AUSSIE TRAVELLER 266210001 12V 2kW Diesel Heater Instruction Manual

AUSSIE TRAVELLER 266210001 12V 2kW Diesel Heater

Specifications:

• Output: 2kW
• Fuel: Diesel
• Voltage: 12V
• Fuel Consumption: (data not provided)
• Power Consumption: (data not provided)
• Working Height Above Sea Level: Up to 5000m
• Working Temperature: (data not provided)
• Weight: (data not provided)
• Dimensions (LxWxH): (data not provided)

Product Introduction:

The Aussie Traveller 12 2kW Diesel Heater is a compact designed heater that efficiently warms caravans or RVs. It operates quietly, providing comfort on cold days with its hot air output. Equipped with Automatic Altitude Adjustment, it ensures consistent performance even at high altitudes.

Structure:

The heater consists of a small fuel furnace controlled by a single-chip micro- processor. The heat exchanger is housed in a hood-shaped case, serving as an independent air passage. Cold air is drawn in, heated, and blown out as hot air by the fan.

Installation:

1. Read the installation manual thoroughly before proceeding. 2. Ensure correct placement of the heater in the desired location. 3. Connect the necessary fuel and electrical connections following the provided instructions. 4. Securely mount the heater to prevent movement during operation. 5. Test the heater to ensure proper functionality before regular use.

Controller Installation:

1. Mount the controller in a convenient and accessible location.
2. Connect the controller to the heater following the provided wiring diagram. 3. Ensure all connections are secure and insulated to prevent any electrical issues. 4. Test the controller to verify proper communication with the heater.

Warranty Statement:

It is essential to follow the installation and operation manual to maintain warranty coverage. Any incorrect installation or operation may void the warranty. For any issues, contact customer support at the provided contact details.

FAQ

• Q: How do I adjust the temperature settings on the heater?
  • A: The temperature settings can be adjusted using the controller provided with the heater. Refer to the user manual for detailed instructions on temperature control.
• Q: Can the heater be used while driving?
  • A: It is recommended to use the heater when stationary to ensure safe operation and proper ventilation.

Read this installation instruction thoroughly.

Incorrect installation or operation may void any warranty. Incorrect use or operation may cause serious injury.

PREFACE

Thank you for purchasing the Aussie Traveller 12V 12kW diesel powered hot air heater. This instruction book describes the structures, working principles, installation, and operation of the heater. For correct use of the heater, please read this instruction book carefully before installation and use. The instruction book should be saved in a convenient place for reference later.

NOTE:

• This instruction book is subject to revision without notice, but the instruction book is in conformity to the purchased product.
• Our effort is to explain all questions you may have. If you have any doubts or find anything incorrect in this manual, please contact us directly.
• Check the heater for any missing parts when unpacking and contact Aussie Traveller immediately if anything is found.

Comply with the operation manual for installation and operation to ensure prolonged and reliable use.

PRODUCT INTRODUCTION

The main parts of the Aussie Traveller 12 2kW Diesel Heater (hereinafter referred to as ‘the heater’) is a small fuel furnace controlled by a single- chip micro-processor. Its furnace body (the heat exchanger) is located in the hood shaped case, which serves as an independent air passage. Cold air is drawn into the air passage by the fan, heated by the heat exchanger and blown out as hot air. The Aussie Traveller 12 2kW Diesel Heater will quickly warm your caravan or RV on those cold Winter days. This compact designed 12V Diesel Heater has excellent fuel efficiency and power consumption. You won’t even notice that the whisper quiet heater is running, enjoy the warmth while you watch TV or have a casual conversation. The 12V 2kW Diesel Heater also comes equipped with Automatic Altitude Adjustment. It has a working height all the way up to 5000m above sea level so you won’t have to worry about getting cold anywhere in Australia. The heater is a small fuel furnace controlled by a single-chip micro-processor. Its furnace body (the heat exchanger) is located in the hood shaped case, which serves as an independent air passage. Cold air is drawn into the air passage by the fan, heated by the heat exchanger and blown out as hot air. The heater is supplied as standard with an easy-to-read digital display and complete installation kit.

