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Appendix A - Lubrication and Capacities

Foretravel Owners Manual

Page A-1

Rev. 06-02

LUBRICATION AND CAPACITIES

See Foretravel Maintenance Schedule Book for scheduled maintenance in-

tervals.

ENGINES

Cummins:

Use SAE Grade 15w40, API designation CH-4. API designation CG-4 may be used

when CH-4 is not available, but the lubricating oil change interval must be reduced.

SAE Grade 15w40 should be used for am5

F and up. For consistent ambi-

ents below +5

F consult your Cummins "Operation and Maintenance Manual.”

Consult your Engine Operation and Maintenance Manual for a more detailed discussion of

engine lubricants and change intervals.

TRANSMISSION

Use TranSynd fluid only.

Make

Model

Oil Change

(with filter)

Cummins

ISL 400 (U270/U295)

26 qts.

Cummins

ISM 450 (U320)

36-38 qts.

Make

Model

Refill Capacity

Allison

U320

4000MH

Approx. 7 Gal.

Allison

U270/U295

3000MH

Approx. 5 Gal.

Summary of Contents for GV320

Page 1: ...rida 30319 Commerce San Antonio FL 33576 Phone 800 278 4192 352 588 0120 Fax 352 588 2789 Foretravel of North Texas 2230 West University Drive Denton TX 76201 Phone 866 494 4040 940 320 4444 Fax 940 382 7799 Foretravel Northwest 23501 E Knox Ave Liberty Lake WA 99019 Phone 800 945 8561 509 325 1911 Fax 509 755 1906 Foretravel of Tennessee Foretravel of Florida Foretravel of Texas Nacogdoches Foret...

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Page 3: ...intenance schedules and procedures In cases of discrepancy between this manual and the separate engine and transmission manufacturer manuals the instructions of the appropriate component manufacturer should be followed PLEASE For your safety and continued satisfaction read this manual thoroughly prior to oper ation and keep it handy in your vehicle at all times The manual should remain with the ve...

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Page 5: ...NTY 2 4 ENGINE WARRANTY 2 5 TRANSMISSION WARRANTY 2 5 TIRE WARRANTY 2 6 BATTERIES 2 6 REPORTING SAFETY DEFECTS 2 6 VEHICLE IDENTIFICATION 3 1 VEHICLE IDENTIFICATION DATA PLATE 3 1 FEDERAL REGULATIONS REGARDING CERTIFIED VEHICLE RATINGS 3 2 ENGINE TRANSMISSION PARTS AND SERVICE 3 2 FAMILIARIZATION OF YOUR NEW MOTORHOME 4 1 DASH 4 1 INSTRUMENT PANELS 4 1 Transmission Shifter 4 1 Retarder ON OFF Swit...

Page 6: ...0 U295 only 4 5 Engine Maint Light Yellow 4 5 Check Engine Light Yellow 4 6 Stop Engine Light Red 4 6 Left Turn Indicator Green 4 6 Driving Light Indicator Green 4 6 Level System Light Yellow 4 6 High Beam Indicator Blue 4 6 Lower Antenna Light Red 4 6 Right Turn Indicator Green 4 6 ABS System Light Yellow 4 6 DRIVER INFORMATION CENTER 4 6 AIR CONDITIONER HEATER CONTROLS 4 7 Fan Switch 4 7 Mode Sw...

Page 7: ...STRIBUTION MANIFOLD 5 1 SANITIZING THE WATER DISTRIBUTION SYSTEM 5 2 RVIA RECOMMENDED SANITIZING PROCEDURE 5 2 WATER DRAINS 5 2 COLD WEATHER OPERATION 5 3 PHYSICAL PROTECTION OF INTERIOR WATER LINES 5 3 PRECAUTIONS FOR USING WASHER DRYER UNITS 5 3 WINTERIZING YOUR MOTORHOME 5 3 WASTE DRAINAGE SYSTEM 6 1 GENERAL 6 1 TOILET WASTE HOLDING TANK 6 1 BLACK AND GRAY WATER HOLDING TANK DRAINS 6 2 DISPOSAL...

Page 8: ...8 5 POWER CONSUMPTION GUIDE 8 5 120 VOLT WATER HEATER OPERATION 8 6 LOCATION OF BREAKERS AND FUSES 8 6 SURGE PROTECTOR 8 7 POWER TECHNOLOGIES AUTO START SYSTEM 8 7 SYNOPSIS 8 7 HEATING AND COOLING 9 1 COMFORT CONTROL SYSTEM 9 1 TO PLACE SYSTEM IN OPERATION 9 1 TO SHUT DOWN FURNACE 9 1 AQUA HOT SYSTEM STD ON U320 MODELS 9 2 OPERATION 9 2 MISCELLANEOUS INFORMATION 10 1 LOADING THE VEHICLE 10 1 LOAD ...

Page 9: ...NCE 11 5 SERVICING YOUR RV 11 7 RV BODY 11 7 Washing Your Coach 11 7 Cleaning the Interior 11 8 DAILY OPERATOR S CHECKS AND SERVICES 12 1 INTRODUCTION 12 1 NORMAL OPERATION CHECKS 12 1 AFTER OPERATION CHECKS 12 3 ENGINE STARTING SHUTDOWN 13 1 ENGINE STARTING 13 1 ENGINE STARTING PROCEDURE 13 1 BEFORE MOVING VEHICLE 13 1 ENGINE SHUTDOWN 13 3 AFTER OPERATION GENERAL 13 4 AIR TANKS 13 4 MAINTENANCE I...

