MDC AUSRV XL13E MkII 2023 Owner's Manual
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MDC AUSRV XL13E MkII 2023 Owner's Manual

Offroad hybrid caravans
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XL13E MkII
I
XL15E MkII
I
XL15-4E MKII
OFFROAD HYBRID CARAVANS
OWNER'S MANUAL
EDITION: 2023 - Version 2
*2023 Models Shown
Copyright ©
AusRV Group Pty Ltd 2020 All Rights Reserved
Phone: 1300 494494
I
I
I
P a g e
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1
www.marketdirect.com.au
Ph: 1300 494 494
©Copyright
www.marketdirect.com.au

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Summary of Contents for MDC AUSRV XL13E MkII 2023

  • Page 1 XL13E MkII XL15E MkII XL15-4E MKII OFFROAD HYBRID CARAVANS OWNER’S MANUAL EDITION: 2023 - Version 2 *2023 Models Shown Copyright © AusRV Group Pty Ltd 2020 All Rights Reserved Phone: 1300 494494 P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright www.marketdirect.com.au...
  • Page 2 Copyright © AUSRV Pty Ltd 2020 All Rights Reserved All files and information contained in this Owner’s Manual are copyright by AusRV Pty Ltd, and may not be duplicated, copied, modified, or adapted, in any way without our written permission. Our Owner’s Manual may contain our service marks or trademarks as well as those of our affiliates or other companies, in the form of words, graphics, and logos.

  • Page 3: Table Of Contents

    Contents Safety Definitions ............. 6 Ball Weight ..............30 Button Battery Warning! ..........6 Effects of Weight Distribution ......... 30 Introduction................ 7 Tyre Pressures ............. 30 AUSRV Contact Details and Stores ....... 7 Towing The Caravan ............31 Towing with Trucks ............ 31 Specifications ..............
  • Page 4 Solar Panels ..............52 Maintenance ..............66 Generators ..............53 Decalcification ............66 Packing Up the Caravan..........53 Fuses ................66 Circuit Breaker ............66 Storage & Care ..............53 Security ................54 Water Heater Trouble Shooting ......67 Care and Maintenance of the Caravan ....... 55 Gas Operation ............
  • Page 5 Highway ..............95 Off Road ..............95 Suspension ............... 95 Shock Absorbers & Bushes ........95 Wheel Alignment ............95 Maintenance Schedule ........... 96 Service Record ............. 96 Hiring Your Camper/Caravan ........118 Warranty Statement ............. 119 Supplier Details ............. 122 Travel Record ..............

  • Page 6: Safety Definitions

    Safety Definitions - Immediate hazards which WILL result in severe personal injury or death if the warning is ignored. - Hazards or unsafe practices which COULD result in severe personal injury or death if the warning is ignored - Hazards or unsafe practices which could result in minor or moderate injury if the warning is ignored - Practices that could result in damage to the trailer or other property INFORMATION- Helpful information and important points.

  • Page 7: Introduction

    It is the intention of AUSRV for you to have the best possible owner experience and enjoy the great outdoors. AUSRV Contact Details and Stores QUEENSLAND MDC Brisbane MDC Caboolture 3/711 Beaudesert Rd 2/4-6 Boeing Place...
  • Page 8 My AUSRV Hybrid Caravan NAME: ADDRESS 1: ADDRESS 2: MODEL: VIN: BUILD DATE: DRY WEIGHT: GTW: TIRE SIZE: DEALER PH: DISCLAIMER: By receiving this handbook, you confirm there you have read and agree to all the terms and conditions and understood the use and maintenance care of AUSRV Pty Ltd.

  • Page 9: Specifications

    WIRELESS REAR 2.4GHz digital wireless rear view camera + 5″ portable monitor VIEW CAMERA COUPLING LOCK MDC LOK – coupling lock BATTERY LiFePRO+™ 12V 200Ah Lithium Iron Phosphate battery AC (240V) CHARGER Projecta IC500L – 12V automatic 50A 5-stage lithium battery charger DC (12V) CHARGER Projecta IDC25L –...
  • Page 10 ANNEX Full annex, enclosed roof, walls, floor, and draft skirt GAS CYLINDER 2x 9kg gas cylinder holders with LCC27 pigtail connector HOLDERS JERRY CAN STORAGE 2x 20L jerry can holders WATER TANK(S) 1x 120L freshwater, 1 x 80L 2x 120L Freshwater & 1 x 1x 120L freshwater, 1 x freshwater &...

  • Page 11: Safety Information

    Safety Information Before using this product, you should read this manual and those manuals supplied by component manufacturers applicable to this product. This manual is supplied as a reference to required maintenance of the product. Failure to use and maintain the product in accordance with what is outlined in this manual may affect your warranty.

  • Page 12: Weight Definitions

    Weight Definitions Tare Weight: The total weight of the trailer (load on tyres plus coupling load) with all options and fittings as supplied by the manufacturer, with empty water tanks, excluding fluids not essential for operation on public roads, and without luggage or personal effects. ATM (Aggregate Trailer Mass) Rating: The total permissible mass of the Trailer.

