Monaco Cayman 2005 Owner'S Manual Download | Manualshive

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Section 1

--- General Information

Cayman 2005

22

Low Point Drain -

The lowest point in the plumbing. Drains are placed here so that water will drain out

of the lower end of the motorhome. These drains must be closed when you fill the water tank.

OEM -

Term for Original Equipment Manufacturer.

OHM -

A unit for measuring electrical resistances.

Ohm’s Law -

Expresses the relationship between Volts (E) and amperes (I) in an electrical circuit

with resistance (R). It can be expressed as follows: E = IR. If any two of the three values are
known, the third value can be calculated by using the above formula.

Potentiometer -

A device for measuring an unknown potential difference or electromotive force.

Pounds Per Square Inch Gauge (psig) -

Pressure measured with respect to that of the atmosphere. This

is a pressure gauge reading in which the gauge is adjusted to read zero at the surrounding atmospheric
pressure. It is commonly called gauge pressure.

Purge -

The blast of air from the air tank Auto Purge valve expels moisture from the air tank with every

brake application.

Roadside -

This refers to the side of the motorhome which faces the road when it is parked. Often called

the off-door side or the driver’s side.

SCA -

Term for Supplemental Coolant Additive. Chemical added to coolant for diesel engines to help

prevent cylinder liner pitting and internal corrosion.

Shore Line -

This is the electrical cord which runs from the motorhome to the campground 120 Volt

electrical supply.

Shore Line Plug -

The 120/240 Volt AC outlet allows the motorhome to be hooked up to a campground

facility.

Stinger -

An arm attachment on a tow truck that is used to lift the motorhome slightly so that it can

be towed.

VIM -

Vehicle Interface Module. Component used to interface engine and transmission functions with

the motorhome chassis operation.

Volt -

The unit of measure for electric potential.

Watt -

The unit for measuring electrical power, i.e. the rate of doing work, in moving electrons by or

against an electric potential.

Wet Cell Battery -

A type of battery that uses liquid as an electrolyte. This type of battery requires

periodic maintenance such as cleaning the connections and checking the electrolyte level.

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Summary of Contents for Cayman 2005

Page 1: ...use whichever occurs first In addition the Limited Warranty provided by Warrantor covers the steel or aluminum frame struc ture of the sidewalls excluding slide outs roof and rear and front walls for...

Page 2: ...on how long an implied warranty lasts so the above limitation may not apply to you What the Warranty Covers Warrantor s Limited Warranty covers defects in the manufacture of your motorhome and defects...

Page 3: ...ect s so that Warrantor can become directly involved in exercising a final repair attempt for the purpose of performing a successful repair to the identified defect s How to Get Service The Warranty R...

Page 4: ...lar phone or flaking peeling and chips or other defects or damage in or to the exterior or finish caused by rocks or other road hazards the environment including airborne pollu tants salt tree sap and...

Page 5: ...EXPIRATION OF THE NINETY 90 DAY WARRANTY COVERAGE PERIOD DESIGNATED ABOVE THE PERFORMANCE OF REPAIRS SHALL NOT SUSPEND THIS LIMITATIONS PERIOD FROM EXPIRING THESE TERMS AND ALL EXPRESS AND IMPLIED WAR...

Page 6: ...hip of the motorhome Limitations of Implied Warranties ANY IMPLIED WARRANTIES ARISING BY WAY OF STATE LAW INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY OF FITNESS FOR A PA...

Page 7: ...f substantially equal quality to complete any repairs Defect and or damage to the Roadmaster Chassis may occur during manufacture at the factory during delivery of the motorhome to the selling dealer...

Page 8: ...aster Chassis by others the motorhome that is mounted upon the Roadmaster Chassis including by way of example the motorhome manufacturer s design manufacture assembly and or installation of the side w...

Page 9: ...MMENCED MORE THAN NINETY 90 DAYS AFTER THE EXPIRATION OF THE ONE YEAR WARRANTY COVERAGE PERIOD DESIGNATED ABOVE IF YOU USE YOUR ROADMASTER CHASSIS FOR COMMERCIAL OR BUSINESS PURPOSES ANY ACTION TO ENF...

Page 10: ...CE link and choose MANUAL ADDENDUMS from the drop down menu WOOD FINISH Because no two trees look alike authentic woods vary in color and character markings such as streaks knots and grain patterns Si...

Page 11: ...5 11 General Information 1 Driving Safety 2 Exterior Interior Care 3 Appliances 4 Equipment 5 Water Systems 6 LP Gas Systems 7 Electrical Systems House 8 Electrical Systems Chassis 9 Chassis Informati...

Page 12: ...ctive holders Brand name products of other companies mentioned in this manual are not endorsed by the manufacturer of the motorhome The information contained in this document is intended to reflect st...

Page 13: ...Responsibilities 17 Dealer Responsibilities 18 Customer Responsibilities 18 SERVICE SUGGESTIONS 18 Prepare for the Appointment 19 Prepare a List 19 Be Reasonable With Your Requests 19 No Looking Over...

Page 14: ......

Page 15: ...ance or harmful chemical NOTE Information and reminders concerning proper operation of the motorhome and or its components INSPECTION Inspection of the motorhome and or its components is required Addi...

Page 16: ......

Page 17: ...ly inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Monaco If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defec...

Page 18: ...idual warranted components whether the service is warrantable or out of warranty Customer Responsibilities As a new motorhome owner you are responsible for regular and proper maintenance This will hel...

Page 19: ...onable With Your Requests Do not leave a list of 20 items to be serviced and expect to have the motorhome back by 5 00 p m If you list a number of items and must have your motorhome back by the end of...

Page 20: ...o this tank CCA Cold Cranking Amperage is the amount of current a battery can deliver for 30 seconds at 0 F without dropping below a specified voltage usually 10 5 Volts DC Chassis Battery Powers chas...

Page 21: ...ugh the drain Dry Camping Camping in the motorhome when there is no city water hook up or shore power In other words using only the water and power that is in the motorhome and not from another source...

Page 22: ...xpels moisture from the air tank with every brake application Roadside This refers to the side of the motorhome which faces the road when it is parked Often called the off door side or the driver s si...

Page 23: ...Port 216 431 2000 www westportaxle com Axle Rear Dana Spicer 800 666 8688 www dana com Batteries Interstate 800 272 6548 www interstatebatteries com Battery Isolator Intellitec 800 251 2408 www intell...

Page 24: ...scsfrigette com Fan Exhaust Fan Tastic Vent 800 521 0298 www fantasticvent com Faucet Moen Faucets 800 289 6636 www moen com Filter Fuel Primary Racor Fluid Filters 800 344 3286 www parker com racor F...

Page 25: ...Electronics Corp 800 237 4277 www sharp usa com Monitor Panel KIB Enterprises 574 294 1504 www kibenterprises com Outside Mirrors Ramco Industries INC 800 321 4819 www ramco eng com Power Converter Pr...

Page 26: ...allisontransmission com Transmission Shift Pad Arens Controls 847 844 4700 www arenscontrols com VCR Optional RCA 877 266 2728 www rca com Video Selector Box Winegard 800 288 8094 www winegard com Wa...

Page 27: ...__________________________________ Address__________________________________________________ City ________________State________Zip _____________________ Phone _________________________________________...

Page 28: ......

Page 29: ...Air Pressure 62 Tire Pressure Inflation Guideline 62 Tire Chart Goodyear 63 Inspecting Pressure 65 Air Pressure Checklist 67 Supporting When Leveling 68 Tire Vibration 69 Tire Rotation 69 Tread 69 Sto...

Page 30: ......

Page 31: ...quire a special license endorsement and motorhome inspection prior to registration Know and observe the laws of the states in which you will be traveling Laws may vary from state to state A systematic...

Page 32: ...the mirror see A on illustra tion Adjust the mirror for a clear side view of the motorhome Tighten the base bolt once proper adjustment is made To adjust the head of the mirror loosen the Allen screws...

Page 33: ...ts while the motorhome is in motion Seat belts must only be used on permanently mounted seats Do not use a single seat belt on more than one person Pilot and Co pilot seats must be locked in a forward...

Page 34: ...r or up to 21 pounds the child is considered an infant A convertible safety seat for an infant must be secured facing rearward The top of the head must be below the top of the safety seat Secure safet...

Page 35: ...ee Example 2 WARNING Installation illustrations are for reference only and are not to be used as a guide Because there are many styles of safety and booster seats refer to the safety seat manufacturer...

Page 36: ...reach highway speed When passing another vehicle allow extra time and space to complete the pass due to the added length of the motorhome When descending a long hill manually shift the trans mission t...

Page 37: ...ication Use a four second rule when following other vehicles at speeds under 40 mph Use a five second rule when following at speeds over 40 mph Right Turns Negotiating a right hand turn in a motorhome...

Page 38: ...outs if traffic is building Once in the pullout if there is sufficient clearance for safety take a break Idle the engine to allow the exhaust and the turbo to cool While these are cool ing the transmi...

