Explorer Group 2003 Tourers, Owner'S Handbook Manual

Page 1: ...Owners Handbook 2003 Tourers...

Page 2: ...ight to alter specifications as materials and conditions demand Please check current details with your retailer and inspect the caravan to ensure it is satisfactory before purchase Retailers are indep...

Page 3: ...every 12 months thereafter Suitable towing vehicles The caravan is manufactured for towing behind normal road cars and is not suitable for towing behind commercial vehicles other than passenger car d...

Page 4: ...t 1998 will also be covered under this code providing they have documentary proof of annual services by approved Explorer Group Limited retailers or service centres Customers exchanging their current...

Page 5: ...ensure that their product is as safe as possible With this in mind all caravans are equipped with either Combustion Modified High Resilient C M H R foam cushions or sprung mattresses These foams are...

Page 6: ...ly etched on up to a maximum of 10 eye level windows To protect yourself and your touring caravan never leave the Registration Document in the caravan For security reasons keep it in a safe place If y...

Page 7: ...als The floor is constructed from a W B P plywood sandwich impregnated with anti damp and rot compounds and adhesives The walls comprise an insulated foam sandwich having pre coated aluminium exterior...

Page 8: ...se down attitude or a nose up attitude could lead to instability when towing VENTILATION All caravans manufactured by the Explorer Group Limited are ventilated at both high and low level in accordance...

Page 9: ...nt fixed ventilation points SECURITY VIN Record your caravan V I N which can be found stamped on the A frame or on one of the eye level windows Make a note of this number in the space provided at the...

Page 10: ...ace provided Corner steadies should not be used as a jacking device loose articles must be stowed securely Do not stow tins bottles or heavy items in overhead lockers prior to towing all lockers and c...

Page 11: ...e of the towing ball Wind up the jockey wheel and retract to the highest position Fit and secure stabiliser if used Plug in the electrical connections Connect the break away cable WARNING The break aw...

Page 12: ...round then finally straighten up Proficiency at reversing can only be achieved with practice SPEED LIMITS Normal road towing 50mph Motorways including dual carriageways 60mph Setting Off Let the clutc...

Page 13: ...11...

Page 14: ...d level Using the adjustment on the jockey wheel and holding the latch of the locking device unhitch the caravan On upward facing pitches when the hydraulically damped drawbar of the hitch becomes ful...

Page 15: ...ake with one hand while gently but purposely inching the caravan or trailer a small distance backwards with the other WARNING If the handbrake is NOT fully applied to the last tooth i e vertical and i...

Page 16: ...r main drain valve Place the submersible pump into the fresh water container ensuring it is fully submerged before operating the system see diagram Using the Carver Waterline direct connection to main...

Page 17: ...n until water flows Prior to operation of the water heater ensure water is flowing from hot tap DRAINING DOWN YOUR WATER SYSTEM It is essential that you drain down your caravan water system when it is...

Page 18: ...and is therefore suitable for all winter caravanning CONNECTION Make sure that heating and cooking appliances and gas cylinders are switched off Ensure that the correct regulator for the gas chosen h...

Page 19: ...general comfort smell and hygiene point of view In extreme cases there could be a build up of carbon dioxide to a dangerous level Caravan owners are advised to allow some fresh air circulation in the...

Page 20: ...y cover from the electricity inlet provided on the caravan and insert the connector of the flexible supply cable obtained from the site owner 4 Remove any cover from the socket outlet provided at the...

Page 21: ...upplies abroad since the supplies can be of REVERSE POLARITY The significance of REVERSE POLARITY is that when equipment is switched off it may not be electrically isolated The only certain way of mak...

Page 22: ...switch is only re settable after elimination of the fault To re set operate the switch as for MCBs Periodically the RCD should be checked by operating the test button marked T The unit should immediat...

Page 23: ...that of the output of the battery charger As the battery voltage increases the input current from the battery charger automatically reduces until it ceases to flow This provides fast and efficient bat...

Page 24: ...ifting upwards the transparent plastic door on the unit The power supply can be removed from the P C II by removing the fuses and then the front cover 4 cross headed screws and unscrewing the 4 batter...

