MDC 15yr Anniversary Edition XT12HR User manual

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XT12HR
OFFROAD HYBRID CARAVAN
OWNER’S MANUAL
15yr Anniversary Edition - Version 1
www.marketdirect.com.au
Phone: [phone]
Copyright © Market Direct Group Pty Ltd 2021 All Rights Reserved

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Copyright © Market Direct Group Pty Ltd 2020 All Rights Reserved
All files and information contained in this Owner’s Manual are copyright by Market Direct Group Pty Ltd, and may
not be duplicated, copied, modified, or adapted, in any way without our written permission. Our Owner’s Manual
may contain our service marks or trademarks as well as those of our affiliates or other companies, in the form of
words, graphics, and logos.
Your use of our Owner’s Manual does not constitute any right or license for you to use our service marks or
trademarks, without the prior written permission of Market Direct Group Pty Ltd.
Our Content, as found within our Owner’s Manual, is protected under Australian and foreign copyrights. The
copying, redistribution, use or publication by you of any such Content, is strictly prohibited. Your use of our
Owner’s Manual does not grant you any ownership rights to our Content.
DISCLAIMER: This manual is provided in good faith and MDC Group PTY LTD may amend or update this owner
manual from time to time.
Use of Product
The intent and purpose of this manual is to assist owners in the correct use and operation of the product and
outline the servicing schedule to be followed, ensuring the correct maintenance of the product.
Servicing
Servicing information contained in this owner manual is provided for those who have appropriate technical skills
and relevant to the subject matter the publication deals with in regard to maintenance and repairs. The servicing
content of this manual assumes a satisfactory technical knowledge and mechanical skills and experience. It is not
suitable for people who are not trained or qualified in the subject matter it deals with. If you do not have the
appropriate skills and experience, or if you do not have access to appropriate tools and equipment, you may
injure yourself or others around you and/or you may cause damage to the Caravan or caravan you are working
on, including making it unsafe. Users of this owner manual must:
•READ ALL CONTENT THOROUGHLY.IT IS ESPECIALLY IMPORTANT TO HAVE A GOOD UNDERSTANDING OF ALL THE CONTENTS
SHOWN IN THE INTRODUCTION AND SAFETY SECTIONS OF THIS PUBLICATION.
•USE ONLY THE CORRECT TOOLS AND EQUIPMENT FOR ALL REPAIRS AND SERVICING.
•IF PART REPLACEMENT IS NECESSARY,REPLACE THE PART WITH THE SAME PART NUMBER OR EQUIVALENT PART.DO NOT
REPLACE IT WITH A PART OF INFERIOR QUALITY.
•OBSERVE ALL ‘CAUTIONS’AND ‘NOTICES’TO REDUCE THE RISK OF PERSONAL INJURY DURING SERVICE OR REPAIR,OR
IMPROPER SERVICE OR REPAIR THAT MAY DAMAGE THE CARAVAN/CARAVAN OR RENDER IT UNSAFE.
•UNDERSTAND THAT THE ‘CAUTIONS’AND ‘NOTICES’IN THIS PUBLICATION ARE NOT EXHAUSTIVE BECAUSE IT IS IMPOSSIBLE
TO WARN OF ALL POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT FROM FAILURE TO FOLLOW THE
INSTRUCTIONS IN THIS PUBLICATION.YOU MUST CARRY OUT YOUR OWN RISK ASSESSMENTS AS YOU WORK.
MDC Group PTY LTD does not accept any and all liability which may arise because a user of this publication fails
to follow directions in the publication or safe work methods associated with use and maintenance of the product.
Those without the required skills, knowledge, tools, and experience to work on and maintain this product should
seek the services of a suitably qualified person or business. This publication is based on the latest product
information at the time of release. However, specifications and procedures are subject to change without notice.