Page 39: ...sure Pay extra attention to hoses and belts that are more susceptible to fatigue in extreme heat Winter and Cold Climate Conditions The motorhome should be prepared for Cold Weather Use Keep speeds sl...

Page 40: ...emperature gauge raises The engine is now ready for travel Whenever coolant temperature is below 160 F idling engine incomplete combustion occurs causing carbon build up and raw fuel to wash lubricati...

Page 41: ...be helpful when on the phone with a technician Battery hydrometer Spare 12 Volt DC continuous duty solenoid if applicable An assortment of spare fuses One link kit for ride height control assembly fo...

Page 42: ...sion hydraulic fluid and washer fluid Inspect belts and hoses for wear Inspect wiring for loose frayed or corroded connections Start engine and listen for unusual noises Driving Preparations Inspect o...

Page 43: ...wo things in mind turning and braking For the motorhome to handle well the load will need to be evenly distributed side to side and front to back Additionally heavy items should be stored as low as po...

Page 44: ...Weight When weighing the motorhome add all passenger weight to the GCVW total The motorhome fully loaded including fresh water LP Gas and any vehicle or trailer towed must not exceed the GCWR Gross Co...

Page 45: ...ual to or greater than the load The use of an extension to the receiver or extended ball mount will significantly reduce hitch receiver weight ratings Modifications to the hitch receiver or use of the...

Page 46: ...m only With the but ton in the Manual out position any one of the three cameras can be selected with the red toggle switch at the bottom of the monitor With the button in the Auto in position the came...

Page 47: ...pilot provide guidance using the five hand signals Use of walkie talkies will also aid in guidance The co pilot will perform just as important a job as the driver When guiding the driver the co pilot...

Page 48: ...vehicle to move in a forward sideways motion that will cause irreparable and expensive damage If neces sary disconnect the tow vehicle to avoid a backing up situation Trailers have one pivot point an...

Page 49: ...o operate any slide room turn the ignition switch to OFF and set the park brake Follow the procedures and guidelines for Leveling the Motorhome in Section 10 Confirm that the parking surface will acco...

Page 50: ...nces This will allow time for the inverter to stabilize charging the batteries Use caution when operating appliances to avoid overloading the sup plied shore service breaker Operate appliances and out...

Page 51: ...onnected open the grey water valve small valve The black water valve large valve remains closed until the tank is full or until time of departure DRY CAMPING TIPS Experience is the best dry camping te...

Page 52: ...ion such as the vanity unscrewing all but one or two bulbs to reduce battery drain Turn on the water pump only when using water Plan what is needed from the refrigerator prior to opening If weather do...

Page 53: ...om the city water faucet Turn shore power breaker off and disconnect the shore line Wind up and store the shore cord and secure the door Inspect fluid level in oil bath hubs if applicable and check al...

Page 54: ...ing or damage of items will not occur Look around above and under the motorhome for obstructions Check for debris stuck between the rear dual tires Walk around the motorhome and camp area checking for...

Page 55: ...ave the equipment and train ing needed to repair or replace the tire In the case of sudden tire failure avoid heavy braking Hold the steering wheel firmly and gradually decrease speed Slowly move to a...

Page 56: ...ect the house batteries to the engine battery in the event the engine will not crank or cranks slowly The solenoid is designed for short term high current intermit tent use Engaging the boost solenoid...

Page 57: ...and the motorhome will require jump starting or an external charger hooked to the chassis battery When using jumper cables to start the engine the cables must connect in a parallel configuration That...

Page 58: ...Assistance They will have the equipment necessary to jump start the motorhome CAUTION A large amount of electrical current is required to jump start an engine The sizes of the battery alternator and j...

Page 59: ...ned to support weight loads imposed by lifting the motorhome from the rear If the rear wheels are disabled place the motorhome on a flat bed trailer or use a heavy duty dolly under the rear wheels and...

Page 60: ...erforming this procedure Remove the plug from the center of brake chamber Remove the caging tool from its holder on the brake chamber and insert the tool into hole Turn clockwise to engage Screw nut a...

Page 61: ...ormed or experienced The tire performs additional functions of traction for moving stopping and steering as well as providing a cushion for the motorhome Modern tire technology blends a unique mix of...

Page 62: ...the specifications for the tire s maximum load rating be molded into the sidewall of the tire The amount of air pressure to use is dependent on the weight of the motorhome when fully loaded The tire c...

Page 63: ...tion reading denoted with a D or S on the Table Single is for the front axle Dual is for the drive axle Find the corresponding PSI at the top columns to see the corresponding maximum weight capacity...

Page 64: ...rer is not the author of this chart and makes no representation or warranty concerning the accuracy of the information disclosed by the chart Monaco is not responsible for the accuracy of the informat...

Page 65: ...r pressure The pressure should be within a couple of pounds of each other on the same axle Never let air out of a hot tire When checking the inflation pressure use a high quality truck tire air gauge...

Page 66: ...iced on one of the dual tires This can cause the good tire paired with it to fail due to exceeding the load limits it is designed to carry Tires with damaged sidewalls can burst upon inflation A flat...

Page 67: ...ove the cap from the valve on one tire 3 Firmly press a tire gauge onto the valve and record reading 4 Add air to achieve recommended air pressure 5 If the tire is over filled release air by pushing o...

Page 68: ...ire should be evenly distributed on the support block In the case of dual tires distribute the load evenly on blocks for both tires If not properly supported the steel cables in the sidewall of the ti...

Page 69: ...mechanical problems may exist and will need to be corrected prior to rotation Tread To prevent skidding and hydroplaning replace tires when the tread is worn down to 4 32 of an inch on the front and...

Page 70: ...ng from prolonged sidewall strain and tread deflection Cover the tires to block direct sunlight and ultraviolet rays The type of surface the motorhome is parked upon will have an affect on how much mo...

Page 71: ...require lubrication Flange nuts generate higher clamping force Always use grade eight studs with hub mount wheels Before installing the wheels lubricate the hub pilot pads with a drop of oil to preven...

Page 72: ...tud threads When all nuts are seated tighten the nuts to 450 ft lbs in sequence as shown in the illustration below The hub mount wheels use two piece flange cap nuts for both front and rear applicatio...

Page 73: ...weigh the motorhome One to find out the Cargo Carrying Capacity CCC and the other to ensure no axle is overloaded The Gross Axle Weight Rating GAWR of the axles is listed on the federal certification...

Page 74: ...rs to consider when loading the motorhome total weight and balance When loading heavy objects keep them as low as possible preferably on the floor or below in storage compartments Load weight must be...

Page 75: ...be charged but this is money wisely spent Weight scale types and weighing methods determine the procedure used to calculate proper tire inflation pressure and axle loading Several types of scales are...

Page 76: ...Section 2 Driving Safety Cayman 2005 76 100179D Weight Label...

Page 77: ...ehicle Certification Label is 13 000 lbs Divide the figure by 2 using chart record 6500 lbs on line 1 2 Weigh the driver side FRONT corner Scale A and record weight on chart scale A line 2 Example 500...

Page 78: ...rloaded axle can cause a component failure of the suspension system Tire blowout or broken suspen sion components can lead to loss of vehicle control resulting in property damage per sonal injury or d...

Page 79: ...to options and accessories The Gross Vehicle Weight Rating GVWR Gross Combination Weight Rating GCWR and or Gross Axle Weight Rating GAWR must not be exceeded GVWR of the vehicle limits the weight of...

Page 80: ...wed vehicle will further reduce this amount Now the motorhome can be fully loaded and weighed to ensure GVWR is not exceeded Once the motorhome is fully loaded it is ready to be weighed to obtain an a...

Page 81: ...Driving Safety Section 2 Cayman 2005 81 020254 Cargo Carrying Capacity Flowchart...

Page 82: ...000 10 000 100 830 9 170 10 83 9 087 40 168 8 919 5 770 8 149 8 149 6 500 6 500 13 000 5 000 4 000 9 000 13 000 4 000 10 000 10 000 20 000 7 100 6 900 14 000 20 000 6 000 23 000 33 000 10 000 020255b...

Page 83: ...Driving Safety Section 2 Cayman 2005 83 020255k Actual Worksheet...

Page 84: ...Section 2 Driving Safety Cayman 2005 84 Weight Record Sheet...

Page 85: ...Driving Safety Section 2 Cayman 2005 85...

Page 86: ...Section 2 Driving Safety Cayman 2005 86 010725 010726c VIEWS Front Rear...

Page 87: ...Driving Safety Section 2 Cayman 2005 87 010723f 010724e Roadside Curbside...

Page 88: ...ves Operation When a 9 Volt DC battery is correctly connected the smoke alarm is operating The LED will flash every minute showing the battery is supplying power A load alarm will sound when a product...

Page 89: ...pairs If the smoke alarm is within the warranty period and the terms indicate the nature of the problem return the unit to your dealer Smoke detectors beyond the warranty period cannot be economically...

Page 90: ...n monoxide CO which can be fatal A concentration of above 100 PPM will cause a warning condition Individuals with medical problems may consider using detection devices with lower car bon monoxide alar...

