Monaco CAYMAN 2007 Manual Download

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CHASSIS INFORMATION - 10

216

CAYMAN 2007

TECHNICAL PUBLICATIONS

MANAGER:

vance Buell

OPERATIONS

Techncal Wrters

william Birch - Or

nate Bondurant - Or

Tony Isom - Or

Thomas Joachim - In

creatve desgners

aaron Graham - Or

Kelly stroble - Or

Julie rice - In

ILLUSTRATIONS:

Kelly stroble, aaron Graham

PRINTING

Holiday Graphics - In

ONLINE

Corporate site: www.monaco-online.com

ONLINE TOURS

www.monaco-online.com/tours/

CAYMAN 2007

Technical writers:

nate Bondurant

layout & Cover Design:

aaron Graham

Summary of Contents for CAYMAN 2007

Page 1: ...other person beyond those expressly set forth in this Limited Warranty Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you WHAT THE...

Page 2: ...ng 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 pollutants salt tree sap and hail Component par...

Page 3: ...lure of the Roadmaster Chassis and or the materials used to assemble the Roadmaster Chassis to conform to Warrantor s design and manufacturing specification and tolerances Also see the section What th...

Page 4: ...ontact your selling dealership or Warrantor directly or review the warranty packet inside the Motorhome EVENTS DISCHARGING WARRANTOR FROM OBLIGATION UNDER WARRANTY Misuse or neglect accidents unauthor...

Page 5: ...ERIOR INTERIOR CARE 49 SECTION 4 APPLIANCES 77 SECTION 5 EQUIPMENT 97 SECTION 6 WATER SYSTEMS 115 SECTION 7 LP GAS SYSTEMS 129 SECTION 8 ELECTRICAL SYSTEMS HOUSE 139 SECTION 9 ELECTRICAL SYSTEMS CHASS...

Page 6: ...will not reflect modifications that may have been performed by previous owners Copyright Monaco Coach Corporation All rights reserved All other trademarks or registered trademarks are property of the...

Page 7: ...WARRANTY INFORMATION FILE 4 REPORTING SAFETY DEFECTS 4 SAFETY TERMS 4 GLOSSARY OF TERMS 5 SURVEY 9 LIMITED WARRANTY 11 CAYMAN 2007 GENERAL INFORMATION SECTION 1...

Page 8: ...9153 for hearing impaired or 1 202 366 0123 in the Washington D C area visit their websites at www nhtsa gov or www safercar gov or write to NHTSA U S Department of Transportation 400 Seventh Street S...

Page 9: ...lding tank The toilet drains directly into 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...

Page 10: ...available Grey Water Term associated with the waste water holding tank Water from the sink drains the shower and the washer dryer if equipped go into this tank House Battery Powers 12 Volt DC lights a...

Page 11: ...or side or the driver 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...

Page 12: ...GENERAL INFORMATION 1 CAYMAN 2007 8 NOTES...

Page 13: ...ur new recreational vehicle If not please address any area s we need to expand or improve on ____________________________________________________________ ______________________________________________...

Page 14: ......

Page 15: ...untry travel on improved roads 3 All information provided by you on face side of this form is true and correct 4 You understand that you are purchasing a pre owned recreational vehicle and Monaco Coac...

Page 16: ......

Page 17: ...r Pressure 31 Tire Pressure Inflation Guideline 31 Tire Chart Goodyear 32 Inspecting Pressure 33 Air Pressure Checklist 33 Supporting When Leveling 34 Tire Vibration 34 Tire Rotation 34 Tread 35 Stora...

Page 18: ...ng area of the motorhome Look high and low when walking around the motorhome Familiarize Yourself Because the location of the driver s seat in the motorhome is higher and farther to the left than most...

Page 19: ...inces may have laws that can exceed the requirements described above It is your obligation to know and comply with the laws in the state or province in which you travel A child safety seat is required...

Page 20: ...speed and can extend the service life of the brake lining Distance required to stop the motorhome is greater than an automobile Practice stopping away from traffic to get the feel of distance require...

Page 21: ...car or driver on the left hand side is easier seen Ascending a Grade When approaching an uphill grade assess the grade and length before beginning the climb Prepare early for long climbs Unlike gasoli...

Page 22: ...stopping place and wait for conditions to improve Avoid using an engine braking device on wet or slippery surfaces which can cause the drive wheels to skid Wiper blades should be in good condition Fi...

Page 23: ...a water pressure regulator and various termination connectors for sewage Inspection Ensure all exterior items are stowed or secured i e TV antenna ceiling vents and windows Check belts hoses battery a...

Page 24: ...consider when selecting a ball mount weight rating pin to ball center length and rise drop The weight rating of the ball mount tongue weight and tow weight must meet or exceed the total load weight P...

Page 25: ...an 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 hitch receiver othe...

Page 26: ...perform a light check before starting a trip and at each rest stop 3 Check the tires frequently Flat tires on a towed vehicle cannot be detected from the motorhome while driving A flat tire is a safet...

Page 27: ...a conscious effort to maintain sight of the driver through the roadside mirror as the motorhome maneuvers If the driver loses sight of the co pilot stop the backing up process until the co pilot retu...

Page 28: ...guide only This information is an overview on hooking up the utilities and preparing appliances for use Specific information on slide room awning and leveling system operations is discussed in detail...

Page 29: ...y to reduce use of the roof air conditioner Frequently monitor water consumption Limit shower usage turn water off when soaping down and back on to rinse When water conservation is critical take a spo...

