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Cartoni Malibu 6 Series 2014 Manual

Box-type van
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Foreword
Congratulations on your new Malibu box-type van!
We congratulate you to your Malibu box-type van and thank you that
you made your decision for a quality box-type van from Malibu....
Taking a short trip or long trip, driving on poor or good roads, going to the
seaside, the mountains or simply in the countryside: as a rolling home,
your vehicle makes sure that you always feel at home when on the go
and that you enjoy your holiday.
We have carefully prepared this instruction manual for you so that
you can use and enjoy the advantages of your Malibu box-type van. It
provides you with a broad range of information and tips. The care and
thus, the value retention of your Malibu box-type van is also considered.
Please ensure that the operating instructions are used properly. You will
also be provided with separate documents for the devices installed as
well as the basic vehicle of your vehicle.
Please also refer to your trusted authorised Malibu authorised work-
shop for maintenance work or whenever you need help. They know
your vehicle better than anyone and will always endeavour to fulfil your
requests quickly and reliably.
And now we wish you great enjoyment, the best relaxation and always
a good and safe trip with your vehicle.
Your Malibu team
Malibu GmbH & Co. KG
Carthago Ring 1
D-88326 Aulendorf
Telephone: +  4 9 (0) 75 25 / 92 00  -   0
Fax: +  4 9 (0) 75 25 / 92 00  -   3 0 03
E-mail: info@malibu-carthago.com
Internet: www.malibu-carthago.com
Emergency hotline: +  4 9 (0) 75 25 / 92 00  -   3 3 33
110-0001-04EN

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Summary of Contents for Cartoni Malibu 6 Series 2014

  • Page 1 Foreword Congratulations on your new Malibu box-type van! We congratulate you to your Malibu box-type van and thank you that you made your decision for a quality box-type van from Malibu.… Taking a short trip or long trip, driving on poor or good roads, going to the seaside, the mountains or simply in the countryside: as a rolling home, your vehicle makes sure that you always feel at home when on the go and that you enjoy your holiday.
  • Page 2 Foreword 110-0001-04EN...
  • Page 3 Delivery protocol Delivery protocol, Malibu box-type van Delivery to end customer Vehicle data Model: Customer: Chassis number: Registration date: Odometer reading: Number plate: The delivery protocol must be discussed and completed together with the customer at the same time as the vehicle is handed over. Do not remove the original from the service record.
  • Page 4 Delivery protocol Delivery protocol, Malibu box-type van Delivery to end customer 2. Document check list / interior / accessories and devices Position Check list Activity: Vehicle documents for box-type van handed over to customer Instruction manual for cabin and devices handed over to customer Two sets of keys for the main cabin &...
  • Page 5 Delivery protocol Delivery protocol, Malibu box-type van Delivery to end customer Please add a short description of any complaints under description at the bottom of the page and repair according to factory instructions. The box-type van is in working order with the exception of the complaints recorded. Date / stamp / trading partner signature Date / customer signature Description...
  • Page 6 Delivery protocol 110-0001-04EN...
  • Page 7 Guarantee certificate Guarantee certificate Do not remove the original from the service record Customer address for first-time owners Surname, Name Street / no. Post code, Town: Country Tel. no. E-mail Vehicle data Model Chassis number Registration date Dealer information Dealer's name Delivery date The trading partner must send a copy to ga.kundendienst@carthago.com on the day of the handover if there has been a change of ownership.
  • Page 8 Guarantee certificate Registered owner / subsequent owner Vehicle data Chassis number Registration date First owner Please enter the name of the first registered owner when handing over: Name First name Postcode Town Street Telephone E-mail Odometer reading at Registered keeper Date of handover handover from/until...
  • Page 9 Overview Overview Malibu 540 10800113 Heater & drain valve Gas shut-off valve, heater Residual-currency circuit-breaker 230 V external socket Cassette toilet door; 2 A fuse for the toilet Living area battery EBL electric block & fuses; Main fuse 50 A Fiat starter battery &...
  • Page 10 Overview Overview Malibu 6xx 10800112 Heater & drain valve Gas shut-off valve, heater Residual-currency circuit-breaker 230 V external socket Cassette toilet door; 2 A fuse for the toilet Living area battery EBL electric block & fuses; Main fuse 50 A Fiat starter battery &...

  • Page 11: Table Of Contents

    Table of contents Table of contents Information on documentation ................1 Before putting into operation ................1 Malibu documents ....................1 Additional documents ..................1 General .......................2 Warranty, guarantee and customer services ............3 Environmental notes ...................4 Safety guidelines ....................5 Legend ........................5 General safety guidelines ..................6 Fire protection .....................6 Traffic safety ......................7 Trailer operation ....................8...
  • Page 12 Table of contents Worktop extension ....................51 6.10 Hatches and door locks ..................51 6.11 Step, relocating ....................53 Electrical system .....................55 General ......................55 230 V on-board electrical system ..............56 12 V on-board electrical system ................58 Charging the living area battery and starter battery ..........60 Control Panel ....................62 Electronic block ....................64 Fuses ........................64...
  • Page 13 Table of contents Wheels and tyres ................... 111 13.1 General ......................111 13.2 Tyre inflation pressure ..................112 13.3 Tyre inflation pressure table ................113 Malfunctions ....................115 14.1 Brake system ....................115 14.2 Electrical system ..................... 116 14.3 Gas system ..................... 117 14.4 Cooking area ....................
  • Page 14 Table of contents 110-0001-04EN...

