Cartoni Malibu 540 2014 Manual Download

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110-0001-04EN

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: + 49 (0) 75 25 / 92 00 - 0

Fax: + 49 (0) 75 25 / 92 00 - 30 03

E-mail: [email protected]

Internet: www.malibu-carthago.com

Emergency hotline: + 49 (0) 75 25 / 92 00 - 33 33

Summary of Contents for Malibu 540 2014

Page 1: ...he 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 y...

Page 2: ...110 0001 04EN Foreword ...

Page 3: ...ussed 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 A copy of the check list does not need to be sent to the factory but it may be requested under special circumstances Any damage must be marked on the image and entered into the text field 1st Visual inspection for external damage 10800010 10800011 Descrip...

Page 4: ...used it must be connected to a 230 V connection for 2 days at least every 4 weeks checked with customer and instructions provided 12 Battery charge levels Living area battery 1 Living area battery 2 Starter battery V V V checked on the control panel 13 Power consumption on 12 V and 220 checked with customer 14 Windscreen wipers screen wiper water horn checked with customer 15 Table furniture shutt...

Page 5: ...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 Version June 2014 ...

Page 6: ...110 0001 04EN Delivery protocol ...

Page 7: ...dress 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: ...any subsequent owner s Name First name Postcode Town Street Telephone E mail Odometer reading at handover Registered keeper from until Date of handover Name First name Postcode Town Street Telephone E mail Odometer reading at handover Registered keeper from until Date of handover Name First name Postcode Town Street Telephone E mail Odometer reading at handover Registered keeper from until Date of...

Page 9: ... external socket 5 Cassette toilet door 2 A fuse for the toilet 6 Living area battery 7 EBL electric block fuses Main fuse 50 A 8 Fiat starter battery 50 A main fuse 9 Additional living area battery with 50 A fuse SA 10 Gas shut off valve cooker and fridge 11 Waste water drain valve 12 Filler neck fresh water 13 Service access water with drain tap 14 Service access gas bottles ...

Page 10: ... external socket 5 Cassette toilet door 2 A fuse for the toilet 6 Living area battery 7 EBL electric block fuses Main fuse 50 A 8 Fiat starter battery 50 A main fuse 9 Additional living area battery with 50 A fuse SA 10 Gas shut off valve cooker and fridge 11 Waste water drain valve 12 Filler neck fresh water 13 Service access water with drain tap 14 Service access gas bottles ...

Page 11: ...Before starting to travel 11 3 1 Key 11 3 2 Approval documents 12 3 3 Payload 12 3 4 Electrically operated entrance step 18 3 5 Windows roof hoods hatches doors 19 3 6 Snow chains 19 3 7 Traffic safety 20 4 While driving 21 4 1 Driving with the Malibu box type van 21 4 2 Brakes 22 4 3 Seat belts 22 4 4 Seats 24 4 5 Seating arrangement 26 4 6 Child seats 27 4 7 ISOFIX child seat 28 4 8 Folding blin...

Page 12: ...lt in appliances 73 9 1 General 73 9 2 Heating 73 9 3 Cooking area 76 9 4 Fridge 77 10 Sanitary facility 79 10 1 Water supply 79 10 2 Fresh water system 80 10 3 Waste water system 84 10 4 Odour trap 85 10 5 Toilet bathroom 86 10 6 Shower grating 91 11 Care 93 11 1 Care outside 93 11 2 water tank 95 11 3 Waste water tank 95 11 4 Entrance step 95 11 5 Care inside 96 11 6 Winter care 97 11 7 Taking o...

Page 13: ...neral 111 13 2 Tyre inflation pressure 112 13 3 Tyre inflation pressure table 113 14 Malfunctions 115 14 1 Brake system 115 14 2 Electrical system 116 14 3 Gas system 117 14 4 Cooking area 118 14 5 Heater boiler fridge 118 14 6 Water supply 120 14 7 Main cabin 120 ...

Page 14: ...110 0001 04EN Table of contents ...

Page 15: ...ng accompanying vehicle documents user manual service manual enclosed separately in the Annex dealer register 1 3 Additional documents Test certificate for liquid gas with test sticker Complete set of documents of the vehicle manufacturer User manual for the liquid gas built in cooker User manual for the cassette toilet User manual for the heater User manual for the fridge User manual for other sp...

Page 16: ...at impair the safety of persons or the Malibu box type van must be rectified by specialist personnel immediately The brake system and the gas system of the Malibu box type van must only be checked and repaired by an authorised specialist workshop Modifications to the main cabin may only be carried out with the approval of Malibu GmbH Co KG The Malibu box type van is only intended for the transport...

Page 17: ...luded as far as this derives from incorrect use All design modifications to the vehicle and or device or the use of spare parts that are not original Malibu spare parts as well as non observance of the user manual leads to the exclusion of the warranty and or guarantee processing and to the exclusion of liability claims The same applies in case changes are made by the customer with respect to carr...

Page 18: ...let cassette must be emptied immediately when the fill level indicator illuminates at the latest Also separate domestic refuse when travelling into glass cans plastic and wet waste Ask about disposal possibilities at the respective host com munity Domestic waste may be disposed of in rubbish bins at parking lots Empty the rubbish bins in the intended dustbins or containers as often as possible Thi...

Page 19: ...type van the electrical system of the Malibu box type van the water system of the Malibu box type van 2 Safety guidelines 2 1 Legend Danger Disregarding this symbol may lead to potential personal injury Caution Disregarding this symbol may lead to damage to the vehicle This symbol is a note for the user that the device can only be used with the knowledge from the manual user information of the man...

Page 20: ...s can be obtained in the vehicle documents When parking the Malibu box type van apply the handbrake When leaving the vehicle lock all doors exterior hatches and windows Warning triangle and first aid kit in accordance with DIN 13 164 are legally prescribed in Germany and must be carried on board Observe the expiry date When selling the Malibu box type van hand over the new owner the user manual of...

