Capron Sunlight A68 2018 User manual

Contents
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Contents
1 Introduction ............................... 5
1.1 General ................................................... 6
1.2 Technical data ........................................ 6
1.3 Environmental tips .................................. 7
2 Safety ......................................... 9
2.1 Fire prevention........................................ 9
2.1.1 Avoidance of fire risks ............................ 9
2.1.2 Fire-fighting............................................. 9
2.1.3 In case of fire ..........................................9
2.2 General ................................................. 10
2.3 Road safety .......................................... 10
2.4 Towing .................................................. 12
2.5 Gas system........................................... 12
2.5.1 General instructions.............................. 12
2.5.2 Gas bottle ............................................. 13
2.6 Electrical system................................... 14
2.7 Water system........................................ 14
3 Before the journey .................. 15
3.1.1 Initial start-up ........................................ 15
3.2 Payload................................................. 15
3.2.1 Terms.................................................... 15
3.2.2 Calculating the payload ........................ 18
3.2.3 Loading the vehicle correctly................ 19
3.3 Towing .................................................. 20
3.4 Entrance step ....................................... 21
3.5 Removable partition wall ...................... 22
3.6 Flat screen ............................................ 23
3.7 Gas regulator........................................ 23
3.8 Snow chains ......................................... 24
3.9 Road safety .......................................... 24
4 During the journey .................. 27
4.1 Driving the motorhome ......................... 27
4.2 Driving speed........................................ 27
4.3 Brakes................................................... 28
4.4 Seat belts.............................................. 28
4.4.1 General ................................................. 28
4.4.2 Fastening the seat belts correctly......... 28
4.5 ISOFIX child safety seat mounting
system .................................................. 29
4.6 Driver's seat and front passenger's
seat ....................................................... 29
4.7 Headrests ............................................. 29
4.8 Seating arrangement ............................ 30
4.9 Filling up with diesel ............................. 30
5 Pitching the Motorcaravan ..... 31
5.1 Handbrake ............................................ 31
5.2 Entrance step ....................................... 31
5.3 Ramps .................................................. 31
5.4 230 V connection.................................. 31
5.5 Refrigerator........................................... 31
6 Living ....................................... 33
6.1 Doors .................................................... 33
6.1.1 Insect screen on the sliding door,
extendable ............................................ 33
6.1.2 Rear doors............................................ 33
6.2 External flaps........................................ 34
6.3 Ventilation............................................. 34
6.4 Windows ............................................... 35
6.4.1 Hinged window ..................................... 35
6.4.2 Roman shade and insect screen.......... 37
6.4.3 Cabin black-out shade.......................... 38
6.5 Skylights ............................................... 38
6.5.1 Skylight with snap latch ........................ 39
6.5.2 Heki skylight ......................................... 40
6.5.3 Wind-up skylight ................................... 41
6.6 Tables................................................... 42
6.6.1 Suspension table with separable
support leg............................................ 42
6.6.2 Folding worktop .................................... 43
6.7 PVC-floor covering ............................... 43
6.8 Lamps................................................... 43
6.8.1 Lighting system and USB socket.......... 44
6.8.2 Lamp in the rear area ........................... 45
6.9 TV unit .................................................. 46
6.10 Beds ..................................................... 47
6.10.1 Transverse rear bed ............................. 47
6.10.2 Longitudinal rear beds.......................... 47
6.10.3 Bunk bed in the rear ............................. 49
6.11 Converting seating group
for sleeping ........................................... 50
7 Gas system.............................. 51
7.1 General instructions ............................. 51
7.2 Gas bottles ........................................... 52
7.3 Gas pressure regulating system
DuoControl CS ..................................... 53
7.4 Changing gas bottles............................ 56
7.5 Gas isolator taps .................................. 57
8 Electrical system..................... 59
8.1 General safety instructions................... 59
8.2 Terms ................................................... 59
8.3 12 V power supply................................ 60
8.3.1 Living area battery................................ 60
8.3.2 Charging batteries via a 230 V
power supply ........................................ 62
8.3.3 Charging batteries via
the vehicle engine ................................ 62
8.3.4 Charging the starter battery.................. 62
8.4 Transformer/rectifier (EBL 119)............ 63
8.4.1 Battery cut-off switch ............................ 65
8.4.2 Battery selector switch ......................... 65
8.4.3 Battery monitor ..................................... 65
8.4.4 Charging the battery............................. 66