• Warms your vehicle
• Compact design
• Automatic altitude adjustment
• Flexible installation with 90° tilt
• Whisper quiet
• Easy-to-use digital display

TECHNICAL DATA

• OUTPUT 2000W
• FUEL Diesel
• VOLTAGE 12V
• FUEL CONSUMPTION 0.12–0.24L/hr
• POWER CONSUMPTION 14–29W
• WORKING HEIGHT ABOVE SEA LEVEL ≤5000m
• WORKING TEMPERATURE -40°C–20°C
• WEIGHT 2.6kg
• DIMENSIONS (LxWxH) 323×120×121mm
• VARIABLE OUTPUT POSITION Current Draw 12V (Amps)
• P01 0.9
• P02 1.1
• P03 1.2
• P04 1.3
• P05 1.5
• P06 1.7
• P07 1.9

STRUCTURE

The structure of the main body as shown:

1. Air Fan
2. E.C.U.
3. Air Motor
4. Bottom Case
5. Insulating Bush
6. Heat Exchanger

INTERNAL STRUCTURE:

1. Heat exchanger
2. Gasket 1 (4 hole)
3. Combustion chamber
4. Burner Assembly
5. Gasket 2 (5 hole)
6. Air Motor Assembly
7. Insulating bush
8. ECU
9. Air Fan Wheel
10. Glow Pin
11. Overheat Sensor

heat exchanger is made of die cast aluminium with radiating fins around and at the rear end. The combustion tube is located inside the heat exchanger, and the burner assembly is fixed on the front end of the combustion tube. Fuel is fed to the burner assembly through the fuel inlet pipe by the aid of the fuel pump. It is ignited by the glow pin, which also serves as a flame sensor after ignition. The flame is supported in the burner assembly and sealed in the combustion tube. All combustion gases exit the heater through the exhaust port. Combustion air is fed into the heater via the combustion air pipe and is supported efficiently by the combustion air fan, located on the rear of the air motor. Cool air enters the air inlet, is heated by the heat exchanger, and is pushed out the air outlet by the fresh air fan of the air motor assembly.

HEATER CASES:

1. Inlet cap
2. Outlet Cap
3. ECU Cover
4. Top Case
5. Bottom Case
6. Grill

INSTALLATION

The kit includes everything necessary for a standard installation.

1. Main Heater Body
2. Control Unit (with accessory plug)
3. Main Wiring Harness
4. To Power Supply
5. Fuse Holder
6. Mounting Gasket
7. Combustion Air Pipe Clamp
8. Combustion Air Pipe
9. Combustion Air Pipe Strap
10. Filter
11. Exhaust Pipe Clamp
12. Exhaust Pipe P-Clip
13. Exhaust Pipe
14. Muffler
15. M6 Nut & Washer (x4)
16. Fuel Pump
17. Fuel Pump Mount
18. Fuel Pump Damper
19. Non-Return Valve
20. Fuel Filter
21. Fuel Pipe Connector
22. Fuel Pipe Connector Clamp
23. Fuel Pipe
24. Fuel Standpipe

ATTENTION:

• Do not mount the heater near any flammable sources
• Do not install the heater in closed spaces without ventilation
• Do not place the heater near anything that can cause a blockage
• Do not mount the heater near any water sources and protect it from any splashing or road debris

INSTALLATION OF THE MAIN HEATER BODY:

For the ease of servicing, fault finding and air flow it’s recommended that the main body is placed in an area with easy access. Illustration below shows the minimum distances required, in millimetres, on the Aussie Traveller 12V 2kW Diesel Heater.

12V 2KW DIESEL HEATER DIMENSIONS:

• A. Air heating inlet
• B. Air heating outlet
• C. Combustion air inlet
• D. Fuel inlet
• E. Exhaust outlet
• F. Non-interference area
• G. Information label

Choose a flat installation surface, any undulations could cause the case to twist and will not ensure an even mount. Make sure there are no foreign bodies between the bottom of the heater and the installation surface itself. This will ensure a good seal between the two. File down any drill holes to again ensure an even mounting surface. Tighten the M6 bolts provided to a torque setting of 6Nm+1Nm. The figure below shows the position of the installation holes. If the installation area is less than 1.5mm thick a mounting plate will be required.

MOUNTING GASKET & PLATE DIMENSIONS:

The mounting gasket and mounting plate required in most vehicle installations is shown below.

NOTE: If the heater is being reinstalled, a new gasket should be used.

