MDC XT15PT POP TOP Owner's manual

XT15-PT

User Manual and Guide

2019 Onward

©Copyright Market Direct Campers & Caravans 2019

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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1300 4X4 4X4 
Table of Contents 
INTRODUCTION ....................................................... 2 
Terminology & Abbreviations .................................. 2 
Handover Video Tutorial ......................................... 3 
Store Locations ........................................................ 3 
Contact Details......................................................... 3 
ABOUT YOUR HYBRID OFFROAD CARAVAN ......... 4 
Specifications ........................................................... 4 
Bearings and Seals ................................................... 4 
Fridge Fitting Chart .................................................. 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 
Set Up Video Tutorial ............................................. 12 
Setting Up the Caravan ...................................... 12 
Setting up kitchen & Electrical ........................... 12 
Setting Up External Shower Tent ....................... 12 
Choosing a Spot to Set Up ..................................... 13 
Levelling Your Caravan .......................................... 13 
Site Power .............................................................. 13 
Electric Awning ...................................................... 14 
Leg Rests ................................................................ 14 
Kitchen ................................................................... 15 
Preparing for Bad Weather .................................... 15 
Packing Down Your Caravan .................................. 16 
Pack Down Video Tutorial ..................................... 16 
Storage & Care .......................................................... 16 
Long Term Storage ................................................. 16 
Interior ................................................................... 16 
Exterior .................................................................. 17 
Batteries................................................................. 17 
Care of Paint and Surfaces ..................................... 17 
Shade and screen care ........................................... 17 
Torque Settings ...................................................... 18 
Wheel Nuts ........................................................ 18 
Hitch ................................................................... 18 
Trailing Arm Pivot Bolts ..................................... 18 
Brakes and Handbrake ........................................... 19 
Features ............................................................. 19 
Operation ........................................................... 19 
Trailer Plug Wiring ............................................. 19 
Breakaway Switch .............................................. 19 
Hand Brake ........................................................ 20 
Adjuster ............................................................. 21 
Correct Use of Your Electric Brakes .................... 22 
Important Safety Notice ..................................... 22 
Brake Adjustment ............................................... 22 
Brake Cleaning and Inspection ........................... 22 
Magnets .............................................................. 23 
Shoes and Linings ............................................... 23 
Corrosion Prevention ............................................. 23 
Wheels and Tyres ...................................................... 24 
Highway .............................................................. 24 
Off Road ............................................................. 24 
Suspension ................................................................. 24 
Shock Absorbers & Bushes ..................................... 24 
Jacking Your Caravan .......................................... 25 
Electrical Systems ...................................................... 25 
Chargers & Inverters .............................................. 25 
Charging from your Vehicle .................................... 25 
Battery Care ........................................................... 26 
12 Volt Wiring Diagram .......................................... 27 
Control Panel .......................................................... 29 
Mains Power........................................................... 29 
RCD Safety Switch .................................................. 30 
Gas & Water Systems ................................................ 30 
Hot Water System .................................................. 30 
Water Pumps .......................................................... 31 
Connecting the Gas ................................................ 31 
Protecting from Mould ................................................ 32 
Shade and screen care .............................................. 32 
Toilet Care and Maintenance ..................................... 33 
Chemicals: .......................................................... 33 
Pre-Trip Checklist ....................................................... 34 
Useful Accessories ..................................................... 34 
Levelling Blocks ...................................................... 34 
Wheel Chocks ......................................................... 35 
Covers ..................................................................... 35 
Stone Protection .................................................... 35 
Modifications ............................................................... 36 
Trouble Shooting ........................................................ 37 
Electrical ................................................................. 37 
Water...................................................................... 38 
Gas .......................................................................... 38 
Brakes ..................................................................... 39 
Handy Tips ................................................................. 40 
Driving Off Road ..................................................... 40 
Trip Planning .......................................................... 41 
Warranty Statement ................................................... 42 
Maintenance ............................................................... 43 
Maintenance Schedule ........................................... 45 
Supplier Contact Details ............................................. 52 
 

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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.

