Kimberley KARAVAN 2021 Installation, Maintenance & Operating Manual Download Page 20

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Mounting the DO35 Tow Pin onto the Tow Bar

For Australian supplied couplings, fi t tow pin to towbar using spring washer

and 7/8” nut supplied and torque to 440Nm (325lbs.ft) It may be necessary

to hold the tow pin in place using the supplied c-spanner.

For American supplied couplings, fi t tow pin to towbar using spring washer

and 1” UNF nut supplied and torque to 530Nm (390lbs.ft) It may be

necessary to hold the tow pin in place using the supplied c- spanner.

Hitching Up Your Kimberley

Attaching a DO35 / D045 Hitch

Your Kimberley may be fi tted with a Cruisemaster DO35 / DO45 hitch.

For more detailed information about using these hitches see the “Operating Instructions” in the Owners

Satchel.

Mounting the DO35 Tow Pin onto the Tow Bar

For Australian supplied couplings, fit tow pin to towbar

using spring washer and 7/8” nut supplied and torque

to 440Nm (325lbs.ft) It may be necessary to hold the

tow pin in place using the supplied c-spanner.

For American supplied couplings, fit tow pin to tow-

bar using spring washer and 1” UNF nut supplied and

torque to 530Nm (390lbs.ft) It may be necessary to hold

the tow pin in place using the supplied c- spanner.

Insert spanner tab into tow pin

cross hole to secure pin while

torqueing nut

Bottle Opener

Bolting the DO35 Coupling onto the Drawbar

Always use four new bolts to secure Coupling to Trailer. Bolt grades to be minimum

M12 Class 8.8 torqued to 90Nm (66lbs.ft) or ½” Grade 5 bolts torqued to 100Nm

(74lbs.ft). Use either nylon insert nuts or spring washers.

DO NOT ATTEMPT TO

WELD

the coupling to the drawbar. The coupling must always be mounted flat on

the drawbar plate.

A drawbar weight of at least 50kg (110lb) and not exceeding 350kg (772lb) is

recommended.

M12 or ½” Bolts

Use of Weight Distribution Hitches

The DO35 can be used with load distribution hitches’ providing the coupling

movement is not obstructed and the maximum downward load of 350kg (772lb)

prior to tightening of bars is not exceeded. With a WDH adaptor attached to the

vehicle, clearance should also be checked to ensure the trailer drawbar does not

foul, particularly in tight reversing situations.

*WDH Adaptors for inproved clearance with Hayman Reese Systems Available (See Accessories)

PRODUCT FEATURES

High Visibility Refl ective Reversing Strip

2. Impact Resistant Bumper

3. Locking Slide Plate

4. Lock Button Push Down to Release Lock Plate

5. Pin Locating Port

6. Tow Pin Shaft (7/8” UNF AU or 1” UNF US Thread)

7. Gen.2 Check-Lock Dust Cap

8. Spindle Bushes

Summary of Contents for KARAVAN 2021

Page 1: ...MAINTENANCE OPERATING MANUAL THE KIMBERLEY KARAVAN Version 160921 2021 ...

Page 2: ...rst point of contact so please have their number handy We are always happy to answer your questions receive your feedback Pleasant Kamping Electronic Warranty Registration System Your Kimberley Warranty is both in this manual and can be found on our website Note your 4 digit chassis number and use this as a reference in all communication You must complete the Warranty Registration Form on the Kimb...

Page 3: ...ling faucets hot water system Energy System batteries solar fuses electrical system diagram sustainable energy system charging solar generator troubleshooting Braking System disc brakes information Canvas Use Care awning layouts and canvas care information Specifications After Sales Service warnings cautions dealer handover checklist service record Contents ...

Page 4: ...tion clause and the clause reducing the time period when suit must be filed for breach Coverage Ends 36 Months Manufacturer Warranty and 60 Months Chassis Suspension Warranty after the first retail owner first takes delivery of the camper trailer caravan from an authorised dealership Any action for breach of this warranty or any implied warranties must be commenced not more than 37 61 months after...

Page 5: ...ge period Any performance of repairs after the warranty coverage ends OR any performance of repairs to those portions of your camper trailer caravan excluded from coverage shall be considered good will repairs Warranty repairs should be expected KK may use new and or remanufactured parts and or components of substantially equal quality to complete a repair Damage to interior or exterior surfaces t...

Page 6: ...nish Note The fine red dust that you see in the outback and other remote locations generally has iron ore in it When trapped in the surface of steel and stainless steel it will start to corrode and rust A very thorough clean will generally remove this rust If left it will attack the stainless steel and the surface condition 12 Dust ingress Note We can t advertise our products as dust proof as a wh...

Page 7: ...s or workmanship KK will in it s sole discretion either replace or repair the camper trailer caravan or the defective part of the camper trailer caravan or cause the camper trailer caravan or defective part of the camper trailer caravan to be replace or repaired by a qualified repairer Warranty repairs shall only be carried out by KK s service department or when directed by KK s Service Manager by...

Page 8: ...h the laws of the state of NSW Any and all claims controversies and causes of action arising out of or relating to this limited warranty whether sounding contract tort or statute shall be governed by the laws of the State of NSW including its statute of limitations without giving effect to any conflict of law rule that would result in the application of the laws of a different jurisdiction Kimberl...

Page 9: ...et to this as the product leaves the factory The base components of a Kimberley are robotic laser cut and assembled then welded and this is to a high degree of precision The canvas floor wall and roof coverings are robotic cut and drilled However every Kimberley is hand built in final assembly Hand built products have a higher defect rate than robotic built products like motor cars This is because...

Page 10: ...we can achieve zero defects other than fair wear and tear Kimberley select quality products which we include and support Customers need to be aware that if the air conditioner or microwave fail the resultant quality reputation is not directly attributable to Kimberley It is attributable to the supplier of that brand product On the road and something doesn t go right If you have any difficulty on t...

