REVCON OWNER'S MANUAL INDEX Page I. OPERATING YOUR REVCON 1 A. Your Vehicle Keys 1 B. Ignition Switch/Anti-theft Steering Column Lock 1 C. Starting the Engine 2 1. Normal Procedure 2. Cold Engine Procedure 3. Warm Engine Procedure 4. Extremely Cold Weather 5. If Engine Fails to Start D. Emergency Starting 4 E. Automatic Transmission 4 1. Forced Downshift 2. Driving Tips F. Break-in Period 7 G. Engine Fuel 7 II. DRIVER/PASSENGER COMPARTMENT 9 A. Steering and Steering Column Controls 9 1. Power Steering 2. Turn Signal Indicator 3. Cruise Control 4. Tilt Steering Wheel 5. Hazard Warning Flasher 6. Horn B. Floor Controls 11 1. Brake System - (1 ton Ford 4 wheel drive wheels & drums) 2. Parking Brake 3. Headlight Simmer Switch C. Instrument Panel 12 1 to 36. (Item Descriptions) D. Driver's Seat Adjustment 18 E. Passenger Seat Adjustment 18 F. Arm Rest Adjustment 18 G. Seat Belts 19 H. Automotive Heater/Defroster and Air Conditioner 20 I. Quadraline 8-Track Tape Deck I J. Vanity/Map Box 21 K. Pullout Desk Shelves 21 L. Windshield Thermal Blanket 21 M. Reading Lights 21 III. HOME SECTION 22 A. Electrical System 22 1. Battery Power 2. Auxiliary Power Plant a. Operation b. Service and Maintenance c. Maintenance Schedules 3. External Shore Power 4. Circuit Breakers 5. Lighting System. 6. Fuses B. Plumbing System 31 1. Water Storage Tank 2. Water Pump 3. Water Heater 4. Waste and Sewage Holding Tanks 5. Sanitizing the Water System 6. Winterizing Procedure C. LP Gas System 35 D. Comfort Control Features 36 1. Furnace a. Lighting Instructions b. Burner Adjustment c. Shutting Off d. Operating Tips e. Pilot Adjustment f. Microswitch g. Maintenance & Cleaning 2. Off-road Air Conditioner a. Operating Instructions b. Maintenance & Protection E. Galley Area 41 1. Range and Oven a. Top Burner Operation b. Oven Operation c. Lighting Instructions d. Shutdown Instructions e. Thermostat Operation f. Pilot Adjustments g. Power Vent and Light II 2. Dual Voltage Refrigerator/Freezer a. Operation b. Maintenance 3. Sink Area a. Sink b. Water Purifier 4. Electrical Outlets F. Lining Area 49 1. L-Shaped Dinette 2. L-Shaped Dinette 3. Gaucho Dinette 4. Magic Bed Sofa (optional) G. Bedroom Area 50 1. Double Bed Conversion 2. Gaucho Conversion 3. Bunk Bed Conversion 4. Vanity Area H. Bathroom 51 1. Toilet 2. Lavatory 3. Shower/Tub 4. Power Vent 5. Vanity Mirror and Lights I. Entry Step 53 1. Pullout Step 2. Electric Step (optional) J. Windows 53 K. Ceiling Vents 54 L. Light and Power Switches 54 M. Decor Features 54 1. Carpets 2. Draperies 3. Upholstery 4. Cabinetry IV. DRIVE TRAIN - SERVICE AND MAINTENANCE 56 A. Engine Access 56 B. Hoisting Instructions 56 C. Lubrication and General Maintenance 56 D. Emission Control Maintenance 62 III V. EMISSION CONTROL SYSTEMS 66 A. Federal Clean Air Act 66 B. Normal Vehicle Use 66 C. Maintenance Source and Evidence 66 D. Emission Control Maintenance Schedule 67 E. Warranty 68 VI. EXTERIOR APPEARANCE MAINTENANCE 70 VII. EMERGENCY EQUIPMENT 71 VIII. SPECIFICATIONS Missing A. Capacities B. Lubricant Recommendations C. Filter Recommendations D. Engine (455 - 4 bbl) E. Fuses F. Lamps IX. MAINTENANCE/SERVICE SCHEDULES Missing X. ELECTRICAL SYSTEM DIAGRAM Missing XI. LOADING YOUR REVCON 72 A. Weight and Distribution 72 B. Outside Storage 72 C. Telescoping Rear Bumper 72 D. Interior Storage 73 1. Galley 2. Bedroom 3. Bath E. Towing 74 IV XII. PRE-TRAVEL CHECK LIST 75 A. Exterior 75 B. Interior 75 C. Automotive 76 XIII. DRIVING TIPS 77 V I. OPERATING YOUR REVCON A. Your Revcon Keys Your coach comes with two sets of three keys. The key with the "GM" trademark operates the ignition switch. The key marked with the "B" locks and unlocks the entry door. The smallest key operates the engine compartment, side compartment, spare tire compartment, gasoline filler, fresh water filler and the shore power cord access doors. B. Ignition Switch and Anti-Theft Steering Column Lock The anti-theft Ignition lock on the right hand side of the steering column has five positions: ACCESSORY - Turn key counter-clockwise (toward the steering wheel). This position permits operation of electrical accessories when the engine is not running. LOCK - This is the normal parking position, locks ignition and provides anti- theft protection by preventing normal operation of steering wheel and shift controls. Key cannot be turned to LOCK position and removed until transmission is placed in PARK. OFF - Is engaged at the first notch turning the key in a clockwise direction. "OFF" position permits turning engine off without locking the steering wheel and shift controls. ON - Normal operation position. START - Is engaged by turning the key all the way in a clockwise direction, and permits engagement of the engine starter. NOTE: Set your parking brake firmly when leaving your vehicle unattended. The anti-theft steering column lock is not meant to be a substitute for the parking brake. -1- PARKING - When leaving your Revcon unattended: 1. Set the parking brake. 2. Place transmission selector lever in "P" park. 3. Turn key to lock position. 