  • Page 15: Information On Documentation

    Information on documentation Chapter Overview This chapter contains important information and instructions for using your Malibu box-type van. The information affects, in detail: • putting into operation • vehicle-specific documents for the Malibu • general notes • Warranty, guarantee and customer services •...

  • Page 16: General

    Information on documentation Our Malibu box-type vans are exposed to continuous development. Please understand that changes in form, equipment and technology are reserved. For this purpose, Malibu GmbH & Co. KG is not liable for contents derived from this user manual. A description is made for the equipment know and introduced at the time of printing.

  • Page 17: Warranty, Guarantee And Customer Services

    Information on documentation Warranty, guarantee and customer services → If the instructions listed in this instruction manual are disregarded and damage occurs to the Malibu box-type van, all claims for guarantee and warranty are rendered invalid. Warranty and / or guarantee processing is carried out according to the direc- tive 1999/44/EC concerning consumer goods, and the conditions usual for the country.

  • Page 18: Environmental Notes

    Information on documentation Environmental notes → The following basically applies: all types of waste-water and domestic waste must not be disposed of in road drains or in open nature. → The waste-water tank and the toilet cassette must only be emptied at dis- posal stations on camping places or at disposal possibilities especially identified for this purpose.

  • Page 19: Safety Guidelines

    Safety guidelines Chapter Overview In this chapter, you will find important instructions on safety. The safety in- structions serve to protect persons and property. The information affects, in detail: • The legend • the general conduct when dealing with the Malibu box-type van •...

  • Page 20: General Safety Guidelines

    Safety guidelines General safety guidelines → Ensure for sufficient ventilation. Never cover or block the forced ventilation installed (roof hood with forced ventilation or mushroom shaped ventilator), e.g., with a winter mat. Keep snow and leaves away from forced ventilation systems.

  • Page 21: Traffic Safety

    Safety guidelines 2.3.2 Fire fighting → Always keep a dry powder fire extinguisher (at least 1 kg) in the Malibu box-type van: it must be approved, checked and accessible ready for use. → The fire extinguisher must be inspected by certified specialist personnel at regular intervals.

  • Page 22: Trailer Operation

    Safety guidelines 2.4.2 Safety instructions, child seats Risk of injury with resulting in death! If a baby carrier is placed on the passenger seat facing away from the direc- tion of travel with the airbag active, the child may suffer fatal injuries regard- less of the severity of the impact.
  • Page 23 Safety guidelines → Before putting a fire point into operation (gas cooker), open a roof hood. → Do not use the gas cooker for heating purposes. → The exhaust gas pipe must be connected tight and fixed to the heater and chimney.

  • Page 24: Electrical System

    Safety guidelines Electrical system → Have work on the electrical system only carried out by specialist personnel. → Before having work carried out on the electrical system, switch off all de- vices and lights, disconnect the battery and isolate the 230 V power supply from the mains.

  • Page 25: Before Starting To Travel

    Before starting to travel Chapter Overview In this chapter, you will find out important information as to what you have to observe before starting to drive, and which activities you have to carry out be- fore driving. The information affects, in detail: •...

  • Page 26: Approval Documents

    Before starting to travel Approval documents Your Malibu box-type van is a vehicle that is subject to registration. In order to register the vehicle in Germany, you need the following docu- ments: • personal ID card / passport • certificate of registration part II •...
  • Page 27 Before starting to travel 3.3.1 Calculating the payload → The technically permissible total mass in the loaded state of this Malibu box-type van must never be exceeded under any circumstances. The payload is the weight difference between: • the technically permissible total mass when in a loaded state •...
  • Page 28 Before starting to travel The basic equipment comprises all equipment objects and fluids that are nec- essary for the safe and correct use of the vehicles. These include: • the filled aluminium gas bottle • a filled toilet flushing system •...
  • Page 29 Before starting to travel Personal equipment The personal equipment includes all objects carried along in the Malibu box- type van, that are not included in the list above. These are, for example: • Provisions • Bed clothes • Crockery • Electronic block •...
  • Page 30 Before starting to travel 3.3.2 Loading the Malibu box-type van correctly → Distribute the payload equally on the left and right side of the vehicle. → Distribute the payload equally on both axles in accordance with the axle loads specified in the vehicle documents. Also observe the permissible load-bearing capacity of the tyres.
  • Page 31 Before starting to travel Example calculation Distance to the front axle 452 (cm) Weight in the rear storage compartment x 100 (kg) Wheelbase of the vehicle ÷ 325 (cm) Load on the rear axle 139 (kg) Weight in the rear storage compartment - 100 (kg) Relief on the front axle 39 (kg)

  • Page 32: Electrically Operated Entrance Step

    Before starting to travel Electrically operated entrance step → Before driving off each time and after short breaks, make sure that the entrance step has been fully retracted. → Do not stand in the immediate movement area of the entrance step when it is being extracted or retracted.