Page 11: ...ently For Electronic Disc the parking brake valve MUST be off before departing We recommend ALWAYS chock wheels when parked on a slope of any sort ALLOY WHEELS CHECK WHEELS FOR TRAPPED STONES GIBBERS WHILST ON TRIP Alloy wheels are vulnerable to damage if stones gibbers stay caught between wheel brake assembly NB There is no warranty by Kimberley Kampers Manufacturing Pty Ltd on damage to alloy wh...

Page 12: ...ator Available The battery charger has compensation for use with a generator so it is possible to get to nearly 100 charge capacity Use a surge protector to protect your power devices on the AC circuit Inverter and Battery Charger DO NOT USE THE INEXPENSIVE GENERATORS AS THEY DO NOT USE A PURE SINE WAVE INVERTER TO THE AC POWER Kamping AC site power available This is the easiest scenario to manage...

Page 13: ...ck your tyres for abnormal wear or damage such as cracks bulges or tears If there is uneven wear on the inside or outside of the tyre this is due to a tracking issue in the suspension You need to have the suspension tracking adjusted to approximately a 1 3mm 0 04 0 12in tow in position Utilise the Spare Tyre For maximum tyre life efficiency ensure that you rotate your tyres at regular intervals an...

Page 14: ...orage with no damage Batteries should be checked periodically during storage to ensure batteries are not fully discharged as there are small devices which draw power all the time Check and charge the batteries in storage at least once every 6 months When it safe to do so plug in the battery charger to AC power and leave on Always check your state of charge periodically to ensure you have not left ...

Page 15: ...ck absorber will over heat causing the shock absorber to fail If the tyre sidewalls are generating too much heat they can be vulnerable to failure In either case the failure is not a defect and would not be warranty A high tyre pressure has a significant effect as you increase tyre pressure it increases the stiffness of the tyre as the pressure increases It also reduces the foot print size of that...

Page 16: ...r 13 psi WARNING This table is a guide only Local conditions the load in your unit and the behaviour of your vehicle under different loads will change the way it handles Control your speed at all times especially in difficult or unknown conditions In our experience we have also found the quality of the tow vehicle tyres can have an affect on the towing behaviour of our trailers Important Informati...

Page 17: ...select App Store desired Kimberley Smart Power Simarine Enerdrive Underbody Lights Fusion Multimedia Wireless battery monitoring Only for KK Brand Batteries Easy access for all of the features of the Simarine Smart Touch system Wireless battery monitoring for Enerdrive batteries Control the underbody lights Power ON OFF and change colour Control the multimedia and entertainment system ...

Page 18: ...1 Left flasher lamps Yellow 2 Reversing Indicators Lights Black 3 Earth White 4 Right flasher lamps Green 5 Service brakes auxiliary Blue 6 Stop lamps Red 7 Tail licence plate clearance lamps Brown 3 4 1 2 5 6 7 Kimberleys are wired to industry standard and feature a 7 pin round connector AS 2513 They may also be fitted with the Optional Anderson Plug for charge current See below for wiring detail...

Page 19: ...heck tow tongue width is suitable 3 Remove nut and spring washer from the bottom of the TREG receiver 4 Place the receiver onto tongue with thread poking through 5 Fasten receiver with spring washer then tighten nut until spring washer is compressed and receiver is held firmly in place The receiver should be tight and checked periodically when travelling Connecting to your vehicle with TREG hitch ...

Page 20: ...ing Instructions in the Owners Satchel Mounting the DO35 Tow Pin onto the Tow Bar For Australian supplied couplings fit tow pin to towbar using spring washer and 7 8 nut supplied and torque to 440Nm 325lbs ft It may be necessary to hold the tow pin in place using the supplied c spanner For American supplied couplings fit tow pin to tow bar using spring washer and 1 UNF nut supplied and torque to 5...

Page 21: ... Up Your Kimberley Hitching up with the DO35 DO45 STEP 1 Ensure the Tow Pin Cover is removed from Tow Pin Step 2 The Tow Pin and Universal should be free of sand dirt and foreign objects Lightly lubricated to ensure premature wear is avoided Step 3 Set the coupling to the unlocked position Do so by pushing down on the Red Lock Button while simultaneously pushing back the Locking slide plate toward...

Page 22: ...Pty Ltd Hitching Up Your Kimberley Attaching a McHitch Trailer Coupling Your Kimberley may be fitted with a McHitch Trailer Coupling For more detailed information about using these hitches see the Operating Instructions in the Owners Satchel ...

Page 23: ...23 2021 Kimberley Kampers Manufacturing Pty Ltd Hitching Up Your Kimberley ...

Page 24: ...24 2021 Kimberley Kampers Manufacturing Pty Ltd Hitching Up Your Kimberley ...

Page 25: ...eight of the tow bar tongue should be approx 520mm 1 ft 8 5 in when the Kimberley is attached For best performance your KK should be slightly lower at the hitch by approx 25mm 1 in This height can be adjusted by the airbags or the Vehicle tow tongue if the vehicle is lifted Loading for Best Stability and Towing Performance Weight distribution in a Kimberley has a significant impact on the towball ...

Page 26: ...y wheel down A 3 Record the weight of the unit when attached to the vehicle B with trailer wheels only on weighbridge 4 Calculate the towball weight by subtracting B from A 5 Load your Kimberley as you intend for your trip and repeat the above process to ensure you do not exceed Towball weight for your vehicle and ATM GVWR for your Kimberley Initial Loading Weights Trip Loading Weights Total KK We...

Page 27: ... units are within 10 meters To tow the trailer or caravan when the tow vehicle is not equipped with a 12 pin trailer socket a temporary towing extension cable is included This plugs in to the tow vehicle socket and a trailer socket mounted under the front storage box For more detailed information about operating the WiTi System see the Operating Instructions in the Owners Satchel WiTi Wireless Tra...

Page 28: ... optional and can be connected to an ignition source in the tow vehicle This circuit works in conjunction with the ignition output on the Anti Theft unit When the units are paired and the ignition is on in the tow vehicle then the ignition output on the Anti Theft Unit will provide 12V The best way to describe this is as a wireless relay This connection can be used for any device on the caravan th...