• A. Mounting Gasket
• B. Mounting Plate

ANGLE OF INSTALLATION:

The angle of installation is shown in figure below. Ensure you do not exceed the inclination angle or normal operation will be affected. After installation, make sure there is no friction between the fan and other nearby parts to ensure smooth operation and make sure the heater label is clearly visible for ease of maintenance in the future

AIR INLET & OUTLET:

Make sure that the hot air outlet does not exit onto any parts affected by heat and that it isn’t directed toward the flow of anything that can cause a blockage, near splashing water or near the vehicles exhaust. Avoid re-entering of the supplied hot air into the inlet port as shown below. If no inlet pipe is required, make sure the grill is installed at the inlet port instead (see Heater Gases, page 4). Additional ducting can be purchased if required

INSTALLATION OF COMBUSTION AIR PIPE & EXHAUST:

The combustion air inlet pipe sucks in fresh air from outside of the vehicle and the exhaust discharges fumes outside of the vehicle. Measures must be taken to avoid the fumes from re-entering the vehicle. The pipes should exit at the bottom of the vehicle, ensuring that the openings are far enough away from any splashing water or dirt that can clog them. Only use the inlet pipe and exhaust provided with the kit for installation. The exhaust pipe is made of corrugated stainless steel while the combustion pipe is aluminium covered in paper and plastic. Do not confuse the two. Use the supplied clamps to fix them securely to the combustion air inlet and the exhaust outlet on the heater. The protective end cap on the outlet of the combustion air pipe and exhaust pipe should be kept in good condition. Do not damage or remove them. Both the combustion air pipe and exhaust pipe should come downward from the heater and face opposite to the vehicle’s direction of travel. If the pipe cannot avoid a curve, make sure the radius is no smaller than 50mm and the sum of all curves does not exceed 270˚. Figure below shows the right and wrong way to install the combustion air intake. Note that it is the same for the exhaust too.

When the heater is operating, the exhaust will get hot, so make sure it is installed away from any parts that could get damaged by high temperatures. The exhaust vent should also point downward to the road surface with an angle of 90˚±10˚. This is best achieved by fixing a clamp 150mm from the pipe end. Any exposed exhaust should be covered with a heat shield to prevent scalding.

INSTALLATION OF FUEL LINES:

1. Fuel Tank
2. Fuel Standpipe
3. Fuel line connector hose clip
4. Fuel Line
5. Fuel line connector
6. Fuel Filter
7. Fuel Pump
8. Damper
9. Heater Body

• A. Blue Plastic Fuel Line
• B. Clear Plastic Fuel Line

Always fit the fuel pump on the anti-vibration mount securely onto the vehicle. Ensure the outlet of the fuel pump tilts upward. The correct angle is shown below. Where possible the fuel line should ideally be placed uphill to the fuel pump to ensure ideal bleeding of the fuel line

1. Heater Body
2. Max. Fuel Level
3. Min. Fuel Level
4. Fuel Pump and Damper

Fuel Pump Angle & Suction Height

• A. 3000mm
• B. 500mm
• C. 2000m
• D. Not acceptable
• E. Acceptable (between 15-35°)
• F. Not acceptable

INSTALLATION OF FUEL LINES (cont.):

The fuel pump’s outlet should tilt upward at an angle between 15˚-35˚ (as shown on previous page). Only use the fuel line provided, ensure the pipe is placed away from any possible debris and avoid any sagging in the line. Make sure the fuel line does not flow downward toward the fuel pump. This will prevent correct fuel flow and produce air bubbles in the line.

THE FUEL FILTER, FUEL PIPE AND CLAMPS SHOULD ALL BE REPLACED AFTER 2 YEARS OF USE.

Figure below shows the correct way to connect fuel lines to prevent the build- up of air bubbles. Ensuring they are flush and minimising bends. When the fuel is being sucked from the tank, a suction pipe is required. Make sure all the openings are appropriate for the installation and a tight seal is maintained for the base of the suction pipe. The bottom of the suction pipe should be about 30-40mm from the bottom of the fuel tank so as to avoid sucking impurities or sediment from the bottom of the fuel tank.

• A. Flush – No Air Bubble
• B. Gap – Air Bubble Formed

FUEL STANDPIPE:

A fuel standpipe (or suction pipe) will need to be installed into the fuel tank.

• Drill a hole in the top of the vehicle’s fuel tank Ø22 ± 0.2mm in size.
• Ensure it is smooth and clean of burrs
• Remove the top nut and washers and bend the standpipe straight
• Cut the standpipe down to size if necessary
• Fit the standpipe by tilting it into position into the newly drilled hole
• Place the rubber and metal washers back on top followed by the nut and tighten it securely on top

WIRING DIAGRAM

The previous page shows the wiring diagram for the heater. The wires of the main heater have been made into bundles. They can be laid according to the positions of various components and should be fixed to the proper locations. The distance between two fixing points should not exceed 300mm. NOTE: Any exposed wire outside the vehicle should be protected so as not to be ripped by any road debris or similar. Connect the main wiring harness to the heater by gently removing the junction box cover. Connect the 12-wire connector of the main wiring harness to the controller socket (X6). The main harness can exit the heater to the left or to the right. Then replace the cover ensuring a good seal is kept all the way round. A fuse will already be inserted into the fuse holder (20A for 12V heaters and 15A for 24V versions). Connect the 2.5mm² red wire and the 2.5mm² brown wire in the wire harness to the spring terminals and then to the positive and negative of the vehicles battery. Straighten the fuel pump leads (two 0.6mm² black wires) and put them through the opening on the wall of the air inlet pipe. They can then be connected via the spring plug straight to the fuel pump or using the fuel pump extension loom if more length is required.

