MDC Forbes11TB Assembly instructions

Forbes11TB
User Manual and Guide
2020 Model Shown
©Copyright Market Direct Campers & Caravans 2020
Read owner’s manual before using the equipment. Third party component manuals should be read in conjunction
with this manual. Maintenance guidelines must be met or exceeded, failing to meet these guidelines may result in
serious injury or death and property damage. Specification may change without notice.

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Table of Contents
INTRODUCTION ......................................................... 2
Terminology & Abbreviations.................................. 2
Store Locations ........................................................ 3
Contact Details......................................................... 3
ABOUT YOUR HYBRID OFFROAD CARAVAN ......... 4
Specifications........................................................... 4
Bearings and Seals................................................... 5
Hitches..................................................................... 5
Towing with Trucks.................................................. 5
How to Hitch your coupling..................................... 6
Coupling................................................................... 8
Uncoupling............................................................. 10
Setting up your Caravan ............................................ 11
Loading Your Caravan............................................ 11
Setup Video Tutorial.............................................. 11
Choosing a Spot to Set Up ..................................... 12
Levelling Your Caravan .......................................... 12
Site Power............................................................. 12
Electric Awning ...................................................... 12
Kitchen................................................................... 13
Kitchen & Electrical Set Up Tutorial....................... 14
Preparing for Bad Weather.................................... 14
Packing Down Your Caravan.................................. 14
Pack Down Video Tutorial ..................................... 14
Storage & Care .......................................................... 15
Long Term Storage................................................. 15
Interior................................................................... 15
Exterior .................................................................. 15
Batteries................................................................. 15
Care of Paint and Surfaces..................................... 16
Shade and screen care........................................... 16
Securing Your Caravan........................................... 17
Torque Settings.......................................................... 17
Wheel Nuts............................................................ 17
Hitch....................................................................... 17
Trailing Arm Pivot Bolts ......................................... 18
Brakes and Handbrake - Electric............................ 18
Features............................................................. 18
Operation........................................................... 18
Trailer Plug Wiring ................................................. 18
Breakaway Switch.................................................. 19
Hand Brake ............................................................ 20
Adjuster ................................................................. 20
Correct Use of Your Electric Brakes........................21
Important Safety Notice.........................................21
Brake Adjustment...................................................21
Brake Cleaning and Inspection...............................21
Magnets..................................................................22
Shoes and Linings ...................................................22
Corrosion Prevention .............................................22
Wheels and Tyres ......................................................23
Highway..................................................................23
Off Road .................................................................23
Suspension.................................................................23
Shock Absorbers & Bushes.................................23
Jacking Your Caravan..............................................24
Electrical Systems ......................................................25
Chargers & Inverters ..............................................25
Charging from your Vehicle....................................25
Battery Care ...........................................................26
Control Panel..........................................................27
Gas & Water Systems.............................................27
Hot Water System ..............................................27
Water Pumps..........................................................28
Connecting the Gas ................................................28
Protecting from Mould ................................................29
Shade and screen care ..............................................29
Toilet Care and Maintenance .....................................29
Chemicals:..........................................................29
Pre-Trip Checklist .......................................................30
Useful Accessories .....................................................31
Levelling Blocks ......................................................31
Wheel Chocks.........................................................31
Covers.....................................................................31
Stone Protection ....................................................32
Modifications...............................................................32
Trouble Shooting ........................................................33
Electrical.................................................................33
Water......................................................................34
Gas..........................................................................34
Brakes.....................................................................35
Handy Tips .................................................................36
Driving Off Road .....................................................36
Trip Planning ..........................................................37
Warranty Statement ...................................................38
Maintenance ...............................................................39
Maintenance Schedule...........................................40
Supplier Contact Details.............................................47