Page 10: ... AND HOSES 17 1 ELECTRICAL TEST INFORMATION 18 1 TRAILER LIGHTS HOOK UP DIAGRAM 18 2 LUBRICATION AND CAPACITIES A 1 ENGINES A 1 TRANSMISSION A 1 REAR AXLE CARRIERS A 2 COOLING SYSTEM A 2 GENSETS A 2 ADDITIONAL CAPACITIES A 4 ALLISON TRANSMISSION DIAGNOSTIC CODES B 1 WORLD TRANSMISSIONS B 1 ON HIGHWAY DIAGNOSTIC CODES B 1 ENGINE PRIMING C 1 FUEL LEVEL C 1 DIESEL ENGINE PRIMING INSTRUCTIONS C 1 CUMM...

Page 11: ...torhome at all times These manuals must remain with the motorhome if transferred to a new owner Complete understanding of this and other manuals will insure familiarity with your vehicle Also be sure you understand all information supplied by manu facturers of separately warranted products since that information contains im portant operation safety and maintenance procedures The information in thi...

Page 12: ...THE MANUALS OF APPLIANCE MANUFACTURERS WHICH ARE INCLUDED IN YOUR COMPONENT INFORMATION MANUAL ENSURE THAT YOUR DEALER WHO HAS BEEN TRAINED TO PER FORM ALL PRE DELIVERY INSPECTIONS AND SYSTEMS CHECKS ASSISTS YOU IN UNDERSTANDING THE OPERATION OF ALL SYS TEMS AND ALL WARRANTY FORMS FOUND IN THE COMPONENT INFORMATION MANUAL DEALER RESPONSIBILITIES Your dealer has many responsibilities to our custome...

Page 13: ...lve the matter OWNERS CLUB Foretravel Inc sponsors one of today s largest and most active owners clubs Known as the Foretravel Motorcade Club it has individual units or chap ters throughout the nation To be a member you must own a Foretravel As a new motorhome owner you are given a complimentary one year membership in the Foretravel Motorcade Club Among the many benefits of fered to club members i...

Page 14: ...o presents the opportunity to learn more about the maintenance upkeep and operation of your motorhome This is achieved through general association with other owners On a jetcade you leave your coach behind and jet to some point on the globe in the company of other club members Again the tour is under the lead ership of the club staff A seacade is the same thing only it is a sea cruise Each of thes...

Page 15: ...fered by their specific makers You will find those warranty state ments in your owner s literature package Foretravel expressly disclaims any responsibility or obligation in connec tion with warranty claims involving any warranties other than the Foretravel 36 36 Full Coach Limited Warranty WHAT ELSE ISN T COVERED Maintenance items such as oil filters lubricants light bulbs wiper blades wheel and ...

Page 16: ...llow incidental or consequential damages to be exclud ed or limited so this exclusion may not apply to you APPLICABILITY This Limited Warranty applies to new 2003 Foretravel motorhomes orig inally sold by an authorized Foretravel dealership registered in the United States or Canada and primarily operated in the United States or Canada War ranty may be transferred to a new owner by notifying Foretr...

Page 17: ... it has been salvaged or declared a total loss as set forth in this paragraph FORETRAVEL WARRANTY REGISTRATION PROCEDURE Warranty registration of your vehicle is accomplished through your Fore travel dealership The warranty registration form is filled out by the retail dealer and signed by the end user when taking delivery of a new vehicle A copy of this form will also be kept on file at Foretrave...

Page 18: ...r repair Damages caused by repairs of or on the painted surfaces Scratches abrasions or chips caused intentionally or accidentally Stone chipping caused intentionally or accidentally through normal use or in transit Blemishes or blistering caused by rust originating from within the coach body Hazing or the paint caused by the use of improper abrasive detergents industrial emissions volatile or cor...

Page 19: ...7 Reparation of the Paint Under Warranty Repair of the painted surfaces under warranty will be completed beyond the warranty period Repair under warranty shall be restricted to clearly confined areas Gloss and tone difference of the repaired and repainted sur face compared to the original paint does not cause the need to repaint the entire outside surface 8 Waxing or Polishing of the Motorhome The...

Page 20: ...s Contact the nearest manufacturer s representative for warranty questions or contact Fore travel inc for the nearest dealer location REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National High way Traffic Safety Administration NHTSA in addition to notifying Foretrav el Incorporated ...

Page 21: ...he Vehicle Identification Number is also found on the vehicle identifica tion data plate which is attached to the inside of the vehicle Always specify the Vehicle Identification Number when ordering parts or requesting service for your Foretravel vehicle VEHICLE IDENTIFICATION DATA PLATE Below is the Foretravel Inc Vehicle Identification Data Plate which is at tached to the inside of the vehicle n...

Page 22: ...lterer of the vehicle by providing new identification plates which in clude the revised ratings information It is the responsibility of the vehicle deal er or owner to provide and mount a revised vehicle identification plate for any configuration changes that they have made to the vehicle Foretravel Inc is not responsible for any vehicle configuration changes which have not been ap proved in writi...

Page 23: ...d when transmission retarder is turned on and is offering resistance The retarder has three levels of operation that are controlled by brake ped al pressure At 2 lbs of pedal pressure the retarder operates at 33 at 4 lbs 66 and at 7 lbs of pressure it operates at 100 The retarder has six levels of operation that are controlled by the hand control lever When the lever is OFF front position the reta...

Page 24: ...ump switch in the ON position Air Tank Switch Controls auxiliary air compressor for coach air system May be used to fill coach air system when engine is not running HWH Reset Switch Resets HWH level and slide out computers Reset if switch light is on Park Brake Pull out to apply brake push in to release brake Ether U320 The ether switch is utilized for cold weather starting purposes on diesel powe...