Page 29: ... the RESET button 3 When the RESET button is released you will notice LED2 flashing rapidly while LED 1 is still solid Let go of the PAIR button The WiTi Wireless Towing Interface is now in PAIRING mode The unit will stay in pairing mode for five minutes while searching for the Wireless Communication Module 4 Repeat the Pairing Process on the Communication Module in the Caravan or Trailer 5 On suc...

Page 30: ...here is inactivity for 24 hours In this mode power draw is less than 2 milliAmps WiTi will exit Low Power Mode when it detects an input from the driving light circuit CanBus and vehicles fitted with advanced towing features WiTi Wireless Towing Interface supports all CanBus vehicles and vehicles with advanced electronics WiTi supports vehicle specific towing modes and features for example disablin...

Page 31: ...ehicle Rear Recovery Points Kamper Karavan Kruiser Locks Keys For your security and ease of use all Kimberley s are supplied with regular square drive keys Types of keys 1 Square drive keys 2 Filler cap keys 3 Tail gate latch keys where fitted It is recommend that these are kept in a secure but easy to access location RECOVERY POINTS SHACKLES EQUALIZER STRAP SNATCH STRAP or WINCH CABLE CAUTION Whe...

Page 32: ...AUTION Avoid cranking jockey wheel to unnecessary height and avoid side loads on jockey wheel that could cause damage or excessive wear Maintenance Minimal maintenance is required to keep your jockey wheel looking new and in good working order Protect the finish by keeping it clean and periodically applying a coating of silicone lubricant spray Lubrication is needed if the jockey wheel ever feels ...

Page 33: ... arm points Accessing the Spare Tyre The spare tyre is located underneath between the suspension swingarms To lower the spare 1 Locate the spare tyre winder 2 Place winder through the hole in the chassis shown below Kamper Karavan right rear chassis rail Kruisers front left chassis rail 3 Feed into the space between the spare tyre and chassis 4 Locate the end within the spare tyre winder the pins ...

Page 34: ...nsuite for Kruisers If you need to replace the glycol in the hot water system at any time you can use standard premix glycol fluid that you would use in your vehicle It must be premix DO NOT USE CONCENTRATE When performing water crossings where the water level is above your Kimberley axles the following precautions need to be taken to avoid any damage to your Diesel Hot Water System or Diesel Spac...

Page 35: ...GHT CONTROL UNLOCK WHEN IN CAMP How to use with external air compressor F 1 To adjust air pressure connect air line to the manual inflation inlet valves F and add or remove air as require Note OPEN CLOSE valve needs to be in OPEN position when adjusting air pressure levels Using on board compressor with Compressor Outlet G Where Fitted 1 Remove blanking bolt with allen key 2 Install coupler air fi...

Page 36: ...is suitable from travel on main highways IMPORTANT DO NOT HAVE LOW LEVEL AIRBAGS IN OFF ROAD CONDITIONS UNDER ANY CIRCUMSTANCES High provides additional guard clearance and upward articulation for off road applications Medium the standard factory setting which allows approximately the same articulation in both up and down directions Low suitable for flat bitumen only RIDE HEIGHT SETTING Ride Heigh...

Page 37: ...021 Kimberley Kampers Manufacturing Pty Ltd Kimberley Air Suspension Manual Filling System Diagram 2021 Kimberley Kampers Generic Air Suspension Layout AIR BAG AIR FILLING INLET IN AIR FILLING INLET AIR BAG ...

Page 38: ...38 2021 Kimberley Kampers Manufacturing Pty Ltd Kimberley Air Suspension PLUS On board Compressor System Diagram AIR COMPRESSOR AIR BAG AIR BAG AIR TANK SOLENOID CONTROLLER KAMPER KARAVAN KRUISER ...

Page 39: ...ible on the gauge B This is preset at 70psi maximum Check once compressor has cut off 6 Airbags operation can now be checked by raising and lowering each side using the height adjustment levers D NOTE The pressure gauge B will show a slight difference between each side as the weight on each side of the unit will vary slightly Care needs to be taken not to over inflate airbags once maximum ride hei...

Page 40: ...tified in Steps 2 4 CHECK for leaks in any fittings between the OPEN CLOSED E valves and the control switches display gauge 6 IF there are no leaks identified in Step 2 5 then check for leaks in any fittings between the air inlet side of the control switches display gauge and the air compressor How to fix a leaking fitting See instructions in previous section Air Suspension Maintenance When the ai...

Page 41: ... at least 50psi each side 2 Climb under the trailer Inspect the air fitting at the top of each air bag by spraying with soapy water you may need to clean fittings if dirty If you notice air bubbles you have found a leak 3 Inspect the back side of the air inlets in the front storage box using soapy water How to fix a leaking fitting 1 FIRST you MUST release all air pressure from the system 2 For th...

Page 42: ... will come out with the airbag 5 Now you can remove the airbag assembly You will need to split the urethane seal on the airbag lower block away from the plate and swing arm This can be done with a knife or sharp blade 6 Using a 14mm socket remove the two bolts securing the upper mounting plate to the airbag 7 Use a flat blade screw driver to split the upper mounting plate off the top of the airbag...

Page 43: ...ter source for non drinking use eg showering washing up How to fill your Karavan water tanks To fill Tank 1 Drinking Water 1 Unlock and open filler cap on top 2 Insert hose fill 3 Stop filling when water reaches the filler 4 Repeat process to fill Tank 2 Non Drinking Water Water level display Located on the dash panel The Smart Touch screen displays the amount of water stored within the Karavan wa...

Page 44: ... Ensure grey water tank outlet pipe with valve is fixed in upper position against chassis rail and valve is in CLOSED position before traveling 13 Connect to vehicle Check jockey wheel away set airbags to travel height and level do visual check on ride height lights working Essentials Kwik Setup Guide 1 Engage parking brake disconnect from vehicle if needed level Karavan open door lower steps 2 Re...

Page 45: ...ARRANTY Kimberley Kampers will replace LED lighting strips if more than 3 LED s in a row fail within 12 months of purchase Underbed Membrane Heater Optional LED lighting is used throughout your Kimberley These lights are low maintenance use little energy and have a long service life Nominal voltage 12V 11V to 14 5V range Service Life 10 000 hours approx 10 years at 3 hours EVERY NIGHT Lights are c...