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My XT12HR Hybrid Caravan
DISCLAIMER: by receiving this handbook, you confirm there you have read and agree to all
the terms and conditions and understood the use and maintenance care of MDC®
NAME:
ADDRESS 1:
ADDRESS 2:
MODEL:
VIN:
BUILD DATE:
TARE WEIGHT:
ATM:
TYRE SIZE:
DEALER:

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Contents
Introduction ............................................................6
Terminology & Abbreviations.............................6
Specifications..........................................................7
MDC Contact Details ........................................ 8
Safety Information .................................................9
WARNING– ............................................................9
Modifications to The Product ..............................9
Gas Systems ....................................................... 9
Chassis ................................................................ 9
Jacking Your Caravan or Camper..................... 10
Electrical Safety................................................... 11
Vehicle Electrical Requirements ....................... 12
Brake Controller............................................... 12
Correct Vehicle Wiring for MDC Caravans .. 12
Trailer Lights ..................................................... 13
Charging Camper/Caravan While Driving..... 13
Vehicle with or without smart alternator: ..... 13
Trail-Assure Electronic Stability Control System...... 14
Gas & Appliance Safety ................................................ 18
Gas Certification ................................................. 18
General Safety..................................................... 18
Gas Cylinder Safety............................................ 18
Gas Appliance Safety ......................................... 19
Removing the Flue Cover.................................. 19
Isolating Appliances ............................................ 19
Using the Caravan.......................................................... 20
Weights and Payload Capacities ...................... 20
How to Load Your Caravan............................... 20
Ball Weight ....................................................... 21
Effects of Weight Distribution ....................... 21
Tyre Pressures.................................................. 21
Pre-Trip Inspection ............................................. 22
Tyres.................................................................. 22
Wheel Nuts....................................................... 22
Hitch and Chains.............................................. 22
Fire Extinguisher .............................................. 22
Brakes & Breakaway System .......................... 22
Lights................................................................. 22
Setting Up the Caravan...................................... 22
Weather ............................................................ 22
Using Wheel Chocks and Ramps ................... 23
Operating the Jockey Wheel.......................... 23
Stabiliser Legs................................................... 23
Electric Awning ................................................ 24
Kitchen.................................................................. 25
Control Panel ....................................................... 26
Charging the Caravan......................................... 27
Charging from your Vehicle .............................. 27
Battery Care......................................................... 27
Packing Down Your Caravan ............................ 28
Towing The Caravan .......................................... 29
Towing with Trucks ............................................ 29
Connecting the Hitch.......................................30
Uncoupling ........................................................33
Connecting the Breakaway .............................35
Connecting the Safety Chains.........................36
Connecting the Electrics..................................36
Wireless Rearview Camera ............................... 37
Troubleshooting................................................37
Charging the Caravan......................................... 38
Preparing for Bad Weather............................... 38
Packing Down Your Caravan ............................ 38
Storage & Care ............................................................... 39
Security................................................................. 40
Care and Maintenance of the Caravan...................... 41
Protection of Finishes ........................................ 41
Paint ...................................................................41
Acrylic Windows...............................................41
Internal Finishes................................................41
Ensuite Finishes ................................................41
Mirrors ...............................................................41
Galvanised Finishes ..........................................41
High Tensile Bolt and Fittings .........................41
Stainless Steel ...................................................41
Fabrics ...............................................................41
Shade and screen care....................................... 42
Corrosion Protection........................................42
Roof Maintenance .............................................. 42
Sealants..............................................................42
Solar Panels.......................................................42
Caravan Body Maintenance.............................. 42
Locks and Latches ............................................42
Rubber Seals .....................................................42
Sealants..............................................................42
Winegard Sensar III Antenna (optional Extra)43
Protecting from Mould....................................... 45
Protecting Your Investment .............................. 45
Stone Protection...............................................45
Caravan Body Maintenance.............................. 46
Locks and Latches ............................................46
Rubber Seals .....................................................46
Sealants..............................................................46
Mechanical Maintenance................................... 46
Wheels and Tyres.............................................46
Brakes ................................................................46
Bearings and Seals............................................46
Suspension ........................................................46
Torque Settings ................................................... 47
Wheel Nuts .......................................................47
Hitch ..................................................................47
Trailing Arm Pivot Bolts ...................................47
Hand Brake .......................................................... 47
Adjuster Automotive Type ..............................48
Correct Use of Your Electric Brakes................ 49
Important Safety Notice .................................... 49