Page 21: ...r a longer standing period approx 10 months have the brake system and the gas system checked by an authorised specialist workshop Before commencing your trip open and secure the roller blinds on the windscreen as well as the driver and passenger window When travelling persons must only remain on the seats The permissible number of seats can be obtained in the vehicle documents Before driving away ...

Page 22: ...ve the path of travel on the side behind the trailer secured by a second person who instructs the driver 2 6 Gas system In event of defects on the gas system smell of gas higher gas consump tion there is a risk of explosion Close the main shut off valve on the gas bottle immediately Open the windows and doors and ventilate Do not smoke do not ignite open flames and do not actuate any electric swit...

Page 23: ...r gas pressure regulators are not permitted and do not satisfy the high demands Use on 11 kg or 5 kg gas bottles Camping gas bottles with check valve installed blue bottle with max 2 5 kg or 3 kg volume may be used with a safety valve in exceptional cases Position the gas bottle vertically in the gas compartment and lash tight so that it cannot turn Check the gas hose at the gas bottle connection ...

Page 24: ...s In order to protect the electrical system a 230 V overvoltage protection can be installed by authorised specialist personnel Protection against overvoltage 2 8 Water system If the Malibu box type van is not heated when there is a risk of frost the water system hoses containers etc must be emptied otherwise insuffi cient protection is provided against damage by frost Standing water in the water t...

Page 25: ...ches and doors the use of snow chains road safety At the end of the chapter you will find a check list where the most important items are summarised again 3 Before starting to travel For emergency cases keep the emergency numbers of the vehicle man ufacturer and appliance device manufacturers at hand see chapter 12 8 Guarantee responsibilities service contacts on page 109 3 1 Key You are provided ...

Page 26: ...rate nationality identification sign is re quired 3 3 Payload Payloads that are too heavy and an incorrect inflation pressure may lead to the tyre bursting You may loose control of your Malibu box type van The technical permissible total mass total permissible weight specified in the vehicle documents must not be exceeded by the payload Accessories installed special equipment the full water tank a...

Page 27: ... of the tyres The technically permissible total mass in the loaded state permissible total mass is specified by the manufacturer in the vehicle documents un der figure 15 The calculation of the payload is partially based on generalised weights Weight in running order The mass in running order is put together from dead weight mass of the empty vehicle with the standard equipment installed ex factor...

Page 28: ...ogether from the conventional loading Additional equipment personal equipment Conventional loading With the calculation of the conventional loading a weight of 75 kg is consid ered for each seat intended by the manufacturer independent of the actual weight of the passenger The drivers place is already included in the weight in running order and must not be included The number of seats is specified...

Page 29: ...n in metres Example for achieving the payload These values are approximate details and depend on the respective model Description Load kg Technically permissible gross weight 3 500 Mass in running order including basic equipment in accord ance with RL 92 21 EEC incl driver 3020 Maximum payload 480 Payload calculated from the passengers 75 kg person 3 x 75 kg 225 Personal equipment comprising 10 kg...

Page 30: ...ilities in the Malibu box type van are more or less strongly influenced by the floor plan Storage compartments with high volumes rear storage compartment in particular temp you to carry heavy holiday utensils As a result the rear axle load front axle load can reach its limit at an early stage The overloading of the Malibu box type van even only on one axle should not be underestimated Decisive fac...

Page 31: ...oard 3 kg per compartment Other compartments 20 kg 3 3 4 Trailer operation When manoeuvring for hitching and removing no persons must be be tween the Malibu box type van and the trailer During the manoeuvring have the path of travel on the side behind the trailer secured by a second person who instructs the driver Trailers with overrun brakes do not hitch or de hitch trailers with applied brakes T...

Page 32: ...step when extracting or retracting The living area battery must be connected and ready for operation for operating the entrance step The switch for operating the entrance step is located in the entrance area An acoustic signal sounds when the entrance step has not been retracted and engaged correctly Fig 1 Single step entrance step Move the entrance step out press rocker switch Fig 1 Pos 2 the ent...

Page 33: ... the valid guidelines in the individual countries They must only be mounted on the drive wheels Tyres suspension and steering of the Malibu box type van are exposed to additional loading when snow chains are mounted In order to avoid dam age being caused to your Malibu box type van drive slowly with mounted snow chains and only on roads completely covered with snow Observe the mounting guidelines ...

Page 34: ...akes react equally Malibu box type van remains in track when braking Main cabin Exterior connections disconnected Roof free of ice and snow in winter Windows and roof mounted fan closed and locked Entrance step retracted Upper shelf cleared away Loose parts stowed away or secured All drawers and hatches closed Living area and sliding doors closed and secured Shower cabin door closed and secured Fr...

Page 35: ...tained in the vehicle documents Before driving away apply your seat belt and keep it on when driving The driver is responsible that the following points are observed persons travelling must remain seated on the intended places the compulsory wearing of seat belts must be observed the door lock must not be opened the safety instructions listed in chapter 2 must be observed Avoid sudden jerky brakin...

Page 36: ...ave damaged seat belts replaced by a specialist workshop Do not modify the belt mounting the automatic rewinder and the belt buck les Check the screw fitting of the seat belts for tight fit every now and then Each seat belt should only be used for one adult person Do not belt objects together with persons Seat belts are not appropriate for persons with a body height below 150 cm In this case use a...

Page 37: ... pregnant women the seat belt should be positioned very low so that it runs over the pelvis and under the stomach 1 2 10800003 Fig 3 Putting on the seat belt Putting on the seat belt 1 Pull the seat belt on the belt tongue Fig 3 Pos 2 out of the roller unit across your shoulder 2 Guide the seat belt diagonally over your upper body 3 Guide the lower belt part over your hips not over the stomach 4 I...