Page 91: ...thorized service technician as soon as possible Never disconnect a CO detector to silence an annoying alarm Evacuate the motorhome immediately when the red light is lit and the alarm sounds Do a head...

Page 92: ...and four red flashes indicate greater than 200 ppm NOTE Memory is erased when power is disconnected for 15 seconds Cleaning Maintenance Use a vacuum cleaner to remove dust or any other buildup on the...

Page 93: ...bottom of the fire and stand 6 to 10 feet away Squeeze the lever to discharge the agent Sweep the spray from left to right until totally extinguished WARNING Road vibration will cause extinguisher pow...

Page 94: ...it label To open lift the red handle and push out ward Pull closed and lower handles to lock the Egress window Hinges along the outside window top identify the Egress window on the motorhome exterior...

Page 95: ...Driving Safety Section 2 Cayman 2005 95 NOTES...

Page 96: ...Section 2 Driving Safety Cayman 2005 96 NOTES...

Page 97: ...ing Codes 106 Fabric Specification Charts 108 Vinyl 110 O Vinyl 112 FLOORS 113 Carpet Cleaning 113 Vinyl Floor 114 Laminate Floor 115 SHOWER 115 CEILING 116 WALL COVERINGS 116 WOOD CARE 117 COUNTERTOP...

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Page 99: ...p to preserve the paint finish The motorhome is painted with a base coat clear coat system Clear coat is a polyurethane based material which brings out the shine and luster to the base coat paint Care...

Page 100: ...orhome twice a year spring and fall Many types of protective barriers are available today that may be applied to the clear coat glazes waxes polishes rubbing com pounds or combinations of these produc...

Page 101: ...r it Avoid repeated wax applications which can cause wax to build up Some very fine scratches or swirl marks may be removed by an application of a glaze These types of glazes fill the scratches or swi...

Page 102: ...rior bright work Do not use rubbing compounds Do not use abrasive cleaners or compounds to clean the mirrors NOTE When using chemicals to remove road tars use only automotive type products that are re...

Page 103: ...ined from recreational vehicle parts suppliers Listed below are some of the more common sealants and the areas in which they are used Approved sealants are available at service centers and authorized...

Page 104: ...to fill holes or other imperfections Black urethane comes in a tube and it applies much the same way as silicone Clean up using solvents such as paint thinner Gloves are required as this material is...

Page 105: ...vent the glass cleaners from contacting the plastic making the plastic brittle and dulling the finish TIP To determine if the lens is glass or plastic simply tap the lens with a fingernail Plastic wil...

Page 106: ...d in a well ventilated room Cleaning only by a professional furniture cleaning service is recommended CAUTION Use of water based or detergent based solvent cleaners may cause excessive shrinking Water...

Page 107: ...to 90 F maximum should be used Do not exceed three to five minutes time on the synthetic cycle If washed at 160 F the maximum temperature which can be used to dry is 140 F Hang or fold immediately af...

Page 108: ...Section 3 Exterior Interior Care Cayman 2005 108 Fabric Specifications Charts...

Page 109: ...Exterior Interior Care Section 3 Cayman 2005 109...

Page 110: ...the above suggestions do not work Indiscriminate use of any solvent or solvent containing cleaner can severely damage or discolor the vinyl Stains may become permanent if they are not immediately rem...

Page 111: ...ned with mineral spirits and rub the stain gently working from the outer edge of the stain toward the center to prevent spreading Rinse with soap and water Crayon Mustard or Ketchup Sponge with mild s...

Page 112: ...ommercial repair products may contain lacquers and cause the vinyl to become brittle and more difficult to repair O Vinyl O Vinyl Cleaning Suggestions The following steps are to be performed in sequen...

Page 113: ...fective some stains may become permanent A B C D E F G H I Use the solution specified in order from 1 8 until stain is removed DRY CLEANING FLUID NAIL POLISH REMOVER DETERGENT SOLUTION WARM WATER VINE...

Page 114: ...ot completely removed contact a professional carpet cleaner Vinyl Floor The vinyl flooring in the motorhome is durable and long lasting when properly taken care of When a spill occurs wipe it up with...

Page 115: ...nail polish remover Stains caused by gum or tar should be allowed to harden completely then gently scraped away Felt protectors on the bottom of furniture and floor mats can preserve the beauty and a...

Page 116: ...blood lipstick etc use a sponge or soft bristle brush and Formula 409 Fantastik or a similar product Rinse well and dry Finish cleaning by applying full strength isopropyl alcohol with a sponge or sof...

Page 117: ...oducts used on the solid wood surface depends on individual preference Always follow product instructions Excessive dampness dryness heat or cold can damage solid wood finishes Sunlight can change the...

Page 118: ...g varnish is visible with dark stained wood underneath only the clear finish may need to be restored Rub the loose varnish with fine steel wool or fine synthetic steel wool until you have removed the...

Page 119: ...denatured alcohol Commercial scratch removers or stick wax to match the wood finish can also be used After the scratch has been hidden polish or wax the entire area Deep scratches should be repaired a...

Page 120: ...oiling water into the Solid Surface sink run cold water to prevent damage Laminate Clean laminate countertops with a damp cloth or sponge Use a spray cleaner to remove stubborn stains Avoid using hars...

Page 121: ...outside air can circulate into the inte rior Increase the ventilation when large numbers of people are in the motorhome Even in raining or snowing conditions the air outside will be far drier than the...

Page 122: ...nvironment the blinds may need to be cleaned regularly using a sponge or dampened soft cloth Use warm not hot water and a mild detergent The mild detergent cannot contain abrasives Rinse the blinds us...

Page 123: ...orhome can reduce or eliminate favorable mold growth conditions Good housekeeping and regular maintenance are essential in the effort to prevent or eliminate mold growth Consequences of Mold All mold...

Page 124: ...ean the affected area with a mild solution of bleach First test to see if the affected material or surface is color safe Should mold growth be severe call on the services of a qualified professional c...

Page 125: ...ing the sewer hose fresh water hose bay doors and items that may be leaning against the outside of the motorhome such as fishing poles and golf clubs When the motorhome is stored outdoors clear the su...

Page 126: ...ll the ants that are away from the colony To eliminate all ants the colony must be destroyed Keep ants away from the sewer hose by spraying the hose ends with a soap and water solu tion Fleas can be r...

Page 127: ...n be costly and most likely will not work on all types of rodents and insects When calling on the services of a professional to combat pest infestation call a reputable business that is licensed in ha...

Page 128: ...power Batteries should be stored fully charged Batteries stored in a discharged state will readily freeze If possible park the motorhome so that the batteries are accessible for charging or chang ing...

Page 129: ...the voltage readings are low Removing the motorhome from storage or moving the motorhome in case of an emergency will be a much easier process NOTE Batteries in a low state of charge will readily fre...

Page 130: ...imize moisture condensing at the top of the tank Diesel fuel is an organic material which will develop a microbe growth black slime Fuel stabilizers may be added to control microbe growth and degradin...

Page 131: ...dows by pulling blinds closing shades or using a separate cover such as a sheet Holding Tank Drain and rinse Close valves LUBRICATION Add a small amount of antifreeze to waste holding tanks to keep va...

Page 132: ...rature Ensure the engine instruments are indicating proper readings While the engine is running check the operation of headlights taillights turn signals back up lights license plate light and emergen...

Page 133: ...verify if the regulator is faulty and should be replaced Have the LP Gas tank inspect ed Operate each LP Gas appliance Observe all burner pilot flames for proper color and size Inspect and clean the...

Page 134: ...Section 3 Exterior Interior Care Cayman 2005 134 NOTES...

Page 135: ...148 COOKTOP W OVEN OPT 149 WALL THERMOSTAT 150 Comfort Control OPT 150 Heat Pump OPT N A w Standard Thermostat 152 AIR CONDITIONER ROOF 153 Operation 153 Return Air Filters 153 FURNACE 154 Operating I...

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Page 137: ...ting in an explosion or fire WARNING Carbon monoxide gas may cause nausea fainting or death Operating an LP Gas appliance with inadequate ventilation or partial blockage of the flue can result in car...

Page 138: ...he refrigerator if there is an ammonia smell inside or outside of the refrig erator or if a yellowish substance appears inside or at the outside access compartment This can be an indication of a refri...

Page 139: ...tor is operating on LP Gas Automatic Mode AU This feature selects AC over LP Gas operation If AC discontinues the alarm sounds and the refrig erator switches to LP Gas operation If the refrigerator fa...

Page 140: ...il down to turn the icemaker on Push the arm up to turn the icemaker off NOTE If the icemaker is in operation while the motorhome is in motion water may spill out of the ice tray Raise the icemaker ar...

Page 141: ...s have passed laws regarding having the primary LP Gas valve open while traveling Know the laws for the particular state in which you are traveling Cooling Unit Fans The cooling unit is equipped with...

Page 142: ...n ish Rinse with a solution of baking soda and water Dry with a clean cloth Lock the doors open CAUTION When defrosting do not use a hot air blower Permanent damage could result to plas tic parts Do n...