  • Page 33: Windows/Roof Hoods/Hatches/Doors

    Before starting to travel Windows/roof hoods/hatches/doors → Before starting to travel, close and secure all windows, roof hoods, hatch- es and doors in all cases. → Hinged windows must not be open when driving. → The respective operating instructions must be observed. →...

  • Page 34: Traffic Safety

    Before starting to travel Traffic safety Go through the check list before driving. Tests Checked Check the inflation pressure and tyre condition A tyre with inflation pressure that is too low may lead to the vehicle tyre bursting with fully loaded Malibu box-type van. You may loose control of the vehicle.

  • Page 35: While Driving

    While driving Chapter Overview In this chapter, you will find information on driving your Malibu box-type van. The information affects, in detail: • the brakes • the seat belts • the seats • the seating arrangement • the child seats •...

  • Page 36: Brakes

    While driving Brakes → Have defects on the brake system repaired by an authorised specialist workshop immediately. When starting your journey each time, carry out a brake test: • do the brakes work? • do the brakes react equally? • does the Malibu box-type van remain in the lane when braking? Seat belts The living area of the Malibu box-type van is equipped with automatic three- point seat belts.
  • Page 37 While driving Wearing your seat belt correctly for pregnant persons Risk of injury! If the seat belt is guided over the persons stomach during a pregnancy, this can lead to injury to the mother and unborn child in event of an emergency braking action or collision.

  • Page 38: Seats

    While driving Seats 4.4.1 Driver’s seat and passenger seat → Turn all swivel seats in the direction of travel and lock in place. These must remain locked when driving, turning them is forbidden. Adjusting the seat Seat longitudinal adjustment Armrest adjustment Backrest adjustment Swivelling the seat Height adjustment, front...
  • Page 39 While driving 4.4.2 Rear single seats Depending on the vehicle, two single seats (special equipment) are installed instead of the seat bench. Backrest adjustment Lateral seat adjustment (only with outer seat) Seat longitudinal adjustment 10800247 Fig. 5 Adjustment of individual seats Backrest adjustment 1.

  • Page 40: Seating Arrangement

    While driving Seating arrangement → When travelling, persons must only remain on the prescribed seats. The permissible number of seats can be obtained in the vehicle documents (figure 12). → It is compulsory to wear a seat belt on all seats that have a seat belt. →...

  • Page 41: Child Seats

    While driving Child seats Risk of injury with resulting in death! If a baby carrier is placed on the passenger seat facing away from the direc- tion of travel with active airbags, the child may suffer fatal injuries regardless of the severity of the impact. →...

  • Page 42: Isofix Child Seat

    While driving ISOFIX child seat Damage to the child seat! If a child seat with the Top Tether system is fitted or removed, the seat may be damaged. → When fitting or removing the child seat with the Top Tether system, observe the instructions of the child seat manufacturer! →...

  • Page 43: Folding Blinds

    While driving 4.7.1 Fastening the child seat → Before travelling, check that the the fastenings are connected correctly to the ISOFIX holders. Top Tether fixing strap Child seat holding strap Strap bracket Child seat holding bracket Belt fastening holding bracket 10800107 Fig.
  • Page 44 While driving 110-0001-04EN...

  • Page 45: Positioning The Malibu Box-Type Van

    Positioning the Malibu box-type van Chapter Overview In this chapter, you will find information on positioning your Malibu box-type van. The information affects, in detail: • the hand brake • the entrance step • the 230 V connection Positioning the Malibu box-type van →...
  • Page 46 Positioning the Malibu box-type van 110-0001-04EN...

  • Page 47: Living

    Living Chapter Overview In this chapter, you will find information on living in your Malibu box-type van. The information affects, in detail: • the ventilation of the Malibu box-type van • opening and closing the windows • opening and closing the roof hood •...

  • Page 48: Window

    Living Window → The windows are equipped with roller blinds and insect protection blinds. Roller blinds and insect protection blinds return automatically to their initial position using spring force when releasing the locking mechanism. In order not to damage the pulling mechanism, hold the roller blind or insect pro- tection blind tight and slowly guide them back to the initial position.
  • Page 49 Living 6.2.1 Hinged window → When opening the hinged window, take care that no warping takes place. Open and close the hinged window equally. → During each operation, press the lock lever of the locking knob (see Fig. 10, Pos. 2). →...
  • Page 50 Living Fig. 11 Roller blind and insect protection blind Closing the roller blind: • Pull the roller blind from the top to the bottom on the handle (Fig. 11, Pos. 2). It can be opened to any position in-between. Opening the roller blind: •...

