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1989 Wanderlodge Wide Body Pusher (WB) (view source)
Revision as of 09:58, 14 November 2019
, 09:58, 14 November 2019→Maintenance Schedule Summary: Completed Section 8 Maintenance
<br />
<br />
===Maintenance Schedule Summary===
=== Maintenance Schedule Summary ===
{| class="wikitable"
{| class="wikitable"
!Item
!Item
!Frequency
!Frequency
|
|
|}
|}
=== 12-Volt Lighting Equipment and Fuses, Current Usage ===
{| class="wikitable"
!Item
!Specification
(Qty)/Amperes
|-
|Automotive Lighting Marker/Clearance / Identification , bulb # 1895
|(16)/4.5
|-
|Stoplights , bulb upper & lower # 1157
|(4)/8.4
|-
|Parking Lights bulb# 1157 & # 194 (front inside)
|w/tag (9)/4.5
|-
|Turn Signal Lights bulb# 1157
|(2)/4.2
|-
|Cornering Lights , bulb# 1156
Side Turn Lights , 2/side , 2 # 1895 bulbs/light Indicator Light WL PIN 2271955
Relay-rear lights , WL P/N 1077718 , located at upper front load center
|14A. ea
|-
|Hazard warning
|(6)/12.6
|-
|Tag Light, bulb #168
|(1 )/.35
|-
|Headlights and Taillights (with park & tag) G.E. Halogen Sealed Beam Units 1A1 &2A1
Hi-beam operation
Low-beam operation
|(13)/13. 7
(11 )/9.9
|-
|Driving Lights , bulb WLP /N2143477
|(2)/15.6
|-
|Instrument Panel- Electroluminescent (inverters)
|(3)/1.0
|-
|Instrument PanelGauges , bulb # 53
|(14)/1.7
|-
|Spot Lights , bulb W/L PIN 2103760
|(2)/13.6
|-
|Stepwell outside , bulb # 53
|(1 )/.12
|-
|Stepwell inside, bulb # 67
|(1 )/.55
|-
|Landing Lights , bulb assy. W/L PIN 2261626
|(4)/27.2
|-
|Backup Lights , bulb # 1156
|(2)/3.8
|-
|Rear Parking Halogen
|(2)/13.4
|-
|Engine Compartment Lights bulb # 67
|(2)/13.4
|-
|Luggage Compartment Lights bulb # 1416
|BA. ea.
|-
|Porch light , bulb # F8T5/CW
|(2)/2.2
|-
|Interior Lighting
Reading Spots , bulb # 1383
Front Living, Flush . bulb# F15T8/CW
Aisle , (night) bulb #53
Bathroom Mirror bulb # F8T5/CW
Bathroom , Flush, bulb# F15T8/CW
Shower , bulb # 1141
Dinette , Flush, bulb # F15T8/CW
Kitchen, Flush, bulb# F15T8/CW
Bedroom Island bed, bulbs F72T12/CW & F96T1 2/CW
Ceiling , Flush, bulb # F15T8/CW
Vent Fans, bulb # 912 (i1 1.0A.
Refrigerator W/L P/N 3783917 Dometic 200-7290 -00/6
|(15)/1.54 ea.
(8)/14.0
(3)/.36
(2)/2.2
(2)/3.5
(1)/1.5
(2)/3.5
(2)/3.5
(2)/6.3
(3)/5.3
(4)/4/Vent
(1 )/.8
|-
|Windshield Wipers
|
|-
|Water Pump
|
|-
|Blower Motors
Front Heater (Hi/Lo) Right
Defroster (Hi/Lo)
Foot Warmer (Hi/Lo) Left
Chassis Heater (Hi/Lo)
LPG Furnace
Portable Fan
Duct Booster
Ceiling Vent (round)
Vent Fan (square)
|(1)9.0/4.5
(1)/9.0/4.5
(1)/9.0/4.5
(3)/9.0/4.5 ea.
(3)/9.0
(1)/1 .0
(1)/1.0
(1)/4.0
(4)/8.8
|-
|Stereo System
|(1 )/15
|-
|Motor Generator
|
|}
=== Changing Wheels/Tires ===
The wheel/tire assemblies used on your motorhome are heavy-duty truck-type. They are heavy and may be difficult to handle. If at all possible , changes should be accomplished by a service station equipped to handle truck equipment . However , if a situation arises where no service facilities are available , the following procedures may be used .
[[File:1989 WB40 - Figure 8-1.png|right|frameless|320x320px]]
==== Front Axle Wheels ====
# Drive motorhome out of traffic lane onto a level surface capable of supporting jack.
# Turn on hazard flasher and apply parking brakes before leaving coach.
# Turn off ignition and set transmission selector to Neutral (N) position .
# Remove white plastic wheel saver , jack , lug wrench and handles from road side storage compartment.
# Place wheel chocks against front & rear of tires on opposite side.
# Place jack under axle and raise slightly until securely in place. See figure 8-1 for location of typical jacking point.