Page 25: ...23...

Page 26: ...ll be fitted with the following control panel The control panel operates the main 12V system via the master switch This switch is in the on position when the I symbol is depressed It also gives a volt...

Page 27: ...for the pump control In the top position the water can be fed from the outside pump to fill the water tank In this position the taps and shower will not work The middle position is off totally The bo...

Page 28: ...26...

Page 29: ...closed The lever should be in the horizontal position e see diagram 2 Set the hot tap in either the washroom or kitchen in the open position 3 Switch on the power for the water pump 4 Leave the tap o...

Page 30: ...caravan has not been used for some time sterilise the water system thoroughly by preparing about 10 litres of water containing a sterilising agent made specially for the purpose This should be availab...

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Page 32: ...ery high so do not lift the lever with the tap turned to the full left position B For winter storage and to prevent frost damage the tap swivel must be the left in the centre up position BATHROOM TAPS...

Page 33: ...vant and Corona caravan will be fitted with either the Whale Elegance tap and shower combination tap or those models with tip up sink basins a separate Whale Elegance tap and Whale Elegance shower uni...

Page 34: ...32...

Page 35: ...rn will stop the pump running Opening a tap will reduce the pressure and the pump will start running At normal flow rates the submersible pump should operate continuously but at low rates the pressure...

Page 36: ...eze in the winter Always drain the system at the end of the season 3 Clean the water system at the start and the end of the season with a sterilising fluid e g Chempro SDP or similar Then flush the sy...

Page 37: ...ter cartridge is pushed fully home into the housing STERILISING When cleaning the water system at the start of the season it is recommended that a new filter cartridge is fitted WINTER USE If caravann...

Page 38: ...oarse wire wool and hard implements will damage the surface 2 All pans should be mounted centrally over the burners even when cooling to protect adjacent walls 3 Do not lower hob cover until hobs have...

Page 39: ...operating instructions are contained within your Owner s Information Pack THETFORD CASSETTE TOILET Your caravan is fitted with a cassette toilet FOR FULL OPERATIONAL INSTRUCTIONS REFER TO THE CASSETT...

Page 40: ...tempting to switch it on again WARNING Never place your hands or other objects within the air inlet openings MAINTENANCE To ensure trouble free running it is recommended that the unit be cleaned once...

Page 41: ...s the glass dome up about 2cm and fasten the toggle catches in the corresponding setting c To close proceed with steps a b in reverse order 4 Closing the blinds a Take hold of the end rod without rock...

Page 42: ...and outside of the caravan and does not restrict door openings When opening or closing the door flyscreen use the finger grip provided which is near the centre do not use the top or bottom as this wi...

Page 43: ...nterior movement sensor to avoid any alarm condition being detected However when part armed the security systems leg sensor will still detect an alarm condition and the personal attack alarm will also...

Page 44: ...e Emergency Override Facility A high security data code is transferred when the handset s override contacts are placed against the systems override receptacle located in the caravan In the event of ha...

Page 45: ...43...

Page 46: ...produces a herringbone pattern type of interference which is caused when you are close to a transmitter or picking up a strong radio transmission from another source Remedy Switch the gain control on...

Page 47: ...L shaped layout the bed frame is pulled out from underneath the rear facing seat Arrange the seat cushions appropriately All high level beds will take a maximum weight of 12 stone 76 5kg When in use...

Page 48: ...ion push button lock Push once to lock Push again to release Windows Your caravan will be fitted with either the Polyplastic pronounced window the Seitz flush window or both Polyplastic Window Opening...

Page 49: ...wax will help to maintain the colour and finish A significant benefit of using GRP components is the ability to repair most scratches or damage that may be inflicted upon the panel GRP components are...

Page 50: ...if care is not taken with their use and cleaning The symptoms caused by bacterial contamination are not purely limited to gastro intestinal diseases but may also manifest themselves as ear nose throa...