  • Page 51: Roof Hoods

    Living Roof hoods Depending on the model, roof hoods are installed in the Malibu box-type van with or without forced ventilation. Roof hoods without sealing rubber are the prescribed forced ventilation. → The ventilation openings of the forced ventilation must always stay open. Never cover the forced ventilation installed (roof hood with forced ventila- tion), e.g., with a winter mat.
  • Page 52 Living 6.3.1 Mini Heki → Check the locking mechanism of the roof hood before travelling. The roof hood can be pushed up on one side. In doing so, three tilt angles are possible. Fig. 12 Mini-Heki Opening the roof hood: 1.
  • Page 53 Living 6.3.2 Lift-tilt roof with hand crank Damage caused by incorrect handling! → Before starting to drive, close the lift-tilt roof and rollers. → When travelling, close the insect protection blind in order to avoid noises fro the roller guide rods. →...
  • Page 54 Living 6.3.3 Opening / closing the roller blind and insect protection blind The roof hoods are equipped with a roller blind and insect protection blind. The roller blind is located in the right roller box, the insect protection blind in the left roller box.

  • Page 55: Exterior Hatches

    Living Exterior hatches Risk of damage → The hatch may swivel open when travelling. • Before commencing your journey, close all exterior hatches and lock all → Only open one hatch at a time. • Depending on the vehicle type, not all hatches and doors can be opened at the same time.

  • Page 56: Table

    Living Table 6.5.1 Pulling out and folding the table The table has a plate that can be pulled out. Fig. 16 Table lever Fig. 17 Extendible table top Pulling out the table top: 1. Pull lever (Fig. 16, Pos. 1) downwards. 2.
  • Page 57 Living 2. Remove the bottom leg part (Fig. 18, Pos. 2). 3. Hold the table plate (Fig. 18, Pos. 1) with both hands, and remove from the hanging rail (Fig. 18, Pos. 3).. Caution: The table plate (Fig. 18, Pos. 1) is only hung on and may fall down if lifted too high.
  • Page 58 Living 6.5.4 Converting the table to a sleeping berth 10800004 Fig. 20 Vehicle seat position Converting the table: 1. Turn the left driver cabin seat (Fig. 20, Pos. 1) by 180° to the living area. 2. Turn the right driver cabin seat (Fig. 20, Pos. 2) by 90° to the living area. 3.
  • Page 59 Living 10800012 Fig. 21 Converting the seat padding Seat padding arrangement: 1. Remove the seat padding (Fig. 21, Pos 3) and replace by the lager addi- tional padding (Fig. 21, Pos 1). 2. Insert the seat padding (Fig. 21, Pos 3) in front of the additional padding (Fig.

  • Page 60: Beds

    Living Beds 6.6.1 Converting to transport position Risk of accident! → Ensure for suitable transport securing equipment. Objects must be secured for transporting. Fig. 22 Rear bed, initial situation Fig. 23 Transport position Opening: 1. Remove the bed covers and pillows in the area to be converted. 2.
  • Page 61 Living 6.6.2 Bunk bed → No persons or obstacles may be in the swivelling area and on the bed section. Fig. 26 Fold the front bunk bed upwards Fig. 27 Fold the front bunk bed downwards Fold the front bed section (Fig. 26, Pos. 1) upwards: •...

  • Page 62: Blackout System

    Living Removing and reinstalling the rear bed section (Fig. 27, Pos. 2): 1. Remove the front bed section (Fig. 27, Pos. 1). 2. Remove the mattress 3. Unscrew the knurled screws (Fig. 29, Pos. 6) under the slatted frame on the right and left sides.
  • Page 63 Living 6.7.2 Roller blinds, side windows, pleated Fig. 31 Roller blinds, side windows Closing the side window roller blinds: 1. Reach into the handle recess of the handle (Fig. 30, Pos. A) with two fingers and unlock by pressing the handle (Fig. 31, Pos. 1). 2.

  • Page 64: Sink

    Living Sink The sink is equipped with matching covers. → Before you start travelling, make sure that all covers are stowed away safely. This prevents damage or injuries being caused due to loose covers. 10800223 10800222 Fig. 33 Sink cover Fig.

  • Page 65: Worktop Extension

    Living Worktop extension Fig. 35 Worktop extension Setting up: • Pivot up the extension of the worktop until it engages. Folding down: • Press lever strip (Fig. 35, Pos. A). Fold down the extension. 6.10 Hatches and door locks Wooden furniture doors, doors and cabinets of the Malibu box-type van are equipped with push-lock locks or handle locks.
  • Page 66 Living 6.10.2 Handle locks Fig. 37 Handle lock Open / close the handle lock: • Press the handle (Fig. 37, Pos. 1) downwards and open or close the furni- ture doors. 6.10.3 Storage hatch flush catch 10800134 Fig. 38 Storage compartment hatch flush catch Opening the flush catch: •...