  • Page 13: Terminology

    Terminology Ball Weight The downward load exerted on the tow point of the vehicle by the trailer. (Gross Combination Mass): This is the total allowable combined mass of tow vehicle and trailer as determined by the tow vehicle manufacturer. Camber The correct camber setting for these models is 0-0.5°...

  • Page 14: Achieving A Safe Towing Combination

    Achieving a Safe Towing Combination Ensuring a camper or caravan is safe and easy to tow is generally an easy thing to achieve, this doesn’t mean it’s always the case and sometimes, a vehicle and trailer combination may need some tweaking to make it ideal. There are a number of aspects that need to be correct in order to maximise towing safety and handling.

  • Page 15: Ball (Coupling) Weight

    Ball (Coupling) Weight The ratio of overall weight of the trailer to the weight exhibited on the tow ball or coupling is an extremely important aspect of making a trailer handle correctly when towed. Generally, the ball or tongue weight allowed by most vehicle manufacturers is 10% of the maximum towing capacity.

  • Page 16: Hitch Movement

    Hitch Movement Most modern tow bars have an adjustable screw fitted to the hitch receiver that can be used to stop the hitch insert from rattling. Unfortunately this is not a sure fire way to limit sideways movement that can affect how well your trailer tows.

  • Page 17: Maximum Weight Limits

    Maximum Weight Limits The following is an outline of the ratings that will be specified by the manufacturer of your vehicle and the camper/caravan manufacturer. These MUST be followed in conjunction with previously mentioned criteria for safe handling. None of the maximum ratings may be exceeded. ATM (Aggregate Trailer Mass) This limit is specified by the trailer manufacturer and must NOT be exceeded under any circumstances.

  • Page 18: Gcm (Gross Combination Mass)

    GCM (Gross Combination Mass) GCM is the maximum combined load of the tow vehicle and trailer, as specified by the tow vehicle manufacturer. Never exceed this maximum weight limit. Towing Combination Summary The above will assist in tuning or trouble shooting handling problems with your towing combination but are not the sole influences.

  • Page 19: Towing Mirrors

    Towing Mirrors Depending on the width of your car mirrors versus the overall width of your camper or caravan, you may be required to fit extended mirrors to your vehicle when towing. The illustration below shows the minimum required field of vision through your vehicle’s mirrors. Note: Mirror extension attachments must be removed when not towing, fitted mirrors that extend must also be retracted when not towing.

  • Page 20: Jacking Your Caravan Or Camper

    Jacking Your Caravan or Camper Your trailer is fitted with purpose built jacking points and supplied with a suitable jack. An appropriately rated bottle jack is an acceptable alternative, however when using the jacking point beneath the trailing arm ensure the jack is of a retracted height that will fit under the jacking point when the tyre is deflated.

  • Page 21: Electrical Safety

    Electrical Safety Failure To Follow These Instructions May Result In Death Or Serious Injury! When working with electrical equipment or lithium batteries, have someone nearby in case of an emergency. Study and follow all the manufacturer’s specific precautions when using and servicing the battery and connected appliances.

  • Page 22: Trailer Lights

    Trailer Lights Plug Type – 12 Pin Flat (Not Negotiable) Charging While Driving Plug Type – 50 amp Anderson Plug. Smart Alternator The Anderson plug can be connected to the start battery on the vehicle and should include the following to protect the start battery.

  • Page 23: Trail-Assure™ Electronic Stability Control System

    Trail-Assure™ Electronic Stability Control System As an added safety feature, your AUSRV caravan is fitted with a Trail-Assure™ BG-5000 electronic stability control system. This is an asymmetric braking system that uses onboard measuring instruments to determine which wheel brakes to apply, and how often, to increase the stability of your caravan while driving. The BG-5000 has been factory fitted precisely with the controller module mounted in the front underneath section of your caravan so that it can make reliable and precise measurements during a trip.
  • Page 24 The BG-5000 is self-diagnosing and in the unlikely event that you need to troubleshoot your unit, identify this module, and determine the series of lights displayed. Refer to the below table to identify the status of the unit. LIGHT ACTION CONDITION CORRECTIVE ACTION Solid GREEN...
  • Page 25 The control module has been strenuously evaluated against the various amount of integrated and aftermarket trailer brake controllers in use today. Compatible controllers include but are not limited to: Aftermarket in-vehicle Brake Controllers Integrated Vehicle Brake Controllers Redarc Fiat/Chrysler: 2014, 2015, 2016, 2017 Dodge RAM 2500 Tekonsha Ford Motor Company: 2013 F-150...

  • Page 26: Gas & Appliance Safety

    Gas & Appliance Safety Gas Certification Your Caravan has been supplied gas tested and certified. Any additions or alterations to the gas system must be performed by an authorized person and will require re-certification and testing. Also note any alterations may affect your warranty on both the system and appliances. General Safety •...

  • Page 27: Gas Appliance Safety

    Gas Appliance Safety • Gas appliances are certified and have a flame safeguard feature to stop gas flow in the event of the flame going out. Never interfere with this function or replace appliances with a non-certified type. • Slide-out kitchens with cookers should only be operated with an annex fully erected. Failing to do so may affect the safety and operation of the gas appliance.

