Refrigerator

3. Heater

4. Leak tested

5. Water heated

6. Fully operational

CARE WARRANTY

Your caravan is covered by the 3 year warranty, it is a condition of this warranty that a service and safetycheck is carried out by your caravan retailer at least once a year (12 months from the date of purchase)in accordance with the National Caravan Council recommendations.

SECTION (F) FINAL

Road test

1st SERVICE

DATE:

RETAILERS STAMP:

I/We certify that an annual service has beencarried out in accordance with themanufacturers’ and National CaravanCouncil recommendations.

2nd SERVICE

DATE:

RETAILERS STAMP:


3rd SERVICE

DATE:

RETAILERS STAMP:


4th SERVICE

DATE:

RETAILERS STAMP:


ANNUAL SERVICE RECORD

CARAVAN MODEL .................................................................................................................................................

VEHICLE IDENTIFICATION NUMBER ...................................................................... YEAR ...........................

21-3

SERVICE DOCUMENTS

5th SERVICE

DATE:

RETAILERS STAMP:


7th SERVICE

DATE:

RETAILERS STAMP:


9th SERVICE

DATE:

RETAILERS STAMP:


11th SERVICE

DATE:

RETAILERS STAMP:


6th SERVICE

DATE:

RETAILERS STAMP:


8th SERVICE

DATE:

RETAILERS STAMP:


10th SERVICE

DATE:

RETAILERS STAMP:


12th SERVICE

DATE:

RETAILERS STAMP:


21-4

SERVICE DOCUMENTS

13th SERVICE

DATE:

RETAILERS STAMP:


15th SERVICE

DATE:

RETAILERS STAMP:


17th SERVICE

DATE:

RETAILERS STAMP:


19th SERVICE

DATE:

RETAILERS STAMP:


14th SERVICE

DATE:

RETAILERS STAMP:


16th SERVICE

DATE:

RETAILERS STAMP:


18th SERVICE

DATE:

RETAILERS STAMP:


20th SERVICE

DATE:

RETAILERS STAMP:


22-1

INDEX

A

Aerial .................................................... 9-16Automatic Charging System ............... 8-2

B

Battery Charger .................................... 9-7Battery Installation ............................... 8-1Battery Maintenance ............................ 8-1Blinds .................................................... 9-13Breakaway Cable, use of ...................... 3-2Bulb Ratings ........................................... 8-2

C

Cables, checking .................................... 3-4Caravan Construction - Main

Components .............................. 15-1Additional Fixings to Your Caravan

Shell ............................................. 15-1Awning Channel ............................ 15-1Body Shell ....................................... 15-1BPW Chassis .................................. 15-1Braking System .............................. 15-1Front Panel and Gas Bottle Locker

Lid ................................................ 15-1Windows ......................................... 15-1

Caravan Handling .................................. 4-1Care of your Caravan ....................... 11-1

ABS Panels & Fittings ................... 11-1Acrylic Windows ........................... 11-1Carpets, Upholstery and

Curtains ...................................... 11-2Chassis Maintenance .................... 11-6Chassis Mounted Spare Wheel

Carrier ........................................ 11-4Cleaning of all Taps ........................ 11-2Cooking Equipment ...................... 11-2Exterior Cleaning .......................... 11-1Furniture ......................................... 11-2Glass Fibre Reinforced Plastic

(GRP) .......................................... 11-1Interior Walls ................................. 11-1

Jacking .............................................. 11-5Lubrication ...................................... 11-5Shower Trays, Shower Room and

Wash Basin Fittings .................. 11-2Thetford Toilet ............................... 11-3Truma Space Heater ..................... 11-3Tyres ................................................. 11-4Water Containers ......................... 11-2Water Systems - Sterilization ..... 11-3Window Blinds & Flyscreens ...... 11-1

Charging System ................................... 8-2Code of Practice - Water Ingress .. 14-1

Conditions ...................................... 14-1Customer Obligation ................... 14-1Mains Electrics ............................... 14-1Remedial Work .............................. 14-2Spare Parts ...................................... 14-1The Code ........................................ 14-1

Covers .................................................. 12-1

D

Doors ................................................... 9-14

E

Electrical Control Panels .................... 9-1Electrical System ................................... 8-1Electricity ................................................ 6-1

12v Systems ....................................... 6-1Connecting To Mains Supply .......... 6-1Disconnecting Mains Supply .......... 6-2Generator/Charger ......................... 6-1Mains Supply ...................................... 6-1Overseas Electrical Connection ... 6-2Power Supply Charger .................... 6-1

F

Fire Safety ............................................... 2-2Fuses ........................................................ 8-3

INDEX

22-2

INDEX

G

Gas ........................................................... 6-3Connection ........................................ 6-3Hoses .................................................. 6-3Regulator ............................................ 6-3

Gas Safety Advice ................................. 7-1Generators / Charger .......................... 8-1Glossary ............................................... 20-1

H

Handbrake .............................................. 3-4

I

Introduction ........................................... 1-1

L

Leveller Jack ........................................... 5-1Levelling, front & back .......................... 5-1Levelling, side to side ........................... 5-1

M

Mains Unit .............................................. 8-1Model Year .............................................. 1-1

P

Parking ..................................................... 5-1Pitch, selecting ....................................... 5-1Power Drain ....................................... 12-1Pre-Tow Checklist ................................ 3-2

R

Ramp........................................................ 5-1RCD ......................................................... 8-1Refrigerator

Thetford N108P ............................... 9-4Reversing ................................................ 4-1Road Lights ......................................... 17-3Rooflights ............................................. 9-12

S

Safety, general ........................................ 2-1Security

Additional Security ....................... 10-2Caravan Theft ................................. 10-1CRIS ................................................. 10-2Electronic Tagging .......................... 10-2Microtag© ....................................... 10-1

Service Documents ........................... 21-1Setting Off .............................................. 4-1Site Regulations ..................................... 5-1Smoke Detector ................................... 9-7Space Heater Operation ..................... 9-6

230V Operation ............................... 9-6Fan Operation ................................... 9-7Gas ...................................................... 9-6Gas Operation .................................. 9-6

Speed Limits ........................................... 4-1Storage

Long Term & Winter ..................... 12-1

T

Taps ....................................................... 9-13Toilet

Thetford C200 CW ........................ 9-8Towing Weight Ratio ............................ 3-1Tyres ..................................................... 11-4

V

Ventilation .............................................. 2-2

W

Warranty ............................................. 13-13-Year Manufacturer’s Warranty 13-1Conditions ...................................... 13-1Years 1 - 3 ....................................... 13-1Years 2 & 3 ..................................... 13-1

Water Heater Operation ................... 9-6Gas Operation .................................. 9-6

Water System ........................................ 6-4

22-3

INDEX

Draining .............................................. 6-4Windows ............................................. 9-13Wiring Diagram ................................. 17-2