Coachmen RV Aurora General Maintenance & Troubleshooting Download | Manualshive

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REVISED

07/03

PN

# 916552

To Our Valued Customer

If you have a problem obtaining satisfactory and timely
warranty service that may substantially impair, use, value or
safety of your Coachmen product, please call our Owner
Relations Department toll free at 1-800-453-6064 so that
we may attempt to resolve your concerns.

You can also contact us through our Service Support
website at:

www.coachmenrv.com

COACHMEN RECREATIONAL VEHICLE COMPANY, LLC

P.O. BOX 1000

MIDDLEBURY, INDIANA 46540

®

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Summary of Contents for Aurora

Page 1: ...RECREATIONAL VEHICLE COMPANY LLC GENERAL MAINTENANCE TROUBLESH TING GENERAL MAINTENANCE TROUBLESH TING ...

Page 2: ...echnician It is also important that your read and follow the instructions in your Chassis if applica ble Appliance and Accessory booklets provided with your RV Maintenance Troubleshooting instructions for appliances and accessories were obtained from the respective manufacturer s owner s manuals and are used with the per mission of the various manufacturers Coachmen reserves the right to present e...

Page 3: ...49 RV STORAGE RV START UP Page 51 MAINTENANCE CHARTS Page 53 TROUBLE SHOOTING Page 59 APPENDIX A Page 73 INDEX Page 77 1 THE FOLLOWING LEGEND IS INTENDED TO EXPLAIN THE VARIOUS ICONS PICTURES WHICH ARE USED THROUGH OUT THE MANUAL THEY ARE USED PRIMARILY FOR YOUR CONVENIENCE AND TO BRING ATTENTION TO THE INFORMA TION AT HAND WARNING THIS SYMBOL IS USED TO ALERT THE USER TO PRECAU TIONS THAT INVOLVE...

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Page 5: ...e satin finish Laminant surface countertops and sinks Clean regularly with damp cloth and mild soap detergent Use a household cleaner detergent and a soft bristled brush to remove stains such as coffee or tea For persistent stains scrub lightly with a paste of baking soda and water Excessive or forceful scrubbing may cause damage to material Quick use of household bleach will work for stubborn sta...

Page 6: ...the cleaning process Always check to see that the cleaner used will not cause damage to the material or fabric by testing on an area out of sight Stain Treatment Type of Stain Cleaning Agent How to Remove Mustard dry clean solvent scrub soak blot dry Ketchup high strength detergent scrub rinse blot dr Coffee high strength detergent scrub rinse blot dry Chocolate detergent scrub rinse blot dry Tea ...

Page 7: ... It has passed exten sive testing for appearance retention pile density height color fastness adhesion of backing and more It is important to keep your carpet as clean as possible To keep your carpet attractive Carpet Vacuum regularly with a vacuum cleaner equipped with revolving brush or beater bar Be sure vacu um has no teeth combs or rough edges as they may damage the carpet It is important to ...

Page 8: ...er based shampoo or foam upholstery cleaner DO NOT over wet DO NOT use solvents to spot clean Pile fabrics may require brushing to restore appearance Cushion covers should not be removed and laundered S Clean only with dry cleaning solvent DO NOT saturate DO NOT use water Pile fabric may require brushing to restore appearance Cushion covers should not be removed and dry cleaned WS Clean with shamp...

Page 9: ...oration and premature deterioration by putting a plastic liner over tire before installing vinyl tire cover MISCELLANEOUS INTERIOR LP CO Detectors require minimal maintenance Test by pressing Test Reset button at Beginning of camping season Prior to each trip Monthly Use damp cloth or towel to clean exterior covers DO NOT spray cleaners on or around detectors According to the manufacturer the LP d...

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Page 11: ...hes Water Column this needs to be done by a qualified technician Inspect and clean flu baffle Presence of heavy soot formation indicates improper burner operation Have a qualified technician clean flu baffle or follow instructions in refrigerator owner s manual FURNACE Due to the complex nature of the appliance a qualified RV technician should perform furnace mainte nance at least once a year more...

