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13-2

CARAVAN CONSTRUCTION

Table of Contents

Table of Contents1
Welcome and Introduction5
Erwin Hymer Group UK Technical Approvals6
General Safety7
Please Read before Using Your New Caravan7
Ventilation8
High-Level Ventilation8
Low-Level Ventilation8
Ventilation in Separate Bedrooms8
Gas Dispersal Holes8
Petrol/Diesel Fumes8
Fire Safety8
In Case of Fire8
Fire Retardant Foams8
Escape Paths8
Your Caravan Payload Explained9
Preparing for the Road11
Caravan Towing Vehicle Weight Ratio11
Loading11
Internal Loading & Checks11
External Loading & Checks12
Pre-Tow Checklist & Hitch-Up12
Towing and Driving17
Reversing17
Speed Limits17
Setting off17
Caravan Handling17
Motorway Driving18
Towing Covers18
Tyre and Wheel Checks18
Arriving on Site19
Check Site Regulations19
Selecting a Pitch19
Parking on a Reverse-Sloping Site or Steep Hill19
Entering and Exiting the Caravan19
Side-To-Side Levelling20
(All Except Buccaneer)20
Leveller Jack20
Ramp20
Front & Back Levelling (All Except Buccaneer)20
The E&P Hydraulics Levelsystem (Buccaneer Only)21
Getting Started37
Electricity37
Power Supply Charger37
12V Systems37
Generator/Charger37
Electricity Mains Supply37
Connecting to Mains Supply on Arrival at Site37
Disconnecting Mains Supply When Leaving Site38
Overseas Electrical Connection38
Gas Safety Advice39
Facts about LPG39
Awning Spaces, LPG and Appliance Exhaust39
LPG Gas System39
Gas Supply40
Connection40
Changing a Gas Cylinder40
Gas Regulator40
Auto Changeover Gas Regulator (Where Fitted)41
High Pressure Gas Hoses42
Whale High Flow Pump with Intelligent Control43
Electrical System49
12V POWER SUPPLY49
Battery Installation49
Battery Maintenance49
Generators / Charger49
230V POWER SUPPLY50
Mains Unit50
Resetting the RCD50
Automatic Charging System50
Internal Lights50
Maximum Power Ratings for Internal Lights (Where Fitted)50
Connecting a Solar Panel And/Or Satellite Dish (Where Fitted)51
External Solar Panel Connection (Where Fitted)51
External Satellite TV Connection (Where Fitted)51
How to Use Your Caravan'sequipment57
Electrical Control Panels57
Control Panel (Xplore)58
Control Panel (Avante/Casita)59
Ivan Control Panel59
Control Panel (Affinity/Capiro)60
Control Panel (Crusader/Camino and Buccaneer)60
Whale Heating System (Xplore)61
Whale Space Heater - User Operation62
Whale Water Heater - User Operation63
Whale Heating System - Troubleshooting64
Whale Space Heater - Reset Button Location (All Other Models)65
Whale Heating System (Avante/Casita)69
Ivan Control Panel - Instructions for Use71
Troubleshooting75
Whale Ivan Control Panel - Water Heater77
Whale Ivan Control Panel77
Winterising81
Alde Heating (3030 Control Panel) (Affinity/Capiro/Crusader/Camino/Buccaneer)84
Turning the Boiler on and off84
Status Screen84
Set the Desired Temperature85
Hot Water85
Energy Sources86
Heating with Electricity86
Heating with Gas86
High Altitude Mode86
Settings Menu87
Glycol Fluid88
Refill the Heating System with Glycol Liquid88
Service Information & Reset89
Oven (All Ranges)90
Safety90
Before Using the Appliance91
Dual Fuel Only91
Oven Shelf: (Applies to K1520 Only)92
Cooling System: (Applies to K1520 Only)92
Maintenance and Cleaning92
Troubleshooting93
Triplex (Xplore Only)94
Use of the Burners94
Use of the Electric Hotplate (if Applicable)95
Use of the Grill95
Use of the Oven96
Safe Cooking96
Temperature Control98
Use of the Burners99
K1520 (All Ranges Except Xplore)99
Use of the Electric Hotplate (if Applicable)100
Use of the Grill100
Use of the Oven101
Safe Cooking101
Temperature Control102
Refrigerator103
Setting the Cooling Capacity103