Page 143: ...gerator will start a 30 second trial for ignition during which the gas safety valve opens and the igniter sparks If the refrigerator fails to light indicated by NO FL No Flame turn the refrigerator of...

Page 144: ...y turned off NOTE When dry camping minimize using the inverter to operate the microwave convection oven due to the high rate of battery consumption NOTE The microwave convection oven is for food prepa...

Page 145: ...crowave convection oven 2 Remove the screw B securing the light cover 3 Remove the light bulb and replace only with an equivalent watt bulb DO NOT EXCEED 30 WATTS 4 Close the cover and re secure with...

Page 146: ...surface with soap and water Wipe away any residue using a damp cloth Dry with a soft cloth To prevent damage to the operating parts inside the oven do not allow water to seep into the ventilation open...

Page 147: ...motorhome interior with the cooktop or optional oven Gas combus tion consumes oxygen inside the motorhome Carbon Monoxide is an odorless color less and highly poisonous gas WARNING If you smell gas e...

Page 148: ...water to clean the burner grates cooktops painted surfaces porcelain surfaces stainless steel surfaces and plastic items on the range or cooktop Grit or acid type cleaners may ruin the surface Use onl...

Page 149: ...olish at 800 325 4026 COOKTOP WITH OVEN Optional The cooktop range oven is operated and maintained the same as the cooktop only with an oven This option allows for a wider variety in floor plans and p...

Page 150: ...ow switch to select the fan speed NOTE The thermostat in the bedroom performs the same function as the living room ther mostat The Furnace position on the bed room thermostat is nonfunctional Furnace...

Page 151: ...de NOTE The Comfort Control must be On to operate any HVAC func tion NOTE The motorhome will not heat or cool faster by selecting a very high or very low temperature setting NOTE Conflicting modes can...

Page 152: ...perature is between 30 to 42 F a defrost cycle is initiat ed approximately every 40 minutes of compressor operation The blower motor will stop for five minutes and Defrost will be displayed After the...

Page 153: ...power or the generator is supplied The interior house power is on and house batteries are charged Return Air Filters Clean the return air filters frequently They are located inside the motorhome behin...

Page 154: ...an float on the floor or hide in corners Open all windows and doors Do not touch electrical switches They may spark which can ignite Keep all open flames spark producing devices and smoking material o...

Page 155: ...le to use the furnace to heat the inside of the motorhome during tran sit NOTE When washing the exterior of the motorhome avoid a direct stream of water into the outside furnace vents This can cause d...

Page 156: ...er sys tem and water heater To Purge the Air and Pressurize the System Remove the interior access panel to the back of the water heater Turn the water heater Bypass Valve located at the back of the wa...

Page 157: ...t board will make three attempts to light the burner If the burner does not light the ignition circuit board will go into lock out Cycling the On Off switch will reset the ignition board Ignition Modu...

Page 158: ...lve manual ly as it may continue to leak The water heater has an internal air pocket to reduce the possibility of dripping or weeping Eventually the expansion of the water will absorb the air pocket W...

Page 159: ...hooked to anything less than 50 Amp shore service When the water heater element is in operation it will use approximately 12 Amps at 120 Volts AC Appliances will need to be operated in sequence to avo...

Page 160: ...he obstruction If the indicator light on the switch does not light and the water heater does not light ensure the battery cut off switch at the entry door is on or check for a blown fuse in the house...

Page 161: ...er dryer is front loading with an extra large door opening for easier access Several wash and dry programs are available along with variable water tempera ture settings Always have the door open when...

Page 162: ...er pump Hook to shore power or start the generator To Conduct the Test Procedure 1 Set the selector knob to Reset 2 Set the Dry Timer knob to 30 minutes Push the On Off button to On Wait five seconds...

Page 163: ...e Wash Temperature knob to the desired temperature setting Choose the desired washing cycle option using the Selector knob Load wash tray with detergent Turn the power ON After the cycle is complete w...

Page 164: ...to Spin Allow the pump to drain the drum 4 Set Selector knob to Reset and Timer to zero The door will unlock in two minutes or less Open door and pour in gallon of RV antifreeze 5 Set Selector knob t...

Page 165: ...Appliances Section 4 Cayman 2005 165 NOTES...

Page 166: ...Section 4 Appliances Cayman 2005 166 NOTES...

Page 167: ...an Automatic OPT 187 POWER SUNVISOR OPT 188 SLIDING DOOR 189 REAR LADDER OPT 189 SEAT CONTROLS 190 Swivel Seats 191 SOFA BED 191 STORAGE UNDER BED 193 DINETTE BED CONVERSION OPT 193 RADIO 194 Dash 194...

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Page 169: ...e circuit is active NOTE When dry camping it is important to note that when the switch is illu minated all step circuits are active and drawing current from the chassis battery Operating the Entry Ste...

Page 170: ...a storage compartment and a sliding stepwell cover The upper step of the stepwell has a compartment to store frequently used items such as gloves for refueling tire pressure gauge flashlight or outsid...

Page 171: ...tments in small increments Tighten the bolt firmly after making adjustments The bolts should have slight up and down movement for vibration control in travel Test the operation of the dead bolt lock t...

Page 172: ...ssure during slide out operation NOTE Do not use any petroleum based products on the slide out seal Petroleum based products can damage the paint and will cause premature aging of the rubber seal WARN...

Page 173: ...Level the motorhome with the leveling system NOTE Perform the slide out room operation with the air suspension system full Extensive dam age could occur to the slide out room and awning when extending...

Page 174: ...ill move slowly in To stop the slide out room release the switch To continue the room movement push and hold the switch in Rain water can pool on the slide out awning Added weight will cause the awnin...

Page 175: ...slide out switch when the room is fully extended a change in motor sound indi cates extension The slide out drive motor will stop automatically Level the motorhome with the leveling system WARNING Fir...

Page 176: ...l people pets and objects from the slide out room path Press and hold the switch in the IN position The slide out room will move slowly IN To stop the slide out room movement release the switch To res...

Page 177: ...nnected Make sure the floor is clean before retracting the slide out room Manual Override for Bedroom Slide out 1 Lift up the mattress and unscrew baseboard to gain access to the slide out cover board...

Page 178: ...de out The slide out cover will extend automatically attaining full coverage when the slide out achieves maximum extension NOTE Water may pool on top of the extended cover As the slide out is retracte...

Page 179: ...knob located on the backside of the awning leg only about six turns are needed This will allow the support brace to move freely 2 Unlock the travel lock by using one hand to squeeze inner and outer ar...

Page 180: ...black locking knob NOTE Ensure the locking tab on the support brace is latched through the hole in the end cap 4 If equipped with Canopy Clamps fasten the clamps at this time 5 Release the outer arm e...

Page 181: ...ap to the center of the awning while holding on to the strap 7 Place the hook end of awning rod into pull strap loop to assist in retracting the awning Make sure pull wand does not slip out of pull st...

Page 182: ...n dle to lock the arms in place 5 Repeat instructions 2 through 4 for the front arm NOTE To move the awning out of the carport posi tion reverse the above steps Securing the Awning for Travel Before t...

Page 183: ...owly allow awning to retract Remove catch rod from pull strap and store Front Door Awning Optional To Extend the Awning Hook the pull strap loop with awning pull rod Pull strap until awning is at full...

Page 184: ...k up into position CAUTION When the awning is at full extension do not allow the awning to snap back into the retracted position Personal injury or damage to the awning or motorhome may occur Patio Aw...

Page 185: ...bristle brush Thoroughly rinse both the top and bottom with a hose This process can be made easier with awning maintenance products Saturate the fabric with the solution and leave it on for 15 20 minu...

Page 186: ...icient slope for water run off One end may be lowered to sufficiently divert the water if the awning is being monitored Water weighs 8 33 pounds per gallon The awning was not designed to withstand the...

Page 187: ...l thermostat With the vent cover knob in the manual position turn the knob counterclockwise to open or clockwise to close the vent cover To operate the fan in the Manual mode Pull vent cover knob to t...

Page 188: ...orhome to obtain the maximum air flow especially on hot sunny days Close all the roof vents The area between the open window s and the Fantastic Vent supplies the maximum air flow and providing the mo...

Page 189: ...ate the portion that is secured to the top of the pocket door and rotate the small lever outward to release the latches LUBE The pocket door rollers should be lubed with just a small drop of oil once...

Page 190: ...provide maximum comfort Seats must be locked in the forward facing direction while traveling The battery cut off switch must be on for the power pilot seat to operate NOTE The pilot seat operates fro...

Page 191: ...ere are several sofa variations that can be installed in the motorhome The standard sofa is com monly referred to as a jackknife sofa This style sofa has storage space below the seat and a removable f...

Page 192: ...2 Open the Convertible Sofa and allow the mattress to lie flat 3 Unzip the corner of the mattress labeled Air Valve Access 4 Ensure the valve is locked firmly in place 5 Open the cap on the valve 6 P...