4. Remove key from steering column lock. 5. Lock all windows firmly and lock the door. 6. Turn water pump switch off. NOTE: Always let go of the steering wheel before turning the Ignition key to "LOCK". When parking on a hill with the wheels turned into the curb, be sure the vehicle has come to a complete stop before turning the key to "LOCK". Turning the wheel left or right after the vehicle is stopped "winds up" the steering system, which can result in a "spring-back" of the steering wheel when the lock is released. C. Starting the Engine CAUTION: When starting the engine with the vehicle parked, always keep the foot brake applied. NOTE: To prolong battery life, turn off radio, lights, air conditioner and all other accessories prior to starting the engine. Leave accessories off until the engine is running smoothly. 1. NORMAL PROCEDURE: Place transmission selector in "P" or "N". A safety switch prevents starting in any drive position. If it ever becomes necessary to start the engine when the vehicle is moving, place the selector lever in "N . Depress accelerator pedal and activate starter. -2- 2. COLD ENGINE PROCEDURE: Fully depress accelerator pedal and slowly release. With foot off the accelerator pedal, turn the key to the "START" position. Release ignition key when the engine starts. If the engine starts, but fails to run, repeat the above procedure. When the engine is running smoothly, the idle speed may be reduced by slightly depressing the accelerator pedal and then slowly releasing. 3. WARM ENGINE PROCEDURE: Depress the accelerator pedal about halfway and hold While starting engine. 4. EXTREMELY COLD WEATHER (below 00 F): If the vehicle has been standing idle for several days or the weather is extremely cold, fully depress and release the accelerator pedal 2 or 3 times before cranking the engine. With foot off the accelerator pedal, turn the key to the "START" position And release when engine starts. 5. IF ENGINE FAILS TO START: After first using the appropriate procedure above, fully depress and release the accelerator pedal several times. Then remove foot from the accelerator and turn the key to "START". If the engine still does not start, fully depress the accelerator pedal and hold it to the floor while holding the key on "START". If the engine has been flooded with gasoline it may star, to run, but without enough power to keep running. In that case, continue cranking with accelerator fully depressed until the engine clears itself of excess gasoline and runs smoothly. NOTE: Do not continue cranking the engine for more than 30 seconds at a time to prevent starter overheating. -3- D. Emergency Starting: The engine cannot be started by pushing the vehicle. To start the engine when the engine battery is discharged, one of three methods may be used. 1. Start the auxiliary power plant and allow to run for approximately one half hour; it will then provide sufficient current to start the engine. Since the auxiliary power plant usually starts from the automotive battery, it will be necessary to start it remotely at the power plant compartment. Simultaneously press the solenoid button at top right of the compartment Then, with dash switch in "run" position depress the auxiliary start button. 2. The automotive battery may be removed and taken to a garage or service station for charging. 3. If jumper cables are available, a car battery (12-volt) may be jumped for the required starting power. CAUTION: When using this method, be absolutely certain that the "positive" terminal of one battery connects to the "positive" terminal of The other. Not all cars use negative ground systems, but the larger terminal will always be "positive" and the smaller "negative". E. Automatic Transmission: The transmission in your Revcon is an Oldsmobile Turbo Hydramatic. The selector lever is located on the right side of the steering column and the shift indicator is located on the instrument panel above the steering column. PARK (P): Provides a positive transmission lock when parking or while starting the engine. Pull the selector lever toward you to select or release this position. Never move selector into PARK unless the vehicle is completely stopped. -4- REVERSE (R): Is for backing the vehicle. Come to a complete stop before moving the selector lever into REVERSE. NEUTRAL (H): Is the out-of-gear position. It is the only other than "PARK" In which the engine may be stared. It is provided for starting a stalled engine while in motion or running the engine while standing with the brake applied. DO NOT coast in neutral as it could cause serious transmission damage. DRIVE RANGE (D): Is the driving range for normal acceleration and cruising speeds. This position permits the transmission to operate through its complete range of gear ratios and to select automatically, the proper ratio for all road conditions. SUPER RANGE (S): Is used when super performance is needed for increased acceleration in traffic, hill climbing or "engine braking" downhill. The selector lever may be moved from "D" to "S" or from "S" to "D" under most operating conditions. "S" should not be used at speeds above 75 mph. LOW (L): Position is available for heavy pulling through mud or sand and for "engine braking" when descending steep hills. The selector lever may be moved to "L" at or below approximately 40 mph. The transmission will not up-shift from low range as long as the selector is in "L" position. 