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Brake Adjustment ............................................... 49
Brake Cleaning and Inspection ......................... 49
Magnets................................................................ 50
Shoes and Linings ............................................... 50
Corrosion Prevention ......................................... 50
Wheels and Tyres .......................................................... 51
Suspension ...................................................................... 51
Shock Absorbers & Bushes ............................... 51
Electrical Systems .......................................................... 52
Charging from your Vehicle .............................. 52
Lithium Battery System...................................... 52
Battery Care......................................................... 53
Lithium (LiFePO4) Battery Reset...................... 53
12 Volt Main Circuit Diagram........................... 54
12 Volt Switch Circuit ........................................ 55
Gas & Water Systems ................................................... 56
Truma Rapid Hot Water System ................................. 56
Operating Instructions..................................... 56
General Safety.................................................. 56
Filling the Truma UltraRapid with Water....... 57
Pressure and Temperature Relief Valve (P&T
safety valve)...................................................... 58
Draining the Water Heater ............................. 58
Switching On Gas Operation.......................... 58
Removing The Cowl Cover ............................. 59
Select Water Heater Mode............................. 59
Switching Off Gas Operation ......................... 59
Red Indicator Lamp “Fault” ............................. 60
Maintenance ........................................................ 60
Decalcification.................................................. 60
Fuses ................................................................. 60
Circuit Breaker ................................................. 60
Water Heater Trouble Shooting....................... 61
Gas Operation .................................................. 61
Water Supply.................................................... 61
Plumbing and Toilet............................................ 62
Truma Hot Water Heater................................ 62
Grey Water Tank ............................................. 62
Fresh Water Tanks .......................................... 62
Toilet Care and Maintenance ......................... 62
Chemicals:......................................................... 62
Water Pumps....................................................... 63
Selecting Fresh Water Tank.............................. 63
Trouble Shooting............................................................ 64
12 Volt Electrical................................................. 64
240 Volt Electrical .............................................. 64
Plumbing.......................................................................... 65
Water Heater Trouble Shooting....................... 65
Gas Operation .................................................. 65
Water Supply.................................................... 65
Water Pump ..................................................... 65
Driving Off Road................................................. 66
Trip Planning ........................................................ 67
Recommended Recovery Products.................. 68
Recovery points................................................68
Hardware...........................................................68
Spare Part Numbers.........................................70
Hub Assembly...................................................71
Trailing Arm Bushes............................................ 72
Warranty Statement...................................................... 73
Travel Record.................................................................. 76
Maintenance ................................................................... 78
Maintenance Schedule & Service Record....... 78
Supplier Contact Details............................................. 100
Video Tutorials ............................................................. 102
New Purchase Handover Video.....................102
Setup Tutorial ....................................................102
Pack Down Tutorial ..........................................102

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Coupling Mass
Reading = Tare Mass
Introduction
WELCOME TO MDC
Off road caravanning is a rewarding way to travel and see our great country. Owning an MDC Caravan
will afford you the opportunity to travel to remote places and stay in comfort. It is the intention of
MDC for you to
HAVE the best possible owner experience and enjoy the great outdoors.
Terminology & Abbreviations
Tare Weight: The total weight of the trailer (load on tyres plus coupling load) with all options and fittings
as supplied by the manufacturer, with empty water tanks, excluding fluids not essential for operation
on public roads, and without luggage or personal effects.
ATM (Aggregate Trailer Mass) Rating: The total permissible mass of the Trailer. This includes the coupling
mass and whatever you add as payload (e.g. water, gas, luggage) up to the specified rating. The ATM Rating
must not be exceeded.
GTM (Gross Trailer Mass) Rating: The total permissible mass that can be supported by the wheels/ tyres of
the Trailer. This includes whatever you add as payload (e.g. water, gas, equipment, and luggage), but does
not include the mass supported by the tow vehicle. The GTM Rating must not be exceeded.
Caravans for illustration purposes only.
Load
Coupling Mass
Reading must not exceed ATM Rating