Page 46: ...RIGHT UP TO TOP OF TANK Use high quality Automotive Radiator Coolant 3 Check Fuel Coolant lines for any leaks 4 The Diesel Heater should be service by an authorized service centre every 2 years IMPORTANT If you turn the Heater off at the controller do not turn off power switch until heater unit performs it shut off process Wait at least 10 minutes Water flow rate for best temperature control is be...

Page 47: ...tion can be adjusted as needed To use Air Heater Check diesel fuel level is sufficient 1 Turn on Hot Water power Kamper only 2 Press display power button once 3 Rotate control dial to select Air Heater 4 Press control dial to start Air Heater 5 Press control dial to start or stop Air Heater Operation For detail instructions use the Operating Instructions included in your owners satchel NB The heat...

Page 48: ...en during use Let some water run into the bowl before use Operate the flush button 1 for this When lifting the toilet seat it locks in an approximately 2 3 position Use a little more force if you want to open the seat fur ther Fig 8 Fig 9 Fig 10 1 2 Operate the flush button 1 again after use to flush the bowl Close the blade handle 2 4 3 Control panel Flush button Cassette tank removed display Fil...

Page 49: ...om liquid wastes trapdoor needs to be closed for liquid waste 4 For solid waste open trapdoor with the handle on the left side of the toilet Return trapdoor to closed position when finished toileting 5 Turn the agitator handle on side after solid waste addition 2 3 revolutions slowly in order to mix the waste into the compost and promote the composting process 6 Most users keep a small spray bottl...

Page 50: ... tank should be emptied frequently and rinsed with water with detergent or vinegar added Allowing urine to remain in the storage container for extended periods is unwise as this will result in increased odor production To empty the solid waste container 1 With the bottle assembly removed lift the seat unit several inches and slide it to the left to disengage the slip hinge You may need to unhook y...

Page 51: ...not leave the liquid wastes in the tank for extended periods While everyone is different some urine will smell bad if allowed to sit for extended periods Cleansing maintenance A quick spray of water and white vinegar or a natural cleaner from the squirt bottle is all that is needed to keep your unit fresh between uses If necessary a moistened paper towel no synthetics is excellent for cleansing th...

Page 52: ...e sphagnum peat moss should rise to the level of or cover the agitator bar in a horizontal position The sphagnum peat moss should be damp and crumbly never wet or soupy If your sphagnum peat moss or coconut fiber is dry add a small amount of water When not in use the lid of the toilet should be in the closed position preventing the entry of insects and allowing proper ventilation The peat moss mus...

Page 53: ...and fan The Kamper has space for mounting the toilet in right side of front storage box for travel How to secure composting toilet in a Kamper Composting Toilet 1 Place travel cover over toilet 2 Connect air vent pipe to outlet on side of toilet and 12V power 3 Connect air vent pipe to outlet 4 Connect 12V power cable and turn power on for toilet fan THIS FAN MUST BE ON WHENEVER THE TOILET HAS WAS...

Page 54: ...me water and turn the agitator after the sphagnum peat moss has absorbed the moisture Cold Conditions Composting works from 13 C 55 F and warmer The warmer it is the faster it composts When the temperature drops to freezing the compost will be dormant until heat is introduced to the area Turn the heater on to raise the temperature in the toilet Fruit flies or gnats If your toilet incurs flies or g...

Page 55: ... box at one time If after checking the above the appliance still does not operate properly contact your closest service agent When reporting the problem state the type of problem the appliance model number product number and serial number This information can be found on the data plate on the bottom of the appliance IMPORTANT Never use a knife or sharp object to remove ice when defrosting freezer ...

Page 56: ...n fuel ON at bottom of tank 3 Switch Cook top Power to ON position press in switch 4 Once the red indicator lamp lights about 2 5 4 minutes adjust the temperature to desired setting 5 The hottest area is on the round plate gentler heat is available on the oblong extension 6 Press the power switch to OFF position when finished Red lamp will flash for approx 5 mins after switching OFF you cannot res...

Page 57: ...power to be supplied via Inverter Optional from batteries OR generator site power How to use your microwave 1 Ensure microwave interior is free of any unwanted objects especially metal 2 Connect AC power or start the inverter and ensure the AC switch in the microwave cupboard is ON 3 Place cooking item inside microwave on turn table close door 4 Adjust Power Program Time to suit 5 Press Start Clea...

Page 58: ...el the satellite dish will raise up and rotate to search for a satellite When satellite found Satellite Found will display on the control panel 3 To finish using press the Power button again and dish will lower ready for travel NOTE Ensure Satellite dish is lowered before any travel Access to the VAST satellite service is managed by a smart card which is supplied with the satellite set top box To ...

Page 59: ...ional How to use the Air Conditioner 1 Turn power switch on overhead console to ON position 2 Adjust temperature and air flow via air conditioner interface controls For more detailed information see the Operating Instructions included in your Owners Satchel IMPORTANT This Air conditioner can only be used when using external shore power supply Symptom Cause Remedy When switching on the unit does no...

Page 60: ...amount of smoke please contact your Dealer as soon as possible for servicing B E S T Water Filter Your Kimberley may be fitted with a B E S T water filter Bacteria Eliminating Silver Treatment This is installed on the cold water line to give filtered water at the sink With the B E S T filter You can safely draw water from town tank creek or bore water Chemicals sediment are removed bacteria is des...

Page 61: ...d on hose to prevent sediment being sucked into system See Hose Filler Kit hose can also be connected to mains water 4 Use water as desired 5 TURN PUMPS OFF WHEN NOT IN USE OVERNIGHT or for an extended time The auto feature of the taps and pumps means that as the vacuum reduces the pump will come on automatically with a Brrr at an unexpected time CAUTION There are Health risks in pumping from exte...

Page 62: ...perature Water System Grey Water Tank Your Karavan may be fitted with a Grey water tank which can receive water from your shower and internal sink systems Grey water can be either diverted to this grey water tank or directly to the outside environment via an outlet pipe 1 To capture grey water turn the flow valve to the CLOSED position and leave outlet pipe attached to the chassis rail upper posit...