ECU CONNECTIONS:

The connection parts on the controller case are designed in such a way that wrong connections are impossible to make.

The following circuit interfaces can be found on the controller case; these are:

• X1: Fan motor
• X2: Glow plug
• X3: Overheat sensor
• X4: Leads to fuel pump
• X5: Unused
• X6: Main Wiring Harness

CONTROLLER INSTALLATION

• The control switch must be installed in the vehicle in accordance with the corresponding technical specifications for vehicle control.

SAFETY INFORMATION

• Find a suitable mounting surface within the driver’s field of vision to fix the control switch.
• Do not use high-voltage devices unless the electronic circuit (PCB board) has been disconnected.
• If welding is required on the vehicle, do not connect the DC power supply to the control switch. Welding will cause serious damage to the switch.
• Do not shorten the original control lead wire. When installing this control switch, the vehicle power supply must be turned off.
• This control switch should be installed in the waterproof and moisture-proof location.

INSTALLATION LOCATION

• The control switch should be installed n the location easy to read and operate.
• The opening size of the control switch is 16 × 22mm, refer to Fig. 3.

INSTALLATION STEPS

1. Clean the installation opening and surface firstly to ensure that the iinstallation surface is smooth and clean without dust and water mist.
2. Insert the tapping screw into the mounting surface as shown in Fig. 3. Fix the back cover on the back cover on the mounting surface.
3. Insert one end of the control switch lead wire into the PCB board terminal as shown in Fig. 4 and the other end through the back cover and installation opening as shown in Fig. 3.
4. Finally, press the top cover firmly onto the back cover as shown in Fig. 5.

NOTE:

• DO NOT make any tensile stress to the control switch lead wire.
• DO NOT pull out the control switch lead wire during the heater working process. Once the plug at both ends of the lead wire falls off from the control switch or controller, it will interrupt the heater heating and fail.

WARRANTY STATEMENT

Aussie Traveller Pty Ltd ACN 642 775 460 (Aussie Traveller) offers the following warranty in relation to the products it supplies directly or through an authorised manufacturer, dealer or approved service repair agent (Product).

Australian Consumer Law

The benefits of this warranty are in addition to any rights and remedies imposed by Australian State and Federal legislation that cannot be excluded. Nothing in this warranty is to be interpreted as excluding, restricting or modifying any State or Federal legislation applicable to the supply of goods and services which cannot be excluded, restricted or modified. If you are a consumer as defined in the Australian Consumer Law: Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Warranty

Aussie Traveller warrants that, subject to the exclusions and limitations below, all parts of the manufacture and assembly of the Product will be free from defects in materials and workmanship (Warranty) for a period of 12 months from the date of purchase as follows:

1. This Warranty is activated at the time of purchase by the final retail customer (being the owner of the Product).
2. In the event the Product is purchased by a manufacturer, dealer or approved service repair agent, this Warranty will commence at the time the final retail customer makes payment for the Product to the wholesale purchaser.
3. If the Product is purchased directly from Aussie Traveller for use by final retail customer and not to be on sold in any way, the Warranty will commence at the time of the original purchase.

Warranty Period

This Warranty cannot be assigned or transferred to a subsequent owner of the Product.
The purchaser or final retail customer should inspect the Product immediately when received or at vehicle handover, to ensure that it appears free from any damage or defect, and matches the description provided.
If after accepting the Product, a defect appears in the manufacture or assembly of the Product before the end of the Warranty Period and Aussie Traveller finds the Product to be defective in materials or workmanship, Aussie Traveller will, in its sole discretion, either:

• a. replace, repair or refund the Product or the defective part of the Product free of charge; or
• b. cause the Product or the defective part of the Product to be replaced or repaired by a qualified repairer free of charge.
  In arranging Warranty inspection, service and repair, Aussie Traveller will seek to provide the details of an approved service agent within your geographic area. Should one not be available, or if the Product is in use in travel, Aussie Traveller reserves the right to seek to arrange a repair or replacement at the next available location on the route of travel. Aussie Traveller reserves the right to replace defective parts of the Product with parts and components of similar quality, grade and composition where an identical part or component is not available. Products presented for repair may be replaced by refurbished goods of the same type rather than being repaired. Refurbished parts may be used to repair the Product.