Page 38: ...to the driving position 1 Fold up both armrests 2 Push the driver s seat passenger seat to the back or in the middle posi tion 3 Press the lever Fig 4 Pos 4 upwards 4 Turn the seat in the direction of travel and lock in place Setting the armrest The height of the armrest can be adjusted infinitely 1 Turn the knurled wheel Fig 4 Pos 2 counter clockwise The locking mechanism of the armrest released ...

Page 39: ...it on the seat 2 Pull and hold the release lever on the backrest Fig 5 Pos 1 3 Push the backrest to the desired position using your back 4 Let go of the release lever Fig 5 Pos 1 Seat longitudinal adjustment 1 Pull release lever Fig 5 Pos 3 upwards and hold 2 Move the seat into the desired position 3 Let go of the release lever Fig 5 Pos 3 Lateral seat adjustment only with outer seat 1 Pull side r...

Page 40: ...n the vehicle documents figure 12 It is compulsory to wear a seat belt on all seats that have a seat belt Seats that can be used when travelling are marked with a sticker 4 5 1 Approved seats 1 Driver s seat 2 Passenger seat 3 Seat 4 Seat Fig 6 Approved seats For equipment with ISOFix system special equipment the 3rd and 4th sitting places are carried out as single seats ...

Page 41: ...senger side via the setup menu check that the airbags are deactivated on the illuminated LED of the button on the dashboard 4 6 1 Universal child seat Group Seats Passenger seat Back row of seats L M 0 up to 10 kg U U U 0 up to 13 kg U U U 1 9 18 kg U U U 2 15 25 kg U U U 3 22 36 kg U U U M Middle if necessary remove the upholstery for the correct installation of the restraint system L Left side i...

Page 42: ...FIX child seat are marked by a sewn label You can obtain further information in the separate operating instructions from the seat manufacturer Group Damage to the child seat Seats Passenger seat Back opposite direction of travel Back in the direction of travel 0 up to 10 kg E 0 up to 13 kg E D C 1 9 18 kg A IUF B B1 C D 2 15 25 kg IUF 3 22 36 kg IUF IUF Also suitable for ISOFIX universal restrain ...

Page 43: ...hild seat fastening Fastening the child seat 1 Hang the child seat into the holding bracket Fig 7 Pos 4 2 Push the Top Tether fixing strap Fig 7 Pos 1 over the backrest 3 Pull the holding strap of the child seat Fig 7 Pos 2 through the Top Tether fixing strap Fig 7 Pos 1 4 Using hooks Fig 7 Pos 3 hang the holding strap of the child seat in the holding bracket Fig 7 Pos 5 4 8 Folding blinds When tr...

Page 44: ...110 0001 04EN 30 4 While driving ...

Page 45: ...r drainage we recommend parking the Malibu box type van on a level sur face using the levelling wedges that are available from an accessories dealer A camping spirit level is useful 5 1 Hand brake The hand brake is located to the left next to the driver s seat When parking the vehicle the hand brake must be pulled on tight 5 2 Entrance step Information on safety instructions and operation of the e...

Page 46: ...110 0001 04EN 32 5 Positioning the Malibu box type van ...

Page 47: ... asphyxiation from increased CO2 content During certain weather conditions despite sufficient ventilation condensa tion may occur on metallic objects e g on the floor chassis screw fittings Additional cold bridges may also be created at breakthroughs e g edges of roof hoods sockets filler necks hatches etc Ensure for continuous exchange of air using frequent and targeted ventila tion This is the o...

Page 48: ... path Risk of damage In vehicles with the table in the outer area special equipment the stop damper on the sliding door is not required The hinged window may be damaged by opening the door Close the hinged window before opening the door Before opening the sliding door always check whether the hinged window is closed 10800179 Fig 8 Hinged window safety label Always close the windows when leaving th...

Page 49: ...position 3 Open the knurled screw on the telescopic catch Fig 9 Pos 1 Open the hinged window to the desired position 4 Close the knurled screw on the telescopic catch Fig 9 Pos 1 Closing the hinged window 1 Support the window with one hand 2 Open the knurled screw on the telescopic catch 3 Close the hinged window 4 Press the locking knob Fig 9 and Fig 10 Pos 2 and keep it pressed 5 Move the lock h...

Page 50: ... the roller blind from the bottom to the top on the handle Fig 11 Pos 2 It can be opened to any position in between Closing the insect protection blind Pull the insect protection blind from the top to the bottom on the handle Fig 11 Pos 1 It can be opened to any position in between Opening the insect protection blind Pull the insect protection blind from the bottom to the top on the handle Fig 11 ...

Page 51: ...ically 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 protection blind tight and slowly guide them back to the initial position Depending on the weather conditions close the roof hoods far enough so that no moisture can enter Close the roof hoods when driving To avoid causing damage to t...

Page 52: ...e same time pull the bar Fig 12 Pos 1 down past the push button Fig 12 Pos 2 into the guide groove Fig 12 Pos 3 2 Open the roof hood by pressing the bar in one of the three opening lock ing mechanisms up In the middle opening lock the roof hood can be secured using a bar Closing the roof hood 1 Close the roof hood by pulling down the bar Fig 12 Pos 1 2 Lock the bar Fig 12 Pos 1 using the push butt...

Page 53: ...ing the lift tilt roof 1 Fold the hand crank Fig 13 Pos 1 out of the recess 2 Turn the hand crank Fig 13 Pos 1 in the direction indicated on the hand crank handle thus moving the lift tilt roof into the desired position 3 Fold the hand crank Fig 13 Pos 1 back into the recess Closing the lift tilt roof 1 Fold the hand crank Fig 13 Pos 1 out of the recess 2 Turn the hand crank Fig 13 Pos 1 in the di...