Page 30: ...heck for fluid leaks under and around the motorhome Engine Checklist Inspect the engine transmission and the engine compartment for fluid leaks Inspect the area under the motorhome for fluid leaks or...

Page 31: ...warn approaching traffic In Case of Flat Tire In the event of a flat tire it is recommended to call for roadside assistance The size and weight of the motorhome and its tires require proper equipment...

Page 32: ...three to five times Next hold the switch down and turn the ignition ON The battery voltage gauge on the dash should indicate at least 12 Volts If voltage is sufficient with the Boost switch held down...

Page 33: ...or cranks slowly DO NOT CONTINUE Extensive damage fire or injury can occur Obtain help from a qualified technician TOWING PROCEDURES If calling a towing company for service it is recommended to use a...

Page 34: ...ion or repair facility WARNING Only trained personnel should perform this procedure Brake chamber spring is under high pressure Removal of retaining band could result in serious injury or death Disabl...

Page 35: ...ular motorhome maintenance WARNING Driving on a tire that is under inflated can exceed the design limits of the tire and may damage the sidewall A damaged sidewall can burst upon inflation resulting i...

Page 36: ...75 s d 4530 4380 4770 4580 4990 4760 5220 4950 5510 5205 5730 5415 5950 5625 6175 g 5840 g 6320 5895 6465 5950 6610 h 6005 h 12R22 5 75 s d 4940 4780 5200 4990 5450 5190 5690 5390 6005 5675 6205 5785...

Page 37: ...or construction on the same axle The difference in traction could cause rear end gear bind and mechanical damage to the drive train CAUTION Never let air out of a hot tire Over in ation can cause Hard...

Page 38: ...ay be damaged and could lead to premature fatigue of the sidewall CAUTION Supporting the tires prevents damage to the sidewall of the tires but does not prevent tire roll Tire Vibration Sudden tire fa...

Page 39: ...n pressure as indicated on the Federal Identification Tag During Storage Cover the tires to block direct sunlight Periodically ensure tires are at proper pressure Move the motorhome every three months...

Page 40: ...tion Label This weight cannot be exceeded CAUTION Most states limit the amount of weight carried by any single axle position It is the responsibility of the operator to know the legal weight limit of...

Page 41: ...oolants UVW does not include cargo fresh water LP Gas occupants or dealer installed accessories Cargo Carrying Capacity CCC Equal to GVWR minus each of the following UVW full fresh potable water weigh...

Page 42: ...heel position requires weighing referred to as a six point weigh to accurately determine the correct tire inflation pressure NOTE The most accurate method to determine proper tire pressure is to weigh...

Page 43: ...e 4000 lbs 4 Add Roadside and Console side from line 1 for Gross Axle Weight Rating GAWR and record on chart under Totals Example 13000 lbs 5 Add chart scale A and C line 2 for actual Gross Axle Weigh...

Page 44: ...ee of dirt and foreign material Material lodged between the valve core and internal stem can cause slow leaks resulting in tire failure Cargo Carrying Capacity When weighing the motorhome it is import...

Page 45: ...taling 716 pounds that doesn t mean the sleeping capacity is reduced to three individuals but rather the CCC is reduced by 100 pounds due to the actual passenger weight c 14 484 2 scWr 716 ccc 13 768...

Page 46: ...8 919 5 770 8 149 23 000 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 CaPaCITy CaPaCITy NOTE These measurements are with...

Page 47: ...larm to normal state when the reason for activation the presence of smoke is completely removed Fires are commonly caused by smoking in bed leaving children unattended or using flammable cleaning flui...

Page 48: ...oting If the alarm does not sound when the test button is pushed or with a smoke test try the following Inspect alarm for obvious damage Check for the recommended battery type Check the battery for pr...

Page 49: ...red it will run through a brief warm up and self check prior to monitoring for CO gas Operation The detector is equipped with a self cleaning CO sensor and requires a ten minute initial warm up period...

Page 50: ...ther buildup on the detector DO NOT wash Wipe the detector with a damp cloth and dry with a towel DO NOT open the detector for cleaning DO NOT paint the detector It is recommend that the Carbon Monoxi...

Page 51: ...d electrical wiring or equipment If electricity to the equipment is turned off a class C fire becomes one of the other two class fires ESCAPE EGRESS WINDOW The Egress window designated for use as an e...

Page 52: ...DRIVING SAFETY 2 CAYMAN 2007 48 NOTES...

Page 53: ...er 56 Fabric Cleaning Codes 56 Fabric Specifications Charts 58 Floors 62 Carpet Cleaning 62 Laminate Floor 63 SHOWER 63 CEILING 63 WALL COVERINGS 63 WOOD CARE 64 COUNTERTOPS 65 Solid Surface 65 Lamina...

Page 54: ...washing the motorhome remove most of the accumulated dirt and road wash behind wheel openings below the windshield and on the rear of the motorhome If build up is excessive run water over a soft cotto...

Page 55: ...ratches or swirl marks may be removed by an application of a glaze These types of glazes fill the scratches or swirl marks The motorhome has a large surface area Washing and waxing may not be complete...

Page 56: ...re are many types of sealants and each has a specific use While the belt line uses a silicone or urethane base sealant to prevent water intrusion roof openings use an acrylic based sealant Moisture in...

Page 57: ...in a caulking tube Two colors are available white and silver Silver is used on items mounted on the forward painted area of the roof White is used at all other points Remove old sealant that is not a...