Page 25: ...tivate the wiper delay system The washer is activated by pressing the wash switch The OFF switch turns the system off Operation of the Wiper Variable switch initially causes the Low Speed Wiper function to activate for one wipe If the switch is pressed again within approximately 30 seconds the Low Speed Wiper function will be activated again and will repeat at an interval determined by the time be...

Page 26: ...s Speedometer Odometer Indicates vehicle speed and records total accumulated mileage Tachometer Indicates engine speed RPM Air Pressure Gauges Indicate air pressure in front and rear sections of system Air pressure should be from 90 120 PSI while operating Warning buzzer indicates low be low 62 psi air pressure Fuel Gauge Indicates approximate amount of fuel in tank when ignition key is on Engine ...

Page 27: ...lly ter rain Warning buzzer indicates high above 250 degrees temperature See transmission booklet for normal operating temperatures and further precau tions CAUTION DO NOT OPERATE VEHICLE WHEN INDICATOR REMAINS IN HIGH TEMPERATURE RANGE TO CONTINUE TO DO SO MAY CAUSE ENGINE OR TRANSMISSION DAMAGE Voltmeter Gauge The voltmeter gauge indicates the amount of voltage that the alternator is producing f...

Page 28: ... may be non functional Drive With Cau tion See page 12 3 DRIVER INFORMATION CENTER The ignition switch must be in the ON position for the display to be acti vated The two lines of the display operate independently and are controlled by the scroll keys on each side of the display line The left keys scroll across the menu tree and the right keys scroll down the tree Each key has two func tions depen...

Page 29: ...oor outlets Bi level Def Compressor is on and cooled or heated air depending on thermostat setting is directed to floor and top dash outlets Def Air is directed to top dash outlets for defrosting windshield Temperature Control Turn knob to blue area for cooler air and to red area for warmer air Passenger A C Control Control air flow on passenger side with this switch NOTE Coaches equipped with a 3...

Page 30: ... the side of the steering column around the ignition switch Turn signal lights in panel will flash when switch is activated NOTE Turn signals will not function if emergency flasher switch is partially engaged CB Radio See manufacturers instruction manual for best results Radio CD Cassette See radio instruction manual for best results 120 Volt AC Engine Block Heater During adverse cold conditions u...

Page 31: ...eturn to the SLEEP MODE This will continue until the system is turned off by pushing the OFF button or the hand auto brake is released If the system was unable to level the vehicle one or two yellow LEVEL SENSING indicator lights will remain on and the EXCESS SLOPE light will come on The system will still maintain level to its best ability and cycle in and out of the 30 minute SLEEP MODE as descri...

Page 32: ...l inflate when the room control key is switched OFF CAUTION DRIVER S CHAIR MUST BE CLEAR OF SLIDE OUT ROOM BE FORE OPERATING ROOM CAUTION REMOVE ANY CUSTOMER ADDED FLOOR COVERINGS IN FRONT OF SLIDE AREA BEFORE RETRACTING ROOM To Retract the Room Place the room control key in the ON position the amber light will flash The amber indicator will stop flashing when the air from the seal is ex hausted T...

Page 33: ...il pressure light and an engine STOP button are included on the panel as detailed below 1 FILTER MINDER Indicates restriction in air filter As the filter becomes restricted a yellow band will move up until it meets the red band at 25 Turbo charged engines must be working under full load to obtain the re stricted air flow condition The FILTER MINDER shows this condition even after the engine is shu...

Page 34: ...g on the type of buckle furnished Do not wear the belt in a twisted condition or pinched between the seat structure members Never use a belt for more than one person at a time Keep the seat belt over the hip pelvic area do not adjust a seat belt across the abdo men Keep belts clean and dry Clean with soap and water Do not bleach Keep sharp and damaging objects away from belts Inspect belts buckles...

Page 35: ...y the key fob supplied with the system or with a switch located inside the entry door on the access panel below the passenger side of the dash The LOCK button locks the storage compartment door locks and the entry door lock The UN LOCK button unlocks the entry door when pressed once The UNLOCK but ton unlocks the entry door and storage compartment doors when pressed twice within five seconds The p...

Page 36: ...Section 4 Familiarization of Your New Motorhome Page 4 14 Foretravel Owners Manual Rev 06 02 This Page Intentionally Blank ...

Page 37: ...ump The tank is pressure filled by a control valve while hooked up to city water via a water hose Pump power must be off and pressure line valve opened for filling To fill fresh water storage tank open valve U320 and GV320 coaches are equipped with an auto shut off valve for fresh water fill Fill valve locations are as follows U270 U295 Under bathroom lavatory U320 GV320 Valves are operated by swi...

Page 38: ...en faucets to release air Pres surize system with pump until water flows Turn off pump 3 Allow to stand for three hours 4 Drain and flush with potable fresh water 5 To remove excessive chlorine taste or odor which may remain prepare a solution of one quart vinegar to five gallons water and allow solution to ag itate in tank by vehicle motion several days if possible The same method of installing b...

Page 39: ... large amount of water used in the washer dryer See washer dryer manual for details WINTERIZING YOUR MOTORHOME 1 Turn off LP gas and electric power to 3 way water heater and hot water dispenser if so equipped Failure to do so could result in damage to these items 2 Open and leave open all faucets in the coach 3 Open pop off valve on water heater tank or Aqua Hot tank to avoid pos sible danger of s...

Page 40: ...a non toxic antifreeze offered by numerous RV supply manufacturers 2 Follow directions given by manufacturer NOTE Units with Aqua Hot Systems Disconnect the INLET and OUTLET and tie together at the Aqua Hot unit instead of above water manifold SPECIAL NOTE Units equipped with a washing machine should use the op tional winterizing method above ...