Page 54: ...mechanism hold the roller blind or insect protection blind tight and slowly guide them back to the initial position To avoid the accumulation of heat close the roller blind max 2 3 during the day Fig 14 Roller blind roof hood small Closing the roller blind Pull the roller blind towards the insect protection blind until both handle strips rest against each other Opening the roller blind Slowly guid...

Page 55: ... close the exterior hatches when leaving the motorhome Always turn the locking cylinder back to the initial position The exterior hatches on the motorhome are equipped with standard lock ing cylinders Always use the same key for all locks When opening exterior hatches open all locks mounted on the respec tive exterior hatch at the same time 6 4 1 Toilette hatch with two hand operation 10800123 Fig...

Page 56: ...2 Pull out the table top counter clockwise 3 Engage lever Fig 16 Pos 1 in any position Pushing the table top in 1 Pull lever Fig 16 Pos 1 downwards 2 Move the table top in position under the table 3 Lever Fig 16 Pos 1 engages 6 5 2 Removing and sliding the table 10800238 3 1 2 Fig 18 Table removable Removing the table plate 1 Lift table plate Fig 18 Pos 1 Caution The bottom leg part Fig 18 Pos 2 i...

Page 57: ...rted and may fall out 2 When the table Fig 18 Pos 1 is in the raised position swivel into the desired position 3 Put the table Fig 18 Pos 1 back down and make sure that the teeth engage 6 5 3 Using the table as an outer table Do not close sliding door with table hooked on Stow the table plate and leg part and secure against slipping Hooking on the outer table 1 Hook table Fig 19 Pos 1 at an angle ...

Page 58: ...e living area 3 Swivel in the pull out table top Fig 17 4 Lift the table Fig 18 Pos 1 slightly with one hand Caution The bottom leg part Fig 18 Pos 2 is only inserted and may fall out 5 Remove the bottom leg part Fig 18 Pos 2 and stow away safely 6 Grasp the table Fig 18 Pos 1 with both hands lift and remove from the top wall rail 7 Positioned at a slight angle hand the table Fig 18 Pos 1 into the...

Page 59: ...the small additional pad ding Fig 21 Pos 2 4 As an option remove the back padding Fig 21 Pos 4 and stow away safely 5 Place the topper Fig 21 Pos 5 over the padding and align The back padding Fig 21 Pos 4 does not have to be removed for the conversion and can remain mounted The sleeping area is reduced Before inserting the topper Fig 21 Pos 5 the head restraints must be moved up With mounted back ...

Page 60: ... 22 and Fig 23 Pos 2 and fold up to the respec tive sides Fig 24 Hook and retaining ring Fig 25 Rectangular tube holder 3 Lift the partitioned bed frame Fig 22 and Fig 23 Pos 3 and fold up to the left and right sides Secure the fastening strap with hook Fig 24 Pos 4 under the overhead cabinet in retaining rings Fig 24 Pos 5 4 Remove the rectangular tube Fig 25 Pos 6 and secure them to the bottom s...

Page 61: ...g 27 Pos 2 downwards Carefully pull the front bed section Fig 27 Pos 1 at handle Fig 27 Pos 4 towards the driver s cabin until the bed lies completely flat Fig 28 Removing and reinstalling the front bunk bed Fig 29 Removing and reinstalling the rear bunk bed Removing and reinstalling the front bed section Fig 26 Pos 1 1 Remove the mattress 2 Fold the front bed section Fig 26 Pos 1 upwards 3 Unscre...

Page 62: ...ing the folding blinds for the windscreen the drivers window and the passenger window must be opened locked and secured 6 7 1 Roller blinds windscreen pleated Fig 30 Roller blinds windscreen pleated Opening the windscreen roller blinds Guide the roller blind back on the handle Fig 30 Pos 1 in the direction of the arrow until the handle engages Closing the windscreen roller blinds 1 Reach into the ...

Page 63: ...ow roller blinds To open guide the roller on the handle Fig 31 Pos 1 in the direction of the arrow until the it engages 6 7 3 TV holder 10800124 1 2 3 4 Fig 32 TV holder Swivelling out the TV holder 1 Pull the locking knob Fig 32 Pos 1 downwards and hold in place 2 Swivel the TV holder to the front horizontally in any position 3 Loosen the fastening screw Fig 32 Pos 3 and swivel the flat screen up...

Page 64: ...vers 10800222 1 2 10800223 3 3 1 Fig 33 Sink cover Fig 34 Work surface Storing the covers The covers Fig 33 Pos 1 2 and Fig 34 Pos 1 can be stowed away in a drawer under the gas cooker Hooking on the additional worktop The cover Fig 34 Pos 1 can be used as an additional work surface Insert the cover Fig 34 Pos 1 into the holder Fig 34 Pos 3 equally with the edge at a slight angle from above and pu...

Page 65: ... furniture doors doors and cabinets of the Malibu box type van are equipped with push lock locks or handle locks Before starting to travel make sure that al hatches and doors are closed tight and secured This prevents stored items form falling out and damag ing door locks 6 10 1 Push lock locks Fig 36 Push lock lock closed opened Open close the push lock lock Pushing on the push lock locks are ope...

Page 66: ...urni ture doors 6 10 3 Storage hatch flush catch 10800134 2 1 Fig 38 Storage compartment hatch flush catch Opening the flush catch Press the flush catch downwards at the marking Fig 38 Pos 1 The hatch handle flips upwards Lift the hatch on the hatch handle Fig 38 Pos 2 Closing the flush catch Close the hatch and pivot the hatch handle Fig 38 Pos 2 back in ...

Page 67: ...3 Pull the divided cover Fig 39 Pos 3 slightly to the front 4 Push the step to the side until you hear it locking in place Assembly is carried out in reverse order 6 11 2 Fixed step Malibu 640 Fig 40 Fixed step Malibu 640 Removing the step 1 Fold up the bed 2 Lift the step up and pull out of the aluminium rails on the side toward the rear doors 3 Remove the step Assembly is carried out in reverse ...