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8.5 Panel (LT 100)...................................... 66
8.5.1 12 V main switch .................................. 67
8.5.2 LED array for battery voltage ............... 67
8.5.3 LED array for tank fill level ................... 68
8.6 230 V power supply .............................. 69
8.6.1 230 V connection (CEE socket
outlet).................................................... 69
8.6.2 Connecting the 230 V power supply..... 70
8.7 Fuses .................................................... 71
8.7.1 12 V fuses............................................. 71
8.7.2 230 V fuse ............................................ 73
9 Appliances............................... 75
9.1 General................................................. 75
9.2 Heater / production of hot water ........... 75
9.2.1 To heat properly ................................... 76
9.2.2 Heater and production of hot water
(Truma Combi) ..................................... 77
9.2.3 Heater and production of hot water
(Truma Combi D).................................. 79
9.2.4 Independent vehicle heater
(Webasto) ............................................. 80
9.2.5 Boiler (Whale)....................................... 80
9.2.6 Wall flue................................................ 82
9.3 Gas cooker ........................................... 82
9.4 Refrigerator........................................... 84
9.4.1 Thetford T1000 ..................................... 84
9.4.2 Refrigerator door locking
mechanism ........................................... 86
10 Sanitary fittings....................... 87
10.1 Water supply, general........................... 87
10.2 Water tank ............................................ 88
10.2.1 Drinking water filler neck with cap ........ 88
10.2.2 Filling the water system........................ 89
10.2.3 Topping up the water............................ 90
10.2.4 Reducing the water quantity for
mobile operation ................................... 90
10.2.5 Draining water ...................................... 91
10.2.6 Emptying the water system .................. 91
10.3 Waste water tank.................................. 92
10.4 Toilet compartment............................... 93
10.5 Toilet ..................................................... 94
10.5.1 Swivel toilet........................................... 95
10.5.2 Emptying the sewage tank ................... 95
10.5.3 Winter operation ................................... 96
10.5.4 Temporary lay-up ................................. 96
11 Care.......................................... 97
11.1 External care ........................................ 97
11.1.1 General................................................. 97
11.1.2 Washing with a
high-pressure cleaner.......................... 97
11.1.3 Washing the vehicle ............................. 97
11.1.4 Windows of acrylic glass ...................... 98
11.1.5 Underbody ............................................ 99
11.1.6 Cleaning the entrance step .................. 99
11.2 Interior care ........................................ 100
11.2.1 Refrigerator......................................... 101
11.3 Stainless steel surfaces...................... 101
11.4 Water system ..................................... 102
11.4.1 Cleaning the water tank...................... 102
11.4.2 Cleaning the water pipes.................... 102
11.4.3 Disinfecting the water system............. 103
11.4.4 Cleaning the waste water tank ........... 103
11.5 Winter care ......................................... 104
11.5.1 Preparations ....................................... 104
11.5.2 Winter operation ................................. 104
11.5.3 At the end of the winter season.......... 104
11.6 Lay-up................................................. 105
11.6.1 Temporary lay-up ............................... 105
11.6.2 Winter lay-up ...................................... 106
11.6.3 Starting up the vehicle after a
temporary lay-up or after lay-up
over winter.......................................... 107
12 Maintenance .......................... 109
12.1 Official inspections ............................. 109
12.2 Inspection work .................................. 109
12.3 Maintenance work .............................. 110
12.4 Boiler (Whale)..................................... 110
12.5 Replacing illuminants, external........... 110
12.6 Replacing illuminants, internal............ 110
12.7 Spare parts......................................... 111
12.8 Vehicle identification plate.................. 111
12.9 Warning and information stickers....... 112
12.10 Dealers ............................................... 112
13 Wheels and tyres .................. 113
13.1 General............................................... 113
13.2 Tyre selection ..................................... 114
13.3 Tyre specifications.............................. 115
13.4 Handling of tyres ................................ 115
13.5 Tightening torque ............................... 115
13.6 Tyre pressure ..................................... 116
14 Troubleshooting.................... 119
14.1 Braking system................................... 119
14.2 Electrical system ................................ 119
14.3 Gas system......................................... 122
14.4 Cooker ................................................ 122
14.5 Heater/boiler....................................... 123
14.5.1 Independent vehicle heater
(Webasto) ........................................... 124
14.6 Refrigerator......................................... 124
14.6.1 General............................................... 124
14.7 Water supply ...................................... 125
14.8 Body ................................................... 126

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15 Helpful notes ......................... 127
15.1 Traffic rules in foreign countries .........127
15.2 Help on Europe's roads ...................... 127
15.3 Gas supply in European countries .....128
15.4 Toll regulations in
European countries ............................ 128
15.5 Tips on staying overnight safely
during travel........................................ 129
15.6 Tips for winter campers ...................... 129
15.7 Travel checklists ................................. 130