Page 63: ...t with typical water usage Tank 1 70L Tank 2 120L External water source Main sink Cold Y Main sink Hot Y Outside sink Cold Y Outside sink Hot Y Shower Hot Cold Y Y Toilet flush Y Y Days of storage typical usage 23 4 with hot showers toilet flush washing up from Tank 2 X Days of storage typical usage 23 14 with hot showers toilet flush washing up from external source ...

Page 64: ...Settings Menu b Arrow down until you come to Wifi and press the bottom right hand button to enter this menu c Arrow down until you come to Password reset and press the bottom right hand button to enter this menu This will now give you your Pico ID number and the password associated Go back to your phone and enter this password into your wifi settings menu 3 Now you should be able to fire up the Ap...

Page 65: ...Battery Cycling To keep your batteries in top condition they must be topped up by charging every month They cannot be OVERCHARGED with the battery charger and can be left plugged in all the time or for extended periods It is also advisable to use and cycle charge the batteries at least once every 6 months Energy System How to charge your Batteries There are 3 main ways to charge the batteries in y...

Page 66: ...attery 4 RECONDITION Never select this function How to charge your batteries with AC power 1 Switch OFF all non essential items that may draw power from the batteries 2 Check the charger settings are correct connect AC power lead to inlet 3 Turn power ON at power source 4 Ensure battery charger is connected switched ON at internal outlet where fitted 5 CHARGING indicator light will glow as batteri...

Page 67: ... with the return earth cable as well 50A Andersen Plug is also available NOTE The Andersen 50A Plug and cable This is a large 2 connector foolproof plug that is positioned in the front of the trailer at the hitch It has the advantages of taking a higher current flow with less voltage drop and is lower maintenance It is also a convenient connection point for high charge Christie Battery Chargers It...

Page 68: ...68 2021 Kimberley Kampers Manufacturing Pty Ltd Energy System Battery Charging Vehicle Set Up Kimberley recommend a vehicle charging system like this ...

Page 69: ...ificant effect As the surface and cell temperature rises the efficiency of mono crystalline cells reduces When the surface temperature hits 65 C 149 F which is the typical temperature in the North of Australia the output may be reduced by 20 30 alone The compound effect of sun angle dust and temperature always reduces the output even before shading Experience is that 50 of the nominal roof capacit...

Page 70: ...cles and battery can be stored at levels as low as 20 without damage What you need to know about Lithium Iron Batteries These batteries are weather sealed and the internals are housed within a rugged plastic casing They are maintainence free the only things you need to do are 1 Ensure they are charged correctly 2 Store them fully charged DO NOT Disassemble crush puncture or incenerate Short circui...

Page 71: ...l circuit breaker has not been knocked off If this is ON press the test switch on the circuit breaker If the main switch trips then power is getting to the circuit breaker Next Test an appliance inside the Kamper on the left side AC plug points If they test OK then the issue is the charger Next Unplug the charger plug out of the Kamper and into the extension lead direct If the charger still does n...

Page 72: ... operating range A fault code will display E02 The charger will recover automatically when it senses the AC input voltage has returned back to the normal operation range Charging A Dead Lithium Battery The charger must be switched to PROGRAM Power Supply mode in order to charge Set the charge current to the lowest setting of 5A to help prevent any possible overheating of the battery during chargin...

Page 73: ...l splutters the AC voltage delivered from the generator can damage your battery charger Protecting your battery charger whilst Discharging The general rule is to discharge to about 50 left and recharge the batteries again as soon as possible You can go lower than 50 ie down to 10 but if you do so you can shorten the lifespan of the battery PLUS if you can t recharge for some reason there is no res...

Page 74: ... 2 more than 5 minutes has elapsed at that value The reason for this is that the batteries would be fully charged if both these conditions are met and the voltage condition is acceptable For the AC and solar charging this will always be the case But for vehicle charging it may not be and this is why the 14V at the vehicle is so crucial If the supply voltage from the vehicle is less than 14V the ba...

Page 75: ...with the isolator off please ensure you have disconnected your solar panels as even with the van switched off the solar is so efficient it can energize some systems in the van This intermittent voltage is not recommended for long term exposure Energy System How to Use DC AC Systems 1 Smart Touch Display Monitor battery capcity voltage current water tank levels solar array power fridge temperature ...

Page 76: ...d plug in using power inlet on rear of Karavan body 2 Turn power on at power source 3 The AC outlet on rear of Karavan and outlets inside are now live and can be used to power appliances This connection allows the Battery Charger to operate The rear of the Karavan features outlets inlets switches for the following 5 There are several fuses used in the Karavan We recommend that you carry the follow...

Page 77: ...Master Battery isolator 30A ANL Fuse Front Box Fuse Block 30A Mini ANL left Red Anderson Plug 50A Mini ANL right DC DC Charger Output FRONT BOX LIGHTS RED WIRE 3A COMPRESSOR BROWN WIRE 30A TANK HEATER RED WIRE 20A UNDERBODY LIGHTS PURPLE WIRE 10A WiTi RED WIRE 10A FRONT FUSE BLOCK SMART TOUCH RED WIRE 3A PUMP 1 PINK WIRE 10A BENCH LIGHT RED WIRE 3A PUMP 2 PURPLE WIRE 10A DASH FUSE BLOCK Console fu...

Page 78: ...ITH FUSE OF SAME RATING IF FAILURE OCCURS HAVE FAULT RECTIFIED PREFERABLE BY AN AUTHORIZED DEALER Energy System Fuses Circuit Breakers 40A ANL Fuse Solar 60A ANL Fuse Battery Charger REAR 12V OUTLETS RED WIRE 25A TOILET WHITE WIRE 10A CANOPY ACTUATOR BROWN WIRE 30A UNDERSEAT POWER GREEN WIRE 10A WATER HEATER ORANGE WIRE 25A AIR HEATER ORANGE WIRE 25A CANOPY GREEN WIRE 25A KITCHEN DASH RED WIRE 30A...