Page 68: ...110 0001 04EN 54 6 Living ...

Page 69: ...in the Malibu box type van must next to the CE mark also have a so called EMC test electromagnetic compatibility from the device manufacturer Defective fuses should only be replaced when the cause of the error is known and has been eliminated If the vehicle is used regularly have the electrical system checked and certified by an electrician every year DIN VDE 0100 721 Regardless of this the system...

Page 70: ...cally charged via the charge module in the electric block To preserve the living area battery connect the Malibu box type van to an external 230 V supply as often as possible Move the switch position of the FI circuit breaker to 1 top for the 230 V operation Fig 41 Pos 2 7 2 1 230V connection The external 230 V supply must be safeguarded via a residual current circuit breaker FI switch 30 mA Unwin...

Page 71: ...n the vehicle these may flicker In such cases the 230 V plug simply has to be inserted turned around 7 2 2 Connecting to the external power supply Damage caused by overheating Before connecting the vehicle to the external power supply unwind the cable drum completely Before connecting the vehicle system to the external power supply check whether the power supply of the pitch is suitable for the vo...

Page 72: ...itched off the living area battery supplies the living area with 12 V DC voltage When the vehicle engine is running the living area battery and the starter battery are charged by the vehicle alternator The living area battery only has a limited supply of energy This is why elec tric consumers should not be operated without 230 V supply voltage for longer periods During heating operation the circul...

Page 73: ...ter returning from your trip charge the battery via the charge module in the electric block with 230 V connection for at least 20 hours as in gener al the living area battery is also never fully charged during longer mobile use The main charge phase of the charger is eight hours Hint remove the 230 V connector of the charger after eight hours and insert it again The main charge phase can start aga...

Page 74: ...enance free means it is not necessary to check the acid level it is not necessary to top up with distilled water A maintenance free lead gel battery also has to be charged at regular in tervals In order to avoid the deep charging of the battery disconnect the living area battery from the current circuit when the Malibu box type van is standing still for longer periods 7 3 3 Installation location o...

Page 75: ... A In order to use the full capacity of the charge module all electric consumers must be switched off during the charging procedure 7 4 2 Charging via the vehicle engine When the vehicle engine is running the living area battery and the starter battery are charged by the vehicle alternator If the vehicle engine is switched off the batteries are isolated from each other automatically using a relay ...

Page 76: ...rging of the living area battery the 12 V main switch should be switched off when leaving the vehicle 7 5 2 Displaying the water or waste water quantity The fill level of the water and waste water tanks can be checked by pressing the buttons Fig 44 Pos 7 and 8 on the control panel In event of incorrect indication of the tank fill level clean the tank sensors 7 5 3 Battery alarm and automatic deact...

Page 77: ...h off consumers No charge Control of the alternator or the isolating relay defective Visit a specialist workshop and have repaired No charge Charge module defective 230 V fuse not switched on Visit a specialist workshop and have repaired 11 1 V to 13 2 V Value during running op eration Normal range If the voltage does not rise above this for several hours 12 V wiring system overloaded Switch off c...

Page 78: ...nection 4 Connection for the Control Panel 5 Connections for the 12 V consumers The blade fuses Fig 46 Pos 2 safeguard the different current circuits Where required check or change the fuses Details and information about the electric block as well as fuse allocations can be found in the vehicle and equipment manufacturer s manuals 7 7 Fuses 7 7 1 Fuses on the electric block Defective fuses should ...

Page 79: ... different lighting elements These can be switched on and off independent from each other Changing of the lighting elements is described separately 12 3 Main cabin lighting on page 102 7 8 1 Switch in the entrance area The switches for the step and the light are located in the entrance area Switch lighting elements on off 1 Switch on the Control Panel see chapter 7 5 2 In order to switch the desir...

Page 80: ...oor 10800008 Fig 49 Function switch next to the sliding door The following settings are available I The lighting in the entrance area switches automatically when open ing and closing the sliding door If the sliding door stays open for a longer period the lighting goes out after approx 15 minutes In order to reactivate the function close and open the sliding door again The light is off permanently ...

Page 81: ...garage no fire points gas cooker gas heater boiler fridge etc may be operated Before putting into operation or at least every 2 years have the gas sys tem checked by an authorised specialist workshop This also applies to vehicles that are not registered for road use If modifications are made to the gas system have the gas system checked by an authorised specialist workshop immediately Have the gas...

Page 82: ...vals Propane gas can be gasified down to 42 C butane gas on the other hand only up to 0 C Gas pressure is no longer present below these tempera tures Butane gas is not suitable for use in winter Only a 5 kg bottle can be transported in any vehicle with the low bed 8 2 Interesting facts about gas The properties of gas Gas is a petroleum product that is officially called condensed petroleum gas It m...

Page 83: ...plete combustion The flame should have a weak blue appearance and a blue green core Gas is exceptionally en vironmentally friendly and does not emit soot when burned completely The bottle has an unlimited shelf life without its quality being affected Pressure The operating pressure for gas operated camping equipment is 30 mbar The gas pressure in the bottle is reduced to 30 mbar by a pressure regu...

Page 84: ...e bot tle with max 2 5 kg or 3 kg volume may be used with a safety valve in exceptional cases Use a hose length as short as possible for gas bottles outside max 150 cm Check the gas hose for wear and cracks at regular intervals Observe the expiry date Screw fittings on the gas pressure regulator have a left hand thread The gas pressure regulator reduces the gas pressure of the gas bottle to the op...

Page 85: ...rrow 3 Open the knurled nut Fig 50 Pos 3 left hand thread 4 Remove the gas hose from the gas bottle 5 Undo the securing strap Fig 50 Pos 4 and remove the gas bottle 6 Place the filled gas bottle in the gas bottle box 7 Secure the gas bottle with the securing straps Fig 50 Pos 4 8 Put the gas hose on the gas bottle and tighten the knurled nut Fig 50 Pos 3 by hand left hand thread 9 Close the furnit...