# Remove spare wheel assembly from mounting and place on ground near work area.
# Pull off lug nut covers.
# Install wheel saver. '''Note''' It is recommended that the wheel saver be used when loosening or torquing lug nuts.
# Loosen lug nuts slightly, then jack up coach until tire is clear of ground. '''Caution''' Severe injury or death may result. DO NOT use the leveling system for changing tires or working under the vehicle. Keep the rear wheels in firm contact with the ground with the parking brake set. With the leveling jacks extended, there is a possibility the vehicle may move either toward the front or the rear. '''Note''' Lug nuts on right side of coach are righthand threaded (turn counterclockwise to loosen, clockwise to tighten); lug nuts on driver's side of coach are lefthand threaded (turn clockwise to loosen, counterclockwise to tighten).
# Remove lug nuts and wheel assembly.
# [[File:1989 WB 40 Figure 8-2 .png|right|frameless]]Install spare and replace lug nuts . Tighten progressively in the sequence shown in figure 8-2 starting with # 1 and proceeding to # 10. Final torque will be 450 to 500 foot-pounds.
# Snap front hub cover into front wheel opening after front lug nuts have been properly torqued.
# Place lug nut covers on all lug nuts. Make certain that these nut covers fit snugly. This is accomplished by squeezing the dimpled sides together before installing.
# Lower coach to ground and remove jack and handle.
# Replace wheel saver , lug wrench , jack and handles in storage compartment and tie down to prevent road noise . Return damaged wheel /tire assembly to holder and have it repaired as soon as possible.
# Remove and stow wheel chocks.
# Turn off hazard flasher before returning to traffic.
==== Drive Axle Dual Wheels ====
# Repeat steps 1 through 10, front axle wheels .
# Loosen inner lug nuts (studs with square heads) , if inner wheel is to be replaced .
# Remove outer lug nuts from the (5) studs which have lock rings and slide hub cover over remaining lug nuts .
# Remove the (5) remaining lug nuts and wheel.
# Remove inner lug nuts and inner wheel , if inner wheel is to be replaced .
# Install replacement wheel and inner lug nuts. Tighten progressively in the sequence shown in figure 8-2 starting with # 1 and proceeding to # 10. Final torque should be between 450 and 500 foot pounds .
# Install outer wheel (or replacement wheel) and lug nuts over inner lug nuts marked 1, 3, 7, 9 and 6. Torque nuts in the following sequence 1, 7, 6, 3 and 9 to between 45 and 500 foot pounds.
# Install hub cover over the (5) lug nuts holding wheel to hub. Place lock rings and lug nuts on remaining inner lug nuts 10, 5, 2, 4 and 8.
# Replace wheel saver.
# Torque nuts in the following sequence 10, 2, 8, 5 and 4 to between 450 and 500 foot pounds.
# Return to step 14 of Front Axle Wheels and continue .
'''Note''' When checking torque on dual wheels loosen all outside lug nuts. Check torque on inner lug nuts (studs with square heads) for torque value shown above then torque outer lug nuts to value shown above.
==== Tag Axle Wheels ====
# Repeat steps 1 through 10, front axle wheels.
# Remove lug nuts from the (5) studs which have lock rings and slide hub cover over remaining lug nuts.
# Remove the (5) remaining lug nuts and wheel.
# Install replacement wheel and lug nuts on studs marked 1, 3, 7, 9 and 6. Torque nuts in the following sequence 1, 7, 6, 3 and 9 to between 450 and 500 foot pound.
# Install hub cover over the (5) lug nuts holding wheel to hub. Place lock rings and lug nuts on remaining studs 10, 5, 2, 4 and 8.
# Replace wheel saver .
# Torque nuts in the following sequence 10, 2, 8, 5 and 4 to between 450 and 500 pounds.
# Return to step 14 of Front Axle Wheels and continue .
'''Caution''' Check lug nuts for tightness every 1,000 miles. Lug nuts should be torqued to 450 to 500 foot-pounds.
<br />
=== Battery Maintenance ===
You r motorhome is equipped with six 6-volt batteries, connected in a series-parallel arrangement to provide 12 volts for engine and motorhome use. This arrangement makes availab le 660 AH (20 hour rate). Batteries are located in the rear engine compartment on the curb side, as shown in figure 4-2. A separate 12-volt battery is contained in the road side front compartment and is used only to start the generator. All batteries are charged from either the engine alternator or battery chargers (when 120 volts ac is available). Note that the 12.5kw generator will supply 120 volt cJ.C to the battery chargers.
'''Periodic Battery Checks and Maintenance'''
Periodically check electro lyte level in the six ~ixvolt batteries. Odorless drinking water may be used to raise the level of the electrolyte. Before charging batteries must be filled only sufficiently to cover the plates. After batteries are fully charged , the maximum should be no higher than it takes for the electro lyte to form a "fisheye" at the bottom of the fill well. The generator battery is sealed so it is not necessary to check the level of the electrolyte. Battery condition depends on battery usage and proper utilization of the battery chargers.