  • Page 67: Step, Relocating

    Living 6.11 Step, relocating 6.11.1 Movable step Malibu 600 Fig. 39 Movable step Malibu 600 Removing the step: 1. Fold the cover (Fig. 39, Pos. 1) to the rear. 2. Open the Push Lock (Fig. 39, Pos. 2). 3. Pull the divided cover (Fig. 39, Pos. 3) slightly to the front. 4.
  • Page 68 Living 110-0001-04EN...

  • Page 69: Electrical System

    Electrical system Chapter Overview In this chapter, you will find information on the electrical system in your Mali- bu box-type van. The information affects, in detail: • safety • the 230 V wiring system and its connection • the 12 V wiring system of the living area battery •...

  • Page 70: On-Board Electrical System

    Electrical system 230 V on-board electrical system Test button FI circuit breaker 10800014 Fig. 41 Circuit breaker → Check the correct operation of the FI circuit breaker(Fig. 41, Pos. 2) monthly. For this purpose, press the test button (Fig. 41, Pos. 1). The FI circuit breaker (Fig.
  • Page 71 Electrical system Fig. 42 Cable connection In order to be equipped for all connecting possibilities, the following combina- tion is recommended: • adapter cable: CEE connection coupling (Fig. 42, Pos. 1) with ground contact and con- nector (Fig. 42, Pos. 2) with ground contact. •...

  • Page 72: On-Board Electrical System

    Electrical system 4. Plug the connection coupling (Fig. 42, Pos. 3) into the power supply of the pitch. 5. Switch on main circuit breaker of vehicle. 6. Check function on control panel (Fig. 44). → If the power supply is unstable or not present after connecting, contact the operator of the pitch.
  • Page 73 Electrical system Capacity Capacity designates the amount of electricity the battery can store. The capacity of a battery is specified in Ampere hours (Ah). If the fully charged batter has a capacity of 80 Ah, 90 Ah/100 Ah-20 % = 70 Ah are avail- able.

  • Page 74: Charging The Living Area Battery And Starter Battery

    Electrical system → During longer standing times, switch off the living area battery via the main switch on the Control Panel and charge at regular intervals via the 230 V connection. → Do not run the vehicle engine with living area battery disconnected. Risk of short-circuit! →...
  • Page 75 Electrical system → Do not connect the battery cables with reversed terminals. → Do not run the vehicle engine with starter battery or living area battery disconnected. Risk of short-circuit! → Before removing the pole terminals, switch off the vehicle engine and switch off the 230 V supply and the 12 V supply.

  • Page 76: Control Panel

    Electrical system Control Panel Main switch On / Off 12 volt power supply on/off Mains voltage LED indicator Battery voltage LED indicator Water/waste water tank filling level LED indicator Sensor, battery voltage, living area battery Sensor, filling level, water tank Sensor, filling level, waste water 10800219 tank...
  • Page 77 Electrical system → If the voltage of the main cabin battery falls below 10.5 V, the battery mon- itoring facility switches off all 12 V consumers. → When the voltage is higher than 12 V, the consumers switch back on au- tomatically.

  • Page 78: Electronic Block

    Electrical system Electronic block The electric block takes over the entire distribution and safeguarding of the 12 V current circuit and other control and monitoring functions. It only works in combination with the Control Panel. Electronic block is installed under the drivers seat (Fig.

  • Page 79: Light Switch / Switches

    Electrical system 7.7.2 Installation location of the fuses 10800046 Fig. 47 Fuses 1 Electronic block 4 50 A fuse for 2nd living area battery (op- tional) 2 50 A fuse for the main cabin 5 230 V circuit breaker 2 A fuse for battery monitoring 3 Fuse, diesel auxiliary heater 6 10 A fuse for satellite system (optional) (optional)
  • Page 80 Electrical system 7.8.2 Lighting function switch sliding door The vehicle is equipped with an additional function switch (Fig. 49) for the il- lumination of the entrance area. The function switch (Fig. 49) is linked to the sliding door. 10800008 Fig. 49 Function switch next to the sliding door The following settings are available:...

  • Page 81: Gas System

    Gas system Chapter Overview In this chapter, you will find information on the gas system of your Malibu box-type van. The information affects, in detail: • safety • the properties of gas • gas consumption • changing the gas bottles •...

  • Page 82: Interesting Facts About Gas

    Gas system → Check the gas hose at the gas bottle connection for tightness at regular intervals. The gas hose must not have any cracks or be porous. Where necessary, have gas hoses replaced by an authorised specialist work- shop. →...

  • Page 83: Gas Consumption

    Gas system → The butane gas mixed to the propane gas can no longer transfer to a gas- eous state below 0 °C. For this purpose, makes sure that there is a resid- ual amount of butane gas in the gas bottle at the end of Winter. The gas tanks can be filled to 80 % with butane gas! Burning →...