Page 86: ...as 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 2 are located underneath the kitchen work surface The gas shut off valve for the heater Fig 52 Pos 1 is located under neath the bed The symbols for the gas shut off valve are each assigned to a gas device ...

Page 87: ... type van user manual Before putting a gas operated built in appliance into operation open the main shut off valve on the gas bottle and the respective gas shut off valve 9 2 Heating Risk of explosion Never allow unburned gas to escape due to the risk of explosion When filling the fuel tanks on ferries and in the garage the heater must be switched off due to the risk of explosion The circulating a...

Page 88: ...1 by pressing the push lock Fig 53 Pos 2 Returning to the original state is carried out in reverse order 9 2 2 Water from the boiler and lines Completely empty the boiler if there is a risk of frost The guarantee does not cover damage caused by frost The drain cock only has a limited frost protection If the drain hose should be blocked due to ice or dirt automatic emptying is no longer possible Da...

Page 89: ...th a Truma CP plus iNet as special equip ment Further details and information on the subject of heating can be found in the device manufacturer s manual provided with the vehicle Setting the operating types Turn the rotary push button to the right or left to select a menu item or to change the values Press the rotary push button to activate the menu item or to take over the set value To switch the...

Page 90: ...on top of it Do not use the gas cooker cover as a cooking zone Do not close the gas cooker cover when the gas cooker is being used Only use matching pots and pan sizes for the respective grids Pots and pans that are too large may lead to damage caused by the accumulation of heat Gently guide the cover onto the gas cooker Do not let it it drop Do not load the gas cooker cover using pressure when it...

Page 91: ...3 Allow gas cooker to cool down before closing the cover If the flame does not go out the ignition safety valve blocks the gas supply automatically Further details and information with regards to the gas cooker can be found in the vehicle and manual of the device manufacture 9 4 Fridge The battery capacity is limited when operating the fridge If the fridge is not connected to a 230 V power supply ...

Page 92: ...utton 230 V 6 Temperature level button 3 Energy selection button Gas 7 Temperature level display 4 Energy selection button 12 V 8 External display Fault Reset gas fault button Further details and information with regards to the fridge can be found in the vehicle and manual of the device manufacture 9 4 2 Compressor fridge The fridge is operated via a 12 V power supply Optimum cooling is no longer ...

Page 93: ...ype van The water pump runs hot without water and may be damaged Never op erate the water pump when the water tank is empty Thoroughly clean the water tanks before each use Before using the Malibu box type van each time rinse through the water lines and the water tank thoroughly using several litres of water For this purpose open all taps and the shower head After using the Malibu box type van eac...

Page 94: ...l water tank Close the water filler neck 1 Put the sealing cap onto the water filler neck Turn sealing cap by a quar ter turn clockwise The sealing cap engages 2 Insert the key in the lock cylinder Fig 57 Pos 1 and turn a quarter turn clockwise 3 Remove the key 4 Check whether the sealing cap turns without opening 10 2 2 Filling emptying the fresh water tank Damage to the water pump from running d...

Page 95: ...59 finger tight Do not force it shut 4 Fill the fresh water via the filler neck 5 Stop filling once the water level display on the control panel indicates 100 6 Close the service hatch Fig 58 Pos 1 7 Close the water filler neck Fig 57 Emptying the fresh water tank 1 Position the Malibu box type van horizontally 2 Remove the service hatch Fig 58 Pos 1 3 Turn drain tap Fig 59 anticlockwise by two tu...

Page 96: ...he pipeline system Damage to the water pump Long periods of dry running will damage the water pump Always operate the water pump with water Risk of frost at cold temperatures Completely empty all lines water taps and spray heads To drain the water pump switch on and off at the control panel for a short time Further details and information on the subject of heating can be found in the device manufa...

Page 97: ...ater taps to cold and leave open The cold water lines are filled with water 7 Keep the water taps open long enough until the water runs our of the water taps without any bubbles 8 Close all water taps again Emptying procedure 1 Switch off the boiler 2 Perform the tank emptying see chapter 10 2 2 3 Switch off the water pump at the control panel Fig 44 Pos 1 4 Open all water taps and the spray head ...

Page 98: ...water pipe system If the fill level display on the control panel indicates that the waste water tank is full empty the waste water tank A backlog will be caused if not emptied In event of incorrect display of the fill level display see chapter 14 6 Water supply on page 120 The waste water tank must only be emptied at disposal stations on camp ing places or at disposal possibilities especially iden...

Page 99: ...d on and off using switch Fig 63 Pos 1 next to the control panel The LED on the switch lights red when the heater is on The LED on the switch does not illuminate when the heater is off 10 4 Odour trap In order to prevent possible unpleasant odours from the waste water system the vehicle is equipped with odour traps Fig 64 Pos 1 10 4 1 Odour trap syphon Fig 64 Odour trap These are are installed on ...

Page 100: ...trap The pipe odour trap is mounted at the shower drain at the washbasin in the bathroom 540 and 600 LE If the pipe odour trap Fig 65 Pos 1 and the pipe connection system Fig 65 Pos 2 require cleaning please contact a service partner 10 5 Toilet bathroom Do not transport loads in the shower tray in order to avoid causing damage to the shower tray or other installations in the toilet Do not sit on ...

Page 101: ...in long bathroom Fig 66 Toilet Fig 67 Toilet locking point Swivelling the toilet away 1 Turn the rotary handle Fig 66 Pos 1 approx 1 4 turn clockwise as far as it will go and hold in place 2 Pull the toilet Fig 66 Pos 2 forwards to the desired engaging point Fig 67 To swivel using your foot use the lever on the bottom side of the toilet Locking point 1 stowage position when taking a shower washing...