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Specifications
SIZE (OPENED WITH AC) 5580mm L x 2265mm W x 3000mm H
SIZE (CLOSED WITH AC) 5580mm L x 2265mm W x 3000mm H
SIZE (OPENED W/O AC) -
SIZE (CLOSED W/O AC) -
TOWBALL WEIGHT Approx. 170kg
TARE WEIGHT Approx. 1830kg
ATM 3000kg
BERTH 2
CHASSSIS 120mm x 50mm x 3mm - Q345 Galvanised Steel RHS
DRAWBAR 120mm x 50mm x 4mm - Q345 Galvanised Steel RHS
BODY CONSTRUCTION Combination of welded 75 x 25 RHS and 50 x 25 RHS and 25 x 25 square
aluminium alloy + bonded composite panels
SUSPENSION X-TRACK Independent coil spring suspension with 2x Shock absorbers on
each side
STRUCTURE ALUMINIUM FRAME AND ALUMINIUM COMPOSITE PANEL
FINISH -
WHEELS & TYRES 265/75 R16 Goodride radial mud terrain + spare wheel
STONE GUARD -
COUPLING CRUISEMASTER DO35 3.5TON
BRAKES 4WD 12” electric brakes with handbrake and emergency breakaway unit
inbuilt
GAS CYLINDER HOLDERS 2 x 9kg gas cylinder holders
JERRY CAN HOLDERS 2 x 20L jerry can holders
KITCHEN CONSTRUCTION External – Slide out stainless Steel body with gas hob cooktop & washboard
sink with plumbed hot & cold water supply
FRIDGE SLIDE 840mm L x 530mm W x 445mm H
WATER TANK 2 x 80L freshwater tank
WATER DELIVERY 12V electric pump
HOT WATER SYSTEM Truma UltraRapid Boiler 14L (gas)
INTERNAL ENSUITE Thetford C400 Cassette toilet + hot/cold shower
EXTERNAL ENSUITE Hot/cold external shower includes van side mounted ensuite tent
AWNING 2.8m 12v electric
ANNEX Optional batwing annex available
BATTER 2 x 100amp 12V deep cycle batteries
AC CHARGER (240V) Projecta IC3500 - 12V automatic 35A 7 stage battery charger
DC CHARGER Projecta IDC25 - 9-32V 25A 3 stage + 50A Anderson Plug
INVERTER Projecta IM1000 - 12V 1000w continuous/2000w peak
INTERNAL POWER 1 x 240V double power point, 3 x 12V outlets & 3 x USB outlets
JOCKEY WHEEL 10” swing up and lockable
STABILISER LEGS 4 x heavy duty lockable and adjustable drop down
LIGHT CONNECTION PLUG 12 pin flat as standard
MATTRESS SIZE Custom pillow-top queen size innerspring
FANS Caframo Sirocco II 12/24V wall mounted fan
AIR CONDITIONER Optional reverse cycle (cooling + heating)
SOUND Stereo head unit with internal & external speakers
SOLAR 2 x 150W solar panels
TV HD LED TV with 12V compatibility, USB and full motion TV bracket
TV ANTENNA Optional Winegard Sensar HV
REAR VIEW CAMERA Included
ELECTRONIC STABILITY CONTROL Included

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MDC Contact Details
QUEENSLAND
Brisbane
3/711 Beaudesert Rd
Rocklea QLD 4107
Caboolture
4 Boeing Place
Caboolture QLD 4510
NEW SOUTH WALES
Sydney
1/12 Avalli Rd
Prestons NSW 2170
Newcastle
Unit 1, 2364 Pacific Hwy
Heatherbrae NSW 2324
VICTORIA
Melbourne
3/123 Canterbury Rd
Kilsyth South VIC 3137
Campbellfield
1551 Sydney RD
Campbellfield VIC 3061
WESTERN AUSTRALIA
Welshpool
18 Bellows Rd
Welshpool WA 6107
SOUTH AUSTRALIA
Adelaide
Units 2,3 & 4/32-50 Weaver St
Edwardstown SA 5042
NATIONAL TOLL FREE
WARRANTY HOTLINE
SPARE PARTS
1300 4X4 4X4
1300 494 494
1300 MDC CARE
1300 632 2273
1300 MDC PARTS
1300 632 72787