Page 12: ...scratch and stain the stovetop Keep burner assemblies clean and adjusted properly DO NOT use caustic cleaners on any part of oven range assembly A V EQUIPMENT TV VCR DVD STEREO Keep electronic equipment clean by frequently dusting with a soft cloth DO NOT spray any type of liquid cleaner or water onto or around electronic equipment Keep CD and DVD discs clean Wipe with a clean soft and moist cloth...

Page 13: ...rioration Exterior cleaning roof and sides is a perfect time to inspect the sealants Have the sealant replaced if you notice any of the above Your local Coachmen dealer has the correct and necessary parts and experience to help you maintain your sealants Always use the same type sealant that was removed Immediately have dealership check moldings windows and exterior attachmentsfor leak source if y...

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Page 15: ... Coachmen dealer as quickly as possible for proper repair In the meantime use Dicor sealant to seal damage or cover to minimize water entry into roof assembly Most RV Dealers Parts Stores carry Dicor s rubber roof patch kit and materials FIBERGLASS ROOFS Wash monthly or more frequently if needed Wash with mild soap such as dish detergent soap Avoid using alkaline or abrasive cleaners Wax once or t...

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Page 17: ...Periodically wax with a quality automotive wax to protect paint and graphics Be careful when waxing around tape graphics as the edge may curl up Wax along the tape not against it GELCOAT FIBERGLASS WALLS CAPS BUMPER Wash monthly or more frequently if needed Wash with mild soap such as dish detergent soap Avoid using alkaline or abrasive cleaners Wax once or twice a year with a high quality paste w...

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Page 19: ...lly vacuum inside window tracks to prevent dirt and dust from building up and clogging weep holes Periodically check outside weep slots for obstructions and clean if necessary NOTE If water is noticed entering the window between the glass and frame take unit to a Coachmen dealer to have sealed If water is entering between window frame and clamp ring and running down wall have your Coachmen dealer ...

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Page 21: ...months check frame for rust and if found sand and paint with rust preventing paint or undercoating Be sure vehicle is on level surface and wheels blocked before working or cleaning underneath ENTRANCE STEPS Clean regularly to keep step free of mud salt and road grime Lubricate all moving parts monthly with a quality moisture and heat resistant penetrating grease Spray silicone and penetrating oils...

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Page 23: ...ep hitch plate and locking mechanism generously lubed with a quality high temperature grease Inspect prior to each trip ENTRANCE STEPS Clean regularly to keep step free of mud salt and road grime Lubricate all moving parts monthly with a quality moisture and heat resistant penetrating grease Spray silicone and penetrating oils are not recommended Inspect for rust If found sand prime and paint usin...

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Page 25: ...n a heavily loaded vehicle Rear Minimum operating pressure 20 p s i Maximum operating pressure 100 p s i Recommended range 60 80 p s i depending on load Check inflation pressure weekly Air bags will normally lose 3 4 p s i per week A higher rate indicates leakage Allow 1 p s i of air pressure for every 40 lbs of weight i e 50 p s i to support 2000 lbs Periodically check bags for any cracking If cr...

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Page 27: ...t is chipped sand and paint with rust preventing paint Using a torque wrench check wheel lug torque prior to each trip 13 wheels require 50 75 ft lbs of torque 14 15 16 wheels require 90 120 ft lbs BRAKES Adjust brakes after first 200 miles then every 3 000 miles or as use requires Make sure brake controller and brakes are properly synchronized prior to each trip Inspect at beginning of season or ...

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Page 29: ...lems TIRE WEAR DIAGNOSTIC CHART NOTE Tire wear should be checked frequently Once a wear pattern becomes established in a tire the stop ping capability is significantly reduced even if underlying cause is corrected TIRES WEAR PATTERN CAUSE ACTION Center Wear Edge Wear Side Wear Toe Wear Cupping Flat Spots Over Inflation Under Inflation Loss of camber or overloading Incorrect toe in Out of balance W...