Page 193: ...amage the struts or mounts In extreme cold gas struts may not hold the mattress plat form in the open position DINETTE BED CONVERSION Optional To Convert Booth Dinette into a Bed Lift seat cushions to...

Page 194: ...Turn ON the house power disconnect switch Turn ON house battery cut off switch located at the entry door Turn ON the radio power switch at the dash panel To turn the radio ON press the Push ON button...

Page 195: ...h Applies 12 Volt DC power to ignite the Water Heater if preferring to operate the Water Heater with LP Gas If the Water Heater fails to ignite the DSI FAULT lamp will illuminate 5 Water Heater Switch...

Page 196: ...cal service center For convenience there are auxiliary outlets located at the co pilot seat and on the optional computer desk This connection is set up for a telephone or laptop computer Entertainment...

Page 197: ...be improved by no amplification or even lowering the antenna NOTE Do not move the motorhome with antenna in the raised position it can be damaged by tree limbs or wires WARNING Before raising antenna...

Page 198: ...on the DVD player must be pushed on to place the system in Stand by mode The DVD player will then respond manually or when using the remote control Home Theater System Optional The remote for the Hom...

Page 199: ...tton on the switchbox Follow the same procedure for TV 2 Bedroom TV NOTE The picture quality from the outdoor TV antenna varies depending on the location of the TV station in relationship to the locat...

Page 200: ...e wire con sists of a Satellite Receiver Connection coax a wire for the Antenna Up indicator on the dash a 12 Volt DC power connection and a phone cable for Pay Per View programming Installing the sat...

Page 201: ...ff VOLUME LEVEL CONTROL To increase the volume level press the up arrow button To decrease the volume level press the down arrow button SELECT BUTTON This button is used to select the audio function v...

Page 202: ...c play press this button to temporarily stop play of the disc Press the button again to resume play of the disc from the point at which it was stopped REPEAT PLAY SELECTOR During disc play press this...

Page 203: ...Equipment Section 5 Cayman 2005 203 NOTES...

Page 204: ...Section 5 Equipment Cayman 2005 204 NOTES...

Page 205: ...EMS 214 Proper Waste Disposal 214 What Not to Put in Waste Holding Tanks 214 What to Put in Holding Tanks Black Water Tank 215 What to Put in Holding Tanks Grey Water Tank 215 Waste Drain Sewage Tanks...

Page 206: ......

Page 207: ...ple gallons of water or less There is plen ty of water to meet personal needs once habits are adjusted Fresh Water System The fresh water system consists of the fresh water tank water pump water filte...

Page 208: ...center has a built in pressure regulator and one way check valve The pressure regulator limits the water pressure to approximately 45 PSI An additional pressure regulator can be connected to the city...

Page 209: ...as soon as possible NOTE When filling the fresh water tank do not leave the hose unattended Turn water off before a full black of water come out of the overflow pipe WATER PUMP The water pump pressuri...

Page 210: ...mponents that are loose Many symptoms can be resolved by tightening the hardware Check the following items Water pump will not start or blows the fuse Check the electrical connections at the water pum...

Page 211: ...uipped with a filtered water dispenser at the galley sink A diverter hose is installed at the factory and the water filter is secured on a clip next to the diverter hose The water filter will need to...

Page 212: ...r filter in galley and install diverter hose Prepare a chlorine bleach solution using one gallon of water and cup of chlorine bleach Use 1 gallon of solution for every 15 gallons of tank capacity For...

Page 213: ...aucet head has a flexible hose allowing the faucet head to extend from the base O rings seal the faucet head to the base preventing water from dripping into the cabinet The faucet can be set to stream...

Page 214: ...ve antifreeze ammonia alcohol or acetone in holding tanks will dissolve plastic Do not put large table scraps in the tanks They could stick in or damage the valve seals Facial tissue is thicker softer...

Page 215: ...pre charge to the holding tank each time the tank is cycled WARNING Most chemical mixtures for holding tank odor control are poisonous Follow the prod uct manufacturer s directions and warnings when...

Page 216: ...le three inch sewer hose attaches between the termination drain and the shore facility The termination drain is adjustable and should be periodically exercised Sewer hoses usually come in 10 or 20 foo...

Page 217: ...ush nozzle located on the curbside to help reduce solid build up Flush the tank each drain cycle Failure to thoroughly flush the tank may result in accumulated solids and a clogged spray nozzle 1 Clos...

Page 218: ...drain process 3 Remove the sewer hose from shore fitting Install sewer hose in carrier and lock door Secure the termination cap required by law in some states 4 If desired add chemicals to the tanks t...

Page 219: ...aucet Close the solid waste drain valve and open the liquid waste drain valve Turn on the waste pump The water in the grey tank will flush the remaining solids from the sewer hose The liquid waste dra...

Page 220: ...down until the sewage leaves the toilet Water flow pressures vary at different locations there fore holding the flush lever down for several seconds may be required Release the flush lever by allowin...

Page 221: ...essary to 7 16 above floor Replace the flange seal if it is damaged Poor flush A good flush should be obtained within two to three seconds If the problem persists remove the water supply line and chec...

Page 222: ...Gas furnace heat does not provide heat to these components A sup plemental 12 Volt bay heater and thermal snap disc are located in the water service bay The System Heat switch on the monitor panel op...

Page 223: ...of winterizing is using air pressure to remove liquids that may freeze and cause damage to the various systems and appliances The lines can then be left empty or filled with an FDA approved RV antifr...

Page 224: ...ve in bypass position 6 Remove water filter under galley sink and install diverter hose 7 Connect an air hose with regulator to the city fresh water fill connection with valve positioned for city wate...

Page 225: ...e run into the black tank to protect the drain valve Use a soft cloth to wipe out the sinks shower and toilet after the antifreeze is poured in to pro tect the surfaces from stains Pour the last pint...

Page 226: ...water filter under galley sink and replace with diverter hose 3 Close all faucets drain valves and low point drains 4 Turn water heater bypass valve to bypass position Remove drain plug and drain wat...

Page 227: ...antifreeze run into the black tank to protect the drain valve Use a soft cloth to wipe out the sinks shower and toilet after the antifreeze is poured in to protect the surfaces from stains Pour the l...

Page 228: ...Black Tank Flush Connection 4 Outdoor Shower Assembly 5 Low Point Drains 6 Storage Light 7 Sewer Hose Storage 8 Water Pump Switch 9 Black Tank Dump Valve 10 Grey Tank Dump Valve 11 System Monitor 12 B...

Page 229: ...Water Systems Section 6 Cayman 2005 229 WATER SYSTEM DIAGRAM 040487c Typical Layout...

Page 230: ...Section 6 Water Systems Cayman 2005 230 NOTES...

Page 231: ...ERGENCY PROCEDURES CHECKLIST 237 LP GAS TANK 238 Measurement 238 Tank Filling 239 Tank Operation 241 LP GAS FUNDAMENTALS 242 LP GAS REGULATOR 243 LP GAS HOSE INSPECTION 245 LP GAS DISTRIBUTION LINES 2...

Page 232: ......

Page 233: ...of rotten eggs or sulfur can be easily found by applying a leak detector solution on all connections Never light a match have an open flame or use any spark producing equip ment or appliance to test f...

Page 234: ...tle to the floor level Sulfated batteries rotten egg odor will also sound the alarm When this occurs reset the detector to stop the alert sound About the LP Gas Detector Be aware of the difference bet...

Page 235: ...r it to operate properly If the power source is disconnected or if the power is otherwise interrupted the detector will not operate The LP Gas leak detector has a self check circuit running at all tim...

Page 236: ...Do Not re enter until the problem is corrected Alarm Mute Press the Test Mute button when the detector is in alarm 1 The red LED will continue to flash and the alarm will beep every 30 seconds until...

Page 237: ...If you smell gas a rotten egg or sulfur smell at any time perform the following steps immediately Shut off gas appliances Manually turn off the primary shut off valve at the LP Gas tank Do not operate...

Page 238: ...the Tank Test switch on display panel Observe the indicator lamps corresponding to the tank of interest NOTE Calibration of the LP Gas gauge is preset and not adjustable 050256 060158m Sensor mounted...

Page 239: ...ed LP Gas exists in both liquid and vapor form within the tank A Full tank is approximately 80 liquid The pressure inside the tank varies with the temperature of the liquid All tanks are required to b...

Page 240: ...ensing pump and fill nozzle Remove noz zle from the fill valve 8 Install the dust cover 9 LP Gas appliances especially the refrigerator may have diffi culty starting after a period of non use To speed...

Page 241: ...Canadian provinces it may be illegal to drive the motorhome while primary valve on the LP tank is open Exterior Gas Line Hook Up Prep An auxiliary remote LP Gas hook up is for external LP Gas accessor...

Page 242: ...6 38 8 66 91 502 21 548 44 F 31 127 196 230 842 F Basic Facts About LP Gas LP Gas detectors are a federal requirement on all LP Gas equipped recreation vehicles LP Gas is a by product produced by refi...