1. FORCED DOWNSHIFT When quick power or acceleration is desired for passing or to climb steep grades at speeds between 35 mph and legal speeds the transmission can be downshifted by depressing the accelerator pedal to the floor. It is also possible to obtain a forced downshift in "Drive" range at speeds under 35 mph by depressing the accelerator pedal part way down. -5- CAUTION: Be particularly careful when shifting into lower gear ratios on slippery surfaces with the vehicle moving. The abrupt braking action could cause the driving wheels to skid. 2. DRIVING TIPS: a. Extended running of the engine (five minutes or more) without depressing the accelerator pedal, could cause damage to the engine or exhaust system due to overheating. b. Before descending a steep or long grade, reduce speed and shift into "L" using the brakes sparingly to prevent them from overheating. c. When driving in the mountains, never let your engine labor. Shift into a lower range before the engine begins to labor or overheat. Try to anticipate any potential overheating conditions and do not use the air conditioner. (Climbing a steep grade on hot days with the air conditioner running will increase the possibility of overheating the engine or transmission). If you ever overheat, pull off the road, determine and correct cause. d. Vacuum gauge readings should never be below five inches vacuum. Downshifting to maintain above five inches vacuum will improve gas mileage. e. As a driving tip for best mileage, the highest vacuum reading in any gear means best performance. f. RPM readings of 1800 or less means a change in gear range for best performance. -6- F. BREAK-IN PERIOD Driving speeds for your new Revcon should be limited to a maximum of 50 mph for the first 100 miles and legal speed for the next 400 miles with no heavy throttle accelerations. During the break-in period, be sure to vary your speeds frequently. Do not drive at a steady 50 mph, but rather drive for five minutes at 55 mph, then back to 50 mph and repeat these speed changes. The mild acceleration and deceleration helps the moving parts to seat properly and ensures the longest life for your vehicle's drive Train. If your initial mileage is of the around-town variety, be sure to include some 25 to 50 mile highway trips during the breaking-in period. Your Revcon should be driven at least 500 miles before attempting to tow another vehicle. DO MOT TOW MORE THAN 2,000 LBS. Tighten all lug bolts to 450 lbs. Re-torque after 500 miles. Also check tire pressure after 250 miles (60 psi all tires). G. Engine Fuel The fuel filler tube is located within the lock compartment on the right side of the vehicle, next to the fresh water filler. The area within the fuel filler compartment is red. CAUTION: Gasoline is flammable and explosive under certain conditions. Always stop the engine and do not smoke or allow open flames or sparks near the vehicle when refueling. If gasoline fumes are noticed while driving, the cause should be determined and corrected without delay. Your Revcon is designed to operate on regular gasoline's. However, any gasoline with 91 Research Octane number or higher will satisfy your engine's octane requirements. Use of unleaded or low- lead gasoline will keep your engine running efficiently and play an important part in reducing exhaust -7- emissions of hydrocarbons and particulates. If unleaded or low-lead gasoline's are not available, you may use a leaded regular-grade gasoline. Since the anti-knock quality of all gasoline's is not the same and factors such as altitude, terrain and air temperature affect operating efficiency, knocking may result even though you are using the recommended fuel. If persistent knocking is encountered, consult your Authorized Dealer. Continuous or excessive knocking may result in engine damage, and constitutes a misuse of the engine for which Revcon cannot be responsible under the terms of the New Vehicle Warranty. In certain foreign countries, there is a possibility that even the best fuels are so low in antiknock additives that excessive knocking and serious engine damage may result from their use. Consult an Authorized Dealer if you plan to travel outside the continental United States. -8- II. DRIVER/PASSENGER COMPARTMENT A. Steering and Steering Column Controls 1. Power Steering: Your Revcon uses a Saginaw Gear Power steering system, which provides exceptional ease in handling and parking. The power to assist is provided by a hydraulic pump driven by the engine. When the engine is not running, or if the power steering pump-driving belt breaks, the vehicle can still be steered, although much greater steering effort will be required, particularly in sharp turns. 2. Turn Signal Indicator: The turn signal indicator is the longest of the levers located on the left side of the steering column. For normal full turns, move the lever UP for a right turn, and DOWN for left turn. The lever will remain in position until the turn is completed, then automatically cancel. 