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INTRODUCTION
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.
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.
Terminology & Abbreviations
Ball Weight: The downward load exerted on the tow point of the vehicle by the trailer
Tare Weight: The total weight of the unoccupied, unladen trailer ready for use with all included fitments from the
supplier. Empty water tanks.
ATM (Aggregate Trailer Mass): The total mass of the laden trailer when carrying the maximum load recommended by
the manufacturer. This includes any mass imposed upon the drawing vehicle when the combination vehicle is resting
on the horizontal supporting plane.
GTM (Gross Trailer Mass): The mass transmitted to the ground by the axle or axles of the trailer when coupled to a
drawing vehicle and carrying its' maximum load approximately uniformly distributed over the load bearing area.
GCM (Gross Combination Mass): This is the total allowable combined mass of tow vehicle and trailer as determined
by the tow vehicle manufacturer
Camber: Camber angle is the measure in degrees of the difference between the wheel’s vertical alignment
perpendicular to the surface. If a wheel is perfectly perpendicular to the surface, its camber would be 0
degrees. Camber is described as negative when the top of the tyre begins to tilt inward towards the chassis rail.
Toe In/out: Negative toe, or toe out, is the front of the wheel pointing away from the centreline of the vehicle.
Positive toe, or toe in, is the front of the wheel pointing towards the centreline of the vehicle. Toe can be measured in
linear units, at the front or rear of the tyre, or as an angular deflection. In the case of MDC products, the “toe in” is
measured in millimetres at the front of the tyre from the chassis rail.

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Store Locations
QUEENSLAND
Brisbane
3/711 Beaudesert Rd
Rocklea QLD 4107
Caboolture
4 Boeing Place
Caboolture QLD 4510
NEW SOUTH WALES
Sydney
178-180 Hume Hwy
Lansvale NSW 2166
Newcastle
Unit 1, 2364 Pacific Hwy
Heatherbrae NSW 2324
VICTORIA
Melbourne
126 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
1246 South Rd
Clovelly Park SA 5042
Contact Details
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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ABOUT YOUR HYBRID OFFROAD CARAVAN
Specifications
CLOSED WITH AC
2450mm H x 5100mm L x 2200mm W
OPEN WITH AC
3040mm H x 5100mm L x 2200mm W
CLOSED NO AC
2350mm H x 5100mm L x 2200mm W
OPEN NO AC
2850mm H x5100mm L x 2200mm W
BALL WEIGHT
110 Kg
TARE
1580 Kg
ATM
3000 Kg
BERTH
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CHASSIS
120 X 50 X 4mm
DRAWBAR
120 X 50 X 4mm
BODY CONSTRUCTION
Aluminium composite panel fully welded frame and chassis
FINISH
GAL chassis +Aluminium composite panel
STONEGUARD
Full aluminium
SUSPENSION
Independent trailing arm suspension with 4 x shock absorbers and coil springs
WHEELS AND TYRES
265/75 R 16Goodride Radial Mud Terrain
COUPLING
Australian Made Cruisemaster D035
BRAKES
12" Electric with Hand brake and Breakaway system
GAS CYCLINDERS
2 x 9 KG cylinder holders
JERRY CANS
2 x 20 litre jerry can holders
KITCHEN CONSTRUCT
Stainless steel slide out with sink and 4 burner stove
APPLIANCE
n/a
AIRCONDITIONER
Dometic Harrier Lite
DIESEL HEATER
n/a
WATER TANK
1 x80 plus 1 x40 fresh water
WATER DELIVERY
13 Volt electric pump
HOT WATER SYSTEM
Truma boiler 14 L gas
TOILET (ENSUIT)
n/a
EXTERNAL (ENSUITE)
external hot and cold side mounted shower tent
AWNING
Electric
BATTERY
2 x 100 Amp 12 V Deep Cycle batteries
AC CHARGER (240 V)
Projecta 35 Amp 7 stage full auto 240-volt charger
BOOST CHARGER
Projecta IDC25, 25 Amp 3 stage
INVERTER
Projecta 1000Watt Modified Sinewave
OUTLETS
Multiple 12 volt and USB
JOCKEYWHEEL
10 " swing up and lockable
STABILISER
4 x heavy duty lockable and adjustable drop-down
LIGHT CONNECTION PLUG
12 pin flat as standard, 7 pin straight and round connection also available
MATTRESS
150mm Inner Spring Queen size
SOUND
HEVXM brand AL-5014BT internal and external speakers
SOLAR
2x 100 Watts