Contents
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Introduction
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1
1 Introduction
Please read this instruction manual completely before
using the vehicle for the first time!
Always keep this instruction manual in the vehicle. Also inform all other us-
ers of the safety regulations.
The non-observance of this symbol can lead to personal injury.
 The non-observance of this symbol can lead to damage being caused
to, or inside the vehicle.
 This symbol indicates recommendations or special aspects.
 This symbol indicates actions which lead to environmental awareness.
With your motorhome you will receive a file with the following vehicle manu-
als and documents:
 Operating and installation instructions of various appliances
 Complete set of documents from the chassis manufacturer
 Test certificate for the gas system in accordance with German regula-
tions
This instruction manual contains sections which describe model-spe-
cific equipment or special equipment. These sections are not specially
marked. It may be that your vehicle has not been fitted with this special
equipment. In some cases, the actual equipment of your vehicle may
therefore be different from that shown in some illustrations and de-
scriptions.
However, your vehicle may be fitted with other special equipment not de-
scribed in this instruction manual.
Special equipment is described when an explanation is required.
Adhere to the instruction manuals which are separately enclosed.
 The details "right", "left", "front" and "rear" always refer to the vehicle in
direction of travel.
 All dimensions and weight details are "approximate".
Should the vehicle be subjected to damage due to a failure to follow the in-
structions in this instruction manual, then the warranty claim is deemed inva-
lid.
Our vehicles are subjected to continuous development. Please understand
that we reserve the right to alter the form, equipment and technology. There-
fore, no claims can be made against the manufacturer as a result of the con-
tents of this instruction manual. The equipment which was known and in-
cluded at the time of going to press is described.
The reprinting, translation and copying, including extracts is not permitted
without prior written authorisation from the manufacturer.

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1.1 General
The vehicle is constructed in accordance with the latest technology and the
recognised safety regulations. Nevertheless, personal injury may result and
the vehicle may be damaged if the safety instructions in this instruction man-
ual are not followed.
Before using the vehicle for the first time, equip it with the legally prescribed
equipment (e.g. first aid kit, warning vest, hazard warning triangle etc.). Ob-
serve the relevant equipment regulations when travelling abroad.
Only use the vehicle in a technically impeccable condition. Follow the in-
structions in the instruction manual.
Malfunctions which impair the safety of persons or the vehicle should be im-
mediately remedied by qualified personnel. To avoid further damages, ob-
serve the duty to avert, minimise or mitigate loss for the user during faults.
Have the vehicle's braking and gas systems inspected and repaired by an
authorised specialist workshop only.
Alterations to the body are only to be carried out with the authorisation of the
manufacturer.
The vehicle is designed for the exclusive transport of persons. Luggage and
accessories may only be transported up to the maximum permissible gross
weight.
Observe the test and inspection periods stipulated by the manufacturer.
1.2 Technical data
 Only the details provided in the actual vehicle documentation shall be
binding with regard to the technical data.
 The measurements as well as the net weight of the vehicle may change
when mounting accessories or special equipment. Differences due to
manufacturing tolerances (+/- 5 %) are possible and admissable.
Further information can be found in the operating manual of the base vehi-
cle. The technical data are not a component of the instruction manual.
The technical data can be obtained from the manufacturer's documentation.
Alternatively, the authorised dealer or service centre will also be happy to
advise you.

Introduction
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1
1.3 Environmental tips
 Be considerate of the environment.
 Remember that: All kinds of waste water and household waste are not to
be disposed of in drains or in the open countryside.
 On board, collect waste water only in the waste water tank or – if neces-
sary – in other containers designed for that purpose.
 Only empty the waste water tank and toilet cassette or sewage tank at
disposal stations at the camping or caravan sites, which are especially
provided for this purpose. When stopping in towns and communities, ob-
serve the instructions at caravan sites or ask where there are disposal
stations.
 Empty waste water tank as often as possible, even when it is not com-
pletely full (hygiene).
 If possible, flush out waste water tank and, if necessary, drainage pipe
with fresh water every time it is emptied.
 Never allow the toilet cassette or sewage tank to become too full. Empty
the toilet cassette or sewage tank frequently, at the latest as soon as the
level indicator lights up.
 Separate household waste according to glass, tin cans, plastic and wet
waste also when on a journey. Enquire at the town or community author-
ity about disposal points. Household waste is not to be disposed of in
waste paper baskets which are situated at car parks.
 When parked, do not allow the engine to run more than necessary.
When running idle, a cold engine releases more contaminants than
usual. The running temperature of the engine is achieved more quickly
whilst the vehicle is in motion.
 Use an environmentally-friendly WC chemical agent for the WC which
can also be biologically degraded and only use small doses.
 When staying in towns and communities for long periods, search for
parking areas which are specially reserved for motorhomes. Enquire at
the town or community authority about parking spaces.
 Always leave the parking places in a clean condition.