Page 102: ...howering washing Fig 69 Pos 1 Locking point 2 Position for removing the cassette and for using the toilet Fig 69 Pos 3 Swivelling the toilet in Push the toilet back in the reverse order When travelling swivel in the toilet Fig 69 Pos 1 10 5 3 Cleaning the toilet cassette The cassette toilet is rinsed directly via the water system of the vehicle The toilet service hatch is located at the level of t...

Page 103: ...parate instructions from the device manufacturer Another toilet is available on request Special equipment 10800114 1 2 Fig 70 Removing the cassette Removing the cassette 1 Open the toilet flap see chapter 6 4 1 on page 41 2 Depending on the vehicle put the toilet into the removal position Fig 67 Pos 2 or Fig 69 Pos 3 3 Pull the handle on the cassette Fig 70 Pos 1 upwards to unlock Depending on the...

Page 104: ...itions in the shower walls When travelling secure the shower walls with the press stud straps Fig 71 Pos 1 10 5 5 Sink When travelling fold in the sink LOW BED version 10 5 6 Sliding door 10800220 1 2 Fig 72 Opening closing the sliding door Open the sliding door 1 To open turn rotary knob Fig 72 Pos 2 clockwise 2 Open sliding door Fig 72 Pos 1 to the left Close sliding door Fig 72 Pos 1 to the rig...

Page 105: ...10 91 110 0001 04EN Sanitary facility 10 6 Shower grating Stow away the shower grating while driving Remove the shower grating before showering ...

Page 106: ...110 0001 04EN 92 10 Sanitary facility ...

Page 107: ...d to a pre mature brittleness of the plastic panelling and subsequent formation of cracks Clean the Malibu box type van only on a washing area that is intended for washing vehicles Avoid direct sun radiation Observe environmental pro tection measures Clean the Malibu box type van thoroughly after trips to the seaside The high salt content in the air may damage the surfaces Clean the Malibu box typ...

Page 108: ...entire wash cycle 11 1 3 Window panes made of acrylic glass Due to their sensitivity acrylic glass window panes need a particularly careful treatment Never rub acrylic glass windows when dry as dust particles might damage the surface Clean only with lots of warm water and a soft cloth Never use cleaning agents containing chemicals scouring agent or alco hol Never use cleaning agents containing sol...

Page 109: ...rked for longer periods either dry manually via the cleaning opening or use recommended care agent e g from Multiman 11 3 Waste water tank Clean the waste water tank after using the Malibu box type van each time Empty waste water tank Thoroughly rinse out the waste water tank with fresh water In event of contamination on the waste water sensor clean carefully by hand The coating of the sensor rod ...

Page 110: ...cially available cleaning agent or a light cleaning agent solution 1 stubborn stains should be treated using stain remover Before doing that first perform a trial at an inconspicuous spot There is a risk of water edges forming Clean upholstery materials with upholstery dry foam or with the foam of a mild washing detergent Do not wash the upholstery material Protect the padding against sun radiatio...

Page 111: ...ation in the storage spaces If there is any risk of frost also cover the windscreen with winter insulation mats 11 6 1 Preparation Check the Malibu box type van for paint and rust damage If applicable repair the damage The metal parts of the underfloor should be protected against rust using a protective agent on the basis of wax Preserve painted outer parts with an appropriate agent 11 6 2 Winter ...

Page 112: ... by corrosion Jack up the Malibu box type van so that the wheels are relieved or move the Malibu box type van monthly This prevents pres sure points being formed on the tyres and wheel bearings Always ensure for sufficient air circulation on the underfloor Humidity or lack of oxygen e g by covering with plastic film may cause optical irregularities to the underbody Interior Put up the padding for ...

Page 113: ...r and hatch hinges Interior Setup a dehumidifier Remove the padding from the Malibu box type van and store in a dry place Empty all cabinets and storage compartments and open furni ture fronts doors and drawers Thoroughly clean the inside Ventilate the interior every 3 weeks Electrical system Starter battery and living area battery Before taking out of operation charge for at least 20 hours Check ...

Page 114: ...Remove the winter cover from the fridge grills if there is one Gas system Put the gas bottles in the gas bottle compartment tie down and connect to the gas pressure regulator Electrical system Connect to 230 V supply via the socket outside Check the operation of the electrical system e g interior lights sockets and all electrical appliances Fully charge the living area battery and starter battery ...

Page 115: ...n structing by the factory as well as equipment and tools give the guarantee for a professional maintenance of the vehicle that corresponds to state of the art In the inspection verification for the main cabin living area in this user manu al the Malibu service stations confirm the work carried out Observe the inspections listed in the inspection certificate and have them carried out in the prescr...

Page 116: ...s Type of inspection Engine Technically permissi ble gross weight Testing interval Emission test Diesel Diesel up to 3 5 t more than 3 t Every 2 years Annually General inspection Diesel Diesel up to 3 5 t more than 3 t Every 2 years Annually Tab 9 Test schedules 12 3 Main cabin lighting Carry out the bulb change in order not to cause damage to the protective glass or the bulb Replace the bulbs onl...

Page 117: ...partment cover 2 batteries Fig 74 Battery operated lamp The lighting element of the light cannot be replaced Please contact your Carthago trade partner to change the lighting ele ment Changing the battery 1 Push battery compartment cover Fig 74 Pos 1 to the side 2 Replace the batteries Fig 74 Pos 2 Make sure that the terminals are correct when changing the battery Use batteries of the same type 3 ...

Page 118: ...hicle pillar behind the insulation Fig 75 The top nut is located in the opening direct under the bed plate The bottom nut is located underneath that in the opening 10800105 1 1 Rear light nut Fig 75 Rear light driver s side 1 Open the rear wing doors 2 Remove protective caps 3 Remove screws PH1 or PZ1 screwdriver 4 Remove cover strip 5 Using a 17 mm socket a joint and a ratchet undo both nuts Fig ...