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Bearings and Seals
Bearings are a consumable item should be removed, inspected, and repacked with grease every 5,000km and
replaced every 10,000km as best practice. See maintenance schedule for guidance.
Bearing Number: Inner Bearing 25590 Cone: 25520
Outer Bearing 25590 Cone: 25520
Seal: 55 x 85 x 12
Hitches
Towing with Trucks
If you intend to tow your caravan with a truck or heavy commercial vehicle you should fit a hitch system to minimise
the lash effect of the commercial suspension and distance from the rear axle to the tow point. Truck suspension can
be harsh, particularly in off road conditions. The long distance between the axle centre and the point of attachment can
be quite long further exacerbating the effect putting stress on components.
Using a shock absorbing hitch will reduce the effect considerably.

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How to Hitch your coupling
Here is a short guide on how to safely use your coupling to couple and uncouple the
trailer from the towing vehicle.
Make sure the handbrake is applied prior to coupling and uncoupling.

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Make sure the dust cap is securely connected to the bump cover. This is done by locating the rear lip on the
dust cap onto the groove of the bump cover and then pushing it in a downward motion until the dust cover is
secure (there should be a slight click when it has been assembled correctly) Test if the dust cover is connected
to the bump cover by applying a slight upward force to the dust cover, it shouldn’t separate.
This procedure should be applied if you are uncoupling or coupling up.

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Coupling
STEP 1
Push down the button (1) and push the locking mechanism back (2). When the locking mechanism (2) is all
the way back, release the button (1) locking the plate in place
STEP 2
Offer up the tow pin to the coupling making sure the tow pin cover is removed and there is no visible debris on
it. Locking plate should be in unlocked position as shown. Lower the coupling onto the tow pin.

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STEP 3
Make sure the tow pin is seated inside the universal and the tow pin top is sticking out of the locking
mechanism (see below). Press the button (1) to release the locking mechanism there will be an audible
locking noise at which point the mechanism will return to the initial position as shown in step 1. Verify the pin is
correctly through the mechanism and assemble the cap. If the cap will not fit check the locking mechanism is
in the correct locked orientation.
Detail view of pin through locking mechanism.

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Uncoupling
STEP 1
Push down the button 1 and push the locking mechanism back 2. When the locking mechanism is all the way
back release the button while holding the mechanism to ensure it does not spring back to the locked position.
STEP 2
Lift the coupling up off the tow pin.

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Setting up your Caravan
Loading 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 optimum ball
weight on a caravan is between 9 and 11% of the total caravan weight.
•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.
The diagram below illustrates best placements of items based on weight.
Setup Video Tutorial
Scan the code or go to https://youtu.be/GEFgnvbih4Y

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Choosing a Spot to Set Up
When choosing a spot to set up your caravan, start with a flat area with no overhanging trees. Birds and bats
occupying trees can defecate leaving droppings on your caravan that can damage paint and leaves and sap can also
stain the coating. Ensure you are not camping in an area prone to flooding or with bad drainage in the event of rain.
Even the slightest hollow in the ground can put you in a mini lake. In hot weather if possible, set your caravan up so
the sun’s arc goes from front to back or back to front with the annex/awning in the general direction the sun is arcing
across. Doing this will keep the bulk of the caravan in shade and the inside cooler as it will be shaded by the awning.
Levelling Your Caravan
The stabiliser legs on your caravan are not designed for supporting the full weight of the trailer, they are there to
stabilise it once it is level. Using your stabilisers as a lifting mechanism will void your warranty as will extending them
with a “rattle gun” or “impact wrench”. Levelling front to back can be done by raising and lowering the jockey wheel
prior to adjusting the stabiliser legs. Getting the trailer level from left to right should be done with drive on stepped
ramps as illustrated below. Once levelled the legs can be lowered to keep the trailer stable. On soft ground you may
want to use timber sole boards under the stabiliser feet.
Site Power
The Projecta charger in your caravan is connected via the 15A exterior socket. To
use site power, you will require a 15A power lead connected to a 15A outlet (figure
1). In the event a 15A outlet is unavailable you will need a conversion box that will
step up from 10A to 15A with a safety switch. Never leave power leads coiled
when in use, lay the lead out back and forward in a manner that won’t be a trip
hazard or risk damage to the lead.
Electric Awning
When extending the awning always support to front as it extends. Do not allow the awning to carry the full extended
weight as this may damage the hinges. Support the end manually by hand or by using the extendable legs. When
used as an awning only with no annex setup, it is only suitable for mild weather conditions and should be packed away
in high winds. During rain one side must be lowered to prevent water pooling which can damage the awning.