'''''Caution''' Avoid sparking of any form in the vicinity of the batteries, especially while caps are off.''
'''''Caution''' Do not wear metal rings , watches or jewelry when working on or near the batteries, cables, solenoids , or chassis wiring. These can short out electrical wiring and cause injury''
To make sure that the batteries are always ready for use, periodically check and charge as necessary . Check batteries at least every two weeks in freezing weather; at least every four weeks in warmer weather. A fully-charged battery will not freeze under normal circumstances , so it is imperative that the batteries remain charged during winter. A safe level of charge is a specif ic gravity reading of 1 .225 to 1 .280. Alway s use a battery hydrometer which has a temperature correction scale. It is advisable to have the coach shoreline connected to the 120 volt ac supply so that the batteries rema in fully charged. A dirty battery may eventually dissipate its charge through conductive surface contamination . Clean battery top surface with a damp cloth and dry thoroughly. Check that battery terminals and associated battery jumer terminals are tight and free of corrosion. To clean terminals, neutralize corrosive deposits with a solution of baking soda, rinse with clear water , and dry. Note that commercial type spray-on battery cleaners are available at automotive supply stores. Use as directed to keep the batteries clean. Spray-on cable and terminal protective coatings are also available, easy to use, and effective.
<br />
=== Exterior Care ===
Exterior paint finish life can be extended by periodic cleaning and waxing. This will preserve the paint and allow easier removal of dirt and road tars. Use touch-up paint for small areas to keep the coach finish in like-new condition.
'''''Caution''' Avoid the use of strong detergents, such as those used in commercial truck washes. These detergents can discolor the aluminum trim on your coach .''
Frequent washing of the coach is necessary to prevent corrosion in areas where heavy salt sprays are evident. A clear acrylic spray may be used, with care, to control corrosive effects of salt spray on metal surfaces.
'''''Caution''' Avoid spraying water through the refrigerator vent door.''
=== Interior Care ===
The interior can be kept in good condit ion with the use of approved cleaning agen ts for vinyl walls and ceilings , plastic fixtures , stainless stee l, formica and so on. Never use abrasive cleaning agents on interior of refrigerators , or on the lavatory, tub/shower , or toilet , as they can cause permanent scratches. Be sure that the cleaning agent will not damage the material. Note that some plastics are incompat ible with certain cleaners . Read the directions on the container before using . For the most part, the cleaners and polishes that would normally be used in your home are equally wellsuited for use in your motorhome .
=== Fluid Level Checks ===
[[File:1989 WB40 Manual - Figure 8-3.png|right|frameless|333x333px]]
==== Crankcase Oil Level ====
The crankcase oil dipstick is shown in figure 8-3. The oil level must be checked only with the engine off. Maintain oil level at the proper fill line. If checking oil level immediately after engine has been operating , allow a few minutes for the oil to drain back into the crankcase before checking the oil level reading . The best time to check the oil is before getting underway because the engine is cool and the reading will be most accurate.
==== Power Steering and Hydraulic Cooling Fan Reservoir Fluid Level ====
Regularly check fluid level in the power steering and hydraulic cooling fan reservoir , figure 8-3 , at each fuel stop. Add only 1 OW-30 motor oil as necessary to maintain the correct dipstick reading , depending on fluid/engine temperature. (Note that dipstick is attached to the bolt on top of the reservoir). If the fluid is at normal operating temperature - about 150 degrees , and hot to touch - the dipstick should indicate 1 /2 to 3/4 full. If engine is cool, fluid level should read about 1 /2 full.
'''''Caution''' The hydraulic fluid used in this unit is 1 OW-30 Motor Oil. Do not use conventional power steering fluid or the pump may be damaged.''
==== Transmission Fluid Level ====
The transmission dipstick is shown in figure 8-3. Importance of Proper Oil Level Since the transmission oil cools , lubricates , and transmits power, it is important that the proper oil level be maintained at all times . If it is too low, the converter and clutches will not receive an adequate supply of oil. This can result in poor performance or transmission failure. If the level is too high, the oil will aerate , causing the transmission to overheat. Check the oil level at intervals specified in your vehicle service instructions, or more frequently , if operating conditions indicate.
==== Oil Check Procedure ====
Always clean around the end of the fill tube before removing the dipstick. Dirt or foreign matter must not be permitted to enter the oil system. It can cause valves to stick , cause undue wear of transmission parts , or clog passages. Check the oil level by one of the following procedures and report any abnormal oil level to your maintenance personnel. Check for abnormal oil level, milky appearance or any trace of coolant in the oil.
===== Hot Check =====
# Operate the transmission in a drive range until operating temperature (160-200 °F; 71-93°C) is reached. '''Note''' The oil must be hot to ensure an accurate check. The oil level rises as temperature increases .