Page 243: ...tage further reduces pressure to a working pressure of 0 4 psig 11 Inches of Water Column or about 6 ounces psi A vent is installed to allow the internal diaphragm to move with atmospheric pressure ch...

Page 244: ...ion during appliance operation Erratic pressure regulation dramatically affects refriger ator operation on LP Gas Manometers The manometer is the best way to accurately deter mine LP Gas pressure Ther...

Page 245: ...ntly the uniformly pricked cover should not be viewed with alarm 2 Damage to the textile reinforcement or wire braid is cause for hose replacement Wire braid reinforced hose which has been kinked or f...

Page 246: ...tribution work be performed by an authorized dealer or an authorized service technician When removing or servicing any gas appliance manually close the primary valve located on the end of the LP Gas t...

Page 247: ...continuously An example would be the typical cycling of the furnace or water heater Determining how long a tank of LP Gas will last Combine the BTU input totals of all appliances and the approximate...

Page 248: ...nders and tanks is in required testing and inspection procedures and in construction of the containers Both tanks and cylinders are required to undergo pressure testing and inspection however the proc...

Page 249: ...flow At the first indication of incomplete combustion yellow flame instead of a blue flame or soot is present contact a service technician immediately Improper com bustion can cause carbon monoxide bu...

Page 250: ...Section 7 LP Gas Systems Cayman 2005 250 NOTES...

Page 251: ...nel 266 Battery State Indicator 267 Circuit Breakers 267 Stand by Mode 267 Power Share 268 Charge Cycles 268 Pass Through Relay 269 Temperature Sensitive Charging 269 Programming the Inverter 269 DIST...

Page 252: ......

Page 253: ...he warranty WARNING Water is electrically conductive Do not use any electrically powered item or electrical outlet that may be exposed to a water source Such use can result in a serious shock causing...

Page 254: ...ery disconnect switch turns the house bat tery power supply on or off by disconnecting 12 Volt DC power to the following items inverter domestic fuse panel in the bed room domestic fuse panel in the f...

Page 255: ...lighting before acti vating or deactivating the battery cut off switch SHORE POWER HOOK UP The power requirement for the motorhome is 50 Amp 120 240 Volt AC single phase The shore cord is stored in th...

Page 256: ...ption Located in the roadside compartment is the shore power cord Extend the cable by extending a sufficient amount of cable to reach the power supply If 50 Amp service is not available install the pr...

Page 257: ...ce rather than all at the same time NOTE No wait period is necessary on motorhomes equipped with a converter CAUTION If shore power service is limited to 15 or 20 Amps use of light duty extension cord...

Page 258: ...ooked to anything less than 50 Amp shore service Shore power service less than 50 Amps consists of one power supply conductor a neutral and a safety ground 30 Amp shore service is limited to 24 contin...

Page 259: ...ch automatically selects generator power as priority over shore power NOTE The shore cord is NOT electrically connected to the generator When the generator is operating the electrical contacts of the...

Page 260: ...nerator is located in the front compartment of the motorhome The generator can be started from the following loca tions Generator remote switch on the dash Generator control panel located on the gener...

Page 261: ...ately 1 4 tank so as not to run the main engine out of fuel Starting the Generator Push and hold the control switch in START position until the generator starts Release switch The control switch may f...

Page 262: ...nd items plugged into the electrical outlets of the motorhome The number of electrical appliances that can be operated at any given time depends upon how much power is available from the generator If...

Page 263: ...If a circuit breaker trips disconnect or turn off as many loads as possible To reset the circuit breaker switch the circuit breaker to OFF then switch back to ON to reconnect the circuit If the circu...

Page 264: ...converter is functioning properly Units with converters require only two house batteries Output on terminals should read 13 6 Volts DC 3 Volts Inspect the fuses to ensure they are not blown The power...

Page 265: ...erator is not going to be used as a secondary AC power source The inverter supplies AC power to most receptacles the television and microwave It is important to remember that using the inverter quickl...

Page 266: ...the inverter status and is used to change variable settings The panel uses LED lights to monitor values when hooked to shore power inverting or in the set up mode LED Indications When Hooked to Shore...

Page 267: ...short circuit condition occurs within the Battery Charger circuitry AC Out Circuit Breakers Two branch circuit breakers are located on the front of the inverter One of the branch circuit break ers sup...

Page 268: ...d ing on the inverter s settings and state of charge of the batteries The charge cycle is done in three steps Inverter three stage charging cycle Bulk Charge Cycle Brings the DC voltage up high initia...

Page 269: ...com pensation with temperature variation is necessary to keep charge voltage at optimum values The sen sor is secured to the terminal of the battery Programming the Inverter Battery Capacity and Idle...

Page 270: ...rcuit breakers The panel label describes the breaker layout and the item outlet or appliance to which they pertain WARNING This panel contains high voltage which can cause serious injury or death Befo...

Page 271: ...o spin and current con sumption may momentarily exceed the rated capacity of the breaker As the electric motor comes up to operating speed the electric motor s current consumption will decrease The AC...

Page 272: ...e If just a small amount of the current comes back on the safety ground wire the electronics will trip the outlet stopping the flow of electricity The amount of current it takes to trip the device fro...

Page 273: ...lines sup plying the remainder of the branch breakers up to 12 Energy Management The 50 Amp Smart EMS automatically senses the available power to the motorhome determining whether it is connected to...

Page 274: ...feature compensates for the differences in current draw over a range of line voltage and ambient temperature by re learning the load each time it is turned off or shed The 50 Amp Smart EMS now waits...

Page 275: ...power Three of these sources are automatically detected and indicated by the EMS namely Gen Set Service 50 Amp Service and 30 Amp Service The 20 Amp service mode is not automatically detected and the...

Page 276: ...s of thousands of volts for a short time period Care should be used when working with this voltage as current values can be quite high like in the case of battery cables Shorting a battery cable to gr...

Page 277: ...eir entirety there are guidelines that can be followed to ensure that the batteries are well maintained The operation of the battery is based on a chemical reaction The battery is a container of lead...

Page 278: ...of water and a mild automotive detergent Battery Maintenance Liquid Lead Acid LLA battery cells should be checked at least once a month The level should be above the top of the plates but not overful...

Page 279: ...e hydrometer tests the battery electrolyte solution measured in specific gravity Distilled water has a specific assigned gravity of 1 000 The hydrometer is calibrated to this mark Pure sulfuric acid h...

Page 280: ...charged battery measure the same as a fully charged battery until the loads are applied The simple answer is A battery creates electrical power by converting energy from a chemical reaction into elect...

Page 281: ...tank could be thought of as the rate of the reaction occurring in the electrolyte When the battery is fully charged the electrolyte has an excess of reactions taking place to feed the battery terminal...

Page 282: ...oximately ten times the DC current needed from the battery when inverting 12 Volts DC to operate the 120 Volt AC item There is also a small efficiency loss of about 10 when inverting For example When...

Page 283: ...contacts of bulb with terminals in fixture base Insert bulb until contacts are firmly seated 6 Replace safety lens 7 Align tabs in trim ring with slots in fixture base Rotate lens clockwise until tri...

Page 284: ...abs 2 Replace with a 12 Volt type 906 bulb 3 Install cover BULB USAGE INTERIOR 080475 LOCATION BULB NUMBER WALL LAMPS CEILING LIGHTS COSMETIC VANITY LAMP PORCH LIGHT ROUND 3 HALOGEN CEILING LIGHT MAP...

Page 285: ...Electrical Systems House Section 8 Cayman 2005 285 ELECTRICAL LAYOUT TYPICAL 060191H Inverter Converter Optional...

Page 286: ...Section 8 Electrical Systems House Cayman 2005 286 NOTES...

Page 287: ...id 293 Relays 293 ALTERNATOR 295 Alternator Testing Procedure 296 STEERING COLUMN 296 Tilt Telescope 296 CONSOLE 297 Transmission Shift Selector 297 Parking Brake 298 Leveling Controls 298 DASH 299 In...

Page 288: ......

Page 289: ...he house interior lighting and appliances WARNING When welding is involved for motorhome repair or modification only qualified experienced technicians should weld on the chassis Improper welding proce...

Page 290: ...for high output cranking power but not for deep cycle like the house batteries are designed to do Starting batteries will not last long in deep cycle application Cold Cranking Ampere is a measurement...

Page 291: ...lown fuse must be replaced with a fuse of the same rating and type Using a fuse of a different type rating will defeat the circuit protection provided by the fuse which could result in damage to the m...

Page 292: ...Section 9 Electrical Systems Chassis Cayman 2005 292 080427f 080387C 080388c...

Page 293: ...87a relay These current ratings differ and if mixed will create problems Ensure the replacement relay is of the current rating to assure proper operation Another indicator to the type of relay is the...

Page 294: ...est not energized the common terminal 30 and the normally closed termi nal 87a have continuity When the coil is energized the common terminal 30 and the normally open terminal 87 have continuity NOTE...

Page 295: ...he amp hours the chassis battery uses to start the engine The function of the alternator is an electrical system voltage maintainer not a battery charger When the engine is operating the alternator ma...