Page 41: ...or fixed use the RV should be reasonably level for best opera tion of the system TOILET WASTE HOLDING TANK When using the tank prime with water containing an odor control chemi cal such as Aqua Chem or Pink Magic Place the recommended amount of chemical in the toilet Flush the toilet to allow mixing with toilet water The toi let waste tank is now ready for use NOTE Be careful not to spill chemical...

Page 42: ...on list Plan ahead and you will have little inconvenience in proper dispos al of wastes SERVICING TOILET WASTE TANK Most of the solid build up in waste tanks is due to using too little water and not flushing the tank out properly after each use If you wish to dump a par tially full tank it is better to fill the remainder of space with water first to pro vide the volume necessary for complete flush...

Page 43: ... colorless and carries an added garlic like odor making it easy to detect Besides being flammable it is potentially lethal to inhale WARNING THIS SYSTEM IS NOT DESIGNED FOR OPERATION ON NATURAL GAS The LP gas tank mounted on your motorhome contains LP fuel in liquid form under high pressure As fuel is used vapor LP gas passes from the top of the tank through a regulator which reduces the pressure ...

Page 44: ...tion is greater when the appliance is used for long periods of time FAILURE TO COMPLY COULD RESULT IN DEATH OR SERI OUS INJURY 3 A warning label has been located near the LP gas container The label reads as follows DO NOT FILL CONTAINER S TO MORE THAN 80 CA PACITY Overfilling the LP gas container can result in uncontrolled gas flow which can cause fire or explosion A properly filled container will...

Page 45: ...e listings of LP gas stations Many travel parks have LP gas available LP gas tanks are designed to permit expansion space within the tank in or der to permit the liquid to vaporize prior to entering the systems regulator NEVER ALLOW THE CONTAINER TO BE FILLED BEYOND 80 OF THE CAPACITY INDICATED ON THE TANKS DATA PLATE If the tank is overfilled liquid gas may flow through the regulator causing it t...

Page 46: ...ress the Test switch The LED should flash RED and the alarm should sound Re lease the switch to end the test If the LP alarm sounds during normal operation 1 Do not touch any electrical switches 2 Do not use the phone in your vehicle 3 Turn off all gas appliances stove furnaces water heater refrigerator 4 Extinguish any open flame 5 Open windows and doors 6 Evacuate the vehicle 7 Turn off the main...

Page 47: ...RESET cycles leave the vehicle and call a qualified tech nician to locate and repair the source of the carbon monoxide Do not re enter until the problem has been fixed 2 CO ALARM RED FLASHING LIGHT AND PULSED SOUND indi cates the presence of at least 100 ppm of carbon monoxide IMMEDIATE ACTION IS REQUIRED See below Procedures To Take During An Alarm After using the Re set switch the RED light will...

Page 48: ...witch in the ON position Green light will indicate water heater ON 5 If red switch light is illuminated heater is not ignited place switch in OFF position and wait 30 seconds Be sure LP tank valve is open 6 Repeat step one and three 7 For complete shut down place switch in OFF position BURNER FLAME If the main burner flame is yellow and causing soot deposits consult water heater owners manual for ...

Page 49: ... 2 Turn lighted switch located on bed base to the ON position NOTE Do not turn on electricity to heater unless water covers the heating element Doing so may burn out the element and void the warranty See Water Heater Operation Manual for more detailed instructions See page 9 2 for Aqua Hot operation MOTOR AID SYSTEMS The motor aid system of water heating utilizes engine water heat conduct ed via h...

Page 50: ... GENERAL LIGHTING INSTRUCTIONS 1 Make sure the supply valve at LP tank is ON 2 Make sure LP leak detector is ON 3 Make sure valve on back of refrigerator is ON 4 Turn refrigerator switch to ON position 5 Refer to manufacturer s instructions for more detailed instructions WARNING DO NOT ALTER THE REFRIGERATOR VENTILATION SYSTEM ON THE OUTSIDE IN ANY WAY THAT WILL RESTRICT THE FLOW OF AIR SUCH RESTR...

Page 51: ...ak detector is ON 3 Push in and turn burner knob counterclockwise to IGNITE position 4 Hold knob down for 5 10 seconds to heat the thermocouple 5 Adjust burner to desired setting WARNING NEVER USE THE BURNERS OF YOUR COOKTOP FOR VEHI CLE HEATING PURPOSES DO S AND DON TS Don t leave the top burners on without a utensil for any length of time Over heating of the grate may cause the porcelain enamel ...

Page 52: ...Section 7 LP Gas Systems Page 7 10 Foretravel Owners Manual Rev 09 02 This Page Intentionally Blank ...

Page 53: ...ts DC has been designed and installed in accordance with the safety requirements of NFPA 501C and the National Electrical Code Any changes additions and or modifications that you make after delivery may develop a hazardous condition Be sure to consult your local authorized dealer for advice concerning changes or addi tions Only qualified electrical technicians should attempt to make any changes or...

Page 54: ...connected to the equipment ground pin The receptacle for the equip ment ground pin then must be connected to earth ground in accordance with The Standard for Recreational Vehicle Parks NFPA 501 C According to these standards 1 The metal skin or trim of an RV must be bonded to the metal frame 2 The frame water pipes gas pipes and all other exposed metal parts must be connected to the grounding bus ...

Page 55: ...cidental shorting of a hot circuit conductor in the RV will blow the fuse in the park circuit giving a warning that something is wrong If the neutral circuit in the RV should short to the metal trim or frame accidentally nothing would happen and it would not be dangerous unless the polarity was reversed and the equipment ground open in some man ner as described earlier In either case having the gr...