Using the Refrigerator Door103
Notes on Storing Food103
Defrosting the Refrigerator104
Positioning the Refrigerator Door in the Winter Position104
Fault Messages and Signal Tones104
Cleaning and Maintenance104
Cleaning the Gas Burner104
Microwave (Where Fitted)105
Battery Charger106
Smoke Alarm106
Carbon Monoxide Alarm108
Thetford C-260 Cassette Toilet Range112
Preparing for Use (Standard)112
Preparing for Use with Optional Features112
Using the Toilet (Standard)114
Using the Toilet with Optional Features114
Emptying114
Emptying with Optional Features114
Cleaning and Maintenance115
Toilet Bowl115
Waste Holding Tank115
Cleaning and Maintenance for Optional Features116
Winter Operation116
Storage116
Toilet Unit Malfunctions116
Rooflights118
The Omivent (12V) Rooflight (Where Fitted)118
The Heki 2 Rooflight (Where Fitted)118
MIDI Heki Rooflight (Where Fitted)119
MPK Rooflight (Where Fitted)119
Stargazer Rooflight (Where Fitted)120
Windows121
Polyplastic Window Opening121
Blinds & Flyscreens121
Door Flyscreen121
Shower122
Taps122
Gas Locker Door (Pivoting Door)122
Gas Locker Door (Crusader/Camino & Buccaneer)122
Internal Doors123
Toilet/Shower Room Doors123
Paddle Latch (Where Fitted)123
Concealed Latch (Where Fitted)123
High Level Locker (Crusader/Camino)124
High Level Locker (Buccaneer)124
Magnetic Catches (Where Fitted)124
Room Divider(Where Fitted)124
Bed Make-Up125
Removable Drawers138
Front Wrap Round Seating (Option)138
Lift up Bed Extensions (Where Fitted)139
Radio with MP3 Connectivity140
Teleco TV Aerial140
How to Use Your TV Aerial142
Digital TV Set-Up Guide142
Connect Aerial and Power142
Troubleshooting Guide142
Protect - Autowatch Alarm System (Where Fitted)144
Basic Operation Arming the System144
Disarming the System144
Panic Alarm144
Emergency Disarm144
Silent Arm and Disarm144
Sensors144
Passive Infra Red Sensor144
Al-Ko Trailer - Control145
Whale Easi-Slide Socket146
Safety Information146
Mobile Internet (Option)147
Pop-Up Wireless Charging and USB Device (Where Fitted)150
Security151
Caravan Theft151
Tracker Retrieve151
CRIS - the Central Registration and Identification Scheme151
Al-Ko Secure Wheel Lock (Option)152
Window & Chassis Marking154
Electronic Tagging154
Care of Your Caravan155
Exterior Cleaning155
Wheels155
Glass Fibre Reinforced Plastic (GRP - Where Applicable)155
Acrylic Windows155
Window Blinds & Flyscreens156
Winterisation/Storage156
ABS - a Frame Cover, Wheel Spats & Panels156
Interior Walls156
Furniture156
Cooking Equipment156
Soft Furnishings156
Winterisation and Storage157
Shower Trays, Shower Room and Wash Basin Fittings157
Cleaning of All Taps157
Water Containers158
Water Systems - Sterilisation158
Thetford Toilet158
Chassis Mounted Spare Wheel Carrier159
Tyre Wear and Damage159
Changing a Wheel159
Jacking160
Lubrication160
The Alko Caravan Chassis161
Chassis Members161
Drilling or Welding of Parts or Accessories161
Independent Suspension161
Coupling Head161
Brake Drum/Hub Assembly161
Jockey Wheel Assembly161
Operating Instructions162
Braking System Adjustment164
Storage167
Long Term & Winter Storage167
Caravan Covers167
Battery Maintenance Storage167
Caravan Warranty Cover169
Non Warranty Repairs171
Remedial Work172
Caravan Construction - Main Components173
Alko Chassis173
Braking System173
Solid Construction Body Shell173
Windows173
Insulation173
Front Panel and Gas Bottle Locker Door13-1173
Awning Channel173
General Questions185
Glossary189
Service Documents193
Notification of Change of Ownership199
Notification of Change to Name and Address201
Index203

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