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Safety Information
WARNING–
Before using this product, you should read this manual, and those manuals supplied by
component manufacturers applicable to this product.
This manual is supplied as a reference to required maintenance of the product. Failure to use
and maintain the product in accordance with what is outlined in this manual may affect your
warranty.
Incorrect and/or insufficient maintenance may cause product failure resulting in property loss, damage or injury
or death. Maintenance intervals are critical for normal use, extreme use may require shorter or additional
maintenance intervals.
Manual content does not imply, express or other any warranty, the owner should read the limited warranty terms
included in this booklet.
MDC does not cover damage due to unauthorised modifications, misuse, abuse, incorrect assembly, improper and
irregular maintenance or accident or collision.
Before using this product, you should be certain your tow vehicle is suitably rated and equipped to tow the
product safely and legally. The trailer and vehicle pairing must we within the safe “Maximum Towing Capacity”,
“Ball Weight Capacity” and “Gross Combination Mass” as stated by the vehicle manufacturer.
This caravan is fitted with electric brakes and a “Breakaway System”. Requirements for breakaway systems can
vary from state to state. It is mandatory to supply a maintenance charge to the breakaway battery source while
driving. You MUST ensure this capability is fitted to your vehicle. The maintenance charge is supplied to the
caravan via the Anderson plug on the drawbar.
WARNING: BALL LOADING (DOWNWARD LOAD ON TOW HITCH) MUST NOT EXCEED 350KG OR THE MAXIMUM
ALLOWABLE LOAD BY THE VEHICLE MANUFACTURER OR TOW BAR RATING, WHICH EVER IS THE LOWEST.
Exceeding these limits may result in an accident causing serious injury or death and/or property damage.
It is important to load your caravan correctly to distribute weight evenly and achieve a suitable ball
weight load andprevent loading in a manner that can cause a Caravan to sway and/or roll excessively left
and right. The industry optimum ball weight on a caravan is between 9 and 11% of the total Caravan
weight. MDC Caravans fit into this category and 10% should be used as the starting point.
Modifications to The Product
Gas Systems
The installed gas system on this product is an approved and certified installation. Any changes,
modifications or adjustment may render the system non-compliant and dangerous. Market Direct Group
Pty Ltd does not condone,recommend, or otherwise consent to any modifications, adjustment, addition
or tampering in any way with the installed gas system on any and all products.
Chassis
All MDC chassis are fully engineered and verified using Finite Element Analysis (FEA) software. This
ensures that the chassis for each model passes the relevant regulations and design rules as originally
provided to the customer. Any modification to the chassis or drawbar whatsoever (no matter how minor)
will inevitably change this – whetherit impacts the towing dynamics, expected loads and stress points,
safety chain attachment points, overall trailer length etc.
Market Direct Group Pty Ltd does not condone, recommend, or otherwise consent to any modifications,
adjustment, addition or tampering in any way with the drawbar, safety chains or safety chain attachment
points.
Market Direct Group Pty Ltd does not condone, recommend, or otherwise consent to any modifications,
adjustment, addition or tampering in any way with the drawbar, safety chains or safety chain attachment points.

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Jacking Your Caravan or Camper
Your trailer is fitted with purpose built jacking points and from January 2021 supplied with a suitable jack. An
appropriately rated bottle jack is an acceptable alternative, however when using the jacking point beneath the
trailing arm ensure the jack is of a retracted height that will fit under the jacking point when the tyre is deflated.
A suitably rated “High Lift” jack may be used on the jacking points on the side of the body behind the wheels
provided it has the correct positive engagement fitting to match the trailer. To ensure safe usage the following
must be followed:
•The jack is to be used on level firm ground wherever possible.
•The wheels of the trailer should be chocked, and no person should remain inside the trailer whilst it is
being jacked.
•No person should place any portion of their body under a trailer that is supported by a jack.
•The trailer should be attached to the towing vehicle whilst being jacked.
•When performing maintenance ensure suitably rated jack stands are used – do not rely on the trailer
being supported by the jack.
Behind the wheels Under the chassis
Under the trailing arm

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Electrical Safety
Warning
Failure To Follow These Instructions May Result In Death Or Serious Injury!
When working with electrical equipment or lithium batteries, have someone nearby in case of an
emergency.
Study and follow all the manufacturer’s specific precautions when using and servicing the battery and
connected appliances.
Wear eye protection and gloves.
Keep unit away from moist or damp areas.
Avoid dropping any metal tool or object on the battery. Doing so could create a spark or short circuit
which goes through the battery or another electrical tool that may create an explosion.
Warning
Shock Hazard! Keep Away From Children
Avoid moisture. Never expose unit to snow, water, etc.
Inverter Unit provides 230 VAC, treat the AC output socket the same as regular wall AC sockets at home.
Read and understand the information in the appliance manuals before operating this equipment
The 240v electrical system in your caravan has been certified by a trade qualified person. Under no circumstances
should an unqualified person interfere with, modify, or repair this system. An RCD safety device is fitted to this
caravan
for your safety.
• Always use a 15amp lead to connect to mains power.
• Do not modify the earth pin to accommodate a lesser lead.
• When connecting to 10amp mains, always use an approved adapter.
• Never coil power leads when in use. Lay the lead out in lengths in a safe manner that prevents
creating a trip hazard.