Page 51: ...doors are correctly fastened Check fixed ventilation apertures are not obstructed Check that the site you have chosen to store the caravan is open fairly high and dry and if possible not exposed to g...

Page 52: ...all taps and remove all plugs from sinks and showers Lever operated taps should have the lever put into the up position 4 Where fitted open the internal drain valves 5 Open the drain outlets on the o...

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Page 54: ...system All essential parts of the wheel brake are defined in the EC test report complete with BPW drawing numbers It is not allowed to change these BASIC PRINCIPLES Never overload axles brakes or cha...

Page 55: ...the traction vehicle Crank jockey wheel fully upwards and secure Release parking brake before setting off Visual check the ball head may no longer be visible in coupled condition UNCOUPLING Lower the...

Page 56: ...f 1 mm the brake shoe has to be replaced Stiff or stretched brake springs the coils of which are no longer closed tightly together must also be replaced For visual check re insert the plug arrow out o...

Page 57: ...the brake adjustment if necessary To test slightly tighten the parking brake and check identical brake torque on left and right side of wheels Remove locking pin 4 mm of swivel cams Adjust brake rod...

Page 58: ...lay adjustment If noticeable bearing play is felt the ECO Compact bearing should be replaced Check hub caps for firm seating every 2000 3000 kilometres Check the firm seating with a screwdriver Check...

Page 59: ...tially every 2000 3000 kilometres then every 5000 kilometres Apply general purpose grease via the grease nipples until fresh grease can be seen emerging by the bushes Deviation lever initially every 2...

Page 60: ...MAINTENANCE OF YOUR CARAVAN 58...

Page 61: ...MAINTENANCE OF YOUR CARAVAN 59...

Page 62: ...MAINTENANCE OF YOUR CARAVAN 60...

Page 63: ...tyre should be made with the tyres cold and using an accurate pressure gauge The checks should be carried out before each journey and at regular intervals during storage If a jockey wheel is fitted wi...

Page 64: ...17 Finally if the road wheels have been removed re tighten using a calibrated Torque Wrench to 88 Nm 65 lbs ft on all M12 wheel bolts in sequence i e North South East West NOT clock or anti clockwise...

Page 65: ...OR NUTS TO SECURE THE WHEEL A corner steady brace is not to be used for the next step f Fit the new wheel and refit the wheel bolts After the bolts have been screwed in as far as possible by hand each...

Page 66: ...inal member The maximum mass which the jockey wheel and its clamping mechanism are capable of withstanding is Part 205678 150kg Part 205736 200kg Wheel dia 240mm LUBRICATION FIG 16 Lubricate the Jocke...

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Page 68: ...MAINTENANCE 66...

Page 69: ...MAINTENANCE 67...

Page 70: ...68...

Page 71: ...ed retailer and give the following information which will help in identifying the required component a Model and make of caravan b VIN number c Description of fault ALL PARTS MUST BE ORDERED AND SUPPL...

Page 72: ...s SECTION A CHASSIS 1 Brakes 2 Suspension 3 Axles and Hubs 4 Tyres and pressures 5 Wheel nuts 6 Towing hitch and reverse 7 Jockey wheel 8 Breakaway chain 9 Corner steadies 10 Adjusted and lubricated 1...

Page 73: ...I We certify that an annual service has been carried out in accordance with the manufacturers and National Caravan Council recommendations 3rd SERVICE DATE RETAILER S STAMP I We certify that an annual...

Page 74: ...ecommendations 11th SERVICE DATE RETAILER S STAMP I We certify that an annual service has been carried out in accordance with the manufacturers and National Caravan Council recommendations 12th SERVIC...

Page 75: ...has been carried out by an approved dealer or service centre at least once every year The interval from purchase date to the first service and the intervals between services must not exceed 12 months...

Page 76: ...mm GRN OR 1 5mm RD 4 0mm RED4 0mm GREEN 2 5mm BL BRN 2 5mm BL BRN 2 5mm RD BRN 4 0mm OR OR WHI BRN WHITE BROWN GR OR GREEN ORANGE BLK NEGS LINKED RED4 0mm BL BRN 1 5mm BLK GRN BLK WHI BRN RED OR RED 1...