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Kitchen
Before sliding out kitchen, raise the pad bolt and turn to lock in the up position (Fig: 2)
Push down blue latch on the slide mechanism and pull kitchen out. (Fig: 2a)
When kitchen is extended fix the support legs into position

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Kitchen & Electrical Set Up Tutorial
Scan the code or go to https://youtu.be/tULp0aN4bgQ
Preparing for Bad Weather
During inclement weather, the following should be done:
•Close all roof vents and hatches to prevent water entering.
•Protect the awning from high winds be retracting or securing with guy ropes and pegs.
•Never allow water to pool on awnings or annex roofs. Always lower one corner so water can freely escape.
•Ensure your caravan is not parked in ground that will become boggy and prevent exiting the camp area
•Close all external doors and hatches to prevent water ingress and wind damage
Packing Down Your Caravan
When packing down your caravan ensure the following:
•All gas and electric appliances are turned off
•Gas is turned off at the gas bottle
•All loose items are secured and unable to move and damage themselves or the caravan
•All cabinet doors are secured and locked along with all drawers closed
•Roof is lowered, and over centre latches are locked with safety pin engaged
•Site power lead is removed and stowed
•Doorstep is raised and secured
•All roof hatches lowered and secure
•All windows closed and locked
•Main door is closed and locked
•All dust covers in place and secure
Pack Down Video Tutorial
Scan the code or go to https://youtu.be/LZNdwnqYOvU

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Storage & Care
Long Term Storage
To maximise the life of your caravan you should consider additional protection from the elements. UV light and
moisture can have an adverse effect on materials when left unprotected outside. This section outlines some of the
things you can do as an owner to protect your investment.
Interior
Moisture in the smallest amounts can cause mould. High humidity and cooling temperatures can create condensation,
additionally condensation can form under mattresses due to temperature differences between warm bodies on top and
the bed base being cold from outside temperatures. As a precaution you can do the following:
•Check under mattress for moisture before packing up. If moisture is found allow to thoroughly dry before
closing your camper.
•Store 1 or 2 moisture absorbing packs/dehumidifier packs in the caravan to draw away any residual water
vapour.
•If packing up with damp or humid conditions, open and dry out the caravan at the first opportunity when
returning home. Dry all canvas thoroughly and follow point 2.
Exterior
Ensure all seals on the caravan have proper compression at 30-50%, are free of dirt and have nothing protruding past
the seals. UV light and the elements can over time cause seals and fittings to perish and become brittle. The use of a
camper cover or tarpaulin will extend the life of components and keep your investment looking better for longer.
Batteries
When storing your caravan, ensure all power is turned off to ensure batteries aren’t drained. Batteries should be
maintenance charged at least monthly when stored. Allowing batteries to drain below 12.05 volts may permanently
damage them.

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Care of Paint and Surfaces
Paintwork
The paint coatings on your caravan are no different to that of your car in that they need regular care and maintenance.
Washing: Only use mild detergents free of ammonia when washing your caravan. Always check the label to ensure
the washing solution is nonabrasive, contains no ammonia or caustics.
Polishing: New caravans should only be polished with wax-based polishes that are nonabrasive. When removing
scratches from paintwork use a fine finishing compound. Cutting pastes are too abrasive and will expose the base
material.
Protection: Carnauba wax is an excellent protection against oxidisation. The paint on your caravan should be waxed
annually regardless of being kept under cover to protect the surfaces from oxidisation.
Internal Surfaces
Laminates and internal wall surfaces should be cleaned with a damp soft cloth. For stubborn marks use a mild
detergent based cleaner.
**Do not use cleaners that contain ammonia or caustics**
Acrylic Windows
Windows should be cleaned with a clean, soft, nonabrasive cloth to avoid scratches and soapy water.
**Do not use any cleaners that contain ammonia or solvents. **
Mirrors
Do not use solvents or chemicals when cleaning mirrors. Warm water and a soft clean cloth is the best method.
Cleaners and solvents may affect the reflective backing causing what’s known as “creep” where the edges of the
mirror discolour.
Shade and screen care
•Do not close blinds while window is open. Air pressure can dislodge the blind material from its guide damaging
it.
•Always open and close blinds and screens carefully and evenly with two hands ensuring screens and blind
material feeds evenly through the guides.