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Page 31: ...CTIONS Twice a year check electrical connectors at the jack and at the wall connector Clean prongs of any corrosion for proper trouble free operation Once each year Extend landing legs as far as possible and clean drop tube and inner ram tube Coat exposed surface of tubes with silicone spray lubricant Coat inside of handle alignment tube with silicone spray lubricant Oil shaft bushing in gearbox a...

Page 32: ...or rust if found sand prime and paint with rust preventative paint Lubricate pivot points and gear assembly every 6 months with a quality silicone lubricant Simply extend jacks to ground until they are snug CAUTION DO NOT lift trailer with stabilizer jacks this may cause damage and require replacement 30 JACKS TOWABLE ...

Page 33: ...s needed to reach split level marker on battery Keep battery cable connections clean and tight Keep batteries fully charged specific gravity should read between 1 215 and 1 250 Be sure vent caps are tight replace if cracked Periodically clean with a diluted solution of baking soda and clean water followed by a clean water flush Battery Storage Instructions During storage it is important to inspect...

Page 34: ...e service power cord depending on your particular model and option Inspect and clean prongs on cord plug regularly Shine prongs with a soft emery cloth if corroded Inspect cord for cuts cracks and worn insulation Replace cord if these symptoms are noticed Not all locations have 50 amp service campsites and sometimes 30 amp service isn t available In these cases you may need to adapt down to the av...

Page 35: ...amps Power Window 12 0 amps Radio CB Stereo 4 0 to 4 6 amps Exterior Lights Clearance Light Ea 1 amps Refrigerator Dometic 14 6 to 13 8 amps Headlights Low Beam 16 0 amps Refrigerator Norcold 1 8 amps Headlights High Beam 24 3 amps Security System 1 0 amps Landing Lights 5 5 amps LED Off 20 milliamps Parking Lights 9 4 amps LED Armed 30 milliamps Porch Light 1 1 amps Television 4 9 amps Spot Light...

Page 36: ...as little as 30 days the gasoline housed in a genset can break down into gums and var nishes Gum and varnish can clog the fuel system causing fuel pump fuel line and carburetor plugging resulting in hard start ing and surging never settling on a stable operating speed To prevent this Onan recom mends you run your generator at approximately 50 of its capacity 2000 watts or one air conditioner for a...

Page 37: ...9 Perform more frequently if there are extended periods of non use MISCELLANEOUS ELECTRICAL GFI Receptacles Test all GFI receptacles monthly Push in test button the reset button should pop out Push in reset button and it should hold Replace receptacle if reset button does not hold and pops out Breakaway Switch Inspect at beginning of camping season and prior to each trip and make sure it is secure...

Page 38: ...ny that are damaged corrod ed or non functional ELECTRICAL Dash fuse location Gas Class A Left side of driver s area Dash fuse location Rear Diesel Class A Under cup holders on dash Travel Trailer 12V mini breakers Front frame Fifth Wheel 12V mini breakers Front compartment Mini Home Class C 12V mini breakers Under step area Rear Diesel battery disconnect solenoid and 12V mini breakers Rear compar...

Page 39: ...15 Amp Power Center Water Heater 5 Amp Power Center Refer 15 Amp Power Center Water Pump 15 Amp Power Center Range Hood 5 Amp Power Center Interior Lights 15 Amp Power Center Generator 175 Amp Battery Compartment Converter Class C 40 Amp Battery Compartment manual reset Class A 50 Amp Battery Disconnects Area Distribution Panel Class C 40 Amp Battery Compartment manual reset Class A 50 Amp Battery...

Page 40: ...h H7U Running Light 168 Running Light 168 Front Turn Signal 3457A Front Turn Signal 3457A Clearance Lights FRT RR 194 Clearance Lights FRT RR 194 Mirror Lights 194 Mirror Lights 194 Side Marker Lights 194 Side Marker Lights 194 Tail Light Stop 1157 Tail Light Stop 2157 Tail Light Turn Stop 1157 Tail Light Turn Stop 2157 Tail Light Running 1157 Tail Light Running 2157 Tail Light Back Up 1156 Tail L...