Page 58: ...the plastic or Plexiglas instrument panels using a cloth dampened in a mild soap and water solution Dry using a separate cotton cloth Plastic polish products that will help to brighten the appearance...

Page 59: ...ning use only small quantities while in a well ventilated area Exercise proper caution by notifying any persons in the area Keep away from any ignition source Always wear protective gloves Oil Base Pa...

Page 60: ...For Oil based Stains Spray soiled area with household cleaner such as 409 or Fantastik and wipe with warm water using a soft cotton cloth For Marker type Stains Dab stained area with solution of 50 Is...

Page 61: ...ervice is recommended for this fabric X Vacuum only A non metallic brush may be used Machine Washing for 100 Polyester Wash Cycle Use synthetic setting and high water level with mild agitation A mild...

Page 62: ...b HB Br Pillow Bedspread accent 75 Polyester 25 Rayon Dry Clean Fairview Natural w suede windshield Privacy Curtain 64 Cotton 36 Polyester Kilimanjaro Dash vinyl vinyl vinyl O vinyl Kilimanjaro Vinyl...

Page 63: ...HB Trim 70 Polyester 30 Cotton Dry Clean lynn Golden Bedspread welt Br lamb Headboard 50 Polyester 50 Cotton Dry Clean lynn rust Bedroom lamb Bedroom Pillow 50 Polyester 50 Cotton Dry Clean Fairview N...

Page 64: ...b Br Pillow welt HB Trim 70 Polyester 30 Cotton Dry Clean Bristol adobe Bedspread welt Br lamb Br Pillow HB 50 Polyester 50 Cotton Dry Clean Fairview Natural w suede windshield Privacy Curtain 64 Cott...

Page 65: ...edspread Br Pillow welt Br lamb 100 Cotton w lynn Tea Bedspread welt Br lamb Br Pillow 50 Polyester 50 Cotton Dry Clean Fairview Natural w suede windshield Privacy Curtain 64 Cotton 36 Polyester O vin...

Page 66: ...acuum or brush the pile to restore texture If the spot is not completely removed contact a professional carpet cleaner Cleaning Solutions A Dry Cleaning Fluid A nonflammable spot removal liquid availa...

Page 67: ...d once a year To replace sealant remove the old sealant using a sharp non metallic instrument Apply a new sealant which can be found at most recreational vehicle supply stores CEILING The ceiling of t...

Page 68: ...tely Solvents alcohol nail polish and polish removers as well as harsh cleaners should not be used on finished wood surfaces Minor damage to solid wood surfaces can be repaired quickly and effectively...

Page 69: ...stored Rub the loose varnish with fine steel wool or fine synthetic steel wool until you have removed the flaking varnish and slightly roughened a small area of the finish surrounding the scratch With...

Page 70: ...on food packages DO NOT use laminated countertops as a cutting board Laminated countertops are resistant to minor heat however hot pans irons and lit cigarettes will damage the surface Use hot pads u...

Page 71: ...may be cleaned while hanging in place using this method Vacuuming For deeper cleaning vacuum gently with the soft brush attachment of a vacuum cleaner CompressedAirorHairDryer non heat setting Blow du...

Page 72: ...f mold or mold spores have not been set Currently there are no EPA regulations or standards for airborne mold contaminants There is simply no practical way to eliminate all mold and mold spores in the...

Page 73: ...epared and eaten Garbage should be placed in a sealed container and removed to an outside receptacle daily Only put out pet food that will be immediately eaten Keep foods such as flour cereal spaghett...

Page 74: ...nts that are away from the colony The colony must be destroyed to eliminate all ants Keep ants away from the sewer hose by spraying the hose ends with a soap and water solution Fleas can be removed by...

Page 75: ...home during periods of short term storage will make bringing the motorhome out of storage a much easier process Winterize the plumbing system if the motorhome is stored in winter months or if stored w...

Page 76: ...eries in a low state of charge will readily freeze Freezing will damage the battery If AC power is available The main battery disconnect switches should remain ON The inverter will charge both house a...

Page 77: ...machined surfaces Only occasional use keeps these surfaces from oxidizing Rusty brake drum or rotor surfaces permeate the brake lining upon the first few applications reducing the friction action of t...

Page 78: ...n of headlights taillights turn signals back up lights license plate light and emergency flasher Operate the dash air conditioner If the air conditioner does not work or the compressor makes unusual n...

Page 79: ...and body seams and windows Reseal if necessary Lubricate all the exterior locks hinges and latches with a graphite lubricant Check the windshield wiper blade condition Check the wiper washer operatio...

Page 80: ...EXTERIOR INTERIOR CARE 3 CAYMAN 2007 76 NOTES...

Page 81: ...re Cleaning 83 COOKTOP 84 Operating the Cooktop 84 Operation Tips 84 Burner Grate 85 Cleaning 85 Porcelain Enamel 85 COOKTOP WITH OVEN OPT 85 WALL THERMOSTAT 86 AIR CONDITIONER ROOF 87 Operation 87 AC...

Page 82: ...cycle is repeated To ensure longevity and proper operation of the refrigerator follow the specific guidelines in the refrigerator manual With proper care and maintenance the refrigerator should provi...

Page 83: ...mode temperature and fault code display MODE Button Controls the operation mode of the refrigerator Press the MODE button to select between Automatic AU AC or LP operation SET TEMP Button Adjusts the...

Page 84: ...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 arm to stop ice production while in transit...