Page 79: ...your regulator and use the KK onboard BC DC regulator as this is programmed for optimal performance with KK batteries If you plug your panel kit into the trailer with your regulator then you may void your battery warranty Where possible we recommend you only use genuine KK products and accessories Optimum sun hours Solar Panels need SUN LIGHT to produce power Here is a table of the average SUN HOU...

Page 80: ...attery voltage going outside of the normal operating voltage range of the inverters an audible alarm will sound or fault code will be displayed and the unit will shut down This protects internal circuitry of the inverter and the battery from excessive discharge Once battery voltage returns to the inverter s normal voltage operating range it can be restarted Unit can be switched off to silence alar...

Page 81: ...ator Front box SHUNT SC301 See page 2 X X 60A Fuse From Rooftop Solar S 30A Fuse Canopy behind console right light Power to SICOM SPLITTER see page 2 D C B To Accessories see page 3 E To Electronic Brakes if fitted See page 5 AC IN BATTERY CHARGER AC OUT INVERTER 300A Master Fuse Front box Solar Regulator MPPT 1 8 For Classic models only A To SCQ25T Shunt OUT 04 If fitted see page 2 To SHUNT SCQ25...

Page 82: ...1 OUT 02 OUT 03 OUT 04 NC 2 NO 3 COM 1 Digital Shunt SICOM 2021 Kimberley Karavan 12V Electrical Circuits Model Eco Suite Date 31 08 2021 2 8 A Fridge C SiCOM Splitter Inclinometer Fridge Temp Digital Display X See Page 1 X 1A Fuse Shock L Shock R F To Canopy 12V Circuits B Tank 1 70L Tank 2 120L From Solar 10A Fuse 25A Fuse Rear Frame 5A Fuse Rear Frame ...

Page 83: ...rley Kampers Manufacturing Pty Ltd X See Page 1 X 2021 Kimberley Karavan 12V Electrical Circuits Model Classic Date 31 08 2021 3 8 C SiCOM Splitter Digital Display 1A Fuse B Tank 1 70L Tank 2 120L 5A Fuse Rear Frame ...

Page 84: ...hts Water Pump 1 Water Pump 2 Narva Outlet 10A Fuse 12V Outlets Interior Rear Hatch Rear Hatch Outside Kitchen Lights Space Heater Fan Underbody Lights Underbody LED Lights Outside Fridge where fitted 10A Fuse 10A Fuse 3A Fuse 20A Fuse 30A Fuse 10A Fuse Smart Touch Display 3A Fuse 3A Fuse Dash Panel 25A Fuse UP OFF DOWN Rocker Switch ACTUATOR 1 Amp 20 Amp Hot Water System 20A CB ACTUATOR ON OFF 30...

Page 85: ... 31 08 2021 5 8 1 4 5 6 2 3 7 NC LT Stop Brake RT Gnd Tail RH Clearance Light LH Clearance Light Number Plate light Right Indicator LH Tail Brake Light Left Indicator RH Tail Brake Light Tail Clearance Lights WiTi Where Fitted Carlisle Electronic Brake Unit Power from Batteries F Manual Brake Actuator Breakaway Switch ...

Page 86: ...t Switch Bottom Left Switch Top Right Switch Bottom Right Switch CANOPY Circuits Power from SHUNT SCQ25T F Cooktop Light Sink Light Seating Lights Dining Light 12V Outlet 6 5dB Antenae System if fitted 4G Internet Modem if fitted Media Player 25A Fuse Rear Frame 10A Fuse Inside Canopy Console 15A Fuse Inside Canopy Console Fans Media Dash ...

Page 87: ...imberley Kampers Manufacturing Pty Ltd 2021 Kimberley Karavan 12V Electrical Circuits Model ALL Date 31 08 2021 7 8 Solar Installation Number of panels will vary depending on solar Option fitted S Rooftop Solar ...

Page 88: ...mpers Manufacturing Pty Ltd 2021 Kimberley Karavan 12V Electrical Circuits Bed Slide Model ALL Date 31 08 2021 8 8 Right Reading Light External Connection Plug fused Keeper Socket Left Reading Light Bed Warmer where fitted ...

Page 89: ...I I Distribution box AIRCON RCBO 10 30 I I Air Conditioner If fitted Dbl Pole Switch 10A Clipsal 30MD 2021 Kimberley Karavan 240V Electrical Circuits Model Eco Suite Date 31 08 2021 1 1 Dbl Pole Switch 10A Clipsal 30MD Inverter With RCD IN OUT Induction Cooktop Cooktop Internal Dbl Outlet 10A Clipsal C2025D Sink Cabinet Dbl Outlet 10A Clipsal C2025D Microwave Dash Panel Outlet 10A Clipsal 12M Surg...

Page 90: ...AIRCON RCBO 10 30 I I Air Conditioner If fitted Dbl Pole Switch 10A Clipsal 30MD 2021 Kimberley Karavan 240V Electrical Circuits Model Classic Date 31 08 2021 1 1 Dbl Pole Switch 10A Clipsal 30MD Induction Cooktop Cooktop Internal Dbl Outlet 10A Clipsal C2025D Sink Cabinet Dbl Outlet 10A Clipsal C2025D Microwave Dash Panel Outlet 10A Clipsal 12M Surge Protector From 12V system 400W Inverter IN OUT...

Page 91: ...lt in overheating of the Carlisle Brake actuator When reversing In cab controller can be used to brake your Kimberley without vehicle brakes being used Please familiarise yourself with your particular brake controller as the function and operation vary from brand to brand and model to model When camping Ensure Park brake is engaged 1 Turn valve CROSS LINE to the frame rail this will release any li...

Page 92: ...ccuracy of manufacturers claims regarding compatibility NOTE For Ford and Dodge factory installed brake controllers 2014 and newer please review vehicle owners manual to ensure proper settings for use with electric over hydraulic brake actuator AFTER MARKET BRAKE CONTROLLER DRAW TITE ACTIVATOR II 5500 YES ACTIVATOR III 5510 YES ACTIVATOR IV 5504 YES HAYES 81741B ENERGIZE III YES 81760 ENGAGE YES Y...