Page 296: ...ne OFF should range from 12 2 to 12 7 Volt DC Chassis battery voltage with the engine at idle should range 13 5 to 14 2 Volts DC The output of the alternator range is 13 6 to 15 4 Volts DC Connect a v...

Page 297: ...Select REVERSE gear by pressing R Select the forward DRIVE range by pressing D The SELECT and MONITOR will indicate D1 indicating the transmission is in 1st gear Throughout the subsequent up shifts o...

Page 298: ...rake can be accidentally released if the air system is charged It is advised to fabricate a device to be placed under the parking brake handle preventing small children and pets from releasing the bra...

Page 299: ...o indicates faults codes for service techni cians 4 Cruise Cruise control is engaged 5 Alt Charge Failure within the alternator charging system WARNING In the event the Alt Charge lamp illuminates pul...

Page 300: ...Warning Out of range condition exists within the engine protection circuits 13 Low Air Air storage tank low and air systems may not operate properly CAUTION The Low Air Lamp will only illuminate when...

Page 301: ...the speedometer This changes the odometer mileage reading to the trip mileage reading The black reset button sets the trip mileage back to zero when held for 2 to 3 seconds Release the button and mom...

Page 302: ...oil in the system Normal ranges are between 15 psi and 60 psi INFORMATION Please refer to manufacturer s instructions for specific oil pressure recommendations NOTE When operating the engine cold the...

Page 303: ...ppery or unpaved Do not shift the transmission into N Neutral with the cruise control on High engine RPM run up will occur until the cruise control is turned off BATT BOOST In the event the motorhome...

Page 304: ...ocated driver side RH SHADE Operates the power sun visor located passenger side GEN START The generator automatically initiates a preheat cycle when the switch is pressed to START The preheat cycle is...

Page 305: ...e the parking lights Pull two clicks to operate the headlights Rotating the headlight switch clockwise will dim the dash lights Rotate switch fully counter clockwise to power maplights Battery cut off...

Page 306: ...will not activate until the Mode Control Switch is set to any position other than Off Temperature Control Switch Setting the switch to the Red zone controls an electric water valve regulating the amou...

Page 307: ...through the floor and defrost lou vers The A C system operates to dehumidify the discharged air DEFROST Fresh air is drawn in and discharged through the defrost louvers The A C system operates to deh...

Page 308: ...ws and vents to hot humid outside air MAX AC and HI blower will provide a quick cool down Using a lower blower speed will produce cooler discharge air Heater Heated engine coolant is pumped to an elec...

Page 309: ...ration system is made of Refrigerant R134a and Polyakylene Gycol PAG synthetic lubricant It is very important that all materials contained within the refrigerant system be chemically compatible NOTE A...

Page 310: ...R 134a Refrigerant R134a is classified non explosive non flammable and non corrosive R134a is ozone friendly however it is not technician friendly Proper care in handling must be observed Under norma...

Page 311: ...hanged to a high pressure liquid Condenser Fan A steady flow of cooling air is maintained across the condenser during system operations Receiver Drier Freon leaves the condenser enters the receiver dr...

Page 312: ...ngine coolant is reaching water valve attached to unit 6 Verify operation of water valve to permit engine coolant to pass through valve to heater core 7 Check unit fuses 8 Check power supply to water...

Page 313: ...wiring 4 Check to ensure ignition switch is ON 5 Check blower and select switch 6 Motor shaft has seized 7 Blower wheel is out of alignment Damper Doors Do Not Operate 1 Is the vacuum generator being...

Page 314: ...TION An engine diagnostic plug is located in the curbside engine compartment There is another located left of the steering column Front Electrical Bay Battery Compartment Diagnostic Plug located on le...

Page 315: ...Electrical Systems Chassis Section 9 Cayman 2005 315 ENGINE NO START FLOW CHART...

Page 316: ...Section 9 Electrical Systems Chassis Cayman 2005 316 NOTES...

Page 317: ...eneral Information 349 Diagnostic Fault Codes 350 STARTING PROCEDURE 351 Normal Starting 351 Cold Weather Starting 352 ENGINE OIL 353 ENGINE SHUTDOWN 354 Extended Engine Shutdown 354 COOLANT SYSTEM 35...

Page 318: ......

Page 319: ...rized modifications or repairs to the chassis could result in a forfeiture of warranty coverage Due to the sensitive nature of the electronics on the chassis the following precautions are required to...

Page 320: ...min imize site selection and provide comfort when camping The Roadmaster chassis design offers unsur passed ease of maintenance and service The towing system rating incorporated in the construction o...

Page 321: ...release pressure in the tank when the pressure exceeds 130 psi With the ignition switched to ON the automatic drain valve standard brake models wired to the brake light circuit will activate each tim...

Page 322: ...once per month or more depend ing on operating conditions where humidity is high The air tank is equipped with an auto drain valve on the wet side and a manual drain valve on the dry side The air tank...

Page 323: ...ng ring portion of the fitting body While holding the release ring down pull hose away from fitting To Connect Hose Push hose into fitting through the release ring and the O ring using a slight twisti...

Page 324: ...e the protective dust cap when finished NOTE There are small air pressure restrictions in the pressure protection valve and tire stem valve Due to this restriction the maximum amount of tire pressure...

Page 325: ...e A separate HCV is installed to control front suspension height The three HCVs mount to the main frame of the motorhome above the axles with a linkage rod connecting the valve to the axle Actuating c...

Page 326: ...8 or 7 64 inch twist drill bit into the plastic arm and valve body This will center the travel of internal piston Tighten adjusting lock nut between 60 80 in lbs 5 Check adjustments made by using the...

Page 327: ...l pump fail to operate Electrical Pump Master Cylinder The electric pump motor provides reserve power for the booster assembly The entire assembly should be replaced when a failure occurs When the ele...

Page 328: ...raking capabilities until the affected system is bled The engine will need to be started to bleed the booster When started applying the brakes two to three times will purge the air from the booster In...

Page 329: ...the brake is released Prior to driving allow time for the air compressor to build up sufficient air to shut off the air warning lamp NOTE When the park brake is released the Park illumination lamp wil...

Page 330: ...from high gear down to second gear Certain road conditions and engine speeds may require the transmission be manually shifted down in order to generate adequate engine RPM and increase the engine brak...

Page 331: ...trical symptoms Will not activate or deactivate Intermittent on off operations Actuates with the switch off Problems related to mechanical symptoms Slow operation Delays in operation Limited performan...

Page 332: ...driving the motorhome be aware of any changes in the feel of steering and have the system checked if there are any apparent differences It is normal to hear some hydraulic noise from the steering esp...

Page 333: ...e tires measured at the vertical center line of the tires Toe in Occurs when the tire front distance is less than the tire rear dis tance Toe out Occurs when the tire front distance is greater than th...

Page 334: ...le on the chassis is an I beam axle design made of forged heat treated alloy steel Pivots for the axle ends are constructed using an inclined king pin configuration which are supplement ed with steel...

Page 335: ...t Type Standard EP SAE 90 wt API GL 5 Lubricant temperature must never exceed 250 F 121 C To Drain Place a suitable container below the bearing cover and remove the drain plug If the cover does not ha...

Page 336: ...andling while minimizing the strain on the steering system and axle components Use NLGI 2 Lithium soap base lubricant for all steering linkage and brake components INSPECTION Wheel bearings should be...

Page 337: ...ry 2 Apply the specified grease at the grease fitting on the universal joint Apply new grease until the new grease purges from all the seals 3 If the new grease does not purge from the seals disassemb...

Page 338: ...interval is six months or every 5 000 miles NOTE It will be necessary to start the motorhome and turn the steering wheel to access fitting s Center Link The center link is located on the backside of t...

Page 339: ...ntrol arm bushings and panhard bar bushings do not require lubrica tion Steering Gear The M 100 series Sheppard steering gear requires no maintenance Using hydraulic pressure to assist rotating the ou...

Page 340: ...ster than normal wear of the axle components if allowed to circulate through the lubricant It is rec ommended that the magnetic plugs be tested if not replaced at each lubricant change These plugs sho...

Page 341: ...e housing bowl 6 Fill the axle with approved lubricant until the level is even with the bottom of the fill plug hole WARNING When checking or changing the lubricant always ensure that the axle is not...

Page 342: ...lean or replace the universal joint Greasing the Drive Shaft Slip Yoke and Splines 1 Check the drive shaft for looseness Repair as necessary 2 With finger cover the rear air hole so grease flows to th...

Page 343: ...and the extended centerline of the shaft of any component to which the U joint connects Because the double oscil lating motion of a U joint that connects angled shafts causes a fluctuating speed diff...

Page 344: ...s the shock absorber must endure will determine the life span However since the only moving part is the piston rod there are no springs hinges or pins to wear out get weak or deteriorate LEVELING SYST...

Page 345: ...position The bong alarm may activate momentarily when driving over rough roads or negotiating curves and corners Usually this indicates a low fluid level in the reservoir WARNING Ensure the potential...