Page 85: ...or cooling unit Wash the interior using mild spray cleaners or a solution of liquid dish detergent and warm water DO NOT use scouring pads or abrasive cleaners that can damage the interior finish Rins...

Page 86: ...al The glass tray and roller guide must always be in place during cooking Ensure the door is firmly closed before use If the control pad is not lit plug another electrical appliance into the same outl...

Page 87: ...he filter is positioned on the supporting tabs 5 Replace louver and mounting screws Oven Light 1 Remove the louver as indicated above 2 Slide the metal light cover forward and lift upwards 3 Remove th...

Page 88: ...s use a piezo type igniter The cooktop should be used for cooking purposes only and not as a heating source When the burner valve is opened the fuel flows through the valve into the mixture tube The f...

Page 89: ...will be more difficult if spills bake on to the surface Glass cleaner sprayed on a paper towel should be used for the cooktop surface DO NOT spray glass cleaner directly on the surface DO NOT use abr...

Page 90: ...ces Zone 1 will operate the living room furnace and Zone 2 will operate the bedroom furnace Press the Zone button to change zones The selected zone will flash The up and down buttons control the tempe...

Page 91: ...as the auxiliary heat source and will begin operation The furnace will remain the primary heat source until ambient temperature rises above 42 F AIR CONDITIONER ROOF The roof air conditioners operate...

Page 92: ...tion Requirements The furnace will operate when the following conditions have been met The LP Gas primary valve on the LP Gas tank is open The house batteries in the motorhome are fully charged NOTE T...

Page 93: ...the system To Purge Air and Pressurize the System Turn the water heater bypass valve located at the back of the water heater to Normal Flow If necessary install drain plug Fill the fresh water tank o...

Page 94: ...nue using the water heater Have the water heater inspected by a qualified technician to determine the cause of the over temperature condition Water Heater Bypass Valve The bypass valve is located at t...

Page 95: ...er to the water heater 2 Shut off the primary LP Gas valve 3 Open low point drains 4 Open both Hot and Cold on all faucets 5 Remove water heater drain plug 6 Turn the bypass valve to the bypass positi...

Page 96: ...in into the black tank on some floor plans WASHER DRYER OPTIONAL The automatic washer dryer is front loading with an extra large door opening for easier access Several wash and dry programs are availa...

Page 97: ...the selector knob to a wash cycle Set Wash Temp knob to Warm Water should flow into washer and the drum should rotate both directions 4 Set selector knob to Reset Wait five seconds 5 Set selector kno...

Page 98: ...Cold water inlet screens may be clogged Remove water pressure and undo water lines at the back of the washer dryer Use tweezers or pliers to remove screens from fittings Clean and install screens and...

Page 99: ...er on each of the cardboard tabs slide the bag on the inlet tube 9 Line up the mark on the bag cover with the unlock symbol and rotate clockwise to lock symbol Replacing Cleaning the Motor Filter 1 In...

Page 100: ...APPLIANCES 4 CAYMAN 2007 96 NOTES...

Page 101: ...n 105 Automatic Fan OPT 105 Tips for Fan Operation 106 Bedroom Ceiling Fan OPT 106 POWER SUNVISOR 106 DOOR SLIDING 106 SEAT CONTROLS 107 Swivel Seats 107 SOFA BED CONVERSION 107 AIR MATTRESS BED OPT 1...

Page 102: ...ge to automatically retract the step 6 Turn the ignition off and open the door The step will extend and lock in the OUT position This is the last out feature When the ignition is on the step will alwa...

Page 103: ...Adjustments Adjusting the Entry Door Latch Determine which bolt needs adjustment Observe the latch and strike bolt alignment while slowly closing the entry door DO NOT attempt to latch if alignment i...

Page 104: ...e damage could occur to the slide room and awning if extended in snow sleet ice or freezing rain In such conditions if the slide room is extended clear the awning and ensure free movement prior to ope...

Page 105: ...al Override A safety feature may be engaged and preventing operation if the slide room does not operate If the slide room does not operate Ensure ignition key is OFF when extending room Ensure park br...

Page 106: ...rquing can result in severe damage 7 Take motorhome to an authorized repair center AWNINGS Slide out Cover The slide out cover automatically reacts to slide out direction A fixed edge of the slide out...

Page 107: ...ull strap with a firm grip until tension is off the inner arms Fold inner arms and attach them to the Velcro Carefully allow material to wind onto awning roll tube while holding strap in a neutral pos...

Page 108: ...ecessary reapply the solution to keep fabric saturated Rinse the awning thoroughly Repeat if necessary until most of the stains disappear Contact Carefree of Colorado for removal of stubborn stains Le...

Page 109: ...l Off button once more to manually control fan speed Fan speed is displayed on the wall control in 10 increments The thermostat is no longer operational in this mode Press the Auto Manual Off button u...

Page 110: ...al 12 Volt DC powered ceiling fan is located in the bedroom Fan operation is controlled by a switch located next to the bed Periodic maintenance consists of cleaning the blades with a soft cloth towel...

Page 111: ...BED CONVERSION To Convert Booth Dinette into a Bed Lift seat cushions to an angled vertical position Rotate the lock bar located underneath the table Push the table down into position Use both seat c...

Page 112: ...e mattress cover and close the convertible sofa AIR MATTRESS BED OPTIONAL The air mattress includes two separate air chambers to allow different firmness settings Each side is equipped with a remote c...