  • Page 28: Diesel Heater Safety

    Diesel Heater Safety Important information before operating the diesel heater. The diesel heater is designed for use in your caravan. • • The heater is designed to heat the main living area of your caravan. Attempting to warm the additional annex area may be beyond the performance of the diesel heater unit.

  • Page 29: Using The Caravan

    Using the Caravan Weights and Payload Capacities The information plate attached to the drawbar of your caravan displays the relevant weights and weight capacities of the van. How to Load Your Caravan It is important to load your caravan correctly to distribute weight evenly and achieve a suitable ball weight load and prevent loading in a manner that can cause a caravan to sway and/or roll excessively left and right.

  • Page 30: Ball Weight

    Ball Weight When loading your camper, the generally accepted tow ball weight once loaded is around 10% of the total weight of the caravan. Use a ball weight scale to identify the ball weight and load the camper in a manner that achieves the desired weight.

  • Page 31: Towing The Caravan

    Towing The Caravan Towing with Trucks If you intend to tow your caravan with a truck or heavy commercial vehicle you should fit a hitch system to minimise the lash effect of the commercial suspension and distance from the rear axle to the tow point. Truck suspension can be harsh, particularly in off road conditions.

  • Page 32: Connecting The Hitch

    Connecting the Hitch Here is a short guide on how to safely use your coupling to couple and uncouple the trailer from the towing vehicle. Make sure the handbrake is applied prior to coupling and uncoupling. Make sure the dust cap is securely connected to the bump cover. This is done by locating the rear lip on the dust cap onto the groove of the bump cover and then pushing it in a downward motion until the dust cover is secure (there should be a slight click when it has been assembled correctly) Test if the dust cover is connected to the bump cover by applying a slight upward force to the dust cover, it shouldn’t separate.

  • Page 33: Coupling

    Coupling STEP 1 Push down the button (1) and push the locking mechanism back (2). When the locking mechanism (2) is all the way back, release the button (1) locking the plate in place. STEP 2 Offer up the tow pin to the coupling making sure the tow pin cover is removed and there is no visible debris on it.
  • Page 34 STEP 3 Make sure the tow pin is seated inside the universal and the tow pin top is sticking out of the locking mechanism (see below). Press the button (1) to release the locking mechanism there will be an audible locking noise at which point the mechanism will return to the initial position as shown in step 1.

  • Page 35: Uncoupling

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

  • Page 36: Safety Chains And Shackles

    Safety Chains and Shackles Rated Shackles Always use load rated shackles applicable to the weight of your trailer. Connecting the Safety Chains Chains should be crossed over and connected with suitable rated shackles. Ensure they are connected in a way to prevent them dragging on the road but not too tight as to restrict the articulation of the vehicle and trailer combination.

  • Page 37: Wireless Rear View Camera

    Wireless Rear View Camera A wireless rear view camera has been factory fitted on the rear of your caravan. The unit is connected to your caravan's parking light circuit, allowing the camera to not just be limited to reversing scenarios but assist in always monitoring your surroundings by turning your vehicle lights on.

  • Page 38: Pre-Trip Inspection

    Pre-Trip Inspection Tyres Before any trip check the following Correct tyre pressures • Tyres are in good condition free from damage and uneven wear. • Tread is of legal and acceptable depth. • Wheel Nuts Ensure wheel nuts are tensioned to the correct torque using a torque wrench. •...

  • Page 39: Setting Up The Caravan

    Setting Up the Caravan Electric Roof The roof can be raised or lowered using the rocker switch beside the door. Finding a Suitable Spot When choosing a spot to set up your caravan, start with a flat area with no overhanging trees. Birds and bats occupying trees can defecate leaving droppings on your caravan that can damage paint and leaves and sap can also stain the coating.

  • Page 40: Campsite Dimensions

    Campsite Dimensions When booking a camping site, ensure you know the dimensions of your van, so you get an adequately sized spot. The dimensions in the diagrams below display the setup area with awning/annex. XL13 MkII Dimensions XL15-4 & XL15E MkII Dimensions P a g e www.marketdirect.com.au Ph: 1300 494 494...

  • Page 41: Jockey Wheel

    Jockey Wheel The rated load capacity of a jockey wheel is achieved when the jockey wheel is retracted to its lowest position. When moving the trailer on the jockey wheel, always lower it as far as possible but still allowing the wheel to swivel as you steer the trailer.

  • Page 42: Electric Awning

    Electric Awning When extending the awning always support to front as it extends. Do not allow the awning to carry the full extended weight as this may damage the hinges. Support the end manually by hand or by using the extendable legs.

  • Page 43: Annex Pole Diagrams

    Annex Pole Diagrams P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

  • Page 44: Slide Out Kitchen

    Slide Out Kitchen Before sliding out kitchen: 1. Pull back the pad bolt in Fig 2 pictured and lock in the retracted position. 2. Depress the blue locking tab Fig 2A and pull out kitchen. When kitchen is extended, install removable support leg firmly under kitchen. CAUTION –...

  • Page 45: Internal Cooktop Xl15-4

    Internal Cooktop XL15-4 When using internal cooktop ensure the following: Roof is raised and vents in roof skirt are clear of obstruction. • Main door vent cover is removed. • Cooktop area is free of flammable materials. • Cooktop is NEVER left unattended when in use. •...