3. Cruise Control: The Cruise Control is an automatic speed control system, which is designed to allow the vehicle to hold a selected speed. To operate turn the control-switch on turn signal lever "ON". Accelerate the vehicle to the desired speed and momentarily push in the engagement button located in the end of the turn signal lever. Take your foot off the accelerator and this speed will be maintained. ' To reset at a faster speed, accelerate to the desired speed, push in the engagement button fully and release slowly. To reset at a slower speed, depress the engagement button fully and hold. Allow the vehicle to decelerate to desired speed, and release the engagement button slowly. -9- If you need to slow down depressing the brake pedal disengages control. Turn switch to resume and the control will resume former speed. You can increase your speed for passing by depressing the accelerator pedal. When you remove your foot from the pedal, the vehicle will slow down to the cruising speed set prior to the acceleration. To disengage the cruise control completely, apply the brake slightly; the control will disengage automatically; or turn the switch to "OFF". 4. Tilt Steering Wheel: The steering wheel in your Revcon can be tilted up above normal position to provide additional room for entrance and exit as well as selected driving positions above or below normal height. The tilt mechanism is operated by lifting up on the small control .lever on the left side of the steering column just below the directional signal lever. Move the steering wheel to the selected position and release the lever. DO NOT attempt to tilt the steering wheel while the vehicle is in motion. 5. Hazard Warning Flasher: The four-way hazard warning flasher system on your Revcon should be used to warn other drivers that your vehicle is a traffic hazard. To activate, push the hazard warning flasher button in. When the system is operating, the turn signal indicators on the instrument panel will flash simultaneously. To cancel flasher pull the button outward. NOTE: The hazard warning flasher will operate with the ignition switch in the locked position and the key removed, allowing the Revcon to be locked while help is sought. If the brake pedal is depressed, the lights will not flash, but glow continuously. 6. HORN: The horn is activated by depressing the padded section in the center of the steering wheel. -10- B. Floor Control's 1. Brake System: Your Revcon is equipped with a service braking system that is designed to operate effectively under all load conditions and at all speeds. The system is so designed that half of the brake system will provide some braking action in the event of a hydraulic fluid leak in the other half of the system. The vacuum power disc brakes, on the front wheels, reduce braking effort and adjust automatically with each brake application. Should power be interrupted due to a stalled engine or malfunction, the vehicle can still be stopped, but greater force is required on the brake pedal. The self-adjusting, drum type rear brakes are automatically adjusted every time the brakes are applied while the vehicle is moving in reverse. If excessive brake pedal travel should develop due to lack of reverse motion and brake application, the vehicle should be driven backward and the brakes applied firmly. If repeated several times this should restore normal brake pedal travel. If not, immediate inspection should be made by your authorized dealer. CAUTION: "Riding the brake" by resting your foot on the brake pedal when unnecessary can cause excessive lining wear, overheating and damage to the brake system. Driving through deep water may affect brake performance. Applying brakes lightly will indicate whether they have been affected. To dry them quickly, lightly apply the brakes while maintaining a safe forward speed with a clear distance ahead until brake performance returns to normal. -11- 2. Parking Brake: A foot operated parking brake is located on the extreme left of the driver's area. To set, simply apply foot pressure; to release, pull brake release knob directly above parking brake pedal. NOTE: The parking brake should be set whenever leaving the driver's seat unattended. Set the parking brake before placing transmission in "Park" position. Before releasing parking brake, remove the transmission from the "Park" position. The precaution will eliminate "torque lock". 3. Headlight Dimmer Switch: To obtain high or low beam headlights, push the foot dimmer switch, located on the floor below the parking brake. Each time the switch is depressed, the light beam changes. A headlight beam indicator is visible on the instrument panel when driving on high beam. NOTE: An overload on the breaker will cause the headlights to flicker or in some cases remain off. If this condition develops, have your headlight electrical circuit checked immediately. C. Instrument Panel 1. Amp Gauge 19. Windshield Wiper Control Switch 2. Tachometer 20. Windshield Washer Control Switch 3. Manifold Vacuum Gauge 21. Heater Fan Control Switch 4. Generator Warning Light 22. Auxiliary Power Plant Switch *5. Temperature Warning Light 23. Auxiliary Power Plant Indicator 6. Fuel Level Gauge 24. Left-hand Turn Indicator Light *7. Oil Pressure Warning Light 25. Speedometer 8. Brake Warning Light 26. Odometer 9. High Beam Indicator 27. Transmission Gear Selector Dial 10. Oil Pressure Gauge 28. Right-hand Turn Indicator Light -12- 11. Oil Temperature Gauge 29. Radio Balance & Volume Control 12. Water Temperature Gauge 30. Radio Selector Dial 13. Defrost Control Switch 31. Radio Selector Dial 14. Temperature Control 32. Brake Release 15. Radio/Tape Selector Switch 33. Air Conditioning Vent 16. Rear Speaker Control 34. Cigarette Lighter 17. Highlight and Instrument 35. Air Conditioning Thermostat Control Panel Light Switch 36. Air Conditioning Selector Switch 18. Courtesy Light Switch * 71-72 Models only 1. AMP Gauge - Indicates the strength of the electric current to the battery system. Normal range is between 0 and 63 AMPS. If not in this range have your system checked as soon as possible. 