Page 113: ...Turn ON the radio Insert CD or select AM FM or Weather Band with the button in the lower right corner NOTE See TV and Entertainment Components for DVD operations Clock Adjust Press and hold the Displa...

Page 114: ...nd house battery status on the monitor panel 5 Water Pump Switch Activates the water pump The pump status light illuminates when the water pump is on 6 Water Heater Switch Applies 12 Volt DC power to...

Page 115: ...eing used Connections Cable TV Computer Phone The motorhome is equipped with cable TV and phone hook ups located in the water service bay For convenience the auxiliary outlet is located at the cockpit...

Page 116: ...DVD Turn the main Radio power switch on rocker switch located on center console Turn on the dash Radio DVD player Turn on the TV and select channel 3 Press the DVD button above the section marked Main...

Page 117: ...e startup routine For Dish 500 subscribers After being locked onto a satellite Dish 500 subscribers can switch back and forth between the 110 and 119 satellites To switch satellites Press and hold the...

Page 118: ...ray the radome directly with high pressure water DO NOT apply abrasive cleaners or volatile solvents such as acetone to the ABS dome Annually Have the satellite system inspected by a professional RV t...

Page 119: ...roper Waste Disposal 119 What Not to Put in Waste Holding Tanks 119 What to Put in Holding Tanks 120 Waste Drain Sewage Tanks 120 Waste Drain System 120 Tank Flush 121 Waste Pump OPT 122 TOILET 122 Op...

Page 120: ...cally powered item or electrical outlet that may be exposed to a water source Such use can result in a serious shock causing injury or death WATER TANKS Measurements The motorhome is equipped with two...

Page 121: ...owner not the manufacturer The water pump can be operated from the following locations Hallway Monitor Panel Water service bay To turn the water pump ON or OFF Momentarily press the water pump switch...

Page 122: ...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 123: ...e now have dump stations available Woodall s Campground Directory Trailer Life s RV Campgrounds and Services Directory Rand McNally s Campground and Trailer Park Guide Good Sam Park Director Good Sam...

Page 124: ...peration of the waste systems The wastewater holding system consists of a grey water tank that stores the sink shower and laundry washer drain water and a black holding tank that stores waste from the...

Page 125: ...ll the grey tank to at least 50 by running water in the shower or sinks 3 Use the tank monitor in the service bay to observe tank levels Stop filling the tank when the grey tank is half full 4 Open th...

Page 126: ...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 drain valve remains open until the ne...

Page 127: ...s Clean out the system by flushing several gallons of fresh water through with one cup of dry laundry detergent Add odor control deodorant in the amount specified for the holding tank capacity after c...

Page 128: ...temperatures can adversely affect water systems below the floor level because the LP Gas furnace heat does not provide heat to these components A supplemental 12 Volt bay heater is located in the wate...

Page 129: ...center panel including fresh tank drain Let all the water drain If equipped with a LP Gas water heater position the winterize valve to by pass Remove drain plug to drain tank 4 Remove filter at kitch...

Page 130: ...starting with the faucet farthest from the pump Turn the faucet off when antifreeze appears Hold the toilet flush mechanism open until antifreeze appears 11 Use a soft cloth to wipe out the sinks and...

Page 131: ...contaminants Discard and replenish the icemaker as necessary SERVICE CENTER 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 13 1 Gravity fill 2 Holding tank monitor 3 Exterior shower 4 Sanicon power switch option...

Page 132: ...WATER SYSTEMS 6 CAYMAN 2007 128 NOTES...

Page 133: ...CHECKLIST 132 LP GAS TANK 133 Measurement 133 Tank Capacity 133 Tank Filling 133 Tank Operation 134 Accessory Hookup 134 LP GAS FUNDAMENTALS 134 LP GAS REGULATOR 135 LP GAS HOSE INSPECTION 136 LP GAS...

Page 134: ...e Keep open flame and spark producing materials away from the LP Gas area Shut off all appliances and the primary LP Gas tank valve when the motorhome is in storage If this warning is ignored a fire o...

Page 135: ...m glue and adhesive used in the manufacturing of the motorhome may also cause the detector to alarm for several months after the date of manufacture If it is determined that the detector has false ala...

Page 136: ...he alarm will beep four times and return to phase 1 4 After two minutes the detector will return to normal operation solid green or resound the alarm if dangerous levels of gas remain in the area Faul...

Page 137: ...nk WARNING Turn off all pilot lights and LP Gas operated appliances before entering a refueling station Most LP Gas appliances used in motorhomes are vented to the outside Fuel vapors can enter those...

Page 138: ...ories only For safety only approved LP Gas quick disconnect fittings and flexible hose should be used to connect external accessories to the remote hookup A LP Gas quick disconnect fitting should be i...

Page 139: ...or about 6 ounces psi A vent is installed to allow the internal diaphragm to move with atmospheric pressure change It is important to keep the vent clean and clear of obstruction or corrosion If the v...

Page 140: ...e amount of pressure needed to raise the column of water 11 represents 11 Inches of Water Column TIP Attach the manometer gauge to the accessory hookup line to avoid loosening any interior LP Gas line...

Page 141: ...capacity is estimated based on calculations provided by the tank manufacturer and represents approximate capacity The actual usable capacity may be greater or less than the estimated capacity Actual f...

Page 142: ...ore using the refrigerator or furnace for the first time each season Insects may have built nests that will obstruct flow At the first indication of incomplete combustion yellow flame instead of a blu...