  • Page 46: Charging The Caravan

    Charging the Caravan Mains Power Your RV will charge from mains power via the Projecta 5 stage charger. Ensure the charger is plugged into its dedicated outlet in its bay and is switched on. The factory battery in your RV is Lithium Iron Phosphate (LiFePO4) Solar Power The roof mounted solar panels will charge automatically provided there is enough radiated energy from the sun.

  • Page 47: Electric Control Panels

    Electric Control Panels XL13E MkII XL15-4E MkII & XL15E MkII *Projecta panel will display charge rate, voltage, and charge stage. Round icons represent panel “Push to Reset” circuit breakers. Icon represents panel circuit switch. P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

  • Page 48: Mains Power

    Mains Power The Projecta charger in your caravan is connected via the 15A exterior socket. To use site power, you will require a 15A power lead connected to a 15A outlet. In the event a 15A outlet is unavailable you will need a conversion box that will step up from 10A to 15A with a safety switch.

  • Page 49: Charging From Your Vehicle

    Charging from your Vehicle A 12-pin trailer plug is also required. In addition to the standard wiring to pins 1 to 7, power must be supplied to the number 12 pin for the trigger wire for the DC-DC charger while the engine is running. The IDC25L is programmed to favour the solar power supply until the supply falls below the minimum •...

  • Page 50: Battery Care

    Battery Care Storage type batteries require periodical maintenance to perform at their peak and extend their service life. The following is an outline of how to gain the best performance and lifecycle from the battery fitted in your RV: Always use a quality charger that caters to the voltage requirements of a LiFePO4 battery. Never leave your battery stored at low voltage.

  • Page 51: Configuring The Bm500-Bt App

    Configuring The BM500-BT App 1. Download the App from Apple Store or Google play depending on your type of smart phone. 2. Open the App and pair with your BM500. The display will show the connection code to enter on the App. Select LFP and Select Battery Select Battery...

  • Page 52: Maximising Battery Use

    SOC Calibrate 1. Charge battery to 100%. 2. Remove all loads from battery 3. Enter General Settings 4. Select SOC 100% Calibration 5. Enter Confirm Maximising Battery Use There are ways to maximise the life of your batteries when off grid. It is important to have your vehicle wired correctly to charge whilst towing to your campsite.

  • Page 53: Generators

    Generators Generators are an excellent way to maximise off grid camping. Generally a good quality 2.2Kva generator will run the air conditioner and keep the caravan well charged. Note: Not all camp sites allow generators, particularly National Parks. Always ensure that generators are permitted in the camping area before using.

  • Page 54: Security

    Security The 15-year anniversary models are supplied with an MDC engineered coupling lock device. This device is designed and manufactured to deter the theft of your new caravan. How to attach your lock to your Coupling: Cruisemaster DO-35 coupling. Make sure the dust cap is securely connected to the bump cover. This is done by locating the rear lip on the dust cap onto the groove of the bump cover and then pushing it in a downward motion until the dust cover is secure (there should be a slight click when it has been assembled correctly).

  • Page 55: Care And Maintenance Of The Caravan

    Care and Maintenance of the Caravan Protection of Finishes Paint The paint coatings on your caravan are no different to that of your car in that they need regular care and maintenance. Rubber seals and applied sealants on caravans can shed polymers and pigments that can stain paint finishes if your caravan isn’t washed regularly.

  • Page 56: Shade And Screen Care

    Shade and screen care Do not close blinds while window is open. Air pressure can dislodge the blind material from its guide • damaging it. Always open and close blinds and screens carefully and evenly with two hands ensuring screens and •...

  • Page 57: Roof Props

    Roof Props The electric opening roof is driven by 2x linear actuator motors, although this system is maintenance-free, electric, or mechanical failure, in very rare circumstances, can occur. If repairs are required on either of the linear actuator motors or ramrods, the equipment will need to be uncoupled from the roof and/or lower wall bracket. Your caravan comes with 4x white rectangular roof props to use in this instance.

  • Page 58: Caravan Body Maintenance

    Caravan Body Maintenance Locks and Latches Locks need regular maintenance to ensure they operate correctly and stay free from corrosion. Diligent use of WD40 or Inox will help in this regard. Both locks and latches need to be checked for adjustment to ensure correct seal compression.

  • Page 59: Hand Brake

    CAUTION: Hand Brake Parking brakes are mechanically operated by cable means. The cable attachment occurs outside of the brake backing plate. Cable force applied to the parking lever creates a torque through the pivot pin and cam assembly. Torque transferred to the parking cam results in a spreading force between the primary and secondary shoes. The shoes in turn, move towards the drum until contact is made.

  • Page 60: Hitch

    Hitch Cruisemaster DO35 To ensure a long service life we recommend the following periodic maintenance procedures. 1. Always keep Tow Pin and Universal mating surfaces clean and lightly lubricated. 2. Check condition of Tow Pin O-Ring and replace if necessary (Part No. 18D-DO35-101). 3.

  • Page 61: Magnets

    Brake Lubrication This should only be done by qualified persons. Do not get grease or oil on the brake linings, drums, or magnets. Magnets Your electric brakes are equipped with high quality electromagnets that are designed to provide the proper input force and friction characteristics.