Page 41: ...tment LP leak detector 1 Amp Behind Detector 5 Amp Power Center Monitor Panel 5 Amp Power Center Range Hood 5 Amp Power Center Radio Cassette 15 Amp Power Center 5 Amp Behind Radio TV Booster 15 Amp Power Center Interior Lights 15 Amp Power Center Refrigerator 15 Amp Power Center Furnace 15 Amp Power Center Water Heater 5 Amp Power Center Water Pump 15 Amp Power Center CO Detector 1 Amp Behind Det...

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Page 43: ...lution for every 15 gallons of fresh water capacity e g 2 gallons of solution for 30 gallon system capacity For products with a Water Filter System remove filter and install bypass line or if equipped place bypass valve in the bypass position Replace with a new filter after the sanitizing procedures are completed For products that have a Gravity Water Fill Diag A pour the chlorine solution into th...

Page 44: ...eze in water or drainage systems It is poisonous and corrosive Drain holding tanks at an appropriate facility Drain system by opening faucets low point line drains and removing water heater drain plug For products with the 4 valve Water Works Panel Diag B place hot and cold water line drain valves in the OPEN position Turn the water heater bypass valve to the bypass position Diag D The bypass valv...

Page 45: ...he gray holding tank Open and close termination valve quickly to let anti freeze coat termination valve blade and seal To de winterize flush system with fresh water and follow sanitizing procedures HOLDING TANKS To keep the sewage system in good working order Empty only when at least 1 2 full Always dump black toilet tank first and then follow with gray tank This will help keep sewer hose and conn...

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Page 47: ...The use of this equipment inside the recreational vehicle may cause fires or asphyxiation WARNING DO NOT bring or store LP gas containers gasoline or other flammable liquids inside the vehicle because a fire or explosion may result A warning label has been located near the LP gas container This label reads DO NOT FILL CONTAINER S TO MORE THAN 80 PERCENT OF CAPACITY Over filling the LP gas containe...

Page 48: ... output Below is a chart detailing BTU ratings relating to pressure and temperature ratings One pound of LP gas will give 21 500 BTU s So in colder climates you will need to figure BTU usage accordingly 65 lb Under Mtd LP Gas Tank BTU Available At Full 20º 0º 5º 10º 15º 60 95 600 47 800 36 000 23 900 12 100 50 86 000 43 000 32 250 21 500 11 750 40 77 000 38 500 29 250 19 250 9 625 30 68 000 34 000...

Page 49: ...djust the sensing unit until all yellow lights are off This is done by drawing up the correspon ding screw if the sensing unit is mounted below the surface as shown in FIGURE A or backing out the corresponding screw if the sensing unit is mounted above the surface Bump the sensing unit to see that it has settled down in the level position Prior to each trip check oil supply in hydraulic oil reser ...

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Page 51: ...ing and the RV Keep clean Clean hardware items once a year to make sure they are tight clean and lubricated Inspect bolts and screws for tightness For vinyl fabric clean with mild soap and water or 1 4 cup of bleach to 5 gallons of water for heavy soil and stains For acrylic fabric spray often with water dry completely before storing Apply a water repellent once a year Be sure fabric is dry before...

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Page 53: ...rs in underbelly material or openings into floor where animals may enter seal if necessary Tape cardboard inside of refrigerator and water heater exterior vent doors to help prevent dust and debris from building up on burner components Wash and wax exterior of unit for easier spring start up Cover furnace intake and exhaust vents with tape and foil to prevent dust and debris and varmints from ente...

Page 54: ...r polarity Remove window coverings open windows and vents and let unit air out Test pilot lights on range refrigerator furnace and water heater Install new dry cell batteries and test smoke detector De winterize and sanitize water system according to instruction in the Plumbing section Inspect and clean air conditioner filter and test run Inspect and work exterior latches and locks lube if necessa...