Introduction
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Safety
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2 Safety
Chapter overview
This chapter contains important safety instructions. The safety instructions
are for the protection of persons and property.
2.1 Fire prevention
2.1.1 Avoidance of fire risks
Never leave children in the vehicle unattended.
Keep flammable materials clear of heating and cooking appliances.
Never use portable heating or cooking appliances.
Only authorised qualified personnel may make changes to the electri-
cal system, gas system or appliances.
2.1.2 Fire-fighting
Always carry a dry powder fire extinguisher in the vehicle. The fire ex-
tinguisher must be approved, tested and close at hand.
The fire extinguisher is not included in the scope of delivery.
Have the fire extinguisher tested at regular intervals by authorised
qualified personnel. Observe the date of testing.
Always keep a fire blanket near the cooker.
2.1.3 In case of fire
Evacuate all passengers.
Cut off the electrical power supply and disconnect from the mains.
Close regulator tap on the gas bottle.
Sound the alarm and call the fire brigade.
Fight the fire if this is possible without risk.
 Acquaint yourself with the position and operation of the emergency exits.
 Keep escape routes clear.
 Observe the fire extinguisher instructions for use.
All windows and doors which meet the following requirements are consid-
ered as emergency exits:
 Open to the outside or can be shifted in horizontal direction
 Opening angle at least 70°
 Minimum diameter of clearance = 450 mm
 Maximum distance from the vehicle floor = 950 mm

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2.2 General
The oxygen in the vehicle interior is used up by breathing and the use
of gas operated appliances. That is why the used air must be replaced
permanently. For this purpose, forced ventilation options (e.g. sky-
lights with forced ventilation) are fitted to the vehicle. Never cover or
block forced ventilations from the inside or outside with objects such
as e.g. a winter mat. Keep forced ventilations clear of snow and
leaves. There is a danger of suffocation due to increased CO2levels.
Observe the headroom of the doors.
 As far as the fitted appliances (heater, cooker, refrigerator, etc.) and the
base vehicle (engine, brakes, etc.) are concerned, the instruction manu-
als are authoritative. It is imperative that they be observed.
 Fitting accessories or special equipment can alter the dimensions,
weight and road behaviour of the vehicle. Some of the add-on parts
must be entered in the vehicle documents.
 Only use wheel rims and tyres which are approved for the vehicle. Infor-
mation concerning the size of the approved wheel rims and tyres is in-
cluded in the vehicle documents or can be obtained from authorised
dealers and service centres.
 Firmly apply the handbrake when parking the vehicle.
 When leaving the vehicle, it is imperative that all doors, external flaps
and windows are closed.
 Always carry the legally prescribed equipment (e.g. first aid kit, warning
vest, hazard warning triangle etc.) with you. The regulations of the host
country apply when travelling abroad.
 The vehicle may only be driven by drivers who hold a driving licence
which is valid for the respective vehicle class.
 When selling the vehicle, hand over all instruction manuals for the vehi-
cle and the fitted appliances.
2.3 Road safety
Before commencing the journey, carry out a functional check of indi-
cating and lighting equipment, the steering and the brakes.
If the vehicle has been stationary for a long period (approx.
10 months) have the braking and gas systems checked by an author-
ised specialist workshop.
Before commencing the journey and after short interruptions of the
journey, ensure that the entrance step is completely retracted.
Before commencing the journey, rotate all swivel seats in the direction
of travel and lock in position. During the journey, the swivel seats must
remain locked in place in the direction of travel.
Carefully store all moving parts and all loose objects before starting
your journey.
Before commencing the journey, store the flat screen securely.