  • Page 62: Gas & Water Systems

    Gas & Water Systems Truma Rapid Hot Water System Operating Instructions General Safety *Read the included Truma operation manual supplied with you trailer The use of upright gas cylinders from which gas is taken in the gas phase is mandatory for the operation of gas regulators, gas equipment and gas systems.

  • Page 63: Filling The Truma Ultrarapid With Water

    Any work involving connection or interconnecting wiring must be carried out by a licensed electrician. If • the mains cable (supply cord) is damaged, it must be replaced by the manufacturer, its service agent, or similarly qualified persons in order to avoid a hazard. Before accessing terminals, please ensure all supply circuits are disconnected (i.e., 230 V –...

  • Page 64: Pressure Relief Valve (P&T Safety Valve)

    Residues of frozen water can prevent filling if there is a frost. The water heater can be defrosted by switching on the heater for a short period (max. 2 minutes). Frozen pipes can be defrosted by heating the room. If just the cold-water system is being used, without water heater, the heater tank is also filled up •...

  • Page 65: Draining The Water Heater

    Draining the Water Heater If the vehicle is not used during periods of frost, it is essential that the Truma UltraRapid be emptied. • Disconnect power for water pump (main switch or pump switch). • Allow the appliance to cool down. •...

  • Page 66: Switching Off Gas Operation

    Switching Off Gas Operation – Switch off the water heater to position (Fig. 3b - c). If the water heater is not to be used for a longer period, mount cowl cover (non-observance of this point can lead to the function of the appliance being impaired through water, dirt, or insects), close stop cock valve in the gas supply line and close the gas cylinder.

  • Page 67: Water Heater Trouble Shooting

    Water Heater Trouble Shooting Gas Operation Symptom Cause Remedy When switching on, the heater No 12 V DC supply Check the power supply (operation voltage does not operate. voltage. min. 10.5 V). Check the Truma UltraRapid fuse (refer to maintenance “Fuses”). When switching on, the heater –...

  • Page 68: Selecting Fresh Water Tank

    Selecting Fresh Water Tank Beneath the water pump location on the outside of the caravan you will find the selector valves to choose which water tank feeds the water pump. Note: Graphic is a visual representation and not a schematic. Layout may differ between models. P a g e www.marketdirect.com.au Ph: 1300 494 494...

  • Page 69: Connecting The Gas

    Connecting the Gas Your caravan is fitted with plumbed gas with the regulator and gas bottle placement at the front of the trailer. Always ensure gas bottles are serviceable and within the 10-year service life. This information is stamped on the bottle base.

  • Page 70: Toilet Care And Maintenance

    Toilet Care and Maintenance Chemicals: Always use water treatment and conditioning products recommended by the manufacturer. Thetford Waste Holding Tank: The recommended product for the waste holding tank on Thetford toilet systems is Aqua Kem Blue or Aqua Kem Green for better environmental performance. Cleaning Cassette Tank: “Cassette Tank Cleaner”...

  • Page 71: Diesel Heater

    Diesel Heater Important information before operating the diesel heater. The diesel heater is designed for use in an RV, caravan, or camper. • The heater is designed to heat the main living area of your caravan or camper. Attempting to warm •...

  • Page 72: Mkii Diesel Heater

    MkII Diesel Heater Operation 1-Control Knob 2- Heating (power on) mode button 3-Heating (power on) indication light 4-Constant temperature indication light 5- Constant temperature mode button 6-Ventilation mode button 7 -Ventilation indicating light Heater Control Switch Power on Press the heating (2 power on) button, the heating (constant power) will flash for 0.3S. The heater will begin the start stage.

  • Page 73: Tv Antenna

    TV Antenna All AUSRV MkII models come standard with a roof mounted Milenco POWER 900L omnidirectional antenna. This antenna comes fitted with a high-gain, low noise amplifier which is pre-wired to all the TV antenna F-type outlets throughout the caravan. Omnidirectional TV antennas do not require rotating to obtain a TV signal, their radiation pattern allows them to receive high-quality reception from all angles without the need to locate the closest signal source.

  • Page 74: Moisture And Mould Protection

    Moisture and Mould Protection Condensation Condensation is caused by a difference in ambient temperature and a surface creating a dew point. If the surface is sufficiently colder than the ambient temperature and there is a degree of humidity, condensation will form on the surface.

  • Page 75: Trouble Shooting

    Trouble Shooting 12 Volt Electrical Trouble Shooting PROBLEM POSSIBLE CAUSE REMEDY No power Main switch turned off Turn on main rotary switch Tripped main circuit breaker Reset CB1 circuit breaker located with batteries (See diagram 1) Flat Battery Battery needs reset: Charge battery on mains power and set charger to “Supply Mode”...
  • Page 76 Charger Error Codes Power On Fault Remedy Slow Flashing Short circuit or reverse Check connections aren’t touching, or connection of terminals check terminals are correctly connected Fast flashing Bulk charging has timed out and Battery may be faulty stopped after 10 hours Charge rate may be too low Load on battery may be too high Fast flashing...