Page 55: ...53 MAINTENANCE CHARTS ...

Page 56: ...54 MAINTENANCE CHARTS ...

Page 57: ...55 MAINTENANCE CHARTS ...

Page 58: ...56 MAINTENANCE CHARTS ...

Page 59: ...57 MAINTENANCE CHARTS ...

Page 60: ...58 MAINTENANCE CHARTS ...

Page 61: ...stat is set below room temperature Make sure 120 Volts AC is available from generator or shore power Check coach circuit breakers Make sure the unit is turned on Runs but coil freezes and compressor cycles too soon Control may be set too low Make sure the filter is clean and unobstructed Check to see if too many outlet vents are closed Doesn t get cold enough Give the air a head start on the heat ...

Page 62: ...ERS FIFTH WHEELS ONLY No brakes Check fuse at battery connection Bargman plug not fully connected Faulty controller test and correct Weak brakes Clean corroded connections at pigtail plug Adjust controller sensitivity Weigh trailer to determine if weight is excessive See Federal sticker or weight sheet located in unit for guidelines Harsh brakes Adjust controller sensitivity on controller Surging ...

Page 63: ...place or lubricate FURNACE Furnace does not ignite Be sure gas bottles are full and have gas pressure set to 11 water column pressure with three appliances running Gas pressure should be checked periodically by dealer Return air grille should not be obstructed DO NOT store anything in furnace compartment Check fuse in fuse panel and replace if necessary Remove any obstructions that may be covering...

Page 64: ...er cool down reduce load Lights dim or half bright Bad battery Check battery condition Possible converter malfunction Have converter checked by an authorized service center Possible low voltage from shoreline Make sure voltage to shoreline is not too low 108 volts minimum LEVELING JACKS The pump runs but the jacks will not extend If the voltage is below 10 volts there is a connection cable ground ...

Page 65: ...e the gas system checked immediately and leakage source corrected by your dealer or qualified service center before using again MICROWAVE OVEN Microwave oven will not operate No power to oven Check power supply and circuit breaker Door open or timer OFF Close door and turn timer ON MONITORING PANEL Full System No lights on panel when switch is pressed Check wiring or voltage supply Check fuse If 1...

Page 66: ...ing Clogged burner ports Clean with a toothpick Oven burner won t light Check to see that the constant pilot is lit Gas smell Check all connections with leak detector solution Never use a match or flame to check for leaks NOTE All LP connections should be checked periodically as vibrations from travel may cause them to loosen Cakes burn on bottom Oven too full for proper circulation Using pan with...

Page 67: ...ns Defrost In extremely hot weather refrigerator performance is better on LP gas RV BATTERY Dead or Depleted Battery Excessive draw over time Bad battery Low water level in battery Check connections for tightness and clean RV battery boiling Water low in battery Refill water to correct level in battery Bad battery Replace battery Defective converter Have converter checked by an authorized service ...

Page 68: ...y Check for bad connections at the switch control and motor For manual operation instructions see Appendix A on page 73 POWER GEAR ELECTRIC SLIDE OUT ROOM Room will not retract Check for disconnected battery or blown fuse Check for a low charge in the battery Check for bad connections at the switch control and motor For manual operation instructions see Appendix A on page 73 TERMINATION VALVE Term...

Page 69: ...Lowering antenna to travel position Step 1 Set rotation clamp to the ROTATION position Step 2 Rotate antenna until pointer on directional handle aligns with the screw on rotation lock lever Step 3 Turn elevating crank counter clockwise in direction of DOWN arrow until resistance is met The number of turns will vary according to the elevation angle the antenna was set to Step 4 Move rotation clamp ...

Page 70: ...68 TROUBLESHOOTING ...

Page 71: ...t rotate or is hard to rotate Inspect antenna on roof Make sure that mount has not been damaged Check for caulking on elevating shaft Contact Dealer or Winegard Service Department WASTE TANK Waste tank will not drain Build up in tank Check for build up in tank at stool Make sure stool holds water WATER HEATERS Temperature pressure relief valve weeping Weeping or dripping of relief valve while wate...