Page 56: ...n if the boost er switch red light remains switched on and no 120v AC power is applied both batteries can be completely discharged If both batteries are fully discharged when 120v AC power is applied there is a possibility the charger may overheat and kick out It is not unusual for this to happen If it does turn off as many 12 volt items as possible to reduce the draw on the batteries and allow mo...

Page 57: ...n 120v AC is available from the shoreline or the generator The charger switch must be in the ON position with the ProSine Charger Inverter Use your inverter wisely remembering you only have as much power as the batteries have stored in them It is not feasible to run some items such as air conditioning on an inverter To determine what items are powered by the inverter see 120 volt electrical schema...

Page 58: ...es are located on a slide out shelf below the refrigerator on 4200 series coaches There are several manual reset 12 volt breakers located on a panel in the consolidated components bay forward of the utility station These breakers power the battery disconnect switch the refrigerator LP leak detector dash electronics memory freezer optional Aqua Hot system where applicable power seat base HWH leveli...

Page 59: ...o start system glow plug pre heat fuel priming and genset cranking are completely automatic Mounted on the genset control panel is an LED status panel on the right side with two tog gle switches mounted one above the other to the immediate left of the LED panel The upper toggle switch is the master and the lower is the Start Stop There are two generator switches in the dash The switches on the das...

Page 60: ...en the coach is stored and the master switch at the entrance door is off We at Foretravel have endeavored to make the batteries charging systems and now the genset with automatic start and a low voltage sensing circuit as user friendly as is possible However it is still you the customer who must be responsible for battery maintenance by keeping the charger turned on keep ing the coach on shore pow...

Page 61: ...r conditioner zone 1 to cool the rear of coach through ducts the temperature will be controlled by the zone 1 thermo stat NOTE The HEAT PUMP mode on U295 and U320 coaches will operate efficiently down to approximately 38 degrees When the outside ambient tem perature is below this point the system will switch to FURNACE mode NOTE The outside storage areas and water tanks are not heated by the heat ...

Page 62: ...DITIONAL INFORMATION PLEASE CALL 1 800 955 6226 The heater should be shut OFF when refueling OPERATION 1 The diesel burner operates on 12 volt battery power When dry camping insure that the diesel burner is not operated with less than 12 volts battery voltage 2 Check diesel fuel level 3 Be certain the battery disconnect switch is in the ON position 4 Activate the Aqua Hot switch on the face of kit...

Page 63: ...ng Foretravel Owners Manual Page 9 3 Rev 06 02 The Aqua Hot burner should be cleaned and inspected annually by a qualified technician See the Aqua Hot operating instructions in your warranty package for more detailed information ...

Page 64: ...Section 9 Heating and Cooling Page 9 4 Foretravel Owners Manual Rev 06 02 This Page Intentionally Blank ...

Page 65: ... so as to distribute the weight evenly between the front and rear axles Distribute weight to obtain even side to side balance of the loaded vehicle Each corner of the motorhome can be weighed by placing each tire or duel tire set on the scale Secure loose items to prevent weight shifts that could affect the balance of the vehicle Store only light objects on high shelves With the motorhome fully lo...

Page 66: ...ed Is towed vehicle s parking brake released Is ignition in the first ON position allowing the steering wheel to turn freely Is the towed vehicle locked for towing Do you have a spare key Have you followed your vehicle manufacturer s instructions for towing FORETRAVEL TOWING REQUIREMENTS The superstructure of a Foretravel motorhome is rated for 10 000 pounds tow ing and 1 000 pounds tongue weight ...

Page 67: ... put off insuring yourself for RV coverage It s not all that expensive CANADIAN AND MEXICAN INSURANCE Consult your individual insurance company for procedures and be sure of your coverage before entering another country STATEMENT ON URETHANE FOAM Some furniture in this motorhome may contain urethane foam WARNING DO NOT EXPOSE URETHANE FOAMS TO OPEN FLAMES OR ANY OTHER DIRECT OR INDIRECT HIGH TEMPE...

Page 68: ...d World Transmission and has a secondary shift schedule option the mode switch should be ON for secondary mode versus OFF for the primary mode Situation Mountainous Driving Up Down Terrain Technique Manually preselect a lower gear in order to maintain engine speed within a range of 500 RPM of engine governed speed Road speed may decrease but power torque will remain at peak output while ascending ...

Page 69: ... engine as a braking force select the next lower gear If the vehicle is exceeding the maximum speed for this gear use the service brakes to slow the vehicle Engine braking provides good speed control for going down grades When the vehicle is heavily loaded or the grade is steep it may be desirable to preselect a lower gear prior to the grade The transmission control system will inhibit a shift int...

Page 70: ...Section 10 Miscellaneous Information Page 10 6 Foretravel Owners Manual Rev 08 02 This Page Intentionally Blank ...

Page 71: ...old and mold spores in the indoor environment the way to control indoor mold growth is to con trol moisture We must point out that there are a few major differences between a home and a motorhome Differences such as Mobility Moisture control procedures will change according to your loca tion A motorhome has six 6 exposed surfaces two 2 sides one 1 top one 1 bottom and two 2 ends All six surfaces a...

Page 72: ...wer walls when shower is completed Place wet bath towels in the dryer or in a plastic container until they can be dried Do not place wet shoes or boots in a closet and close the door Darkness will aid the dampness in causing mold to grow Keep air circulating Do not close off the bedroom area for extended peri ods of time Keep windows and doors closed in rain or very humid weather Management of the...