  • Page 77: Solar Charging Trouble Shooting

    Solar Charging Trouble Shooting Symptom Possible Cause Remedy No solar power DC to DC solar Tripped circuit breaker Reset circuit breaker CB6 in Fig. 1 light not showing & Fig. 3 DC to DC overloaded Reset DC to DC by disconnecting from battery and solar input.

  • Page 78: Control Panel & Accessories

    Control Panel & Accessories Symptom Possible Cause Remedy Control panel won’t switch on Flat batteries Charge batteries Tripped circuit breaker Reset circuit breaker CB1 Fig.1 & Fig. 2 Accessory circuit not working Tripped circuit breaker Reset circuit breaker above circuit switch by pushing in.
  • Page 79 Fig. 1 XL13E MkII Note* This is a simplified diagram of the electrical layout for trouble shooting explanation only. This is not a schematic for repair purposes. P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...
  • Page 80 Fig. 1 XL15-4E & XL15E MkII P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

  • Page 81: Resetting Breakers

    Resetting Breakers There are primarily 3 types of breakers in AUSRV caravans and campers. The most obvious are the push to reset breakers on the control panel. These you simply push and if it resets you will hear a click. High Load Breakers These are for higher current loads such as CB1 and CB2 fig 1.

  • Page 82: 12V Main Circuit Xl13E Mkii

    12V Main Circuit XL13E MkII P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

  • Page 83: 12 Volt Switchboard Circuit Xl13E Mkii

    12 Volt Switchboard Circuit XL13E MkII P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

  • Page 84: 12 Volt Main Circuit Xl15-4 & Xl15E Mkii

    12 Volt Main Circuit XL15-4 & XL15E MkII P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

  • Page 85: 12 Volt Switchboard Circuit Xl15-4 & Xl15E Mkii

    12 Volt Switchboard Circuit XL15-4 & XL15E MkII P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

  • Page 86: Secondary Idc25L Dc To Dc & Solar Panels

    Secondary IDC25L DC to DC & Solar Panels Your XL15-4E MkII caravan boasts an impressive 650W of solar capability across 2x arrays of roof-mounted solar panels. Solar Panel Breakdown Array 1 Array 2 2 x 100W 2 x 150W 1 x 150W 350W 300W TOTALS...

  • Page 87: Water Trouble Shooting

    Water Trouble Shooting Problem Possible Cause Remedy No power from control panel Check circuit breaker Flat Battery Charge battery Replace pump, Contact dealer for Pump not working (no noise) Faulty pressure switch replacement Check connections with Bad electrical connection multimeter or test light Turn on tap and hold finger over nozzle for 5 seconds and release.

  • Page 88: Brakes Trouble Shooting

    Brakes Trouble Shooting Problem Possible Cause Remedy Open Circuits Find and correct Severe under adjustments Adjust brakes No Brakes Faulty controller Test and correct/replace Short circuits Find and correct Great or oil on linings or magnets Clean or replace Corroded connection Clean or replace connectors Worn lining or magnets Replace...

  • Page 89: Spare Part Numbers

    Spare Part Numbers Hub & Suspension Components Timken Bearing (inner & outer bearings) 25590 Bearing Cone (Inner and outer bearings) 25520 Bearing Seal 55 x 85 x 12mm Round Bush YJJJ036-2 Steel Bush Insert 30 x 114mm YZCN002 Adjuster Cam YDZS030 LHS Backing plate Assemble (with pads) DM00025...

  • Page 90: Hub Assembly

    Hub Assembly P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

  • Page 91: Trailing Arm Bushes

    Trailing Arm Bushes P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

  • Page 92: Driving Off Road

    Driving Off Road Towing your caravan off road adds many dimensions to the driver’s responsibilities and factors to be considered. When travelling remote always carry enough spare parts and supplies to cater for a “worst case scenario.” Always perform preventative maintenance and daily checks. Minimum trailer spares would consist of: Wheel Bearings •...

  • Page 93: Recommended Recovery Products

    Recommended Recovery Products Recovery points Do not attempt to recover via points that aren’t designated recovery point. Your vehicle must be fitted with rated points that exceed the safe load of any recovery straps or tow straps being used. Hardware Shackles are an integral part of any recovery kit.
  • Page 94 Tyre repair kits are an excellent investment when travelling remote in the event you are unlucky enough to damage more tyres than you have spare. A compressor is a must have to reinflate your tyres after deflating for rough and corrugated roads. A tyre gauge is a must have to deflate your tyres to the correct pressure when travelling off road.

  • Page 95: Wheels And Tyres

    Wheels and Tyres Highway Your caravan is fitted with 16” wheels and 265/75 R16 Goodride Tyres. The tyres are a “Light Truck” tyre with a mud terrain tread and a maximum load rating on single axle of 1550kg at 80psi. See the tyre pressure recommendation chart.