Safety
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2
During the journey, persons are only to sit on the permitted seats (see
chapter 4). The authorised number of seats is stipulated in the vehicle
documents.
Seat belts must be worn by all passengers.
Fasten your seat belts before the beginning of the journey and keep
them fastened during the journey.
Always secure children with the children safety equipment prescribed
for the respective height and weight.
Only attach the child restraint system to seats that are specified for
this purpose. Only forward-facing child restraint systems are permit-
ted.
The base vehicle is a commercial vehicle (small truck). Adjust your
driving technique accordingly.
In case of underpasses, tunnels or similar obstacles, note the total
height of the vehicle (including the roof load).
In winter, the roof must be free of snow and ice before commencing
the journey.
Check tyre pressure before a journey or every 2 weeks. Wrong tyre
pressure causes excessive wear and can lead to damage or even to
tyre burst. You can lose control of the vehicle (see section 13.6).
Do not operate the heater at petrol stations. Danger of explosion!
Do not operate the heater in closed spaces. Danger of suffocation!
 Before commencing the journey, distribute the payload evenly within the
vehicle (see chapter 3).
 When loading the vehicle and when taking a rest from driving, in order to
load luggage or food, for example, observe the maximum permissible
gross weight and axle loads (refer to vehicle documents).
 Before commencing the journey, ensure that all cupboard doors, the toi-
let compartment door and all drawers and flaps are secure. Engage the
refrigerator door securing device.
 Before commencing the journey, close windows and skylights.
 Before commencing the journey, close all external flaps and lock them.
 Remove external supports (if installed) before commencing the journey.
 During the initial journey and each time after changing a wheel, re-
tighten the wheel bolts/wheel nuts after 50 km (30 miles). Subsequently
inspect them at regular intervals in order to ensure that they are firmly
seated. See chapter 13 for tightening torque.
 Tyres must not be older than 6 years as the material becomes brittle
over time (see chapter 13).
 When using snow chains, the tyres, wheel suspension and steering are
subjected to an additional load. When using snow chains, drive slowly
(maximum speed 50 km/h) and only on streets which are completely
covered with snow. Otherwise the vehicle could be damaged.

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2.4 Towing
Care is to be taken when connecting and detaching a trailer. Risk of
accident and injury!
No persons are to be between the motorhome and the trailer during
positioning for connecting and detaching.
2.5 Gas system
2.5.1 General instructions
The operator of the gas system is responsible for the performance of
recurring inspections and for complying with the maintenance inter-
vals.
Before commencing the journey, when leaving the vehicle or when
gas equipment is not in use, close all gas isolator taps and the main
regulator tap on the gas bottle.
All gas-operated devices (heater, cooker) must be switched off for re-
fuelling, on ferries or in the garage. Danger of explosion!
Do not use gas-operated devices in closed spaces (e.g. garages).
Danger of poisoning and suffocation!
Only have the gas system maintained, repaired or altered by an au-
thorised specialist workshop.
Have the gas system checked by an authorised specialist workshop
according to the national regulations before commissioning. This also
applies for not registered vehicles. For modifications to the gas sys-
tem have the gas system immediately checked by an authorised spe-
cialist workshop.
The gas pressure regulator, the gas tubes, and the exhaust gas pipes
must also be inspected. The gas pressure regulator and the gas tubes
must be replaced observing the nationally defined deadlines (the lat-
est after 10 years). The vehicle owner is responsible for seeing that
this is carried out.
In case of a defect of the gas system (gas odour, high gas consump-
tion) there is danger of explosion! Close regulator tap on the gas bot-
tle immediately. Open doors and windows and ventilate well.
If the gas system is defective: Do not smoke; do not ignite any open
flames, and do not operate electric switches (light switches etc.).
Check the tightness of gas-conducting parts and lines with leakage
search spray. Do not check with an open flame.
Only the stipulated devices may be connected to internal connections.
Do not operate any device outside the vehicle if it is connected to an
internal connector.
Cooking is prohibited during the journey.
Before using the cooker make sure that there is sufficient ventilation.
Open a window or the skylight.
Do not use the gas cooker for heating purposes.
If there are several gas devices, each gas device must have its own
gas isolator tap. If individual gas devices are not in use, close the re-
spective gas isolator tap.