Page 77: ...LIGHTS 9 WAY CONNECTOR NEARSIDE SIDE MARKER LIGHT NEARSIDE TAIL LIGHTS BLUE YELLOW BLACK RED WHITE FOG FLASH TAIL STOP WHITE NUMBER PLATE LIGHTS OFFSIDE SIDE MARKER LIGHT OFFSIDE TAIL LIGHTS WHITE BR...

Page 78: ...Single 1830 x 730mm 1x Single 1820 x 650mm 5 8 5 x 1 10 6 6 x 3 9 5 9 5 x 2 6 3 x 4 5 6 x 2 5 5 11 5 x 2 1 5 1x Single 1915 x 580mm 1 x Single 1690 x 580mm 1x Single 1830 x 710mm 1x Single 1760 x 650m...

Page 79: ...x Single 1830 x 730mm 1x Single 1820 x 650mm 5 8 5 x 1 10 6 6 x 3 9 5 9 5 x 2 6 3 x 4 5 6 x 2 5 5 11 5 x 2 1 5 1x Single 1915 x 580mm 1x Single 1690 x 580mm 1x Single 1830 x 710mm 1x Single 1760 x 650...

Page 80: ...1 0mm GRN OR 1 5mm RD 4 0mm RED4 0mm GREEN 2 5mm BL BRN 2 5mm BL BRN 2 5mm RD BRN 4 0mm OR OR WHI BRN WHITE BROWN GR OR GREEN ORANGE BLK NEGS LINKED RED4 0mm BL BRN 1 5mm BLK GRN BLK WHI BRN RED OR RE...

Page 81: ...LIGHTS 9 WAY CONNECTOR NEARSIDE SIDE MARKER LIGHT NEARSIDE TAIL LIGHTS BLUE YELLOW BLACK RED WHITE FOG FLASH TAIL STOP WHITE NUMBER PLATE LIGHTS OFFSIDE SIDE MARKER LIGHT OFFSIDE TAIL LIGHTS WHITE BR...

Page 82: ...1909 x1354mm 1x Single 1830 x 730mm 1x Single 1820 x 650mm 5 8 5 x 1 10 6 6 x 3 9 5 9 5 x 2 6 3 x 4 5 6 x 2 5 5 11 5 x 2 1 5 1x Single 1915 x 580mm 1x Single 1690 x 580mm 1x Single 1830 x 710mm 1x Sin...

Page 83: ...m 1x Single 1830 x 730mm 1x Single 1820 x 650mm 5 8 5 x 1 10 6 6 x 3 9 5 9 5 x 2 6 3 x 4 5 6 x 2 5 5 11 5 x 2 1 5 1x Single 1915 x 580mm 1x Single 1690 x 580mm 1x Single 1830 x 710mm 1x Single 1760 x...

Page 84: ...0mm OR 1 5mm RD BRN 4 0mm BLK WHI YEL RD 12 S PLUG COLOUR CODE RD RED WHI WHITE WHI BRN WHITE BROWN BL BRN BLUE BROWN GR OR GREEN ORANGE GRN GREEN OR ORANGE RD BL RED BLUE BL BLUE YEL YELLOW RD BRN RE...

Page 85: ...T LIGHTS 9 WAY CONNECTOR NEARSIDE SIDE MARKER LIGHT NEARSIDE TAIL LIGHTS BLUE YELLOW BLACK RED WHITE FOG FLASH TAIL STOP WHITE NUMBER PLATE LIGHTS OFFSIDE SIDE MARKER LIGHT OFFSIDE TAIL LIGHTS WHITE B...

Page 86: ...mm 28 1 9074mm 29 9 9590mm 31 5 5 9590mm 31 5 5 9732mm 31 11 9732mm 31 11 Bed Sizes Option 1 1x Single 1880 x 675mm 1x Single 1880 x 675mm 1x Single 1880 x 675mm 1x Single 1880 x 675mm 1x Double 2120...