  • Page 96: Maintenance Schedule

    Maintenance Schedule Service Record 500KM FIRST SERVICE (Should be completed by a professional) CHECKED Check hitch bolts to 90Nm. • Hitch Lubricate with high temperature bearing grease • Handbrake Inspect and adjust handbrake if necessary • Brakes & Inspect and adjust brakes. Check bearings are well greased and crown •...
  • Page 97 Every 6 MONTHS / 5,000KM SERVICE CHECKED Hitch Check hitch bolts to 90Nm • Handbrake Check cable and adjust if necessary • Canopy Lifters Lubricate canopy lifting scissors • Lubricate and check bushes for excess movement. • Suspension Torque bolts to 190Nm •...
  • Page 98 12 MONTHS / 10,000KM SERVICE (Should be completed by professional) CHECKED Chassis and Suspension Hitch Inspect for damage and lubricate. Check bolt Torque to 90Nm • Jockey Wheel Inspect for condition and operation • Check for correct operation. • Breakaway Inspect lanyard and clip •...
  • Page 99 Inspect joint sealants inside and out. • Body Ensuite joints checked for damage and adhesion. • Inspect for soft spots on floor • General fixings Check all structural fixing are secure. • Ventilation Inspect for obstruction and vents operating correctly •...
  • Page 100 18 MONTHS / 15,000KM SERVICE CHECKED Hitch Check hitch bolts to 90Nm • Handbrake Check cable and adjust if necessary • Canopy Lifters Lubricate canopy lifting scissors • Lubricate and check bushes for excess movement. • Suspension Torque bolts to 190Nm •...
  • Page 101 24 MONTHS / 20,000KM SERVICE (Should be completed by professional) CHECKED Chassis and Suspension Hitch Inspect for damage and lubricate. Check bolt Torque to 90Nm • Jockey Wheel Inspect for condition and operation • Check for correct operation. • Breakaway Inspect lanyard and clip •...
  • Page 102 Inspect joint sealants inside and out • Body Ensuite joints checked for damage and adhesion. • Inspect for soft spots on floor • General fixings Check all structural fixing are secure. • Ventilation Inspect for obstruction and vents operating correctly •...
  • Page 103 30 MONTHS / 25,000KM SERVICE CHECKED Hitch Check hitch bolts to 90Nm • Handbrake Check cable and adjust if necessary • Canopy Lifters Lubricate canopy lifting scissors • Lubricate and check bushes for excess movement. • Suspension Torque bolts to 190Nm •...
  • Page 104 36 MONTHS / 30,000KM SERVICE (Should be completed by professional) CHECKED Chassis and Suspension Hitch Inspect for damage and lubricate. Check bolt Torque to 90Nm • Jockey Wheel Inspect for condition and operation • Check for correct operation. • Breakaway Inspect lanyard and clip •...
  • Page 105 Inspect joint sealants inside and out. • Body Ensuite joints checked for damage and adhesion. • Inspect for soft spots on floor • General fixings Check all structural fixing are secure. • Ventilation Inspect for obstruction and vents operating correctly •...
  • Page 106 42 MONTHS / 35,000KM SERVICE CHECKED Hitch Check hitch bolts to 90Nm • Handbrake Check cable and adjust if necessary • Canopy Lifters Lubricate canopy lifting scissors • Lubricate and check bushes for excess movement. • Suspension Torque bolts to 190Nm •...
  • Page 107 48 MONTHS / 40,000KM SERVICE (Should be completed by professional) CHECKED Chassis and Suspension Hitch Inspect for damage and lubricate. Check bolt Torque to 90Nm • Jockey Wheel Inspect for condition and operation • Check for correct operation. • Breakaway Inspect lanyard and clip •...
  • Page 108 Inspect joint sealants inside and out. • Body Ensuite joints checked for damage and adhesion. • Inspect for soft spots on floor • General fixings Check all structural fixing are secure. • Ventilation Inspect for obstruction and vents operating correctly •...
  • Page 109 54 MONTHS / 45,000KM SERVICE CHECKED Hitch Check hitch bolts to 90Nm • Handbrake Check cable and adjust if necessary • Canopy Lifters Lubricate canopy lifting scissors • Lubricate and check bushes for excess movement. • Suspension Torque bolts to 190Nm •...
  • Page 110 60 MONTHS / 50,000KM SERVICE (Should be completed by professional) CHECKED Chassis and Suspension Hitch Inspect for damage and lubricate. Check bolt Torque to 90Nm • Jockey Wheel Inspect for condition and operation • Check for correct operation. • Breakaway Inspect lanyard and clip •...
  • Page 111 Inspect joint sealants inside and out. • Body Ensuite joints checked for damage and adhesion. • Inspect for soft spots on floor • General fixings Check all structural fixing are secure. • Ventilation Inspect for obstruction and vents operating correctly •...
  • Page 112 66 MONTHS / 55,000KM SERVICE CHECKED Hitch Check hitch bolts to 90Nm • Handbrake Check cable and adjust if necessary • Canopy Lifters Lubricate canopy lifting scissors • Lubricate and check bushes for excess movement. • Suspension Torque bolts to 190Nm •...
  • Page 113 72 MONTHS / 60,000KM SERVICE (Should be completed by professional) CHECKED Chassis and Suspension Hitch Inspect for damage and lubricate. Check bolt Torque to 90Nm • Jockey Wheel Inspect for condition and operation • Check for correct operation. • Breakaway Inspect lanyard and clip •...
  • Page 114 Inspect joint sealants inside and out. • Body Ensuite joints checked for damage and adhesion. • Inspect for soft spots on floor • General fixings Check all structural fixing are secure. • Ventilation Inspect for obstruction and vents operating correctly •...
  • Page 115 78 MONTHS / 65,000KM SERVICE CHECKED Hitch Check hitch bolts to 90Nm • Handbrake Check cable and adjust if necessary • Canopy Lifters Lubricate canopy lifting scissors • Lubricate and check bushes for excess movement. • Suspension Torque bolts to 190Nm •...
  • Page 116 84 MONTHS / 70,000KM SERVICE (Should be completed by professional) CHECKED Chassis and Suspension Hitch Inspect for damage and lubricate. Check bolt Torque to 90Nm • Jockey Wheel Inspect for condition and operation • Check for correct operation. • Breakaway Inspect lanyard and clip •...
  • Page 117 Inspect joint sealants inside and out. • Body Ensuite joints checked for damage and adhesion. • Inspect for soft spots on floor • General fixings Check all structural fixing are secure. • Ventilation Inspect for obstruction and vents operating correctly •...