Safety
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2
Ignition safety valves must close within 1 minute after the gas flame
has extinguished. A clicking sound is audible. Check function from
time to time.
The built-in gas devices are exclusively meant for use with propane or
butane gas or a mixture of both. The gas pressure regulator as well as
all built-in gas devices are designed for a gas pressure of 30 mbar.
Propane gas is capable of gasification up to -42 °C, whereas butane
gas gasifies at 0 °C. Below these temperatures no gas pressure is
available. Butane gas is unsuitable for use in winter.
Due to its function and construction, the gas bottle compartment is a
space which is open to the exterior. Never cover or block up the
standard forced ventilations. Otherwise gas that is emitted can not be
diverted to the outside.
The gas bottle compartment must not be used as storage space.
Secure the gas bottle compartment against unauthorised access. To
do this, lock the compartment.
The regulator tap on the gas bottle must be accessible.
Only connect gas-operated devices (e.g. gas grill) which have been
designed for a gas pressure of 30 mbar.
The exhaust gas pipe must be fitted tightly to the heating system and
to the vent and must be sealed. The exhaust gas pipe must not show
any evidence of damage.
Exhaust fumes must be able to escape into the atmosphere unhin-
dered and fresh air must be able to enter unhindered. For this reason,
keep the exhaust pipe and intake openings clean and unobstructed
(e.g. free from snow and ice). For this reason, no snow walls or
aprons may lie against the vehicle.
2.5.2 Gas bottle
Handle full or emptied gas bottles outside the vehicle only with closed
regulator tap and attached protective cap.
Gas bottles are only to be transported within the designated gas bottle
compartment.
Place the gas bottles in vertical position in the gas bottle compart-
ment.
Fasten the gas bottles so that they are unable to turn or tilt.
Connect the gas tube to the gas bottle without tension.
If the gas bottles are not connected to the gas tube, always place the
protective cap on top.
Close the regulator tap on the gas bottle before the gas pressure reg-
ulator or gas tube are removed from the gas bottle.
Depending on the connection, unscrew the gas tube from the gas bot-
tle and screw it on the gas bottle again by hand or using an suitable
special spanner. The screw connection on the gas bottle generally
has a left-hand thread. Do not tighten too firmly.
Only use special gas pressure regulators with a safety valve designed
for vehicle use. Other gas pressure regulators are not permitted and
cannot meet the demanding requirements.

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Use the gas pressure regulator defroster if the temperature falls below
5 °C.
Use only 11 kg or 5 kg gas bottles. Camping gas bottles with built-in
check valve (blue bottle with max. 2.5 or 3 kg content) are can be
used in exceptional cases with a safety valve.
Use the shortest possible tube lengths (150 cm max.) for external gas
bottles.
Never block the floor ventilation openings below the gas bottles.
2.6 Electrical system
Only allow qualified personnel to work on the electrical system.
Prior to carrying out work on the electrical system, switch off all de-
vices and lights, disconnect the battery and disconnect the vehicle
from the mains.
Only use original fuses with the stipulated values.
Only replace defective fuses when the cause of the defect is known
and has been remedied.
Never bridge or repair fuses.
2.7 Water system
Water left standing in the water tank or in the water pipes becomes
undrinkable after a short period. Therefore, before each use of the ve-
hicle, thoroughly clean the water pipes and the water tank. After each
use of the vehicle completely empty the water tank and the water
pipes.
In the case of lay-ups lasting more than a week disinfect the water
system before using the vehicle (see chapter 11).
 If the vehicle is not used for several days or if it is not heated when there
is a risk of frost, empty the entire water system. Make sure that the 12 V
power supply on the panel is switched off. Otherwise, the water pump
will overheat and may get damaged. Leave the water taps on in central
position. Leave all drain cocks open. Frost damage to appliances, frost
damage to the vehicle and deposits in water-carrying components can
be avoided in this way.

Before the journey
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3
3 Before the journey
Chapter overview
This chapter contains important information which has to be noted before
commencing your journey or carrying out any tasks before the journey.
At the end of the chapter there is a checklist which once again summarises
the most important points.
3.1.1 Initial start-up
 During the initial journey and each time after changing a wheel, re-
tighten the wheel bolts/wheel nuts after 50 km (30 miles). Subsequently
inspect them at regular intervals in order to ensure that they are firmly
seated. See chapter 13 for tightening torque.
The motorhome is supplied with a set of keys, consisting of keys for the
base vehicle and keys for the body.
Always deposit a replacement key outside the vehicle. Make a note of the
key number. Our authorised dealers and workshops can offer assistance in
case of loss.
3.2 Payload
Overloading the vehicle and wrong tyre pressure can cause tyres to
burst. You can lose control of the vehicle (see section 13.6).
The maximum permissible gross weight and the weight including spe-
cial equipment fitted at the factory (actual weight) is shown in the vehi-
cle documents, but not the weight of the loaded vehicle (see sec-
tion 3.2.1). For your own safety, we recommend that you have your
loaded vehicle (with all passengers, luggage and personal objects)
weighed on a public weighbridge before you set out on your journey.
Adapt the speed to the payload. The stopping distance is increased if
the payload is high.
 Do not exceed the maximum permissible gross weight (permissible total
weight) stated in the vehicle documents and the maximum axle loads as
a result of the payload.
 Built-in accessories and special equipment reduce the payload.
On loading, make sure that the payload's centre of gravity is as low as pos-
sible (directly above the floor of the vehicle). Otherwise this may affect the
driving characteristics of the vehicle.
3.2.1 Terms
 Technically speaking, the term "mass" has now replaced the term
"weight". However, "weight" is still the term more frequent in common
use. For better understanding, "mass" is therefore only used in the fol-
lowing sections for fixed formulations.