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 and

prevent loading in a manner that can cause a camper to sway and/or roll excessively left and right. The optimum ball

weight on a caravan is between 9 and 11% of the total camper weight.

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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Handover Video Tutorial

Scan the code or go to https://youtu.be/eb5ikok5NiQ

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

SIZE (CLOSED WITH AC)

2350mmW x 6600mmL x 2650mmH

SIZE (OPENED WITH AC)

4250mmW x 6600mmL x 3050mmH

STYLE

15’ offroad caravan

TOWBALL WEIGHT

200kg

TARE WEIGHT

Approx. 2280kg

ATM

3000kg

BERTH

2

CHASSIS

150mm x 50mm x 3mm

DRAWBAR

150mm x 50mm x 4mm

BODY CONSTRUCTION

Aluminium composite panel fully welded frame +

chassis

STONE GUARD

Included with stone tamer mudflaps

SUSPENSION

Independent trailing arm with 4x shock absorbers and coil springs

WHEELS & TYRES

265/75 R16 Goodride radial mud terrain

COUPLING

DO35 offroad coupling 3500kg

BRAKES

4WD 12” electric with hand brake & brake away system

GAS CYLINDERS

2 x 9kg gas cylinder holders

JERRY CAN HOLDER

2 x 20L jerry can holders

KITCHEN CONSTRUCT

External 304 grade stainless steel

AIR CONDITIONER

Dometic FJ2200 air conditioner

WATER TANK

2 x 80L fresh water & 80L grey water

WATER DELIVERY

12V electric pump

TOILET (ENSUITE)

Thetford toilet

SHOWER (ENSUITE)

Hot/cold external includes van side mounted shower tent

AWNING

Electric

BATTERY

2 x 100amp 12V deep cycle batteries

INVERTER

Projecta 12v 1000w modified Sine inverter

OUTLETS

5 x 12V, 6 x USB, 4 x double 240V socket

JOCKEY WHEEL

10” swing up and lockable

STABILISER LEGS

4 x heavy duty lockable and adjustable drop down

LIGHT CONNECTION PLUG

12pin flat as standard. 7 pin round or 7 pin flat connection available (NSW by law must have a 12-

pin flat installed)

MATTRESS

200mm custom Queen innerspring

SOUND

Kenwood head unit with internal & external speakers

SOLAR

2 X 150W solar included

DIESEL HEATER

Included

*All weights do not include gas bottles, jerry cans, annex walls & roof

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

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Fridge Fitting Chart

Engel

Evakool

Bushman

Ironman

LARB

MT35FP

ED65

35L

30L

35

Glacier G61

40L

35L

RF40

RF47

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.

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.

The diagram below illustrates best placements of items based on weight.

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Set Up Video Tutorial

Setting Up the Caravan

Scan the code or go to https://youtu.be/aRRAjbJ5AxU

Setting up kitchen & Electrical

Scan the code or go to https://youtu.be/S4tX7aWiOp0

Setting Up External Shower Tent

Scan the code or go to https://youtu.be/HJiCZqr9R5M

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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. 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.

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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.

During rain, the awning should be lowered on one side as illustrated below.

Leg Rests

The extensions to the lounge area seating are NOT SEATS they are leg rests. Do not under any circumstances use

for seating.

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Kitchen

To extend the kitchen from the caravan, press down the blue slide tabs and pull kitchen out. The kitchen will lock into

place when extended. To put kitchen away, again press down the blue tabs and push back into place.

To connect the water and gas, plug the hoses and gas bayonet as per the diagram below.

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 by retracting or securing with guy ropes and pegs.

• 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

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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/QO9pFn5awLk

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.

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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

caravan cover 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.

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 with 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.

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

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Brakes and Handbrake

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 pin plug

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. In the event that 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 mandatory 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

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MDC XT15PT POP TOP Owner's manual

MDC XT15PT POP TOP Owner's manual

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