Page 73: ... mold Research on mold and health effects is ongoing This brochure provides a brief overview it does not describe all potential health effects related to mold exposure For more detailed information consult a health professional You may also wish to consult your state or local health department HOW DO I GET RID OF MOLD It is impossible to get rid of all mold and mold spores indoors some mold spores...

Page 74: ...airduct html or call 800 438 4318 for a free copy If the water and or mold damage was caused by sewage or other contami nated water then call in a professional who has experience cleaning and fixing buildings damaged by contaminated water If you have health concerns consult a health professional before starting cleanup ADDITIONAL RESOURCES For more information on mold related issues including mold...

Page 75: ...and refreshing the appearance 3 For tough stains a slightly abrasive cleaner is a quick and efficient cleaner 4 For solid colored white tops a mixture of four parts water and one part chlorine bleach along with a Scotch Brite pad will refresh the appearance quickly and easily 5 After cleaning the application of a coat of a light spray wax refreshes and protects the surface 6 To remove hard water b...

Page 76: ...acturer s specifications 12 Maintain correct tire pressure too much will make tires wear out the tread more in the middle and it will give you a very rough ride Low tire pressure will wear both outside treads more and can cause damage to tire from heat build up from sidewall flexing If there are any signs of uneven wear dif ferent from above two or excessive wear have tire alignment and balance ch...

Page 77: ...subject to leaks at least once a year If the caulking looks bad remove old caulking clean and re caulk Make sure all points where water might leak behind the fiberglass skin windows end caps trim wind shield antennas vents air conditioners etc have a waterproof seal Motorhomes due to their size are subjected to a great deal of stress while traveling over bumps in the roads This alone can cause a l...

Page 78: ...roved cleaning agents for vinyl walls ceilings plastic fixtures stainless steel For mica etc Never use abrasive agents on interior of refrigerators or on plastic sinks as they may cause permanent scratches Be sure the cleaning agent will not damage the material to be cleaned Some plastics are incompatible with cer tain cleaners Read the directions on the cleaner container ...

Page 79: ...tems 1 through 7 are accessible through the rear engine access 1 Remove the engine oil dipstick Figure 1 and add oil if needed If the oil level is low see Appendix A for quantity and type of lubrication needed NOTE If there is sufficient oil quantity indicated on the oil dipstick but a more accurate reading is desired operate the engine until it reaches normal operating temperature stop the engine...

Page 80: ...n depth instructions found in your Allison World Transmission Operator s Manual 7 Check the FILTER MINDER air restriction indicator for the air intake system on the remote start panel The indicator should be checked more often in extreme weather conditions snow ice dust cold wet etc Refer to page 4 10 for more information 8 Check the vehicle exterior for a missing parts b leaks oil water fuel or h...

Page 81: ...ng a fault has been detected and the ABS may be nonfunctional DRIVE WITH CAUTION At the first opportunity the system should be checked by a qualified service technician 15 Check generator oil level The latch release red button for the genera tor door is found in the front drivers side storage compartment Uni coach or front passenger side com partment GV The generator coolant air bleed valves yello...

Page 82: ...Section 12 Daily Operator s Checks and Services Page 12 4 Foretravel Owners Manual Rev 11 02 This Page Intentionally Blank ...

Page 83: ...r should register more than before which will indicate that charg ing is taking place This needle may read as high as 14 volts A significant amount more than this indicates overcharging and needs attention If needle does not move higher than it did before starting and revving engine charging system or batteries may need attention 6 Turn switch Key to the START position Release the instant the engi...

Page 84: ... engine run at idle speed for approximately two minutes 9 Check the oil level after wiping the dipstick clean The safe operating level is between the HOT RUN and REF ADD marks on the dipstick This fluid level check can also be performed with the pushbutton shifter Complete steps 7 9 a Simultaneously press the UP and DOWN arrow buttons on the shift se lector Oil level information is displayed in tw...

Page 85: ... Foretravel Maintenance Schedule See your dealer for the proper change procedure 12 Check all controls for freedom of operation 13 FASTEN SEAT BELTS 14 Test parking brake for proper operation 15 THROTTLE PEDAL Check for proper action to prevent injury or acci dent from engine overspeed caused by a malfunction in the linkage Re place broken return springs bent rods or binding linkage before operati...

Page 86: ...the air in the tanks WARNING Do not smoke or use an open flame near fuel tanks when filling or at any other time 3 Check under the engine for signs of coolant fuel or oil leakage AIR TANKS 4 Drain any moisture from tanks Daily cold weather Weekly warm weather The drain valves are located on the driver s side of the coach One valve is located in the wheelwell in front of the rear dual wheels The ot...

Page 87: ... deflection WARNING Safety goggles should be worn to protect eyes when performing the following checks 2 FUEL TANK DRAIN Drain fuel tank by removing drain plug and drain until all water and sedi ment is discharged Replace drain plug 3 AIR CLEANER Check air intake system to be sure all ducting is air tight a Check the air transfer duct between the air cleaner and the engine to be sure all clamps ar...

Page 88: ...rmostat starts to open A thermostat is fully open at approximately 20 F 11 C above the opening temperature Observe engine temperature gauge to check thermostat operation 9 SERVICE BRAKES For brake service and overhaul refer to parts catalog for replacement parts and available repair kits 10 ELECTRICAL SYSTEM The troubleshooting chart in Section 15 should be used when isolating some of the difficul...

Page 89: ...in any position except OFF or MAX A C Bring outside air into the vehicle by the side panel air inlets or fully open vent windows as far as they will go to force outside air into front of the vehicle A partially open vent window will increase possibility of entrance of exhaust fumes through rear window openings CAUTION If passengers are riding in the rear area the rear vented win dows should be ful...