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Vehicle Electrical Requirements
Brake Controller
All MDC campers and caravans require an electric brake controller to be fitted to the tow vehicle by law. There is
a wide range of controllers available that are suitable.
Correct Vehicle Wiring for MDC Caravans
To comply with national laws on breakaway systems, you must supply a maintenance charge to the
battery/batteries that power the system should it be activated. In all MDC products, the breakaway is powered by
the house batteries in the caravan. For this purpose and Anderson plug connection is fitted to all MDC caravans
on the drawbar. Your vehicle will need to be fitted with a power supply to a 50 amp Anderson plug near the
towbar so the trailer can be connected. The vehicle only needs to supply power while it is running so a voltage
sensitive relay or switching device may be used to protect the start battery when the car engine is stopped.

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Trailer Lights
Plug Type – 12 Pin Flat (Not Negotiable)
Charging Camper/Caravan While Driving
Plug Type – 50 amp Anderson Plug.
Vehicle with or without smart alternator:
The Anderson plug can be connected to the start battery on the vehicle and should include the following to
protect the start battery.
1. 50amp relay to stop power supply when vehicle is not running.
2. 50amp fuse or circuit breaker at the battery
Notes: The Projecta IDC25L DC to DC controller fitted in your MDC trailer is programmed to favour the solar
panel input exclusively until it drops below a threshold voltage input. By providing accessory power to the
number 12 pin, the trigger for the IDC25L will be set off to take power from both the Anderson plug and the
solar panels. It will also trigger the IDC25L to activate the vehicle’s ECU to make the alternator provide power to
fully charge the multiple batteries in your Caravan.

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Trail-Assure Electronic Stability Control System
As an added safety feature, your 15-year anniversary model caravan is fitted with a Trail-Assure BG-5000
electronic stability control system. This is an asymmetric braking system that uses onboard measuring
instruments to determine which wheel brakes to apply, and how often, to increase the stability of your caravan
while driving.
The BG-5000 has been factory fitted precisely with the controller module mounted in the front underneath
section of your caravan so that it can make reliable and precise measurements during a trip. It also features a
factory pre-set algorithm to sense off-road conditions and automatically disables the stability braking to avoid
nuisance brake applications in off-road conditions, minimizing unnecessary brake wear. The system will
automatically re-engage once you are back on the road.

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There is a status light indicator used to determine the functionality and modes of the unit. It is located on the
drawbar for ease of access.
When inactive the system will enter sleep mode to conserve power. To wake the system and check operation,
connect the tow plug to your vehicle and turn on your vehicle.
After a moment, the status light indicator will light up solid green to indicate normal operation.