2. Tachometer - Indicates engine's revolutions per minute in 100 decimals. Driving at 65 mph, the tachometer will register approximately 2500 RPM's. When on steep grades or while towing another vehicle, and tachometer reads below 1800 RPM's, shifting into lower gear ratios is indicated. 3. Manifold Vacuum Gauge - Indicates the vacuum running in the engine. The most economical driving is done with the highest reading. 4. Generator Warning Light - Indicates the alternator output. The "GEN" light will appear with the ignition key "ON", but without the engine running to indicate the light is functioning. Should the light fail to come on, it indicates a possible burned out bulb. After the engine is started the light will go out. The light remaining on indicates there is no electrical output from the alternator and the system should be checked immediately. *5. Temperature Warning light - Indicates abnormally high engine temperature. The light will momentarily light when starting the engine to indicate it -13- is operational. Should this light appear while traveling, stop the engine immediately, determine the cause and correct. * Model year 71-72 only. 6. Fuel Level Gauge - Indicates the fuel level and operates only with the ignition in the "ON" position; with or without the engine running. *7. Oil Pressure Warning Light - Indicates inadequate oil pressure in the engine. The "OIL" light will appear momentarily when the ignition is turned "ON". After the engine is started and oil pressure builds up, the light will go out. * Model year 71-72 only. 8. Brake Warning Light - will glow when the parking brake has not been released fully. If the red warning light glows continuously when the ignition is on and after the brakes have been firmly applied, it may indicate there is a malfunction in one half of the braking system. If this is the case, braking effectiveness may be impaired. However, it is still possible to brake the vehicle by applying greater force to the brake pedal. If the brakes should become totally ineffective, do not hesitate to use the parking brake. DO NOT attempt to shift gear selector into "Park". The cause of any braking problem should be determined and corrected immediately. 9. High Beam Indicator - a blue "HIGH" light is visible when driving with headlights on high beam. Failure of the light to come on can indicate a blown fuse. 10. Oil Pressure Gauge - measures the pressure of oil being fed into the engine. The consistency of the oil in a cool engine will cause a high reading when the engine is first started. As the engine warms, the pressure will recede to normal. Minimum pressure at idle should be 10 -14- psi. At normal operating speeds, minimum pressure should be approximately 35 psi. Should the pressure drop below this minimum, stop the engine immediately and check the cause. Low oil pressure could be the result of a dangerously low oil level in the crankcase, and can cause extensive engine damage. 11. Oil Temperature Gauge - registers the temperature of the oil circulating in the engine. Extremely high oil temperature in excess of 200° F. can cause damage to the engine. Should your gauge indicate high oil temperature, stop the vehicle, let the engine cool off completely and check the oil level in the engine. DO NOT attempt to check the oil level when the engine is hot. 12. Water Temperature Gauge - Indicates the water temperature in the engine. Should the temperature rise above 240° F., stop the engine as soon as possible, let it cool completely, then check water level in the radiator. This can be done by viewing the coolant bottle next to the radiator. DO NOT remove radiator cap when the engine is hot; this could cause extreme injury. 13. Defrost Control Switch - Operates the defrosting system for the front windshield. If its operation malfunctions check the defroster vents on the dash panel and vent pull lever under the dash. Heater malfunction could also cause defroster malfunction. 14. Temperature Control Knob - Controls the temperature of the air used in the heating and defrosting system. Pull the knob out for the desired temperature; fully extended is the hottest position. 15. Radio/Tape Selector Switch - Turns to "Radio" for its operation and "Tape" for its operation. -15- 16. Rear Speaker Control - Will reduce output of rear speakers only. 17. Headlight & Instrument Panel Light Switch - Controls three positions. 1. Pulling the switch knob to the first position provides parking, tail, clearance and side marker lights as well as lights on the instrument panel. 2. Pulling the switch all the way out turns on headlights in addition to the above lights. 3. Rotation of the knob controls the brightness of instrument panel lights. Clockwise dims, counter-clockwise brightens. 18. Courtesy Light Switch - Illuminates the driver's compartment and entry step. Upper level "in" turns on the lights. (The switch panel inside the entry door has the same function.) 