Aussie Traveller Awning Products

This Warranty covers specified defects in materials or workmanship for Awning Products as follows:

1. The vinyl fabric is warranted against:
   • a. holes caused by mildew (mildew will form on dust and dirt and stain fabric if fabric is not kept clean).
   • b. excessive cracking, peeling, hardening or loss of strength while used under normal conditions.
   • c. excessive fading (a slight colour change may occur due to ultraviolet rays).
2. All hardware components including the roller are warranted not to bend or break under normal use (excluding high winds, water pooling and accidents).

Making a Warranty Claim

If a defect covered by this Warranty appears, the Customer must first contact Aussie Traveller within 7 days of first becoming aware of the defect. Aussie Traveller will assist the Customer to rectify and resolve any Product issue that may arise. When making a claim under this Warranty, Aussie Traveller requires that the following information be provided before any further action will be taken.

1. Original Invoice (Document or Number);
2. Make and model of the Product;
3. Make and model of the vehicle (if Product fitted);
4. Vehicle build date (if Product fitted);
5. Vehicle chassis number;
6. Description of damage and/or repair required;
7. Photos of the damage and/or repair; and
8. Appropriate documentation (such as historical and maintenance records).

Aussie Traveller reserves the right to request more information or images should what is provided not be sufficient to make an assessment for the Warranty claim. The Product must be made available to Aussie Traveller or its authorised repair agent for inspection and testing. If such inspection and testing find no defect in the Product, the final retail customer must pay Aussie Traveller’s usual costs of service work and testing. The final retail customer must bear the cost of the transport of the Product to and from Aussie Traveller or the authorised repair agent, and all insurance of the Product.

Exclusions

This Warranty will not apply where:

• the Product has been repaired, altered or modified by someone other than Aussie Traveller, or without the written consent of Aussie Traveller or an authorised repair agent;
• the alleged defect in the Product is within acceptable industry tolerances and variances;
• Aussie Traveller cannot establish any fault in the Product after testing and inspection;
• the Product has been used other than for the purpose for which it was designed;
• the alleged defect in the Product has arisen due to the final retail customer’s failure to properly use and
• maintain the Product in accordance with any of Aussie Traveller’s instructions, recommendations and specifications (including applicable maintenance schedules);
• the alleged defect in the Product has arisen due to the final retail customer’s request to customise the Product;
• the Product has been subject to abnormal conditions, including environment, temperature, high or excessive wind, water, fire, humidity, pressure, stress or similar;
• the alleged defect has arisen due to abuse, misuse, neglect or accident;
• unauthorised parts or accessories have been used on or in relation to the Product;
• the Product has been overloaded or involved in an accident;
• the alleged damage or defect has been caused by normal wear and tear;
• the alleged damage to fabric has been caused by storm, wind or rain, or stretching of fabric caused by water pooling on fabric;
• breakage or bending of hardware components has been caused by storm, wind or rain, or water pooling on fabric.

Replacement Warranty Item

If, under Warranty, a Product is replaced or repaired by Aussie Traveller or an Aussie Traveller agent, unless provided in writing to indicate otherwise, the replacement Product will carry the remaining Warranty terms and conditions, including length of time, of the original purchased Product.

Change of Mind

Aussie Traveller understands that at times, final retail customers may change their mind. Choose carefully as return and credit requests for items purchased by mistake or “change of mind” reasons may not be approved. Aussie Traveller will not accept Product returns under these circumstances unless by written approval by an authorized Aussie Traveller representative. If approved, an administration and restocking fee may apply. Limitations Aussie Traveller makes no express warranties or representations other than set out in this Warranty. The repair or replacement of the Product or part of the Product is the absolute limit of Aussie Traveller’s liability under this express Warranty.

Contact

• Australia Wide: 1300 663 868
• Melbourne Office
• 235 Barry Road
• Campbellfield, Melbourne, 3061
• Ph: +61 3 9357 6565
• enquiries@aussietraveller.com.au
• Brisbane Head Office, Factory & Showroom
• 11-15 Oasis Court
• Clontarf, Brisbane, 4019
• Ph: +61 7 3284 3284
• enquiries@aussietraveller.com.au

To receive a copy of the Aussie Traveller Warranty Terms & Conditions or information regarding specific Aussie Traveller products, please contact Aussie

• Traveller Head Office on (07) 3284 3284 or
• email enquiries@aussietraveller.com.au.

References

• AussieTraveller.com is for sale | HugeDomains

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