  • Page 84: Gas Bottles

    Gas system Gas bottles → Transport the gas bottles only in the gas compartment. → Position the gas bottle vertically in the gas compartment and lash tight so that it cannot turn. → Close the main shut-off valve on the gas bottle before removing the gas pressure regulator or the gas hose from the gas bottle.
  • Page 85 Gas system Fig. 50 Gas compartment Changing the gas bottles: 1. Open the furniture doors (Fig. 50, Pos. 1) for the gas compartment. 2. Close the main shut-off valve (Fig. 50, Pos. 2) on the gas bottle (observe the direction of the arrow). 3.

  • Page 86: Gas Shut-Off Valve

    Gas system Gas shut-off valve 10800006 10800007 Fig. 51 Gas shut-off valve, cooker and fridge Fig. 52 Gas shut-off valve, heater A gas shut-off valve is installed in the Malibu box-type van for every gas de- vice. • The gas shut-off valve for the hob (Fig. 51, Pos. 1) and the fridge (Fig. 51, Pos.

  • Page 87: Built-In Appliances

    Built-in appliances Chapter Overview In this chapter, you will find information on the built-in appliances of your Mali- bu box-type van. The information only refers to the operation of the built-in appliances. Further information on the built-in appliances can be obtained from the operating in- structions of the built-in appliances that are enclosed separately in the vehi- cle.
  • Page 88 Built-in appliances → Further details and information with regards to the operation and mainte- nance of the heater can be found in the vehicle and equipment manufac- turer's manual. 9.2.1 Installation position and access to the heating The heating is on the left-hand side of the vehicle beneath the bed behind the hatch.
  • Page 89 Built-in appliances 9.2.3 Truma CP plus The rotary / push button (Fig. 54, Pos. 8) is used to select the menus or to change the values to be set. Display Status line Menu line (top) Menu line (bottom) 230 V mains voltage display (grid current) Time switch clock display Settings / values...

  • Page 90: Cooking Area

    Built-in appliances Cooking area Risk of explosion! → Never allow unburned gas to escape due to the risk of explosion. → Before putting the cooking area into operation, ensure for sufficient venti- lation. Open the hinged window or roof hood. →...

  • Page 91: Fridge

    Built-in appliances 4. Press the switch (Fig. 55, Pos. 2). The ignition process starts. 5. After igniting the burner, keep the rotary knob (Fig. 55, Pos. 1) pressed for another approx. 15 seconds until the ignition safety valve keeps the gas flow open alone.
  • Page 92 Built-in appliances Fridge RMxx 53xx: Fridge trim control elements Risk of explosion! → When filling the vehicle with fuel, the fridge in gas operation must be switched off due to the risk of explosion! 10800096 Fig. 56 Fridge RMxx 53xx 1 Button On / Off Selection button "Automatic"...

  • Page 93: Sanitary Facility

    Sanitary facility Chapter Overview In this chapter, you will find information for the sanitary facilities of your Mali- bu box-type van. The information affects, in detail: • the water supply • the fresh-water tank • the waste water tank • the toilet •...

  • Page 94: Fresh Water System

    Sanitary facility 10.2 Fresh water system 10.2.1 Water filler neck The water tank is located on the right side of your Malibu box-type van. The water filler neck (Fig. 57, Pos. 1) is marked by the lettering "Water". The sealing caps can be opened and locked using the vehicle key. 10800027 Fig.
  • Page 95 Sanitary facility open close 10800240 10800246 Fig. 58 Fresh water tank service hatch Fig. 59 Filling / emptying the fresh water tank → Close the drain tap to fill the fresh-water tank. Filling the fresh water tank: 1. Position the Malibu box-type van horizontally. 2.
  • Page 96 Sanitary facility 10.2.3 Weight reduction when driving open 10800218 Fig. 60 Weight reduction The filling quantity of the water tank can be reduced to 20 litres when driving. Weight reduction: • Close the stopcock (Fig. 60, Pos. 1) by rotating it 3/4 of a turn in the anti- clockwise direction.
  • Page 97 Sanitary facility → Move the tilting lever (Fig. 61, Pos. 3) of the drain taps (Fig. 61, Pos. B) either vertical or horizontal and no other position! Twisting the tilting lever could damage the seal in the drain tap leading to it leaking. Filling process: 1.

  • Page 98: Waste Water System

    Sanitary facility 10.3 Waste water system 10.3.1 Waste-water tank The Malibu box-type van is equipped with a fixed installed water tank. The dirty water is drained via the waste water line. Position of the drain tap: In direction of travel at bottom right-hand side, in front of the rear wheel →...

  • Page 99: Odour Trap

    Sanitary facility 10.3.2 Waste water tank heating The additional heating of the waste water tank and the waste water pipes prevents the waste water from freezing at low temperatures. 10800239 Fig. 63 Waste water tank heater switch The heater can be switched on and off using switch (Fig. 63, Pos. 1) next to the control panel.