Page 119: ...om panelling Fig 76 Rear light driver s side 1 Open the rear wing doors 2 Remove the panelling Fig 76 Pos 2 3 Using a 17 mm socket a joint and a ratchet undo both nuts Fig 76 Pos 1 and remove them 4 Continue in chapter 12 4 5 Changing the bulbs on the rear light mould ing on page 107 When returning to the original state tighten the nuts Fig 76 Pos 1 fin ger tight Returning to the original state is...

Page 120: ...t Fig 77 Rear light passenger side Malibu 600 1 Open the rear wing doors 2 Remove the mattress or padding 3 Remove the cover above the fresh water tank 4 Undo the filling hose Fig 77 Pos 2 and the venting hose Fig 77 Pos 1 on the fresh water tank and put aside 5 Using a 17 mm socket a short extension and a ratchet undo both nuts Fig 77 Pos 1 and remove them 6 Continue in chapter 12 4 5 Changing th...

Page 121: ...in the opening 10800104 1 Fig 78 Rear light passenger side Malibu 640 1 Open the rear wing doors 2 Using a 17 mm socket a short extension and a ratchet undo both nuts Fig 78 Pos 1 and remove them 3 Continue in chapter 12 4 5 Changing the bulbs on the rear light mould ing on page 107 When returning to the original state tighten the nuts Fig 78 Pos 1 fin ger tight Returning to the original state is ...

Page 122: ...tted by the manufacturer or an author ised specialist workshop The Malibu trade partners and service stations are available for any spare parts requirement When ordering spare parts specify the chassis number and vehicle type to your Malibu trade partner The Malibu box type van described in this user manual is built and equipped according to factory standards Useful special equipment is offered de...

Page 123: ... the respective documents supplied or can be obtained in internet Chassis manufacturer Fiat Camper Service In event of breakdown Fiat Camper Service can provide you and your Malibu box type van on the Fiat basis with quick assistance The Fiat Camper Ser vice is available 24 hours a day The emergency number applies anywhere in Europe Telephone number 0 08 00 34 28 11 11 You can obtain more informat...

Page 124: ...110 0001 04EN 110 12 Maintenance ...

Page 125: ... the last two figures the year of manufacture Example 1510 Week 15 year of manufacture 2010 Observe the minimum tread depth specified by law Always use tyres that have the same design the same brand and the same model summer tyres or winter tyres Use only the tyres approved for the rim type The permissible rim size and tyre size are listed in the vehicle documents of the motorhome Your Malibu trad...

Page 126: ...ck the inflation pressure at regular intervals Check the inflation pressure only when the tyres are cold The maximum pressure specified on the tyres must not be exceeded Use the documents of the tyre manufacturer to obtain the correct tyre in flation pressure 10800138 1 Fig 79 Sticker position The inflation pressures can be obtained from a sticker Fig 79 on the vehicle The sticker is located on th...

Page 127: ...o Winter 110 108 R E Zw 1360 2560 1540 2890 1710 3220 1880 3540 1950 3700 1990 2040 2100 195 75 R16 CP Michelin Agilis Camping 107 Q E Zw 1170 2160 1350 2500 1530 2820 1700 3140 1870 3450 1950 3600 1990 3630 2030 3650 2100 3700 225 75 R16 C Continental Vanco Four Season 118 116 R E Zw 1690 3200 1910 3620 2130 4020 2340 4420 2440 4620 2490 4690 2550 4810 5000 225 75 R16 CP Michelin Agilis Camping 1...

Page 128: ...110 0001 04EN 114 13 Wheels and tyres ...

Page 129: ...ystem the gas cooker the heater the boiler the fridge the water supply the main cabin The malfunctions listed can be rectified by yourself in a few actions without having much professional knowledge If the remedies listed in this user manual do not lead to the rectification of the malfunction have an authorised specialist workshop search for and eliminate the cause 14 Malfunctions 14 1 Brake syste...

Page 130: ...p Starter or supply battery is not charged during 230 V operation Blade fuse 50 A at starter battery or supply battery defective FIAT Charge module in the elec tric block defective Change the blade fuse 50 A on the starter or living area battery Visit the customer services specialist workshop Living area battery is not being charged by the vehicle Blade fuse 50 A on the starter or supply battery d...

Page 131: ...ery Living area battery discharged Charge the living area battery immediately In event of pro longed deep charging the liv ing area battery will be damaged irreparably In event of longer standing times of the Mal ibu box type van fully charge the living area battery beforehand Control Panel without func tion Fuse in the electric block defective Replace the fuse in the elec tric block 14 3 Gas syst...

Page 132: ... valve correctly do not bend The sensor tip should pro trude by 5 mm beyond the burner The sensor neck should not be more than 3 mm away from the burner ring If necessary visit the cus tomer services specialist workshop Flame extinguishes when be ing reduced to its minimum setting Ignition safety valve is not set correctly Set the ignition safety valve correctly do not bend The sensor tip should p...

Page 133: ...r manufacturer in this vehicle 14 5 2 Fridge Fault Cause Corrective action Fridge does not switch on during 230 V operation 230 V circuit breaker or FI switch has tripped Switch on the 230 V circuit breaker or FI switch No 230 V supply available Battery voltage of 230 V too low Connect the 230 V supply Have the 230 V voltage sup ply check by a specialist The fridge does not switch on during 12 V o...

Page 134: ...ter drain in the opposite direction using the water hose Water tap leaking Damage by frost Renew the cartridge in the water tap Can be ordered from the Malibu trade part ners 14 7 Main cabin Fault Cause Corrective action Hatches door hinges are difficult to operate Hatches door hinges are not insufficiently lubricated Lubricate the hatch door hinges with acid free and resin free grease Hinges join...

Page 135: ...Angelestraße 56 D 88214 Ravensburg info tef de www tef de ...

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