Page 143: ...VERTER OPT 146 Providing AC Power with Inverter 146 Battery Charging with the Inverter 147 Factory Default Settings 147 Battery Temperature Sensor 147 DISTRIBUTION PANEL HOUSE 120 240 VOLT AC 147 Circ...

Page 144: ...t in a serious shock causing injury or death The motorhome has two 12 Volt DC systems chassis and house These two systems for the most part are separate from one another The house system does not oper...

Page 145: ...ctrical maintenance If possible leave the motorhome plugged into outside electrical service with the battery disconnect switch on to help prevent the possibility of dead batteries Use of this battery...

Page 146: ...and flashing of electrical contacts Make the connection to the outlet and turn the shore power breaker on The transfer switch should make an audible click When Hooked to 50 Amp After verifying proper...

Page 147: ...he 50 Amp shore cord to a 30 Amp shore power outlet Another common adapter is the 30 20 Amp adapter Always install the adapter to the cord prior to making the connection to the outlet TRANSFER SWITCH...

Page 148: ...up to 15 seconds indicating engine preheat WARNING Excessive cranking can overheat and damage the starter motor DO NOT crank the engine more than 30 seconds at any one time Wait at least two minutes...

Page 149: ...of its rated power for every 1000 ft gained in elevation High and low temperatures can also affect generator output Power decreases 1 for every 10 F above 85 F Counteract these effects by operating ap...

Page 150: ...ot charging there may be a problem with an open wire between the converter and battery If the fuses are blown the battery was connected in reverse It only takes one second of reverse connection to blo...

Page 151: ...o one of the house battery terminals to measure battery temperature and send that information to the inverter When battery temperature rises the inverter will decrease charge voltage to prevent boilin...

Page 152: ...hange slightly with voltage fluctuations As voltage increases current consumption decreases As voltage decreases current consumption increases This may explain why in some instances items operated at...

Page 153: ...loads in the motorhome and a system of energy management to minimize the over loading and tripping of circuit breakers Circuit Breakers The distribution panel offers slots for eight single or dual sta...

Page 154: ...Recreational Vehicle Industry Association in conjunction with the NEC National Electrical Council have established rules regarding the rating of electrical systems and the use of energy management sy...

Page 155: ...be quite high as in the case of battery cables Shorting a battery cable to ground with a battery at a reasonable state of charge can result in a fire or serious personal injury from a burn House Batt...

Page 156: ...rged This is highly explosive DO NOT smoke around batteries and keep all sources of ignition or flames away from batteries The hydrogen gas may explode resulting in fire personal injury property damag...

Page 157: ...ry If the battery electrolyte is splashed in the eyes or on skin immediately flush the affected area for 15 minutes with large quantities of clean water In case of eye contact seek immediate medical a...

Page 158: ...s equals 16 Amps DC battery current Add the revised 10 efficiency loss figure this calculates to a total of 17 6 Amps DC If the battery bank capacity is rated at 500 Ahrs actual elapsed time to the su...

Page 159: ...place with a 12 Volt DC 4 Watt type 1816 bulb and install cover by realigning the pointer to the same location Turn cover to OFF or ON position If Map Lights Fail to Operate Ensure interior house powe...

Page 160: ...ELECTRICAL SYSTEMS HOUSE 8 156 CAYMAN 2007 NOTES...

Page 161: ...nator Testing Procedure 161 STEERING COLUMN 162 Tilt Telescope 162 CONSOLE 162 Parking Brake 162 Leveling Controls 163 DASH 163 Gauges 163 Indicator Lights 164 Switches 165 DASH AIR CONDITIONER HEATER...

Page 162: ...rials may weaken the assembly or result in damage that is not obvious and may not cause an immediate problem or failure Unauthorized modifications or repairs to the chassis could result in a forfeitur...

Page 163: ...eplaced and it blows repeatedly that may be an indication that a fault exists or an electronic component has failed It is recommended that the motorhome be taken to a qualified RV technician before an...

Page 164: ...st is the opposite side of the coil tripped different ways 4 The 87 posts are not common to the 30 post until the relay is tripped When the relay trips both 87 posts are common to the 30 post 5 Using...

Page 165: ...the motorhome CAUTION Long term use of the inverter to operate the microwave while in transit will damage the alternator Use the generator to operate the microwave while in transit Alternator Testing...

Page 166: ...l alarm will sound To turn off the flashers push the button in CONSOLE NOTE Switch and component placement on panels may vary The transmission shift selector is used to select and display gear selecti...

Page 167: ...res are preset at the factory It is an indication of an air system malfunction if the air system does not maintain normal operating pressure Use caution and stop the motorhome in a safe area Contact a...

Page 168: ...ensure there is enough fuel to run the main engine 8 Transmission Temperature Shows approximate temperature of the transmission fluid DO NOT let the transmission cooler oil temperature exceed OEM spec...

Page 169: ...desired side The middle position is to prevent accidental bumping of the switch and changing the mirror position The outside mirrors are easily adjusted with the Allen wrench After taking delivery of...

Page 170: ...When the knob is rotated from OFF to DELAY the wiper will turn on and time delay between wipes will occur The amount of delay time changes as the knob is rotated A continuous low or high speed can be...

Page 171: ...Operates the passenger side power sun visor DASH AIR CONDITIONER HEATER CONTROLS Dash AC and Heater Control Designed to provide heating cooling and defrost capabilities for the pilot co pilot area The...

Page 172: ...ambient temperatures and relative humidity A large amount of cooling capacity is used to dehumidify as well as cool air After three to five minutes of A C operations discharged air temperature should...