  • Page 100: Toilet/Bathroom

    Sanitary facility Cleaning the odour trap with cover: 1. Unscrew the cap of the odour trap (Fig. 64, Pos. 1) anticlockwise to remove. 2. Clean the odour trap and the inside of the cover (Fig. 64, Pos. 1). 3. Screw the cover (Fig. 64, Pos. 1) back onto the odour trap clockwise. 10.4.2 Pipe odour trap with flap The pipe odour trap (Fig.
  • Page 101 Sanitary facility → For venting during or after taking a shower, or for drying wet clothing, close the toilet door and open the roof hood of the toilet. This allows better cir- culation of the air. → After taking a shower, rinse any soap residues from the shower tray pre- venting cracks forming in the shower tray over time.
  • Page 102 Sanitary facility 10.5.2 Swivelling toilet in short bathroom (LOW-BED version) 10800102 10800216 Fig. 68 Toilet flushing Fig. 69 Toilet locking point Swivelling the toilet away: 1. Unlock the toilet by lifting the locking lever (Fig. 69, Pos. 2). 2. Pull the toilet out of the side wall (Fig. 69, Pos. 1) to locking point 2 (Fig.
  • Page 103 Sanitary facility → The toilet cassette may only be emptied at disposal stations, at camp sites or at disposal facilities that are specially intended for this purpose. → Further information about cassette toilets can be found in the separate instructions from the device manufacturer. →...
  • Page 104 Sanitary facility 10.5.4 Shower walls 10800109 Fig. 71 Securing the shower walls To open the shower walls, release the press stud straps (Fig. 71, Pos. 1) and move to the intended positions in the shower walls. → When travelling, secure the shower walls with the press stud straps (Fig.

  • Page 105: Shower Grating

    Sanitary facility 10.6 Shower grating → Stow away the shower grating while driving. Remove the shower grating before showering. 110-0001-04EN...
  • Page 106 Sanitary facility 110-0001-04EN...

  • Page 107: Care

    Care Chapter Overview In this chapter, you will find information on the care of your Malibu box-type van. The care instructions affects, in detail: • the exterior of the Malibu box-type van • the interior • the winter operation At the end of the chapter you will find check lists with measures that you have to carry out if you do not want to use the Malibu box-type van for a longer pe- riod.
  • Page 108 Care 11.1.2 Using a high-pressure cleaner for washing → Do not clean the tyres with a high-pressure cleaner. The tyres might be damaged. → Do not direct the water jet direct on the door gap, electric attachment parts, plug connectors, seal or in the fridge ventilation grille. The Malibu box-type van may be damaged.

  • Page 109: Water Tank

    Care 11.1.4 Care and maintenance of exterior applications → Exterior applications are wash-proof and must be cleaned in the same manner as the Malibu box-type van.. → Do not clean exterior applications with solvents. 11.1.5 Cleaning the chrome parts To clean the chrome parts, use the following cleaning agents: •...

  • Page 110: Care Inside

    Care 11.5 Care inside → In order to avoid tension cracks in acrylic glass, do not use aggressive cleaning / care agents. → Only use cleaning agents of the window manufacturer. → Due to their sensitivity, plastic parts need a particularly careful treatment. Never use cleaning agents containing solvents or alcohol as well as scouring agent containing sand! This procedure will help you to avoid brittleness and formation of cracks.

  • Page 111: Winter Care

    Care • Seat belts can be unrolled and cleaned using warm soap suds. The seat belt must be completely dry before rolling it back in. • Bring curtains and drapes to the dry cleaners. → If the curtains are secured using hook and loop fasteners, they can be removed from the trim.

  • Page 112: Taking Out Of Operation

    Care 11.6.3 At the end of the winter season • Wash the undercarriage and engine thoroughly. This removes thawing agents (salt, lye residues) that promote corrosion (have this carried out by an authorised specialist workshop). • Carry out cleaning work on the outside and preserve the vehicle with com- mercially available car wax.
  • Page 113 Care 11.7.2 Ceasing of options during winter Supplementary measures are necessary for temporary ceasing of operation during winter. Town Activity Com- plete Basic vehicle • Thoroughly clean the chassis and underfloor and spray with hot wax or preserve with paint care agent. •...
  • Page 114 Care 11.7.3 Putting the vehicle into operation following temporary ceasing of opera- tion or after ceasing of options during winter → After a longer standing period (approx. 10 months), have the brake system and the gas system checked by an authorised specialist workshop. →...

  • Page 115: Maintenance

    Maintenance Chapter Overview In this chapter, you will find information on the maintenance of your Malibu box-type van. The information affects, in detail: • maintenance work • official inspections • changing bulbs • spare parts • guarantee responsibilities Maintenance 12.1 Maintenance work As with every technical device, this vehicle requires maintenance.