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The BG-5000 is self-diagnosing and in the unlikely event that you need to troubleshoot your unit, identify this
module, and determine the series of lights displayed. Refer to the below table to identify the status of the unit.
LIGHT
ACTION
CONDITION
CORRECTIVE
ACTION
SOLID GREEN
PULSING
NORMAL OPERATION -NO SYSTEM FAULTS
NO ACTION -SYSTEM OK
GREEN FLASH
2
TIMES PER
SECOND
SWAY CONTROL BRAKING IS ACTIVE NO ACTION -SYSTEM OK
1GREEN FLASH
EVERY 2SECONDS
FIRMWARE CHECKSUM ERROR.KEEP THE TRAILER
SITS STILL FOR A MINIMUM OF 60SECONDS,THEN
DRIVE NORMALLY.
IF THE MODULE DOES NOT RETURN TO NORMAL
SOLID GREEN PULSING LIGHT,HAVE THE UNIT
CHECKED AT A SERVICE CENTRE.
1GREEN FLASH
EVERY 4SECONDS
MODULE RESET TO MFG.DEFAULT VALUES.KEEP
THE TRAILER SITTING STILL FOR A MINIMUM OF 60
SECONDS,THEN DRIVE NORMALLY.
IF THE MODULE DOES NOT RETURN TO NORMAL
SOLID GREEN PULSING LIGHT AFTER 3SYSTEM
RESTARTS,HAVE THE UNIT CHECKED AT A SERVICE
CENTRE.
RED
,
GREEN
,
RED
,
GREEN,
CONTINUING…
SWAY CONTROL AUTOMATICALLY
DISABLED DUE TO ROUGH TERRAIN
THE UNIT WILL RETURN TO NORMAL GREEN LIGHT
WHEN NOT ON ROUGH TERRAIN
NO LIGHT
UNIT IN "SLEEP"MODE
ACTIVATE MANUAL OVERRIDE ON THE BRAKE
CONTROLLER TO "WAKE UP"UNIT
NO POWER AFTER "WAKE UP"FROM
BRAKE CONTROLLER
VERIFY THE UNIT HAS GOOD QUALITY POWER,
GROUND,AND BRAKE CONTROLLER WIRE
CONNECTIONS.CHECK FOR ANY BLOWN FUSES
ON THE TRUCK AND TRAILER.
OVERVOLTAGE -OVER +20 VOLTS
CHECK THAT THE POWER SOURCE IS NOT
EXCEEDING 20 VOLTS –CORRECT VOLTAGE TO
12-15 VOLTS
LOW VOLTAGE -UNDER 3VOLTS
CHECK THAT THE POWER SOURCE IS 12-15
VOLTS.VERIFY GOOD POWER AND GROUND
CONNECTIONS
5RED FLASHES GROUND WIRE INTERMITTENT OR DISCONNECTED CHECK GROUND WIRE CONNECTIONS TO THE
TRAILER BATTERY AND TOW VEHICLE
4RED FLASHES BRAKE SHORT (RIGHT SIDE)
CORRECT THE SHORT ON THE RIGHT-SIDE BRAKE
WIRING
3RED FLASHES BRAKE SHORT (LEFT SIDE)
CORRECT THE SHORT ON THE LEFT SIDE BRAKE
WIRING
2RED FLASHES
SENSOR MALFUNCTION -NO SWAY CONTROL
SERVICE CENTRE REPAIR REQUIRED
1RED FLASH BLUE WIRE SHORT –SYSTEM MALFUNCTION
CORRECT THE BLUE WIRE SHORT,SERVICE CENTRE
REPAIR MAY BE REQUIRED.
FAST RED
FLASHING
LOW VOLTAGE -BETWEEN 3TO 6VOLTS CHECK THE POWER AND GROUND CONNECTIONS
For more information on how the system works, wiring information and support, please refer to the Trail-Assure
BG-5000 user manual provided.

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The control module has been strenuously evaluated against the various amount of integrated and aftermarket
trailer brake controllers in use today. Compatible controllers include but are not limited to:
If for any reason you become aware of a compatibility issue with a particular trailer brake controller, please refer
to the provided manual for contact details.
Disclaimer: Electronic stability control systems are NOT substitutes for safe driving or towing practices. In no
event shall MDC be liable for loss or damage caused by misuse, modifications, or unsafe driving/towing practices.
AFTERMARKET IN-VEHICLE BRAKE CONTROLLERS
REDARC
TEKONSHA
CURT
DRAW-TITE
HAYES
HOPKINS
DIRECLINK
INTEGRATED VEHICLE BRAKE CONTROLLERS
FIAT/CHRYSLER:2014, 2015, 2016, 2017 DODGE RAM
2500
FORD MOTOR COMPANY:2013 F-150
FORD MOTOR COMPANY:2017 F-250
GENERAL MOTORS:2016 CHEVY TAHOE
TOYOTA:2017, 2018 TUNDRA