Page 72: ...y have triggered It will reset when cool Check charging system for correct voltage and good ground Check for an open or grounded circuit or motor Will not prime sputters No discharge Motor runs Check for hose kinked between tank and pump Check the in tank strainer to see if clogged with debris Check if there is water in the tank or if air collected in the hot water heater Check to see if the inlet...

Page 73: ...Customer Assistance 800 367 2438 Chevrolet Motorhome Assistance 800 222 1020 Chassis Contacts Ford Ford Customer Assistance Hotline 800 392 3673 Ford Motorhome Assistance Hotline 800 444 3311 Chassis Contacts Freightliner Freightliner Customer Assistance 800 385 4357 Chassis Contacts Spartan Spartan Service 800 543 4277 Allison Transmission 317 242 3549 Cummins Diesel 800 343 7357 800 DIESELS Chas...

Page 74: ...1 Steps Electric Kwikee 800 736 9961 Suspension Hickory Springs 800 643 2102 Dexter Axle 574 295 1900 Mor Ryde 574 293 1581 Ride Rite 800 248 0892 Tanks Fuel LP Manchester LP 800 877 8265 Tanks Fresh Holding Amerikart 574 848 7462 Televisions VCRS Audiovox 800 688 3135 Samsung 800 726 7864 RCA 800 626 2224 Sony 800 222 7669 Tires B F Goodrich 800 521 9796 Carlisle 800 827 1001 Firestone 800 356 46...

Page 75: ...Locate and remove plug on outside of slide out that covers manual crank access port Insert manual crank that is provided or use 3 4 socket begin cranking the room in When the room is fully retracted return the override switch to the normal position IMPORTANT Please be sure to place override switch in on position before traveling Should you require additional assistance please do not hesitate to ca...

Page 76: ...UAL OPERATION CROSS COUNTRY MAIN SLIDE OUT ROOM Locate the manual override switch at the main control panel and have someone depress and hold Locate override shaft in driver s side front wheel well behind the tire Using a 1 1 8 socket and ratchet crank room in When retracted release switch POWER GEAR ELECTRIC BEDROOM SLIDE OUT ROOM IF EQUIPPED Remove access panel located on bed base side facing li...

Page 77: ...75 APPENDIX A POWER GEAR SLIDE OUT ROOM TOWABLES ...

Page 78: ...76 APPENDIX A POWER GEAR SLIDE OUT BEDROOM TOWABLES ...

Page 79: ...19 Underbelly Material 19 FRAME CHASSIS TOWABLE 21 22 Couplers 21 Entrance Steps 21 Fifth Wheel Coupler 21 Frame and Metal Bumpers 21 Safety Chains 21 Underbelly Material 21 INTERIOR 3 8 Ceiling Fabric 4 Countertops 3 Helpful hints 3 Laminate surface countertops and sinks 3 Solid surface countertops and sinks 3 Decor Items 4 5 Pleated shades and doors 5 Wall paper border 5 Window treatments curtai...

Page 80: ...mponent Manufacturer List 71 72 Electrical Braking Systems 60 Electrical Power 61 Electrical Step 61 Furnace 61 Generator 62 Interior Lights 62 Leveling Jacks 62 63 LP Gas 63 Microwave Oven 63 Monitoring Panel 63 Outside Receptacle 64 Ovens 64 Power Converter 64 Refrigerators 65 RV Battery 65 Running Lights 65 Slide Out Rooms 65 RBW Electric Slide Out 66 HWH Hydraulic Slide Out 66 LIFTCO Electric ...

Page 81: ...ially impair use value or safety of your Coachmen product please call our Owner Relations Department toll free at 1 800 453 6064 so that we may attempt to resolve your concerns You can also contact us through our Service Support website at www coachmenrv com COACHMEN RECREATIONAL VEHICLE COMPANY LLC P O BOX 1000 MIDDLEBURY INDIANA 46540 ...

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