# Shift through all drive ranges to fill the clutches and oil passages .
# Park the vehicle on a level spot , shift to neutral N and apply the parking brake. Let the engine run at idle speed.
# Wipe the dipstick clean and check the oil level. The safe operating level is any level within the Hot Run band on the dipstick.
# If not within this range, add or drain oil as necessary to bring the level to the middle of the Hot Run band.
===== Cold Check =====
# A cold check may be made when the sump temperature is 60-120 °F ( 15-40°C).
# Run the engine for at least one minute to clear the oil system of air.
# With the engine running at idle, wipe the dipstick clean and check the oil level. Any level within the Cold Run band is safe for operating the vehicle. If the level is at or below the bottom of the Cold Run band, add oil until it reaches the middle of the Cold Run band.
# Operate the vehicle and make a hot oil check when operating temperature is reached (160- 2000F; 71-93°C).
=== Racor Fuel Filter and Water Separator System ===
==== Filter/Separator Operation ====
[[File:1989 WB 40 Manual Figure 8-4.png|right|frameless]]
The three stages of the Racor filter/separator, figure 8-4, work in series to progressively clean the diesel fuel. Because virtually all water and larger particles of solid contamination are removed in the primary and secondary stages, the effective life of the fine micron replaceable element is 2-3 times longer than standard filters.
'''Primary Stage (Separation)''' - In the primary stage. liquid and solid contamination down to 30 microns are separated out by centrifugal action created by the turbine centrifuge. There are no moving parts in this highly efficient design. Because the contamination is heavier than the fuel it falls to the bottom of the clear bowl.
'''Secondary Stage (Coalescing)''' - This stage functions when minute particles of liquid contaminants (lighter than the fuel) remain in suspension and flow up with the fuel into the lower part of the filter/separator shell. Here the minute particles tend to bead on the inner wall of the shell and the bottom of the replaceable cartridge . As the beads accumulate , they become larger and heavier and will eventually fall to the bottom of the filter/ separator bowl.
'''Final Stage (Filtration)''' - In this stage the fuel enters the replaceable cartridge where the minute solids are removed.
'''In-Filter Fuel Heater''' - Internal automatic thermostats turn on the Racor in-filter fuel heater as the fuel temperature drops below 35°F. (1.7°C.) The in-filter fuel heater operates from the 12-volt battery source, supplying heat to the fuel filter just below the replaceable element. This critical placement provides increased fuel temperature as the fuel passes through the fine micron filtering element.
When the engine is not running and the temperature is below 35°F., the heater is operated by turning on the ignition switch for a maximum of 10 minutes prior to starting the engine. With the diesel fuel temperature above 35°F, _there is no waxing or icing of the filter element. The in-filter heater is primarily a cold starting aid. Note that the top two terminals imbedded in the glass filter bowl connect to the internal heater.
==== Water-In-Filter Alarm ====
The electronic water sensor alerts the operator when liquid contaminants filtered out of the system should be drained from the collector bowl, thereby maintaining maximum filter/separator efficiency. When water reaches a pre-determined level in the collector bowl, sensing probes activate the '''Water-In-Filter''' alarm circuit. The light illuminates, warning the operator to drain excessive water contamination collected in the bowl. Shut down engine before draining the bowl to avoid sucking air into the system. Note that the bottom two terminals imbedded in the bowl connect to the water sensors.
==== Maintenance ====
'''Filter Element''' - Routine maintenance of the Racor unit consists of periodic filter replacement and drainage of the moisture collected at the bottom of the bowl. (Engine is off durng maintenance.)
'''Filter Element Replacemen'''t - Replace the element as follows:
# Loosen handle and remove lid.
# Inspect lid gaskets and replace, if necessary .
# Remove filter element by grasping bale and lifting upward while rotating.
# Replace Racor element by positioning over center return tube and twisting downward into place.
# Top off by pouring clean diesel fuel into filter cylinder until full.
# Replace lid and hand-tighten handle.
'''Draining''' - Drain . bowl of accumulated moisture by opening petcock on bottom of bowl. Allow to flow until clean fuel appears.
=== Hydraulic Cooling Fan ===
The hydraulic cooling fan is thermostatically controlled to maintain engine temperature at approximately 195 degrees F. The oil reservoir for the fan, figure 8-3, is the large canister located between the fan assembly and the engine. Add oil as indicated by dipstick markings. Note that this reservoir also supplies the power steering system as well.
'''''Note Use only engine oiI, SAE 10W-30'''''
Oil and filters should be changed every 6 months or 25,000 miles, whichever comes first. Check condition of oil frequently when engine is hot. Run engine to 2100 R.P.M.; if red light (located on rear switch panel) comes on change oil and filters. One filter is in Parker unit at left rear axle. The three stacked elements must be replaced in the reservoir.
=== Leveling Jacks Reservoir ===
[[File:1989 WB 40 Manual Figure 8-5.png|right|frameless]]
The leveling jacks oil fill is located beneath the center entry step, as shown in figure 8-5. Lift up the hinged portion of the step and remove the screws attaching the square metal cover plate to gain access to the oil fill to check oil level.