Page 90: ...in lead and lead compounds Wash hands after handling GENERAL BATTERY CARE PROCEDURES 1 Cycle the battery lightly 20 or less depth of discharge the first few cycles This helps complete the forming process of the plates in case they are not finished forming 2 Never charge a wet battery with a sealed gel cell battery charger The wet battery needs higher voltages to finish the charge and without it th...

Page 91: ... gel battery CAUTION Before washing batteries make sure no safety vents have stuck open to prevent baking soda solution from contaminating electrolyte Rinse with clear water CAUTION It is essential when replacing the cables on the battery that the positive cable is attached to the positive post and the negative cable is attached to the negative post Battery posts are marked positive and negative a...

Page 92: ... rating other than indicated may result in dangerous electrical overload If a proper rated fuse continues to blow it indicates a problem in the circuit that must be cor rected POWER STEERING CAUTION Some systems use oil other than conventional power steering fluid Refer to Appendix A for fluid recommendation Do not overfill Fluid level should be checked with the engine off to prevent injury from m...

Page 93: ...ng and of the steps to take to prevent this phenomenon from occurring Therefore we recommend following these simple precautionary measures when re fueling your motorhome 1 Do NOT stand directly in front of the fuel cap when removing Standing off to one side will prevent spray from striking operator 2 Remove cap SLOWLY This will allow pressure to be released prior to complete removal of cap similar...

Page 94: ...Section 15 Automotive Industry Precautions Page 15 6 Foretravel Owners Manual Rev 06 02 DIESEL ENGINE PRIMING INSTRUCTIONS For use when changing fuel filters See Appendix C ...

Page 95: ...gency may the vehicle be towed up to 1 2 mile 80 km at no more than 5 mph 8 04 kph without first disconnecting propeller shaft from transmission In all situations use special precautionary procedures safety equipment and proper emergency warning lighting when towing a vehicle Most larger tow vehicles are now equipped with a hydraulic lift that at taches directly to the front axle If the tow vehicl...

Page 96: ...e driveline components 1 If the transmission is inoperative the output driveshaft from the transmis sion must be removed 2 If the rear axle is inoperative it is necessary to raise the rear wheels off the ground or remove the rear axle shafts and seal the ends of the wheel hubs to prevent entry of dirt CAUTION Failure to keep contaminants out of the wheel bearings and or axle lu bricant could resul...

Page 97: ...ill not inflate as long as the ignition key is in the OFF position Consequently if the vehicle should ever require emergency towing the ig nition key must be left in the ON position in order to build and store air in the suspension IMPORTANT Tow chain attachments must be made directly to the vehicle axle The chains must be routed under the bottom edge of the bumper in such a manner that they do no...

Page 98: ...Section 16 Towing Page 16 4 Foretravel Owners Manual Rev 06 02 This Page Intentionally Blank ...

Page 99: ...35980 Ell Engine End 2 1 4 molded P33614 Bypass Hose Engine End P06160 Gates 4230 0135 Cooler Hose In P37298 Gates 21472 Out P37267 Gates 21400 ISM 450 450HP CUMMINS U320 Belts Alternator Cummins Gates KO50340 Cummins 3028521 Air Conditioner Compressor Gates 9440 Dayco 17440 Filters Air Filter Donaldson P14 8043 Fleetguard AF1838M Coolant Filter Fleetguard WF2077 Primary Fuel Filter WINN 200200 Se...

Page 100: ...PA 6332 Air Filter Cannister Kubota 70000 11221 NAPA 6270 Fan Belt Kubota 14911 97010 NAPA or Gates 7300 Thermostat 19203 73010 19434 73010 Thermostat Gasket 15676 73270 Fuel Pump PT 05RDE6061 Glow plugs 16261 65510 other prefixs include 16421 16851 Oil Capacity 1 51 gal 6 qts w filter Upper Rad Hose rad to bulkhead P56720 Gates 25253 bulkhead to gen P56723 Gates 25262 Lower Rad Hose P25400 rad to...

Page 101: ...voltage The A terminal should read zero voltage 2 Engine running and alternator charging 1 and 2 terminals of the isolator should read the same voltage which will be voltage regulator setting or slightly less depending on each battery condition The A terminal should read 8 to 1 volt higher than the read ings of 1 and 2 terminals ALTERNATOR SYSTEM Alternator Wire to auxiliary battery Isolator Origi...

Page 102: ...Section 18 Electrical Test Information Page 18 2 Foretravel Owners Manual Rev 06 02 TRAILER LIGHTS HOOK UP DIAGRAM ...

Page 103: ...ange interval must be reduced SAE Grade 15w40 should be used for ambients 5 F and up For consistent ambi ents below 5 F consult your Cummins Operation and Maintenance Manual Consult your Engine Operation and Maintenance Manual for a more detailed discussion of engine lubricants and change intervals TRANSMISSION Use TranSynd fluid only Make Model Oil Change with filter Cummins ISL 400 U270 U295 26 ...

Page 104: ...o 1 Use the fill hole on the axle housing not the hole on the carrier COOLING SYSTEM Use Shell Rotella or Texaco Extended Life Coolant Antifreeze GENSETS Make Model Capacity Meritor All Coaches RS21 145 32 Pints Chassis Series System Capacity U270 U295 ISL 400 Cummins 15 gal Approx U320 ISM 450 Cummins 16 gal Approx Make Model Oil Change with filter Oil Type Coolant Capacity Power Tech SI or SIK 1...