Page 93: ... cloths Pliers To tighten the pins in the safety shackles Gas cooker lighter Heavy Duty 15A 30A Caravan RV Power Cord essential for powering your Kimberley at caravan and RV parks Sullage hose for disposing grey water Bucket use for catching grey water from outside sink Hose for filling water tanks Kamper Kruiser use a garden hose with 12mm Click On fittings for using the Kwik Pressure Filler Kara...

Page 94: ...erproofed production process ensures the chemical formulation is penetrated into the yarns of the base fabric This is achieved by fully immersing the fabric into a padding bath and then squeezing the formulation into the fibres This system also allows the fabric to breathe as the woven base fabric is not sealed by a coating Waterproofed The Weatherproofed process guarantees to be waterproof with e...

Page 95: ... front and rear 4 Release velcro straps securing awning Caution Awning may fall down without support 5 Roll out awning evenly 6 Install support poles with claw end first 7 Extend support pole blank end up and in to pocket 8 Locate support pole spigot through holes in these catches and secure with R clips 9 Adjust support pole and lock in place with cam lock Repeat steps 6 9 to finish the awning ...

Page 96: ...ith canopy still lowered 4 Attach Rear Wall with Zip Start Zip at end closest to canopy 5 Lift canopy now if only using rear wall This can be good if wind direction suits 6 Install Front Wall 7 Raise canopy to full height and install vertical support poles to stabilise awning and walls 8 Door Window flap can be rolled up for improved airflow and lighting 9 Enjoy the breeze with the end Window Flap...

Page 97: ...ured quickly with the integrated tension straps Mesh inserts provide privacy whilst allowing airflow for comfort when relaxing or cooking outside Front Rear walls can still be used with the Bedouin Extension as it has a second zip ready for hanging the walls 4 Front wall installed 5 Attach and fasten Zip of Rear Wall along full length 6 Continue Zip along side to the awning center secure zip with ...

Page 98: ...0 072 0 0 0 5 4 7 B7 2 3 0 2 1 4 2 78 5 C 1 7 37 4 7 2 1 4 7 1 7 1 0 0 4 07 5 D 7 27 1 4 1 3 84 1 2 7 0 7 5 E 0 F 28 4 1 G 78 4 7 2 4 1 37 5 722 4 7 3 0 22 5 6 1 3 2 H 07 0 4 4 C 0 I7 JE 3 K 4 F3GG H 67 4 4 9I L 87 3 0 8 0 7 M 3 N 1 7 0 B7 B7 5 8 0 7 0 5 2 7 1 KO KDC 1 789 0 8 4 0 5 E 2 0 1 00 8 0 7 1 0 3 2 1 0 28 0 0 5 P Q7 70 1 7 M RHSTN 1 C665 J 39 9 51 I E 0 0 1 7 G 0 0 1 M7 7 4 4 1 7 7 4 0 0 ...

Page 99: ... 2 0 0 4 ZTT 2 7 4 8 5 K 3 7 1 7 1 0 2 5 E 4 7 7 8 3Y 8 0 7 4 7 3 1 7 87 7 B7 8 0 7 2 V 7 5 7 8 3 8 0 7 37 5 L 0 7 7 H B7 H B7 1 3 3 3 B7 0 2 V 4 1 3 785 K V0 8 3 1 7 3 0H 0 0 B7 4 7 1 7 5 U 7 RHST B7 5 U 5 L E 45 64 E 3 M N 1 7 3 G 0 P 1 7 J W 1 4 2 2 1 7 M0 22 4 70 N P O 0 B7 5 4 UA 70 MO 0 X TN 1 87 2 1 2 2 07 5 2 0 0 B7 3 7 3 B7 0 4 XTT 2 3 8 2 5 J1 DM 4 51 56 N3 67 H63 1 4359 1 5 E 4 0 0 7 97...

Page 100: ...12 426 702 252 12 7 1 8 917 7 6 7 1 52 A 20 2 6 2BA2 72 2 C 2C 7 28 912 2 17 AA472 DE 12 66 0 C 72 2 28 43 12 C 4 1 1 52 12 C 4 12 0 12 426 702 2 4 28 91 7 2 C B DE 426 702 1224 DE 7 1 7028F A1H 9 51 9O 7 8 0 5 K 2 0 0 B7 7 KURG 4 1 V 0 0 2 5 2 0 2 1 7 3 0 0 8 7 2 3 2 4 1 7 1 1 3 4 5 C 0 7 3 7 1 0 4 0 0 0 1 V 1 7 5 7 7 1 8 7 7 V 0 5 2 1 0 3 4 8 V 0 5 0 3 0 4 0 8 1 0 1 7 1 7 70 5 0 3 0 1 0 3 1 0 7 ...

Page 101: ... ABN 51 089 659 370 www kimberleygroup com au sales kimberleygroup com au 6 N3 4 A1 359 4 2 5 00 12 3 0 1 2 0 1223 0 4 0 5 60 7 0 0 1 02 01 3 4 4 5 06 7 34 1 4 8 7 9 40 4 0 1 2 23 032 24 1 0 122 3 4 5 6 7 8 6 01 02 3 4 2 5 0 1 2 0 1 2 1 0 10 0 1 02 3 4 5 1 6 5 788 4 01 2 33 4 5 60 7 8 57 9 57 3 5 1 5 45 3 5 8 3 Q 37 4 XTT O 0 7 1 K 4 1 ZbZU2 1 0 072 5 _ K737 XZ XTZS Ballina August 2021 ...

Page 102: ... are the most important components on any vehicle After all if the wheels fall off it s never a pretty picture In this article we ll discuss the basics of wheel fasteners and the handling and proper installation of alloy wheels which deserve even greater attention due to their higher cost and because of the potential for cosmetic damage WHEEL FASTENERS Instead of referring to these all critical pi...

Page 103: ...nded for a conical seat etc Only the correct matching type seat will provide the required wheel clamping In the case of blind capped enclosed wheel nuts make absolutely sure that the nut does not bottom out against the stud tip this can occur if the nut is too short for the application This situation will prevent full clamping force resulting in wheel wobble and almost certain failure of the threa...