Page 87: ...x 580mm 1x Single 1880 x 675mm 5 7 5 x 1 11 6 2 x 2 2 5 Bed Sizes Option 2 1x Double 1982 x 1480mm 1x Double 1982 x 1480mm 1x Double 1982 x 1480mm 6 6 x 4 10 6 6 x 4 10 6 6 x 4 10 1x Double 1682 x 127...

Page 88: ...x Double 1900 x 1340mm 6 2 x 2 2 5 6 2 x 2 2 5 6 2 x 2 2 5 6 2 x 2 2 5 6 2 5 x 4 4 5 6 2 5 x 4 4 5 1x Double 1682 x 1270mm 1 x Single 1800 x 610mm 5 6 x 4 2 6 2 x 2 1x Single 1725 x 580 1 x Single 171...

Page 89: ...0 x 1340mm 1x Double 1900 x 1340mm 6 2 x 2 2 5 6 2 x 2 2 5 6 2 x 2 2 5 6 2 x 2 2 5 6 2 5 x 4 4 5 6 2 5 x 4 4 5 1x Double 1682 x 1270mm 1 x Single 1800 x 610mm 5 6 x 4 2 6 2 x 2 1x Single 1725 x 580 1...

Page 90: ...d to Ground 8560mm 28 1 9074mm 29 9 9590mm 31 5 5 9590mm 31 5 5 9732mm 31 11 9732mm 31 11 Bed Sizes Option 1 1x Single 1880 x 675mm 1x Single 1880 x 675mm 1x Single 1880 x 675mm 1x Single 1880 x 675mm...

Page 91: ...89...

Page 92: ...m RED 1 0mm RD BL 1 0mm GRN 1 0mm OR 1 5mm RD BRN 4 0mm BLK WHI YEL RD 12 S PLUG COLOUR CODE RD RED WHI WHITE WHI BRN WHITE BROWN BL BRN BLUE BROWN GR OR GREEN ORANGE GRN GREEN OR ORANGE RD BL RED BLU...

Page 93: ...DE SIDE MARKER LIGHT NEARSIDE TAIL LIGHTS BLUE YELLOW BLACK RED WHITE FOG FLASH TAIL STOP WHITE NUMBER PLATE LIGHTS OFFSIDE SIDE MARKER LIGHT OFFSIDE TAIL LIGHTS WHITE BROWN BLACK BLUE GREEN BROWN RED...

Page 94: ...BLUE YEL YELLOW RD BRN RED BROWN NEGS LINKED REVERSING LIGHT RED4 0mm BL BRN 1 5mm BLK GRN GRN GRN BLK WHI BRN RED OR RED WHI FUSE HOUSING 15 A 15 A 15 A 10 A 10 A 1A 5A 5A 5A 5A 10 A 10 A CONNECTING...

Page 95: ...IGHTS 9 WAY CONNECTOR NEARSIDE SIDE MARKER LIGHT NEARSIDE TAIL LIGHTS BLUE YELLOW BLACK RED WHITE FOG FLASH TAIL STOP WHITE NUMBER PLATE LIGHTS OFFSIDE SIDE MARKER LIGHT OFFSIDE TAIL LIGHTS WHITE BROW...

Page 96: ...34 8 10571mm 34 8 10571mm 34 8 Bed Sizes Option 1 1x Single 1880 x 740mm 1 x Single1880mm x 740mm 1x Double 2120 x 1742mm 1x Single 1880 x 740mm 1x Double 2120 x 1329mm 1x Single 1880 x 740mm 6 2 x 2...

Page 97: ...4 4 5 6 2 x 2 5 6 2 x 2 5 1 x Single 1880mm x 610mm 1x Double 2120 x 1400 1x Double 2120 x 1400 6 2 x 2 6 11 5 x 4 7 6 11 5 x 4 7 1 x Single 1710mm x 580mm 5 7 x 1 11 Bed Sizes Option 2 1x Double 212...