Page 173: ...sses the refrigerant into the evaporator according to the cooling requirements The pressure is reduced in the restrictive effort of the expansion valve A part of the valve is the capillary tube assemb...

Page 174: ...lect switch 5 Thermostat control valve is faulty 6 Expansion valve is faulty 7 Compressor is faulty 8 Low refrigerant charge No Heating 1 Verify A C switch is turned off 2 Verify blower switch is turn...

Page 175: ...ostics will notify the operator of deviations from the programmed limits of the engine through the Check Engine lamp in the dashboard Should a system component with the engine develop a deviation the...

Page 176: ...In THe TanK FIll Fuel TanK TanK Is Full nO Fuel TO enGIne CHeCK FOr lOOse FITTInGs Or ClOGGeD FIlTer no sTarT enGIne wIll nOT CranK BuT Has sHIFTer lIGHT CHeCK enGIne BaTTery vOlTaGe CHarGe Or rePlaC...

Page 177: ...o Leveling 190 Manual Leveling 190 Automatic Leveling 191 Retracting Leveling Jacks 191 ENGINE GENERAL INFORMATION 192 STARTING PROCEDURE 193 Normal Starting 193 Cold Weather 193 ENGINE OIL 195 ENGINE...

Page 178: ...ural integrity and overall uniform stress distribution The Roadmaster chassis includes four outboard air springs and four Monroe shock absorbers The location of the air springs and shock absorbers com...

Page 179: ...cut out pressure is reached the governor will send an air purge signal to the Air Dryer This opens the purge port of the Air Dryer expelling moisture The purge action of the Air Dryer is identified by...

Page 180: ...DO NOT remove air hoses from fittings while system is pressurized Serious injury may occur WARNING Never place yourself under motorhome without first properly blocking frame jackstands from coming dow...

Page 181: ...from the compressed air system to prevent freezing of brakes or other pneumatically operated items The three functions of the air dryer are cooling filtering and drying the system air This prevents v...

Page 182: ...dge seal with a thin layer of grease 7 Thread the replacement cartridge onto the base until the seal touches the base Tighten the cartridge ONE additional turn DO NOT OVERTIGHTEN NOTE If an excess amo...

Page 183: ...lves or height control valves assist in ensuring the total air spring system works as required Clean inspect and replace if necessary Make sure to check shock absorbers for leaking hydraulic oil and w...

Page 184: ...brake pads against the rotor The air system must be charged above 35 psi to allow the park brake to release Pushing down on the park brake handle charges the rear brake chambers with air pressure ove...

Page 185: ...tem fail the pressure protection valve PPV reserves the remaining air pressure of 65 psi for braking This will leave the motorhome with one air tank fully charged for safety backup The rear air tank a...

Page 186: ...ABS ATC system combined with safe driving practices will reduce the possibility of wheel skid and loss of lateral stability ABS Component Function Speed sensors and tone rings on each wheel monitor w...

Page 187: ...s necessary Shimmy and looseness should be checked and corrected as soon as possible If looseness is felt in the steering the steering linkages can be observed while someone turns the steering wheel l...

Page 188: ...caster is the tilt of the top end of the kingpin toward the rear of the motorhome Negative caster is the tilt of the top end of the kingpin toward the front of the motorhome Setting the caster angle m...

Page 189: ...ft for looseness Repair if loose or worn 2 With finger cover the rear air hole so grease flows to the front seal Apply the specified grease at the grease fitting on the slip yoke Apply until new greas...

Page 190: ...the axles perpendicular with the frame The panhard bar controls side to side motion of the axles in the frame Control arm bushings and panhard bar bushings do not require lubrication Steering Gear The...

Page 191: ...level with bottom of the hole Important The lube level close enough to the hole to be seen or touched is not sufficient The lube must be level with the hole Correct the level as necessary Re install t...

Page 192: ...inger away from the air hole in the end of the slip yoke WARNING Rotating shafts can be dangerous Rotating shafts can snag clothes skin hair hands etc causing serious injury or death DO NOT work on or...

Page 193: ...acks Down LED and warning alarm if a jack is down and the transmission is placed in gear or the park brake is released The leveling system can be operated in manual or automatic modes Safety Features...

Page 194: ...to help disperse the weight If blocking up a rear jack pad to gain added clearance when the motorhome is on a slope place a wheel chock at the opposite set of rear wheels to prevent the motorhome from...

Page 195: ...ng Operation Follow the instructions in Prior to Leveling Turn the ignition switch to On or ACC position Press the ON OFF button to turn the system on Press the Auto switch The pump motor activates an...

Page 196: ...es a low fluid level 1 Ensure all jacks are retracted 2 Chock a wheel fore and aft for safety 3 Remove the weep hole screw 4 Unscrew the fill cap from the top of the pump Slowly fill the reservoir wit...

Page 197: ...ow specified level approximately 40 F Grid heater activation is indicated by the Wait To Start indicator lamp WARNING Use of Ether starting fluids may cause an explosion upon grid heater activation To...

Page 198: ...cord to a separate power cord rated for 15 Amps and a GFCI protected outlet rated at 20 Amps The engine may require several hours of pre heating before starting It is recommended to start preheating...

Page 199: ...ly affect the engine warranty Oil additives should not be used unless the oil supplier or oil manufacturer has been consulted and provided positive evidence or data establishing satisfactory performan...