=== Engine Air Filter Replacement ===
Check the air filter condition indicator , figure 8-6, on a regular basis. Sometimes the red band will show after a high power run. This is a normal condition. Reset to green band and run engine at a maximum of 2000 rpm. Filter should be replaced if red band is shown.
[[File:1989 WB 40 Manual Figure 8-6.png|right|frameless]]
'''''Caution Do not operate the engine without the air filter in place or sensitive air metering systems may be damaged.'''''
=== Engine Cooling System Refill ===
Use of low silicate ethylene glycol base antifreeze (formulation standard GM 6038-M) is recommended for summer or winter operation because of it's corrosion inhibition and lubrication properties. A 50-50 solution of antifreeze and water is preferred and it gives freeze protection to about 30°F below zero. Ultimate protection is attained at 68% antifreeze (about 92°F below zero): a higher concentration of antifreeze should never be used. The approximate (dry) cooling system capacities for 6V92 engine are:
{| class="wikitable"
|+
!
!
|-
|Engine, Radiator, & Engine Hoses
|18.5 gallons
|-
|Right front heater system
|5 gallons
|-
|Rear coach heater system
|4 gallons
|-
|Total
|27.5 gallons (110 quarts)
|}
... so the system would require 14 gallons of antifreeze for a 50% solution or 19 gallons for a 68% mixture. The 8V92 engine has approximately a 117 quart capacity so similar calculations would show anti-freeze required. Final solution should always be tested with a thermo-hydrometer or equivalently reliable testing device to determine actual protection. If it becomes necessary to completely re-fill the chassis coolant system, the following procedure must be followed (see figure 10-1 ). Pure antifreeze can be used initially until prescribed amount has been installed, and then water for final filling.
# Fill the engine, radiator, and engine hoses. Locate and close the manual gate valves separating the engine from the heater systems. Pressure and return gate valves (four) are located at the engine . In addition , a pressure valve for the front heater is electric solenoid operated . Close the front heater electric solenoid valve by placing the FRONT HEAT switch in the pilot's control area to the OFF position. Remove the radiator surge tank cap and fill to the top. Replace cap and run engine @ 1500 to 1800 RPM for one minute to purge air from the engine water jacket. Shut off engine; carefully remove the radiator surge tank cap; re-fill and replace the cap. Note Use extreme care at all times when removing the radiator surge tank cap as hot coolant under pressure can cause injury.
# Fill the front heater and rear heater systems . An air bleeder valve for the front heater is located behind the right side front bumper. Leave the return line gate valves closed and open the pressure line valves for front and coach (chassis) heaters . Place the FRONT HEAT selector to the HEAT position and the HEAT SELECTOR switch to the WINTER position. Press the AUX . PUMP switch to WINTER .
Using suitable containers to catch coolant , open the bleeder valve at front heater and remove right side hose from return TEE (above the chassis serial number end of the identification plate) and run the engine at 1,800 RPM until a steady flow of coolant passes through the front bleeder valve and open hose at rear. The radiator must be refilled often during this time as coolant from the engine will be filling the heater lines. When steady flow is attained from the bleeder valve , close it and open return line gate valve (bottom valve at left rear of engine) allowing coolant to flow back into the engine. When a steady flow comes from the open hose , shut off engine , reconnect hose , and open return gate valve (just below TEE) . Refill radiator using coolant caught from bleeding operation and add water as necessary . Restart engine and run at 1800 RPM for at least two minutes to complete system purge. Test heater blowers to make sure heaters are filled with hot coolant. Allow engine and radiator to coo l. Remove cap and fill radiator surge tank to the top of sight glass. Replace cap - refill procedure is completed .
=== Cooling System Additives ===
Automotive cooling systems are subject to various types of corrosion, rust, pitting and cavitation-erosion. These are common factors which prevent efficient cooling and contribute to engine overheating and higher maintenance costs resulting from replacement of hoses, fittings , filters and cracked heads . The manufacturer of the engine used in your motorhome recommends the use of Nalcool 2000 - a chemically buffered liquid additive which effectively neutralizes the formation of acids caused by dissolved exhaust gases , and inhibits the cool ing system against corrosion and scale formation . This additive is compatible with most commercial automotive anti-freeze solutions containing ethylene glycol ; however , its use is not recommended in coo ling systems using Dow Therm 209. When refilling the coolant system , add seven pints of Nalcool before topping off with anti-freeze solution. To ensure constant system protection, replenish Nalcool 2000 additive , periodically , in accordance with manufacturer's instructions.
=== Windshield Washers ===
Check reservoir fluid level periodically and use a prepared washer solution if possible. (Note that low reservoir levels are indicated by a dash monitor light.) During freezing weather, use a solution additive , or a solution specifically designed for cold weather usage. The washer reservoir is accessible through the front road side storage compartment.