Page 98: ...BLUE YEL YELLOW RD BRN RED BROWN NEGS LINKED REVERSING LIGHT RED4 0mm BL BRN 1 5mm BLK GRN GRN GRN BLK WHI BRN RED OR RED WHI FUSE HOUSING 15 A 15 A 15 A 10 A 10 A 1A 5A 5A 5A 5A 10 A 10 A CONNECTING...

Page 99: ...DE SIDE MARKER LIGHT NEARSIDE TAIL LIGHTS BLUE YELLOW BLACK RED WHITE FOG FLASH TAIL STOP WHITE NUMBER PLATE LIGHTS OFFSIDE SIDE MARKER LIGHT OFFSIDE TAIL LIGHTS WHITE BROWN BLACK BLUE GREEN BROWN RED...

Page 100: ...BLUE YEL YELLOW RD BRN RED BROWN NEGS LINKED REVERSING LIGHT RED4 0mm BL BRN 1 5mm BLK GRN GRN GRN BLK WHI BRN RED OR RED WHI FUSE HOUSING 15 A 15 A 15 A 10 A 10 A 1A 5A 5A 5A 5A 10 A 10 A CONNECTING...

Page 101: ...DE SIDE MARKER LIGHT NEARSIDE TAIL LIGHTS BLUE YELLOW BLACK RED WHITE FOG FLASH TAIL STOP WHITE NUMBER PLATE LIGHTS OFFSIDE SIDE MARKER LIGHT OFFSIDE TAIL LIGHTS WHITE BROWN BLACK BLUE GREEN BROWN RED...

Page 102: ...Single 1880 x 740mm 1 x Single 1880mm x 740mm 1x Double 1900 x 1340mm 1x Single 1880 x 740mm 6 2 x 2 2 5 6 2 x 2 5 6 2 x 2 5 6 3 x 4 4 5 6 2 x 2 5 1 x Single 1880mm x 610mm 1x Double 2120 x 1400mm 6...

Page 103: ...5x673mm 1 xSingle 2044x673mm 1xSingle 1805x673mm 1xSingle 1853x673mm 1xSingle 1805x673mm 1xDouble 1795x1130mm 1xSingle 1800x610mm 1xSingle 1795x570mm 1xSingle 1710x580mm Bed Sizes Option 2 1xDouble 19...

Page 104: ...E CAR BATTERY 7 S PLUG CONSUMER UNIT YEL CONNECT TO REV LIGHT YEL BLK RED GRN BLU WHT OR WH BRN RED BRN WHT RED GRN GRN GRN WHT BRN GRN GRN GRN OR GRN OR RED WH BRN WH BRN WH BRN WH BRN GRN BLK GRN BR...

Page 105: ...LIGHTS 9 WAY CONNECTOR NEARSIDE SIDE MARKER LIGHT NEARSIDE TAIL LIGHTS BLUE YELLOW BLACK RED WHITE FOG FLASH TAIL STOP WHITE NUMBER PLATE LIGHTS OFFSIDE SIDE MARKER LIGHT OFFSIDE TAIL LIGHTS WHITE BR...

Page 106: ...AGE CORONA AMAZON BROADWAY CONCERTO CARRON MAGNUM DIAMOND WARREN ELUSION SHIRAZ EMPEROR FIRESTORM INVICTA OMEGA LIBERT KENSINGTON MAGNUM CLASSIC KNIGHTSBRIDGE PENTARA RACECOURSE RIVA ODYSSEY GTI RIVER...

Page 107: ...yst Yes Water heater Truma ultrastore Sink drainer Argent stainless Oven unit Midi copper Hob unit Argent stainless Taps kitchen Reich chrome Kama Shower equipment Whale white Taps vanity Whale white...

Page 108: ...INDEX 106...

Page 109: ...b 36 I Introduction 2 J Jacking 64 L Lubrication 56 59 M Maintenance 55 O Oven 36 P Preparing for the Road 8 R Refrigerator 36 Retailer Special Index 104 S Servicing 69 Servicing Documents 70 Servicin...

Page 110: ...The Explorer Group Limited Explorer House Delves Lane Consett Co Durham DH8 7PE Tel 01207 699000 Fax 01207 699001 www explorer group co uk...