Page 200: ...l times resulting in increased cooling efficiency The coolant level should be at or slightly above the appropriate mark on the reservoir tank when the system is cold CAUTION To avoid scalding hot stea...

Page 201: ...hoses and loose clamps and fittings Correct any deficiencies found Coolant Overheated If the engine is overheated never pour cold coolant into a hot engine The sudden change in temperature may crack t...

Page 202: ...distance to avoid bending the fins When performing maintenance it is also necessary to inspect other components of the cooling system The charge air cooler and radiator also requires an inspection fo...

Page 203: ...he gear range selected by one If the button is held continuously the selected range will continue to change up or down until the button is released or until the highest lowest possible range of gears...

Page 204: ...lly reduced Direction changes i e forward to reverse will not be allowed Locate a safe secure place to park the motorhome If the engine is shut off then engaged after a Check Trans indication the tran...

Page 205: ...rvice intervals listed in the transmission OEM Original Equipment Manufacturers manual Fluid and filters may require changing earlier than recommended in the transmission OEM manual depending on the s...

Page 206: ...hin the Cold Check band on the dipstick This allows safe operation of the transmission until a Hot Check or fluid level check from the shift selector can be performed If the level is not within this b...

Page 207: ...llow optimum flow to the engine The generator intake tube is set to approximately of a tank This will prevent depleting the fuel supply while dry camping Internal baffles slow fuel slosh A check valve...

Page 208: ...t be detected by checking for accumulation of fuel under the tank Engine performance and auxiliary equipment is dependent upon the ability of flexible hoses to transfer lubricating oil air coolant and...

Page 209: ...e reservoir is rated at ten micron The reservoir is filled with Dexron III Automatic Transmission Fluid from the factory The primary function of the power steering reservoir is to keep the steering sy...

Page 210: ...he various components have received proper service Failure to follow maintenance guidelines or perform scheduled maintenance results in inefficient operation premature component wear or component fail...

Page 211: ...ubricating greases are made from different base compounds giving the grease different lubricating consistencies properties and maximum operating temperatures Most containers list the base compound and...

Page 212: ...nent Wrap the nozzle with a paper towel or rag to prevent contamination and accidental soiling of other areas If the component does not accept grease the Zerk fitting may be plugged or damaged Zerk fi...

Page 213: ...air Tank Drains Drains Monthly 19 leveler reservoir Keep to Full Mark 6 000 or 3 Months TF 20 Tire Pressure Check Before each Trip Daily en route 21 Generator refer to OeM Manual refer to OeM Manual...

Page 214: ...Oil 17 Qts Transmission Oil initial amount 14 8 Qts Transmission Oil with service 10 5 Qts w filter radiator Coolant initial amount 1 5 Gal A C Refrigerant initial amount 3 5 lbs 134 A rear end 15 Qt...

Page 215: ...prox Gallons all Models water Heater 10 gallons Grey water 55 gallons Black water 39 gallons Fresh water 95 gallons Diesel Fuel 75 gallons lP Gas 38 gallons Actual lled LP Gas Tank Capacity is 80 of l...

Page 216: ...allel con guration CCA Ratings are 0 F These are the minimum requirements approx mate hours of ampere load u2200 5 AMPS 10 aMPs 15 AMPS 20 aMPs 25 AMPS 110 44 25 18 14 Four batteries optional connecte...

Page 217: ...ading and who performed 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...

Page 218: ...CHASSIS INFORMATION 10 214 CAYMAN 2007 BaTTery record MaKe Type daTe insTalled repairs daTe replaced serVice MonThs Miles...

Page 219: ...CHASSIS INFORMATION 10 215 CAYMAN 2007 Tire record MaKe Type ply daTe insTalled repairs daTe replaced serVice MonThs Miles...

Page 220: ...rant Or Tony Isom Or Thomas Joachim In creat ve des gners aaron Graham Or Kelly stroble Or Julie rice In ILLUSTRATIONS Kelly stroble aaron Graham PRINTING Holiday Graphics In ONLINE Corporate site www...

Page 221: ...m Ceiling Fan OPT 106 B Backing Up A Motorhome 23 Battery Chassis 158 Battery Cut Off 141 Battery Disconnect Chassis 158 Battery Disconnect House 141 Brake Auxiliary 181 Exhaust Brake 181 Brake System...

Page 222: ...ngine Drive Belt Diagram 210 Engine Oil 195 Engine Shutdown 195 Extended Engine Shutdown 195 Entry Door 99 Latch Adjustments 99 Screen Door 99 Entry Step 98 Operation 98 Stepwell 98 Assist Grab Handle...

Page 223: ...r 147 L Ladder Rear 109 Leveling Hydraulic 189 Prior to Leveling 190 Manual Leveling 190 Automatic Leveling 191 Retracting Leveling Jacks 191 Lights 154 Interior Halogen 154 Map Lights 155 Bulb Usage...

Page 224: ...2 Storage 71 Short Term 71 Long Term 72 Winter Storage Checklist 73 Removal from Storage 74 Storage Under Bed 108 Storage Slide OPT 109 Survey 9 T U V Tires 30 Importance of Air Pressure 31 Tire Press...

Page 225: ...Pump 117 Water Pump Troubleshooting 117 Water Systems 119 Troubleshooting 119 Disinfecting Fresh Water 119 Water Systems Introduction 116 Water Tanks 116 Measurements 116 Weighing the Motorhome 36 We...

Page 226: ...INDEX 222 CAYMAN 2007 NOTES...

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