=== Battery Jumper Terminals and Jump-Starting ===
For your convenience and safety when jumpstarting, terminal posts are provided in the curb side of the engine compartment (open rear door). Proper procedure for jump-starting is as follows:
# Turn off all main battery-operated accessories in both vehicles - lights, radio , etc.
# Connect one end of the positive-coded jumper cable to the positive (red) battery jump er terminal, and the opposite end of the cable to the positive ( + )terminal on the other battery.
# Connect one end of the negative-coded jumper cable to the negative ( - ) terminal on the other battery and the opposite end of the cable to the negative (black) battery jumper terminal.
# Once the engine of the disabled vehicle is started and brought up to idle , reverse the above procedure to remove the jumper cables. Always remove the jumper cable connected to the Wanderlodge ~ negative (black) battery jumper terminal first to prevent sparks at the other battery.
'''''Caution Avoid sparks in the vicinity of a charging battery: the gas produced is explosive.'''''
=== Generator ===
Keep the generator operating at peak efficiency by following a regular schedule for inspections and servicing , based on operating hours. Keep an accurate logbook record of maintenance, service and hours of operation , following regular schedules for normal operating conditions , and a more frequent service schedule for operation under dusty or dirty conditions. Check condition of crankcase oil and change air filter frequently until the proper service 'time periods can be determined based on you r usage. After the first 15 to 30 hours of operation , arrange to have the following performed at an authorized service center.
* Drain and refill engine oil.
* Replace engine oil filter.
* Check external nuts and bolts for tightness.
* Torque cylinder head nuts.
* Check and adjust valve tappets .
* Check for fuel or lubricating oil leaks.
* Check radiator coolant level and inspect cooling system for leaks.
* Check and adjust water pump belt tension
* Check mounting tray bolts and vibro mounts for tightness.
* Operate generator set a full or rated load , checking for proper output and governor operation.
==== Maintenance Schedules ====
[[File:1989 WB 40 Manual Figure 8-7.png|right|frameless]]
Use the generator maintenance schedule in table 8-7 as a guide for routine and periodic maintenance. Neglecting generator maintenance can result in failures or permanent generator damage. Refer to the generator service manual for detailed repair and maintenance.
{| class="wikitable"
|+Generator Maintenance Schedule (Table 8.8)
!Frequency
!Service
|-
|Daily , or before each startup
| - Check oil level
- Check coolant level
- Clean radiator intake screen
|-
|Every 50 hours , or 3 months , whichever occurs first
| - Change lubrication oil
- Change oil filter
- Service air cleaner
- Check engine for oil, water , or fuel leakage
- Check belt tension
|-
|Every 200 hours , or 12 months, whichever occurs first
| - Check hoses and clamps
- Check and tighten electrical connections
- Check exhaust system for leakage
- Check and tighten mounting bolts
- Replace fuel filter element
- Check electrical system for frayed wires, corroded connections
|-
|Every 400 hours or 12 months
| - Contact authorized service center for tuneup to include:
- Injector inspection - Check and adjust valve tappets
- Clean sliprings and inspect brushes
- Check governor ope
|-
| colspan="2" |Periodically, perform a complete visual inspection of the generator when operating at full load.
|}
'''Caution''' The generator tray is electrically operated and extends outward with considerable force. To extend the tray, move around to the road side and operate the tray switch in the front compartment to out position. Be sure that there is sufficient clearance in front of the tray and that nobody is in the way! Use extreme caution when observing and operating generator with tray extended.
===== Battery =====
Check the condition of the generator battery periodically. See that battery connections are clean and secure. A light coating of nonconductive grease will prevent corrosion at terminals. Refer to Battery Maintenance procedures provided earlier in this section.
===== Air Cleaner =====
[[File:1989 WB 40 Manual Figure 8-8.png|right|frameless]]
Proper maintenance of the air cleaner, figure 8- 8, is extremely important. Allowing this vital element to become clogged with dirt restricts the flow of intake air into the engine. Operating with an over-rich fuel mixture caused by a poorly serviced or clogged air cleaner leads to formation of harmful carbon /sludge deposits. This air cleaner should be serviced every 100 hours or six months as follows:
# Loosen thumbscrew in Marman clamp while holding bowl.
# Remove bowl.
# Remove element thumbscrew and element.
# Wash bowl in non-flammable cleaner. Allow to air dry .
# Install new element & replace thumbscrew .
# Replace bowl and tighten Marman clamp thumbscrew. Be sure letters TOP are up.
If operating under extremely dusty conditions, use dry compressed air to blow out generator at frequ ent intervals . Do this with the generator set operating and direct the stream of compressed air in through the cooling louvres at the end of the generator.
===== Oil Filters =====
To ensure cleanliness of the lubricating oil. a sump strainer and a main full flow type of oil filter are used. The sump strainer consists of a gauze wire container which is fitted over the end of the lubricating oil pump suction pipe. All oil must pass through this strainer before it reaches the oil pump.