  • Page 116: Main Cabin Lighting

    Maintenance An authorised specialist workshop has to inspect the gas system every 2 years. This also applies to vehicles that are not registered for road use. Modi- fications made to the gas system must be checked by an authorised special- ist workshop immediately.
  • Page 117 Maintenance 12.3.2 Lamp with battery Depending on the vehicle, there may be a battery-operated lamp in individual storage compartments or cabinets. The lamp is switched on automatically when the hatch/door is opened. Battery compartment cover batteries 10800221 Fig. 74 Battery-operated lamp →...

  • Page 118: Changing The Bulbs On The Rear Light Moulding

    Maintenance 12.4 Changing the bulbs on the rear light moulding → If the tool or a nut falls down when undoing the rear light moulding, you can reach the parts via an opening in the underfloor at the rear. The opening on the underfloor can be accessed on the vehicle from out- side.
  • Page 119 Maintenance 12.4.2 Undo the rear lamp on the driver’s side (low bed) → The openings for the nuts (Fig. 76, Pos. 1) are located in the vehicle pillar behind the cover (Fig. 76, Pos. 2). Rear light nut Bottom panelling 10800224 Fig.
  • Page 120 Maintenance 12.4.3 Loosening the rear light on the passenger side (floor plan 600) → The openings for the nuts (Fig. 77, Pos. 3) are located in the vehicle pillar next to the fresh-water tank (Fig. 77). – The top nut is located in the opening direct under the bed plate. –...
  • Page 121 Maintenance 12.4.4 Loosening the rear light on the passenger side (floor plan 640) → The openings for the nuts (Fig. 78, Pos. 1) are located in the vehicle pillar on the right side in the storage compartment under the bed plate (Fig. 78). –...

  • Page 122: Spare Parts

    Maintenance 12.5 Spare parts → Every alteration of the original state of the vehicle can alter road behaviour and impair road safety → The special equipment and original spare parts recommended for your vehicle by Malibu have been specially developed and approved by us. Your Malibu trade partner has these products.

  • Page 123: Warning And Information Stickers

    Maintenance 12.7 Warning and information stickers There are warning and information stickers on and inside the vehicle. Warn- ing and information stickers are for the sake of safety and must not be re- moved. → Replacement stickers can be obtained from your Malibu trade partner. 12.8 Guarantee responsibilities, service contacts The devices installed in the Malibu box-type van are subject to the guarantee...
  • Page 124 Maintenance 110-0001-04EN...

  • Page 125: Wheels And Tyres

    Wheels and tyres Chapter Overview In this chapter, you will find information on the topic wheels and tyres The information affects, in detail: • the general inspection • the inflation pressure • the tyre inflation pressure table Wheels and tyres 13.1 General •...

  • Page 126: Tyre Inflation Pressure

    Wheels and tyres 13.2 Tyre inflation pressure → Incorrect inflation pressure of the tyres leads to irregular wear and can lead to damage to the tyres up until it blowing. For this reason, check the inflation pressure at regular intervals. →...

  • Page 127: Tyre Inflation Pressure Table

    Wheels and tyres 110-0001-04EN...
  • Page 128 Wheels and tyres 110-0001-04EN...

  • Page 129: Malfunctions

    Malfunctions Chapter Overview In this chapter, you will find information on possible malfunctions of your Malibu box-type van. The malfunctions are listed with their possible causes and suggestions for rectification. The information affects, in detail: • the brake system • the electrical system •...

  • Page 130: Electrical System

    Malfunctions 14.2 Electrical system → Replace a lead-gel battery only with a lead-gel battery. Fault Cause Corrective action Lighting system • LED defective • Undo the housing cover of not fully functional the light affected • Replace the LED • Observe the Volt and Watt specifications •...

  • Page 131: Gas System

    Malfunctions Fault Cause Corrective action 12 V power supply does not • 230 V circuit breaker or FI • Have the electrical installa- function in 230 V operation switch has tripped tions checked by customer services • Blade fuse (50 A) on the •...

  • Page 132: Cooking Area

    Malfunctions No gas • Quick-connect valve closed • Open the quick-connect valve • Main shut-off valve on the • Open the main shut-off valve gas bottle is closed on the gas bottle • Outdoor temperature too • Wait for higher outside tem- low (-42°C for propane gas, perature or replace butane 0°C for butane gas)
  • Page 133 Malfunctions 14.5.1 Heater/boiler Fault Cause Corrective action Heater does not ignite, error • Lack of gas • Open the main shut-off valve message visible on the CP and gas isolating valve Plus display • Connect a full gas bottle • Air in the gas line system •...

  • Page 134: Water Supply

    Malfunctions 14.6 Water supply Fault Cause Corrective action No water • Water tank is empty • Fill with water • Fuse for the pump is defec- • Replace the fuse on the elec- tive tric block • Pump is defective •...
  • Page 135 Angelestraße 56 – D - 88214 Ravensburg info@tef.de – www.tef.de...

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Malibu 540 2014

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