Page 346: ...ract a particular jack press and hold the appropriate rocker switch to the Extend or Retract position until the desired extension is reached Turn the jack control panel OFF Turn the ignition switch to...

Page 347: ...motorhome is equipped with manual emer gency retract valves The manual retract system releases fluid that is under pressure in each jack and allows the fluid to return to the reservoir The manual retr...

Page 348: ...e system are volt ages above 9 6 Volt DC Adding Fluid An indication of a system needing fluid is the bong alarm intermittently sounding when turning cor ners or the pump whining or gurgling Use Dexron...

Page 349: ...eed The maximum engine speed on a diesel engine is controlled by an engine speed governor set by the engine manufacturer WARNING Do not operate a diesel engine where there are or can be combustible va...

Page 350: ...ilure and repaired at the first opportunity The indication is not considered an emergency Solid RED STOP ENGINE Indicates a major failure has occurred that can result in progressive damage or affect s...

Page 351: ...is in NEUTRAL 3 Turn the ignition switch to the ON position 4 Look at the dash warning lights the CHECK TRANS light as well as the PARK BRAKE light on should illuminate The CHECK ENGINE light should...

Page 352: ...rting and operating the motorhome during cold weather requires extra care and consideration Use the following guidelines and refer to the OEM Engine Manual to help ensure safe trouble free operation o...

Page 353: ...guidelines in the Cummins Operation Maintenance Manual recommendations for the engine will help to extend engine life and improve performance resulting in cost efficient operations A good maintenance...

Page 354: ...ve minutes is not neces sary Extended Engine Shutdown When the motorhome has been sitting for extended periods 30 days or more verify all the fluid levels are correct Follow the normal starting proced...

Page 355: ...e cooling system is very important One neglected component could result in cooling problems Maintenance of the cooling system includes a proper coolant levels using the correct mixture of coolant and...

Page 356: ...ant system serves as the base It is critical to use as pure of water as possible Salts and other minerals in the water can solidify in the cooling system causing scaling and clogging of the radiator N...

Page 357: ...oolant and SCA element Coolant Hoses Rotten swollen and worn hoses as well as loose connections are frequent causes of coolant system problems Overheating can be caused by a collapsed hose or a clog c...

Page 358: ...sed and heated to approximately 300 to 375 F depending on the engine load and throttle position Before air enters the intake manifold the CAC cools the intake air temperature to the engine manufacture...

Page 359: ...are needed for shift calibration Transmission Key Pad Functions Selects Neutral by pressing N The area around the N button has a raised ridge so the driver can orient his hand to the Neutral button by...

Page 360: ...will optimize engine braking effi ciency Service If the Service display is illuminated a fault may exist with the Shift By Wire system A qualified service technician should inspect the system Flashing...

Page 361: ...oesn t go to the Electrical Troubleshooting Section 4 Press the D button for DRIVE See if D1 is displayed If DD is displayed the J1939 is not working or the connector is not making contact If D3 is di...

Page 362: ...into the position sensor Ensure both connectors are in good condition no pushed out pins or damage and properly connected Transmission Check Light The electronic control system is programmed to inform...

Page 363: ...the transmission should be kept clean Make periodic checks for loose bolts and leaking fluid lines Check the condition of the electrical harnesses regularly Check the engine cooling system occasionall...

Page 364: ...ns The fluid and internal filters may require changing earlier depending on the severity of operating con ditions The fluid must also be changed whenever there is evidence of dirt or high temperature...

Page 365: ...ensure an accu rate check Be sure the fluid has reached normal operating temperature 160 200 F 71 93 C If a transmission temperature gauge is not present check the fluid level when the engine water te...

Page 366: ...kept clean and free of dirt or water Dirt or water in the system can cause severe damage to both the fuel pump and the fuel injectors Fuel additives for lubricity are not recommended There are numerou...

Page 367: ...he SEND terminal of the gauge on the dash 4 ALARM Makes a connection internally to the negative NEG terminal when the low fuel alarm level is reached when the fuel gauge is reading about 1 8 tank This...

Page 368: ...n the blanks troubleshooting test is provid ed to test the sender It is easier to find the problem that way than after the sender has been removed from the system since the problem is not necessarily...

Page 369: ...ckwise to close the drain valve NOTE Replace the primary filter every six months or 11 000 miles Refer to the engine OEM manual for Secondary filter replacement intervals NOTE When draining or changin...

Page 370: ...l level in the reservoir every 6 000 miles or three months The oil dipstick fill is located on top of the reservoir in the rear compart ment The oil level should be kept between the full and add marks...

Page 371: ...d filter 3 Remove the spring and washer to remove the filter assembly 4 After replacing the filter assembly reverse the process to re assemble the reservoir 5 When attaching the cover plate in the rub...

Page 372: ...cedures lower level service should also be performed NOTE Maintenance schedules are based on normal operating conditions and use Operating under unusual or adverse condition shortens service intervals...

Page 373: ...ommends a particular type of lubricant with a minimum approval rating Most lubricants are tested under strict guidelines set by the ASTM American Society for Testing and Materials The NLGI National Lu...

Page 374: ...intru sion When greasing these types of components care must be given to prevent excess lubricant pressure from rupturing the seal WARNING Always chock wheels before going underneath the motorhome Br...

Page 375: ...ly available at most auto supply stores Zerk fittings come in a variety of angles depending on the application Every effort should be made to lubricate the component as neglect will only result in pre...

Page 376: ...Section 10 Chassis Information Cayman 2005 376 LUBRICATION CHARTS 070166G FRONT...

Page 377: ...ctual mileage to protect seals bearings and gaskets from drying out and failing The motorhome must be started and driven for at least 20 miles bi monthly It is important to remember the gen erator mai...

Page 378: ...ated due to variances in the manufacturing process and or installed components The actual length may be greater or less than that indicated NOTE This chart reflects product specifications available at...

Page 379: ...160 amp Engine Specifications Chassis Fluid Capacities Chassis Liquid Capacities Engine Oil 17 qts Transmission Oil Initial Amount 22 qts MH 2 000 3 000 Transmission Oil With Service 19 qts w filter R...

Page 380: ...e for incorrect filter or belt usage Please refer to the engine manufacturer s operating instructions for specific maintenance information ISB FILTERS BELTS MANUFACTURER NUMBER A C Belt Dayco 15410 Ai...

Page 381: ...the minimum requirements Application 12 Volt Chassis Group 31p MHD 2 each 6 Volt Domestic U2200 4 each AH 20HR CCA RC 25A 80 F MINUTES 950 195 450 75Amp 80 F 230 Min Battery Charge Voltage chart eps...

Page 382: ...Section 10 Chassis Information Cayman 2005 382 METRIC U S CONVERSION CHART...

Page 383: ...rformed the service in the boxes provided after the maintenance interval Any additional information from Owner Checks and Services or Periodic Maintenance can be added on the following record pages In...

Page 384: ...Section 10 Chassis Information Cayman 2005 384...

Page 385: ...Chassis Information Section 10 Cayman 2005 385...

Page 386: ...Section 10 Chassis Information Cayman 2005 386...

Page 387: ...Chassis Information Section 10 Cayman 2005 387...

Page 388: ...Birch OR Aaron Graham OR James Magee OR Julie Slagle IN Nate Bondurant OR Fran Weisenstein IN TECHNICAL ILLUSTRATIONS Kelly Stroble Aaron Graham Josh Means Cayman 2005 Technical Writer James Magee Ca...

Page 389: ...Cayman 2005 INdex...

Page 390: ......

Page 391: ...attery 290 Battery Cut off Switch 255 Battery Disconnect Chassis 290 Battery Disconnect House 254 Battery Specification Chart 381 Bedroom TV Swivel 202 Brake System 327 Electrical Pump Master Cylinder...

Page 392: ...Engine Shutdown 354 Entertainment Center Exterior OPT 201 Entry Door 171 Screen Door Maintenance 171 Entry Step 169 Operation 169 Stepwell 170 Equipment Introduction 169 Escape Egress Window 94 Exhau...

Page 393: ...ry Charging w the Inverter 266 Battery State Indicator 267 Charge Cycles 268 Circuit Breakers 267 Pass Through Relay 269 Power Share 268 Programming the Inverter 269 Remote Panel 266 Stand by Mode 267...

Page 394: ...he Technician s Shoulder 19 Prepare a List 19 Prepare for the Appointment 19 Set up Procedure Checklist 49 Shock Absorber 344 Shore Power Hook up 255 Shower 115 Slide Out Operation 172 Main Room Slide...

Page 395: ...116 Wall Thermostat 150 Comfort Control OPT 150 Heat Pump OPT N Aw Standard Thermostat 152 Warranty Limited 2005 Roadmaster Chassis 6 Disclaimer of Consequential Damages 9 Events Discharging Warranto...

Page 396: ...Disinfecting Fresh Water 212 Troubleshooting 212 Water Systems Introduction 207 Water Tanks 208 Measurements Calibration 208 Weighing the Motorhome 73 Cargo Carrying Capacity Flowchart 81 Four Point...

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