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The maximum permissible gross weight in a laden condition is the weight
that a vehicle may never exceed.
The maximum permissible gross weight in a laden condition consists of the
actual weight and the payload.
In the vehicle documents, the manufacturer has specified the maximum per-
missible gross weight in a laden condition.
The actual weight consists of the mass in ready-to-drive condition and the
weight of the special equipment fitted at the factory.
The mass in ready-to-drive condition is the weight of the ready-to-drive
standard vehicle (excluding special equipment fitted at the factory).
The mass in ready-to-drive condition is made up as follows:
 Unladen weight (mass of the empty vehicle) with factory-installed stand-
ard equipment (excluding special equipment fitted at the factory)
 Driver's weight
 Basic equipment weight
Unladen weight includes lubricants such as oils and coolants which have
been filled, the on-board tool set, the spare wheel or the tyre repair kit and a
fuel tank which has been filled up to 90 %.
75 kg are calculated for the weight of the driver, regardless of how much the
driver really weighs.
Basic equipment includes all equipment and fluids required for safe and
proper vehicle use. The weight of the basic equipment includes:
 A full fresh water system
 A gas bottle filled up to 90 %
 A full heating system
 The power cables for the 230 V power supply
 A full toilet flushing system
 The installation kit for an auxiliary battery if an auxiliary battery can be
used
The waste water and sewage tanks are empty.
The weight in ready-to-drive condition and the actual weight are shown by
the manufacturer in the vehicle documents.
The payload is made up as follows:
 Conventional load
 Additional equipment
 Personal equipment
 The vehicle's payload can be increased by reducing the actual weight.
To do this, it is allowed for example to empty the fluid containers or to re-
move the gas bottles.
You will find explanations on the individual components of the payload in the
following text.
Maximum permissible
gross weight in a laden
condition
Actual wei
g
ht
Mass in ready-to-drive
condition
Payload

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3
The conventional load is the weight specified by the manufacturer for the
passengers.
Conventional load means: 75 kg are calculated for every seat specified by
the manufacturer, regardless of how much the passengers actually weigh.
The driver's seat is already included as part of the mass in ready-to-drive
condition and must not be calculated as part of the conventional load.
In the vehicle documents, the manufacturer specifies the number of seats.
Additional equipment includes accessories and special equipment. Examp-
les of additional equipment include:
 Caravan coupling
 Roof rail
 Awning
 Bike or motorcycle rack
 Satellite unit
Information about the weights of the various special equipment devices can
be obtained from the manufacturer.
Personal equipment includes all items in the vehicle that are not included in
the conventional load or in the additional equipment. For example, personal
equipment can include the following:
 Foodstuffs
 Crockery
 Clothes
 Bedding
 Toys
 Books
 Toiletries
 Small electrical appliances (e.g. coffee machine)
No matter where kept, personal equipment also includes:
 Animals
 Bikes
 Sports equipment
For the personal equipment, according to the applicable regulations, the
manufacturer must use a minimum weight that is determined according to
the following formula:
Minimum weight M (kg) = 10 x N + 10 x L
N = maximum number of people including the driver, as stated by the manu-
facturer
L = total length of the vehicle in metres
Conventional load
Additional equipment
Personal equipment
Formula
Explanation

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3.2.2 Calculating the payload
The payload calculation at the factory is partly based on all-inclusive
weights. For safety reasons, the maximum permissible gross weight in
a laden condition must not be exceeded.
The maximum permissible gross weight and the weight including spe-
cial equipment fitted at the factory (actual weight) is shown in the vehi-
cle documents, but not the weight of the loaded vehicle (see sec-
tion 3.2.1). For your own safety, we recommend that you have your
loaded vehicle (with all passengers, luggage and personal objects)
weighed on a public weighbridge before you set out on your journey.
The payload (see section 3.2.1) is the difference in weight between
 the maximum permissible gross weight in a laden condition and
 the actual weight.
Mass in kg to be
calculated
Calculation
Example for calculating
the payload
Maximum permissible gross weight ac-
cording to vehicle documents
3300
Actual weight including basic equipment
according to vehicle documents
- 2720
This results in a permissible payload of 580
Conventional load e.g.: 3 persons each
weighing 75 kg
- 225
Additional equipment - 40
For the personal equipment this re-
sults in
= 315
The calculation of the payload from the difference between the maximum
permissible gross weight in laden condition and the actual weight specified
by the manufacturer is however only a theoretical value.
Only if the vehicle is weighed with full tanks (fuel and water), full gas bottles
and complete additional equipment on a public weighbridge, can the actual
payload be determined.
To do this, proceed as follows:
 First only drive the vehicle on to the weighbridge with the front wheels
and have it weighed.
 Then drive the vehicle on to the weighbridge with the back wheels and
have it weighed.
The individual values give the current axle loads. These are important for
the correct loading of the vehicle (see section 3.2.3). The sum of these val-
ues is the current weight of the vehicle.
The actual payload is the difference between the maximum permissible
gross weight in laden condition and the weighed vehicle weight.
This can be used to determine the weight that remains for the personal
equipment:
 Determine the weight of the passengers and subtract it from the value
for the actual payload.
The result is the weight that is permitted for the actual load of the personal
equipment.