Page 105: ...atic Adjusters on disc brakes Lubrication should be left to qualified personnel U270 U295 U320 AND GV320 1 Tie Rod 1 Fitting Each End 7 Universal Joints 2 Disc Brake Caliper Slide Rails 8 Propeller Shaft Spline 3 Kingpins 2 Fittings Each Side 9 Disc Brake Caliper 3 Fittings Each Brake 4 Drag Link 1 Fitting Each End 10 Front Wheel Bearings 6 Steering Column Extension 11 Rear Axle Differential HYDRA...

Page 106: ...ject to change without notice U270 U295 U320 GV320 U320 4200 Fuel Tank 180gal 180 gal 180gal 180gal LP Tank 190lb 190 lb 75 lb 75 lb Fresh Water 112gal 112gal 112gal 112gal Gray Water 115gal 115gal 115gal 115gal Black Water 56 gal 56 gal 56 gal 56 gal GVWR 33 000lb 34 880lb 34 880lb 42 000 Front GAWR 13 000lb 13 880lb 13 880lb 13 880 Rear GAWR 20 000lb 21 000lb 30 000lb 30 000 GCWR 43 000lb 44 880...

Page 107: ...icle park ing brake applied For each code stored in memory beginning with any code that is presently in hibiting the transmission the 4 digits of the code and the pertinent parameters are continuously flashed on the display Pressing the mode button once will cause the next code with its pertinent information to be displayed Dashes indicate all stored codes have been displayed To clear any active i...

Page 108: ...Appendix B ATEC Transmission Codes Page B 2 Foretravel Owners Manual Rev 06 02 This Page Intentionally Blank ...

Page 109: ...in the tank but due to the design of fuel pickup tubes all fuel in the tank may not be able to be used Sometimes on diesel models when low on fuel foaming may occur in the tank and cause air to get in the lines This may cause erratic engine performance which would alert you to a low fuel situation AGAIN We recommend keeping the fuel level above the 1 4 mark DIESEL ENGINE PRIMING INSTRUCTIONS For u...

Page 110: ... button on Racor control panel at rear of coach The Schrader valve at the top of the filter may be opened to speed the air purge operation Release the valve at the first sign of fuel 3 Wait 80 seconds until the unit shuts off 4 The engine can be restarted Check H2O light after every 2 3 fill ups more often if fuel contamination is suspected If H2O light is on press H2O PURGE button ...

Page 111: ...result in sudden tire destruction property damage and personal injury You should not exceed reasonable speeds as indicated by the legal limits and driving con ditions See Tire Limited Warranty and Operators Manual in your warranty packet for more tire information REAR TIRE PRESSURES FOR TAG AXLE COACHES ONLY PSI 70 75 80 85 90 95 100 105 110 115 Front lbs 9120 9650 10 180 10 730 11 250 11 840 12 3...

Page 112: ...Appendix D Tires Page D 2 Foretravel Owners Manual Rev 06 02 This Page Intentionally Blank ...

Page 113: ...ble leak rates even for new components It is not within the scope of Foretravel Inc or any manufacturer to completely eliminate air leaks This is why D O T sets the standard for al lowable leakdown rules in the interest of safety However Foretravel Inc s leakdown rate is set as follows Foretravel Inc Allowable Leakdown 1 6 P S I in the front air system in a one hour time period 2 6 P S I in the re...

Page 114: ...Appendix E Air System Page E 2 Foretravel Owners Manual Rev 06 02 This Page Intentionally Blank ...

Page 115: ... grills 7 2 Charge Boost 4 2 CHASSIS LUBRICATION A 3 Check Engine Light 4 6 Circuit breakers 4 1 City Driving 10 4 City water 5 1 cleaners 11 4 Cleaning the Interior 11 8 CO ALARM 7 5 CO Detector 7 4 Comfort Control 9 1 consolidated components bay 8 6 Cooking appliances 7 2 Cooktop 7 9 Coolant Temperature Gauge 4 4 COOLING SYSTEM A 2 cooling system 15 3 Countertops 11 5 Cruise Control 4 3 Cummins ...

Page 116: ...dlights 4 3 HEAT PUMP 9 1 HEATER 4 7 HEATING AND COOLING 9 1 Heavy Duty Hitch 4 12 High Beam Indicator 4 6 Highway Driving 10 4 hose reel 5 1 HOSES 17 1 Hot Water Dispenser 7 7 humidity 11 2 HWH 4 10 HWH Reset Switch 4 2 hydraulic fluid 12 2 HYDRAULIC SYSTEM A 3 hydrogen gas 15 3 I ICC Courtesy 4 3 Idling 13 3 IF YOU SMELL GAS 7 2 Improper towing 16 2 Insurance 10 3 Inverter Converter Operation 8 ...

Page 117: ...Right Turn Indicator 4 6 Roof Air Conditioner 8 3 RV BODY 11 7 RVIA 1 2 S sanitizing the water system 5 2 SCWR 10 1 Seat Belts 4 12 SEL Button 4 8 Service Tips 14 1 SEWER FLUSHER 6 1 Shell Rotella A 2 shoreline reel 8 1 Shower Walls 11 5 Sinks 11 5 Slide out Room 4 10 Smart Wheel 4 3 soapy water 7 3 Speedometer 4 4 SRCE Button 4 8 starting motor 13 1 steering operation 12 3 steering system 14 2 St...

Page 118: ...1 2 Warranty Claims 2 3 Warranty registration 2 3 washer dryer 5 3 waste drainage 6 1 WASTE HOLDING TANK 6 1 water distribution manifold 5 1 Water drains 5 2 Water Heater 7 6 water pump 5 1 Water Supply 5 1 wheel lug bolts 11 6 wheels and tires 12 2 WIDE Button 4 8 Windshield Wiper 4 3 winterization 5 2 Winterizing 5 3 ...

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Foretravel GV320, Owner'S Manual

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