19. Windshield Wiper Control Switch - Operates the two-speed windshield wipers. Push the switch to the first position for low speed, or the second position for high speed. The windshield wipers work electrically and are not affected by engine operation. Malfunction usually indicates a blown fuse. 20. Windshield Washer Control Switch - Operates washer by momentarily depressing the control button. Malfunctions may indicate an air bubble in the water line. If this occurs, disconnect the tube from the reservoir, let a little run out and reconnect. 21. Heater Fan Control Switch - Operates the fan by pushing the switch to the first position for low speed and second position for high speed. 22. Auxiliary Power Plant Switch - Operates the auxiliary power plant from the driver's seat. Depress and hold until the power plant is started. DO NOT start the power plant under electrical load. -16- 23. Auxiliary Power Plant Indicator Light - Glows red when the auxiliary power plant is operating. 24. Left-hand Turn Indicator Light - Flashes green when signal lever is in the down position and indicates signal is operating. 25. Speedometer - Indicates the forward speed of the vehicle. 26. Odometer - Registers the accumulated mileage the vehicle has been driven. 27. Transmission Gear Selector Dial - indicates the position of the gear selector. "Park", reverse "R", neutral "N", drive "D", super range "S" and low range "L". 28. Right-Hand Turn Indicator Light - flashes green when signal lever is in the up position and indicates signal is operating. 29. Radio Balance and Volume Control 30. Radio Selector Dial 1. Radio Selector Control Dial 32. Brake Release - pull lever to release parking brake. 33. Air Conditioning Vent - Adjustable directional air-flow from air conditioner. 34. Cigarette Lighter - Push in to ignite, the lighter will release when functional. 35. Air Conditioning Thermostat - Selection control for degree of cooling desired. (High, Medium or Low) 36. Air Conditioner Control Switch - Turns the automotive air conditioner on and off. -17- D. Driver's Seat Adjustment: . To adjust the driver's seat, release the seat lock lever at the lower side of the seat, exert a slight body movement to slide the seat forward or rearward. To swivel single seats, slide the seat to forward position, release swivel lock to the rear of the seat lock lever; using body pressure, swivel seat 90 degrees into position and lock. E. Passenger Seat Adjustment: To swivel double passenger seat, pull back knob on left end of the seat. At the same time, using the wooden handle, pull the seat toward you and it will slide away from the side of the coach. This will give the seat enough clearance to swivel. Next pull the swivel handle mechanism located at the lower rear of the passenger seat, and swing it 90 degrees until it is facing the driver's seat. Then push the seat toward the dashboard; it will slide forward and lock into position. Reverse the process to return to forward facing position. NOTE: Slide seat toward center prior to rotating to avoid damage to the inside wall of the driver's compartment. In most areas, the law requires that the seat face forward when the vehicle is in motion. F. Arm Rest Adjustment: To adjust arm rest, pull straight up into position. To lower, pull slightly then push down. G. Seat Belts: For proper protection, pull seat belt over lower lap, across the large hipbone. Insert catch plate into buckle, pull strap to fit snugly. To unfasten, push center of buckle. -18- NOTE: NEVER use the same belt for more than one person. Periodically check for weakened areas of damage to seat belts, buckles and anchors. Child restraints are recommended for small travelers. When other restraints are being used, secure seat belts that are not in use to avoid injury from free flying buckles. H. Automotive Heater and Air Conditioner 1. Automotive Heater: The automotive heater operates with the simple operation of the fan control switch located on the left side of the instrument panel, and the temperature control knob. Pull out for desired heat. 2. Automotive Air Conditioner: To operate your automotive air conditioner, move the fan switch knob to either high, medium or low position for maximum cooling in stop and go traffic. On long trips, once the temperature inside the driver's compartment becomes comfortable, the temperature control knob should be moved back slightly to prevent the cooling coil from becoming too cold and freezing up. 3. Service and Maintenance: a. Service center check of your unit should be made each Spring. Check refrigerant, belt tension, condenser and evaporator coils and switches. b. Periodically check hoses for proper clearance from sharp metal edges and engine manifold. c. Wash radiator and condenser when you wash your Revcon. d. Have compressor belt tension compressor mounting bolts and clutch checked periodically by your service center. -19- e. Never polish the faceplate of your unit with car or household wax. Use an oilcloth to remove fingerprints, etc., from the faceplate. I. Quadra line 8-Track Tape Player (Optional) Your Quadraline 8-track tape player automatically operates as a four-channel or two-channel system, depending upon the cartridge inserted into the tape deck. The deck is normally in four-channel operation, but a two-channel cartridge activates a mode switch and the system becomes a conventional two channel player. 