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Gas & Appliance Safety
Gas Certification
Your Caravan has been supplied gas tested and certified. Any additions or alterations to the gas
system must be performed by an authorized person and will require re-certification and testing.
Also note any alterations may affect your warranty on both the system and appliances.
General Safety
•Your Caravan may have a number of gas safety labels affixed throughout containing important
information. Allinstructions are to be followed and the labels shall not be removed for any reason.
•Make sure to close appliance valves before opening the cylinder valves.
•Where readily accessible, check connections at the appliances, regulator, hoses and cylinders
periodically forleaks with soapy water (or an equivalent) – this should be done every time a cylinder is
changed or at least annually.
CAUTION – the ammonia present in some soaps and detergents can react with brass fittings and
cause such fittingsto crack after a short period of time. Therefore, caution should be exercised
when using soap solutions on brass fittings and all connections should be rinsed thoroughly with
fresh water as soon as possible after the application of the soap solution.
•Never use a match or flame when checking leaks.
•Never use cooking appliances for comfort heating.
•In the event of a fire, immediately close cylinder valve if safe to do so.
•Appliances must not be altered without the authorisation of the manufacturer.
•In the event of an accidental gas leak, close cylinder valve and ventilate the area using a safe method
until the air is clear.
•Flexible hoses are used between the LP Gas Cylinder and regulator as well as between your slide-out
kitchen cooker (if fitted) and the gas bayonet. These flexible hoses are easily accessible and shall be
inspected regularlyby a competent person.
Gas Cylinder Safety
•LP Gas cylinders have a 10-year lifespan between inspection and re-certification. Always use gas
cylinders that
are within their compliance date.
•For drawbar mounted cylinders (if applicable), orient the cylinder relief valves of both cylinders
discharge awayfrom both the trailer and towing vehicle as shown.
•For gas cylinders stored in a dedicated LP Gas Locker ensure the locker is kept closed at all times
unlesschanging or operating the cylinders.
•Close cylinder valves when appliances are not in use or while refueling is in progress.
•Ensure cylinder valves are closed to prevent the unintended release of gas from a cylinder.
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Gas Appliance Safety
•Gas appliances are certified and have a flame safeguard feature to stop gas flow in the event of the
flame goingout. Never interfere with this function or replace appliances with a non-certified type.
•Slide-out kitchens with cookers should only be operated with an annex fully erected. Failing to do so
may affectthe safety and operation of the gas appliance.
•Slide-out kitchens with cookers must only be used with a flexible connecting hose that is
disconnected from thegas bayonet fitting when in its stored position. Under no circumstances
permanently connect this appliance.
•Only approved and suitable gas appliances with flame safeguard systems shall be connected to the
gas bayonet(if fitted).
Removing the Flue Cover
Caution! To use your inbuilt Truma hot water system, the external flue covers must be removed prior to starting
the unit.
First, open the flue dust cover shown.
Remove lockable cover Remove plastic cover Ready for use
Caution
To use your inbuilt Truma hot water system, the external flue
covers must be removed prior to starting the unit.
Ventilation and Flues
•Check all permanent ventilators, flues (if applicable) and vents to ensure they are clear, open and
unrestricted.
•Any supplied or 3rd party vent cover(s) (e.g. low level door vent) should only be used for covering the vents
during storage between use with all LP gas system valves closed. All vents (e.g. low level door vent) shall be
uncovered at all times the Caravan is in use.
Isolating Appliances
Internal gas appliances have an isolation valve fitted in the gas line. During travel these should be turned to the
off position where practical and always turn the valve on the active gas bottle off when towing or refueling.

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Using the Caravan
Weights and Payload Capacities
The information plate attached to the drawbar of your caravan displays the relevant weights and weight
capacities of the van.
How to Load Your Caravan
It is important to load your caravan correctly to distribute weight evenly and achieve a suitable ball weight load
and prevent loading in a manner that can cause a Caravan to sway and/or roll excessively left and right. The
industry optimum ball weight on a caravan is between 9 and 11% of the total Caravan weight. AusRV Caravans fit
into this category and 10% should be used as the starting point.
WARNING: BALL LOADING (DOWNWARD LOAD ON TOW HITCH) MUST NOT EXCEED 350KG OR THE
MAXIMUM ALLOWABLE LOAD BY THE VEHICLE MANUFACTURER OR TOW BAR RATING, WHICH EVER IS
THE LOWEST. Exceeding these limits may result in an accident causing serious injury or death and/or property
damage.
• Always load evenly to both sides of the caravan
• Load heavy weight over or as close to over the axle as possible and as low as possible
• Overhead cupboards should only be used for lightweight items such as clothes, personal items, bedding etc.
• Heavy cooking equipment should be stored in lower cupboards.
• Tinned food, bottled goods for cooking etc should be stored in the pantry cupboard.
• Never load in a manner that causes the ball weight to exceed the limit of the tow vehicle.
• Ensure no items can move during travel. Secure all items to prevent damage to the caravan.
• Consider water tank levels and how they may affect the balance front and back and the percentage of ball
weight.
• Never store heavy items in overhead cupboards.
Load Distribution Guide
The diagram below illustrates best placements of items based on weight.