The main full flow type oil filter is mounted externally on the side of the cylinder block. All the oil passes through this filter after it leaves the pump, but before it reaches the bearings.
The full flow filter is a spinon cartridge in which the element is an integral part. Filter should be replaced at each oil change.
'''Replacing Oil Filter Cartridge'''
# Unscrew the cartridge from the adapter.
# Discard the old cartridge. Clean the filter adapter surface.
# Using clean engine lubricating oil, lightly oil the top seal of the new cartridge. Prime filter by partially filling with new oil.
# Screw the new cartridge until the seal just touches and then tighten by hand a further half of a turn. If the cartridge is overtightened, it may be difficult to remove later on.
# Since the filter cartridge will normally be changed at the same time as the engine lubricating oil, refill the sump with oil, run the engine and check for oil leaks. Recheck the oil level after running the engine and add oil as necessary.
===== By-Pass Valve =====
If the lubricating oil filter element becomes contaminated to the extent where the lubricating oil has difficulty in passing through the element , a pressure difference will build up between the inlet and outlet sides of the filter assembly. When this pressure exceeds 50 psi (approximately) , a ball valve opens in the filter headcasting and allows unfiltered oil to by-pass the filter element to protect the engine from oil starvation.
===== Oil Check =====
To be on the safe side, check oil in engine crankcase daily, or before each start, to ensure that the level is in the safe range between the upper and lower marks on the dipstick . Do not operate generator if level exceeds the upper mark, or is below the lower mark.
'''Caution''' Do not check oil level while engine is operating. Engine must be stopped to obtain a true reading, as well as for safety reasons!
===== Oil Change =====
Whenever possible , drain the oil while the engine is still warm. To drain , place a container below the unit, open the oil drain and allow sufficient time for the old oil to drain completely . After draining, close drain plug and tighten securely.
===== Cooling System =====
To avoid having the inconvenience of the generator shutting down due to overheating , or becoming damaged as a result of an overheat condition , be sure to keep the cooling air inlets to the compartment clean and unobstructed at all times. Cooling system capacity is about 16 quarts of liquid. When operating in climates subject to freezing temperatures , make sure that enough antifreeze solution is added to the coolant to prevent system freeze-up. (A drain petcock is provided on the underside of the radiator.) When draining the coolant , remove the radiator cap and open the block drain valve near the oil filler cap to prevent air pockets from forming and blocking water in passages in the block . Check coolant level frequently and add antifreeze mixture as needed to maintain surge tank 1 /2 full.
{| class="wikitable"
|+Table 8-9 Anti-Freeze Protection Chart
!Anti-Freeze Protects to:
!Mixture Proportions (ethylene glycol)
|-
| + 16 degrees F ( - 9 degrees C)
|20%
|-
| + 3 degrees F ( -16 degrees C)
|30%
|-
| - 11 degrees F ( - 24 degrees C)
|40%
|-
| - 31 degrees F ( - 35 degrees C)
|50%
|}
===== Generator Troubleshooting =====
Refer to the generator service manual for repair and maintenance data. Generator repairs should be accomplished by a qualified repair agency.
===== Generator Overloads =====
If the rated capacity of the generator is exceeded, the safeguard circuit breaker, located 0n the front of the controller box, will trip to protect the generator against damage . This condition could be caused by a short in the coach ac supply circuits, or by operating too many appliances simultaneously, resulting in an overload condition. If the safeguard circuit breaker trips , the generator will continue running but no ac output will be supplied. Before resetting the circuit breakers , turn off some of the coach appliances and lighting to reduce the load to within the operating limits of the generator. If this is done, and the generator breakers still trip, a short circuit is indicated. Turn off the generator , locate and correct the cause of the short circuit.
===== Generator Battery Charging =====
Generator battery charging current is supplied from either the engine alternator or the battery chargers (when ac power is available).
===== Storage Procedures =====
If the generator is to be out of service for a long period of time, perform the following procedures before placing the unit in storage:
# Drain oil from crankcase (while hot) then flush with clean lightweight oil. Refill crankcase with regular-weight oil after flushing
# Clean exterior surfaces of generator set then spread a light film of oil over any unpainted metallic surfaces which could corrode.
=== Refrigerator ===
To ensure that your refrigerator will provide trouble-free operation , the following routine maintenance procedures should be performed at least once each year.
# Inspect all gas connections for leakage, using a solution of soapy water. Tighten, as necessary.
# See owners installation and operating instruction manual for periodic maintenance requirements.
=== Toilet ===
No routine maintenance is required. If the bowl sealing blade fails to operate freely or does not close completely, clean foreign material out of sealing groove with stiff bristle brush. To clean the toilet, use a high-grade, non-abrasive cleaner. Do not use highly concentrated or high-acid household cleaners. They may damage seals and finish.