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3.2.3 Loading the vehicle correctly
For safety reasons, never exceed the maximum permissible gross
weight in a laden condition.
Distribute the load evenly on the left and right sides of the vehicle.
Distribute the load evenly on both axles. In doing so, observe the axle
loads specified in the vehicle documents. Observe the permissible
load-carrying capacity of the tyres (see chapter 13).
Heavy loads behind the rear axle can reduce the load on the front axle
due to the leverage effect ( ). This applies especially to long rear
extensions, if a motorbike is transported on the rear carrier or if there
is a heavy load in the rear storage space. The release of the front axle
negatively affects the driving quality, especially for front-driven vehi-
cles.
Store all objects in such a way that they cannot slip.
Store heavy objects (awning, tin cans, etc.) close to the axles. Low-ly-
ing storage spaces whose doors do not open in the direction of travel
are particularly suited for storing heavy objects.
Stack light objects (laundry) in the roof storage cabinets.
 Only load the drawers with a maximum of 10 kg.
However, the individual axles may not be overloaded under any circum-
stances. That is why it is important, at which distance to the axles the load is
stored.
To distribute the load correctly, you will need a scale, a tape measure, a cal-
culator and some time.
Two simple formulas are needed to calculate the effect of the weight of the
load on the axles:
A x G : R = weight on the rear axle
Weight on the rear axle – G = weight on the front axle
A = distance between storage space and front axle in cm
G = weight of the load in the storage space in kg
R = wheelbase of the vehicle (distance between axles) in cm
 Measure the external distances horizontally from the centre of the front
wheel to the centre of the storage space or to the centre of the back
wheel.
 Multiply the distance between storage space and front axle (A) with the
weight of the load in the storage space (G) and divide the result by the
wheelbase (R). The result is the weight of the load in the storage space
on the rear axle. Make a note of this weight and of the storage space.
 In a second step, subtract the weight in the storage space (G) from the
weight calculated beforehand. If the result is a positive value (exam-
ple 1), this means that the load on the front axle is reduced by this
value. If the result is a negative value (example 2), this means that the
load on the front axle is increased. Make a note of this value, too.
Formulas
Explanation
Calculatin
g
axle loads:

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 Calculate all storage spaces of the vehicle in the same way.
 In a last step, add all weights calculated for the rear axle to the rear axle
load and add (or subtract) all weights calculated for the front axle to
(from) the front axle load.
How to determine rear axle load and front axle load is described in sec-
tion 3.2.2.
If the calculated value exceeds the permissible axle load, the load must be
distributed in a different way.
If the load on the front axle is too low, the grip of the tyres on the road is re-
duced (traction). This applies in particular to vehicles with front-wheel drive.
In this case, the load must be redistributed, too.
Example 1 Example 2
Example calculation Distance to the front axle A (A1) 450 (cm) (A2) 250 (cm)
Weight in the storage space G x 100 (kg) x 50 (kg)
Wheelbase of the vehicle R ÷ 325 (cm) ÷ 325 (cm)
Load on the rear axle
(add to the axle load)
138.5 (kg) 38.5 (kg)
Weight in the storage space - 100 (kg) - 50 (kg)
Load relief to the front axle
(subtract from the axle load)
38.5 (kg)
Load on the front axle
(add to the axle load)
-11.5 (kg)
3.3 Towing
Care is to be taken when connecting and detaching a trailer. Risk of
accident and injury!
No persons are to be between the towing vehicle and the trailer during
positioning for connecting and detaching.
Observe the permissible nose weight and rear axle load of the mo-
torhome. Refer to the vehicle documents for the rear axle load.
 Trailer with an overrun brake: Do not connect or detach trailer with the
overrun brake on.
 Caravan coupling with detachable ball neck: If the ball neck is mounted
incorrectly, there is the danger of the trailer breaking away. Observe the
instruction manual for the caravan coupling.