  • Page 118: Hiring Your Camper/Caravan

    Hiring Your Camper/Caravan We want you to get the best experience you can have from your Camper Trailer or Caravan for many years. To help you achieve that, we encourage you to read the below information prior to considering hiring your camper trailer or caravan to third parties.

  • Page 119: Warranty Statement

    Warranty Statement These Warranty Terms form part of the contract between you and Market Direct Group Pty Ltd (ACN 115 038 483) (“we” or “us”) for the purchase of your new Off-road Caravan or Camper Trailer. Please read these Warranty Terms carefully.
  • Page 120 2. REMEDIES AND LIMITATION OF LIABILITY a) Except as otherwise required by law, your remedy if we accept a warranty claim will be limited to our choice between repair works with our chosen repairer, replacement goods, or a refund, as we reasonably consider appropriate to rectify the basis of the claim.
  • Page 121 6. LODGING A CLAIM If you purchased a caravan or camper which you believe is covered by warranty, and you become aware of something you believe to be a defect or damage resulting from a defect, then you should follow the process set out below to obtain the fastest response and greatest chance of having your claim approved: a) As soon as reasonably possible after becoming aware of what you believe to be a defect or damage caused by a defect, lodge a warranty claim through our website using our online Warranty Claim Form;...

  • Page 122: Supplier Details

    Supplier Details Dometic Thetford Australia Address: 41 Lara Way, Campbellfield VIC 3061 https://www.dometic.com/en-au/au/contact-us Phone: (03) 9358 0700 Email: infoaus@thetford.com.au Cruisemaster Leisure-Tec Australia Pty Ltd (Truma Hot Water) Address: 352B Bilsen Road, Geebung QLD 4034 50 Metrolink Circuit Campbellfield VIC 3061 Phone: (07) 3624 3800 Phone: 1300 072018 Email: sales@cruisemaster.com.au...
  • Page 123 Karratha Kalgoorlie 51 Orkney Road, Karratha WA 6714 5 Darcy Lane, Kalgoorlie WA 6430 Ph: (08) 9144 2333 Ph: (08) 9091 4111 Email: karratha@statewidebearings.com.au Email: kalgoorlie@statewidebearings.com.au Wangara Wingfield 70 Distinction Road, Wangara, WA 6065 Grand Jct Rd & South Rd Wingfield SA 5013 Ph: (08) 9303 6900 Ph: (08) 8260 6299 Email: wangara@statewidebearings.com.au...

  • Page 124: Travel Record

    Travel Record Trip Name Date Km Start Km Finish Cumulative P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...
  • Page 125 Trip Name Date Km Start Km Finish Cumulative P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

  • Page 126: Appendix

    Connecting the Safety Chains Appendix Contact Details and Stores Topic Page Control Panel & Accessories 12 Volt Electrical Trouble Shooting Correct Use of Your Electric Brakes 12 Volt Main Circuit XL15-4 & XL15E MkII Correct Vehicle Wiring 12 Volt Switchboard Circuit XL13E MkII Corrosion Protection 12 Volt Switchboard Circuit XL15-4 &...
  • Page 127 Hiring Your Camper/Caravan Recommended Recovery Products Hitch Recovery points Hitch and Chains Red Indicator Lamp “Fault” Hitch Movement Removing The Cowl Cover Hot water Removing Flue Cover Resetting Breakers Hot Water Ventilation and Flues Rock Tamer Hub Assembly Roof Maintenance Inclement Weather Roof Props Internal Cooktop XL15-4...
  • Page 128 Towing Mirrors Towing The Caravan Towing with Trucks Trail-Assure™ Electronic Stability Control System Trailer Level Trailer Lights Trailing Arm Bushes Travel Record Trouble Shooting Trouble Shooting Truma Rapid Hot Water System TV Antenna Tyre Pressure Guide Tyre Pressures Tyres Uncoupling Using the Caravan Using Wheel Chocks and Ramps Vehicle Electrical Requirements...
  • Page 129 P a g e www.marketdirect.com.au Ph: 1300 494 494 ©Copyright...

This manual is also suitable for:

Ausrv xl15e mkii 2023Ausrv xl15-4e mkii 2023

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