=== Water Pump ===
Under normal usage , the water pump should require no periodic maintenance other than ensur ing that the input water supply is properly filtered of particles that could damage the pump mechanism. Pump failures can generally be tied in to the plumbing system , or to electrical wiring. If the pump fails to operate properly, refer to the general trouble-shooting guide given in table 8-9. Note that detail pump repairs and overhaul should be performed by a qualified repair facility. A pumpgard filter is provided on the suction side of the water pump. This should be cleaned periodically.
{| class="wikitable"
|+Table 8-10
Water Pump Trouble Shooting Guide
!Symptom
!Possible Cause
!Corrective Action
|-
| colspan="3" |Pump operates but no water flows through faucet.
|-
|
|Low water level in tank
|Add water
|-
|
|Suction lines or filter clogged
|Clear water lines and clean filter
|-
|
|Kink in water suction hose
|Check water hose connections to tank and straighten or replace as necessary
|-
|
|Air leak in suction line
|Replace suction line
|-
| colspan="3" |Pump cycles on and off when faucets are closed
|-
|
|Water leaking in plumbing
|Check for signs of leakage and tighten or replace fittings, pipes, etc.
|-
|
|Defective toilet flush valve
|Repair flush valve
|-
| colspan="3" |Pump operates roughly and has excessive noise and vibration
|-
|
|Intake line is restricted, kink in suction hose or fittings too small
|Check hoses and straighten or replace as necessary
|-
|
|Loosened screws at pulleys and connecting rod
|Tighten screws
|-
|
|Deforemed or collapsed pulsation dampener in pump
|Replace dampener
|-
| colspan="3" |Pump fails to start when faucet is opened
|-
|
|Clogged pressure piping
|Blow out water lines with compressed air
|-
|
|No voltage to pump
|Check input wiring, circuit breaker and switches
|-
| colspan="3" |Pump fails to stop when faucets are closed
|-
|
|Empty water tank
|Add water
|-
|
|Insufficient voltage to pump motor
|Check battery voltage. If voltage is ok, pump is defective.
|}
=== Holding Tank Drain Valves ===
Periodically the drain valve may become hard to open . It is recommended that the (2) two screws in top of mechanism be removed and pull paddle out. After cleaning paddle a coat of vaseline should be added to both surfaces and valve reassembled.
=== Clock /Thermometer Calibration Procedures ===
The thermometer section of the Clock/Thermometer indicates either the inside temperature or outside temperature , depending on the position of the panel pushbutton. It may be necessary to recalibrate the unit if there are differences between the actual inside or outside temperatures and the corresponding displays. Thermometer Calibration Procedures
# Place an accuratel y calibrated thermometer unit next to the outdoor temperature probe (located under metal shield on outside of lower roof rail near refrigerator vent) while the coach is in a protected environment away from direct sunlight, rain, winds, etc. Note the thermometer reading.
# Press in the outdoor panel switch and compare the digital display reading with the actual outside temperature noted previously. If the reading disagrees sufficiently to require calibration , open the monitor panel so that the rear of the thermometer unit is accessible. (If the readings agree , proceed to step 3.) Adjust the outdoor calibration control , located in the extreme left center of the rear panel, as necessary , to make the display agree with the thermometer reading.
# Place the calibrated thermometer unit next to the indoor temperature probe and note the thermometer reading.
# Press the Indoor panel switch and compare the digital display reading with the actual inside temperature noted previously . If the readings disagree sufficiently to require calibration , open the monitor panel so that the rear of the thermometer unit is accessible . Adjust the indoor calibration control , located on the lower lefthand side of the rear panel, as necessary , to make the display agree with the thermometer reading. Replace the monitor panel.
=== Tub /Shower Mixing Valve ===
[[File:1989 WB 40 Manual Figure 8-9 .png|right|frameless]]
The water mixing valve used in the tub/shower contains a pressure balancing spool valve , figure 8-9, to make sure there are no sudden temperature changes. Water mineral deposits which can accumulate in the valve body and spool valve will affect the normal operation of the mixing unit. To gain access to the valve body , remove the screws which hold the faceplate to the shower wall. (Water supply must be turned off.) Remove the control knob, then lift off the faceplate. To remove the spool, unscrew the large center screw and carefully withdraw the spool from the valve body. Inspect O-rings for damage and replace, if necessary . Flush out spool of any foreign material , then replace in valve. Replace faceplate and secure with screws . Replace knob.
'''Note In some units this pressure balancing valve is in a remote location under the bathroom lavatory vanity.'''
=== Air Step Speed Adjustment ===
The adjustments for the entrance step are located under the center portion of the step and are combined with sintered bronze exhaust filters. The extend adjustment is close to the center of step and the retract adjustment is to the rear. To adjust the extend or retract function, loosen the lock nut (7/15" wrench) and turn adjustment with blade type screw driver as follows. To increase speed turn counter-clockwise . To decrease speed turn clockwise. When adjustment is complete tighten lock nut.
<br />
<br />
== Parts & Crossreferences ==
==Parts & Crossreferences==
Lights
Lights
* Landing Lights
*Landing Lights
** Morse docking lights
**Morse docking lights
**
**