1. Operation Instructions: a. Turn tape player on by inserting tape cartridge into tape slot, (label side up and open end first) until it is firmly seated. b. Adjust volume control for desired sound level. Adjust tone control for desired bass and treble response. c. Adjust the balance controls (Right to Left and Front to Rear) to optimize the sound level from each of the four speakers, d. To change programs, depress the program selector button. The tape player will automatically change to next program when the end of a program is reached. e. To turn tape player off, depress eject button. NEVER allow cartridge to remain seated when tape player is not in use. Store tapes in a cool area (in their containers) with the open end down. Protect tapes from direct sunlight and dust. 2. Maintenance: In time, oxide from recording tape will accumulate on the tape head and capstan shaft which can cause poor fidelity and erratic operation. The more often the tape player is used, the more often it should be cleaned. To clean the tape head, hold the player cartridge door open and clean -20- the head with a cotton swab moistened with isopropyl alcohol. Do not use carbon tetrachloride. To clean the capstan shaft, first turn on the motor by depressing the motor switch (next to the capstan shaft) with the eraser end of a pencil. Use a cotton swab moistened with alcohol on the shaft. Warranty Practices: Your Quadraline 8-track player is warranteed by its manufacturer. The warranty is enclosed in the warranty packet. Familiarize yourself with its coverage and limitations. J. Vanity/Map Box: Lifts for storage of driving aids and other miscellaneous items. K. Pull out Desk Shelves: Lift up on edge of desk and pullout. The desktop will automatically stop when fully extended. To close, simply push back in position. L. Windshield Thermal Blanket: Snaps into position, acting as a curtain at night and in cold weather, preventing loss of heat through the windshield. M. Reading Lights: There are two directional reading lights, one on each side of the driver's compartment. The switch knob for each light is located on the fixture. Turn on by rotating clockwise. -21- III. HOME SECTION A. Electrical System 1. Battery Power: All lights, water pump, furnace blower, etc., are operated by two six Volt 180 AMP batteries located in the locked battery- compartment on the curbside, rear of the coach (street side in 250 MB). The engine is operated by one 105 AMP 12-Volt automotive battery located at the rear of the engine with access through the engine hatchway. The home section batteries are charged automatically by the converter, or when on shore power or using the auxiliary power-plant. The engine alternator also charges all of the batteries when driving. Be sure the power switch on the batteries is turned off when coach is stored. This switch is in the battery compartment for 1973 model year and later. The converter in your Revcon is a 11O-Volt AC to 12-Volt DC and is located under the dinette (220 models, under the curb side bed; 250 MB, under street side bed). The converter supplies 12-V DC and automatically charges coach battery only, when connected to shore power or operating on the auxiliary power plant, and automatically shuts off when batteries are up to full charge. NOTE: All switching operations in the converter are automatic and should remain plugged in at all times. Do not restrict the air-flow around the converter, do not let the unit get wet and keep it as clean as possible. Clean with low-pressure air (30 psi maximum) if necessary. Operating Tips: a. Keep battery cells filled with distilled water. Separators exposed to air dry out and crack or split, permitting short circuits. Plates exposed to air harden. To avoid these difficulties be sure that -22- batteries are serviced twice a month. b. Avoid Corrosion. Acid fumes or acid spilled on terminals causes corrosion, weakening battery power and shortening life; Remove corrosion regularly and coat terminals, posts and connectors with a light grease. c. Be sure to keep your battery from freezing in winter months. A fully charged battery will not freeze in severe sub-zero weather, but a nearly discharged battery will freeze at 5 degrees F.. A frozen battery is ruined. d. Be sure your batteries are properly secured. A battery that is loose in its carrier will vibrate, causing damage. Clamps screwed down too tightly may crack or warp battery box. Warranty Practices: Your batteries are warranteed by their manufacturer. The warranty is enclosed in your warranty packet. Familiarize yourself with its coverage and limitations. 