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Securing Your Caravan
When parked and unhitched you should always use suitable wheel chocks to ensure the trailer can’t move in the event
of a handbrake failure. For security, a wheel clamp or and hitch lock are highly recommended.
Torque Settings
Wheel Nuts
Wheel nuts should be tightened to correct torque using a torque wrench. Never trust a “rattle gun” as these may over
or under tighten. A quality torque wrench will ensure nuts are tightened correctly. It’s important to remember to check
your wheel nuts at 50km, 500km and 1000km and periodically thereafter. The correct torque setting of 125Nm for
12mm studs, 140nm for 14mm studs and alloy wheels and 200nm for 14mm studs with steel rims. Refer to the plate
on your drawbar.
Hitch
The high tensile bolts securing your hitch should be tightened to 76Nm. These should be checked at 5000km intervals
or 2500km in harsh off-road conditions.

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Trailing Arm Pivot Bolts
The pivot bolts are a high tensile steel. The service interval for these bolts is 5000km under normal use and 2500km
for harsh off-road conditions. During travel they should be inspected daily to ensure they have not rotated or become
damaged. Correct torque is 190Nm
Brakes and Handbrake - Electric
Features
Your trailer is fitted with electric brakes that require a brake controller that can be operated from the driver’s seat.
1. Manual adjusted to provide the correct braking capability for varying road, off-road and load conditions.
2. They can be modulated to provide variable braking force, thus easing the brake load on the towing vehicle.
3. There is very little lag time between the moment the tow vehicle’s brakes are actuated and the moment the
trailer brakes are actuated.
4. They can provide some braking independent of the tow vehicle in the event of an emergency.
Operation
When electrical current is fed into the system by the controller, it activates the electromagnets in the brakes. These
electromagnets are energized and are attracted to the rotating surface of the drums which moves the actuating levers
in the direction that the drums are turning thus applying pressure from the brake linings to the drum surface
Trailer Plug Wiring
The following diagrams outline the correct wiring for 7 & 12 pin plugs

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Breakaway Switch
By law, all trailers with an ATM of 2000kg or greater must have a “Breakaway System” to halt the trailer in the event it
becomes detached from the tow vehicle whilst traveling. Your caravan is fitted with this system with the switch
mounted on the drawbar with a steel wire lanyard to connect to your tow vehicle. If the caravan becomes detached,
the lanyard will pull the pin from the breakaway switch and the onboard batteries will activate the brake system. The
lanyard must be attached to a solid part of the vehicle. It is a requirement that power be supplied by the tow vehicle to
the breakaway power source while towing. This is done via the 50amp Anderson Plug on the drawbar. Consult a
qualified auto electrician to ensure this is fitted to your tow vehicle.
In NSW there is an additional requirement that the breakaway power source be monitored from the driver position with
a minimum of a “visual alarm” for low battery voltage. Consult a qualified auto electrician to ensure this is fitted to your
vehicle.
Breakaway Switch Anderson Plug
CAUTION:
DO NOT CONNECT THE BREAKAWAY LANYARD TO THE SAME POINT AS THE SAFETY CHAIN SHACKLES.
DO NOT USE THE BREAKAWAY AS AN ALTERNATIVE TO THE HANDBRAKE AND DO NOT REMOVE THE PIN
AS AN ALTERNATIVE SECURITY MEASURE. REMOVING THE PIN WILL RAPIDLY DISCHARGE THE
BATTERIES.