Page 104: ... format the first number indicates the thread shank diameter in millimeters 12mm 14mm etc However met ric thread pitch numbers indicate the distance between threads For example a thread pitch of 1 25 indi cates that the distance between two adjacent threads is 1 25mm If the thread pitch is 1 50 the distance between threads is 1 5mm The last number of a stud or bolt size indi cates length A size of...

Page 105: ...ead pitch gauges one inch and one metric That s all you need to quickly and accurately read any wheel bolt or nut without any guesswork BOLT CIRCLE The term bolt circle or bolt pat tern refers to the diameter of the circle formed by the wheel or hub fastener mounting locations Toyota models use bolt circles of 100mm 3 93 inches 114 3mm 4 5 inches and 139 7mm 5 5 inches A desig nation of 4x100 indi...

Page 106: ...ete loss of the tire wheel assembly Do not confuse the style or shape of the fastener head with the shape of the fastener s seat If a wheel nut features a radiused head rounded head some folks may call this an acorn nut However others will interpret the term acorn as a radiused or ball style fastener seat Always make sure that you clearly understand the terminology for seat styles The majority of ...

Page 107: ...walled shank that serves to help center the wheel the shank drops through the wheel hole serving as a guide pin to center the wheel s hole over the hub s threaded stud The shank length varies depending on wheel thickness and stud length When using a capped nut where the female threaded hole does not pass all the way through the nut it s important to pay attention to thread engagement length FASTEN...

Page 108: ...y the biggest area of concern is inaccurate and or excessive clamping loads which can distort the wheel and its mated hub rotor leading to vibra tion complaints Additional wheel cosmetic damage can result if sock et to fastener recess is minimal or if a thick walled socket is used that minimizes clearance the outer wall of the socket can abrade against the wheel s nut recess If the socket is dirty...

Page 109: ... wheel bolt holes and the fas tener locations on the hub A hub centric wheel is centered onto the hub via the fit of the wheel center hole at the hub face The hub face will feature a center lip that engages into a recess on the wheel s hub face Hub centric designs more precisely locate the wheel onto the hub to minimize the chance for installed radial runout All later model Toyota wheels and hubs ...

Page 110: ...sed make sure they don t effect the wheel track and or the number of threads on the wheel studs If old rings are stuck to the hub but the new wheels don t need them or if you try to double up old rings that are stuck to the hub and new rings on the wheels the wheels won t mate flush to the hub which will cause severe axial runout Always check closely NOTE If the aftermarket wheels that the custome...

Page 111: ...unting surface If the cap pro trudes beyond the mounting sur face this will create an obstruction that won t allow flush seating of the wheel to the hub This will result in false torque value readings and can cause an axial runout condition To avoid corrosion that may cause an alloy wheel to stick to a steel or iron hub apply a very thin coating of an anti seize paste to the hub face where the whe...

Page 112: ...ing in the outback under extreme conditions Please check regularly minimum 5000km and no more than 10000km Clean and replace bearings with high quality marine grease or similar Always inspect for dust inﬁltration The grease will look brown if dust has inﬁltrated If you are doubtful about the bearings change them How to Grease your Suspension Bearings The Trailing Arm Brackets have two greasing poi...

Page 113: ...s Design This shock absorber is a high pressure mono tube design These are a newer design and the Monotube design allows them to operate at cooler temperatures Monotubes are under high pressure from around 200 psi 1379 kPa to as high as 360 psi 2482kPa The hydraulic oil and Nitrogen gas are in separate chambers separated by a floating piston This allows the shock strut to function without any aera...

Page 114: ... 6 12mm 38Nm 28 ft lb X YELLOW Wheel Nuts Lugs 14mm 5 Stud 130Nm 96 ft lb WHITE DOT Wheel Nuts Lugs 12mm 6 Stud 120Nm 89 ft lb WHITE DOT The above nuts and bolts should be torqued to the required Nm settings with a good quality torque wrench Once secured to the correct setting the bolt nut head should marked with a paint pen as a visual guide denoting the fixture has been torqued correctly Impact ...

Page 115: ...ur dealer can supply Empty your tanks when in storage IMPORTANT Do not clean water system with Vanilla or Vinegar as these will damage pipes 2 Alloy Wheels There is a possibility that gibbers and sharp stones can get caught between the alloy wheel and the brake system or the hub This is more prevalent on 17 inch wheels and larger format exotic wheels As these alloys are a special format our hubs a...

Page 116: ... trip in rugged conditions Date ___ ___ ___ After 4 Year or after a major trip in rugged conditions Date ___ ___ ___ After 5 Year or after a major trip in rugged conditions Date ___ ___ ___ Service the Kimberley check all points of inspec tion grease all points repack wheel bearings and inspect electrical operation Inspect winch cable Report to your dealer and issues that you have Service the Kimb...

Page 117: ...117 2021 Kimberley Kampers Manufacturing Pty Ltd Record all important Serial Numbers from your unit in the table below Serial Numbers ...

Page 118: ...pray To further enhance spot cleaning results Warwick have introduced the Halo Fabric Care Kit which includes Halo spot cleaner for most household stains Halo fabric deodoriser to help neutralise pet and general odours and Halo fabric protector to restore liquid repellency on fabric sections that have been spot cleaned For treatment of specific stains see the stain removal guide Professional fabri...

Page 119: ...119 2021 Kimberley Kampers Manufacturing Pty Ltd Notes ...

Page 120: ... 4051 2545 Mobile 0418 181 989 Contact Terry Rhook Email costasrad internode on net Ozzie Camper Trailers 48 Charles St Aitkenvale QLD 4814 Ph 07 4779 0900 Fax 07 4775 2930 Contact Tim Gillman Email mail ozziecampers com au Web www ozziecampers com au NSW Active 4x4 263 Anderson Drive Beresfield NSW 2322 Ph 02 4966 3277 Fax 02 4966 3288 Contact Steve Atkins Email steve active4x4 com Web www active...

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Kimberley KARAVAN 2021, Installation, Maintenance & Operating Manual

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