2. Auxiliary Power Plant: a. Operation Your Revcon is equipped with a 5 KW or 6.5 KW auxiliary power plant, located in the exterior compartment on the street side of the coach (curb side in 250 MB). It is a gasoline engine-driven electric power plant that will allow the operation of any appliance which does not exceed the electrical output of the unit. Under normal conditions, the power plant will adequately supply almost all types of electrical hand tools, lights, kitchen appliances, radio and television equipment, the off-the-road air conditioner, and nearly any 110-V appliance found in the home. -23- Before starting the power plant, be sure the crankcase has been filled with oil to the "FULL" mark on the oil level indicator. DO NO OVERFILL. "Regular" grade gasoline is recommended for longer spark plug life and less lead deposit in the carburetor and combustion chamber. (DO NOT use highly leaded premium type gasoline). The power plant draws its fuel automatically from the main tank and may be operated while the vehicle is underway. However, the vehicle's gasoline supply will be depleted at a faster rate. It is impossible to exhaust the fuel supply in the main tank by using the power plant. The gasoline supply to the power plant will be depleted when the main tank shows 1/4 full. When operating the power plant for the first time, use the following sequence using MS/DG oil: 1/2 hour at 1/2 load; 1/2 hour at 3/4 load; then a load. (Change the oil in the crankcase after the first 50 hours of operation). NOTE: Rust inhibitor oil has been placed in the power plant engine combustion chamber at the factory and may foul spark plugs. If plugs should foul, remove and clean thoroughly. Then dry and replace in engine. NOTE: Before starting generator be sure air conditioner is turned OFF. Generator should not be started under a load. The auxiliary power plant may be started inside the coach by depressing the top half of the power plant rocker switch on the instrument panel. Release the switch as soon as the engine starts. When the power plant is running, the small red light next to the switch will be lit. To stop the unit, depress the bottom half of the switch and hold until power plant comes to a full stop. The "start/stop" switch on the power plant itself operates in a similar manner, however, the rocker switch on the -24- instrument panel must be in its neutral position (switch automatically places itself in "neutral" after start depression). Circuit Breakers: The power plant circuit breakers, located on the right side of the compartment will trip when the demand for electricity in amperes exceeds the power plant's capabilities. If the circuit breakers do trip, remove part of the electrical load and reset the breakers. High Temperature Operation: Make sure that nothing obstructs airflow to and from the unit. Keep cooling fins clean. The power plant housing should be unaltered and undamaged. Keep the ignition and timing properly adjusted. Low Temperature Operation: Use correct SAE number oil for temperature conditions. Change oil only when engine is warm. Keep fuel system clean and home section batteries in well charged condition. Use fresh regular grade gasoline. Protect against moisture condensation. Below 0 degrees F. adjust carburetor main jet for slightly richer fuel mixture, and partially restrict cool airflow, but use care to avoid overheating. High Altitude Operation: For operation at altitudes 2500 feet above sea level close carburetor main jet adjustment slightly to maintain proper air-to-fuel ratio. Maximum power will be reduced approximately 4% for each 1000 feet above sea level after the first 1000 feet. Operation Protection: 1. Keep power plant clean. 2. Keep cooling surfaces clean. 3. Service air cleaner as frequently as necessary. 4. Change crankcase oil every 50 operating hours. 5. Keep governor linkage clean. -25- 6. Clean generator brushes, clip rings and commutator. DO NOT remove normal film. DO NOT polish. NOTE: When your auxiliary power plant is to be OUT-OF-SERVICE for More than 30 days: 1. Run the power plant until thoroughly warm. 2. Turn off fuel supply and run until plant stops. 3. Drain oil from oil base while still warm. Refill and attach a Warning tag stating oil viscosity used. 4. Remove each spark plug. Pour 1 oz. of rust inhibitor into each cylinder. Crank engine slowly (by hand) several times. Install spark plugs. 5. Service air cleaner. 6. Clean governor linkage and protect by wrapping with a clean cloth. 7. Plug exhaust outlet to prevent entrance of moisture, dirt, bugs, etc. 8. Wipe generator brushes, clip rings, etc. DO NOT apply lubricant or preservative. 9. Wipe entire unit. Coat rustable parts with a light film of grease or oil. b. Service and Maintenance: Regularly scheduled maintenance is the key to lower operating costs and longer service life for the power plant. The following maintenance schedule can be used as a guide, however, actual operating conditions under which the unit is run should be the determining factor in establishing a maintenance schedule. When operating in very dusty or dirty conditions, some of the service periods may have to be reduced. -26- For any abnormalities in operation, unusual noises from engine or accessories, loss of power, overheating, etc., contact your nearest recreational vehicle service outlet. Checking Oil Level: Check the oil level daily, or at least every eight Hours of operating time. Check more often on a new unit as oil consumption is generally higher until piston rings seat properly. Fill to the "F" mark on the oil level dipstick. Use a good quality detergent oil. Use the proper SAE number of oil for the expected temperature conditions. DO MOT mix brands or grades. Extremely dusty or low temperature conditions require oil change at 50 hours. Oil capacity is five U.S. quarts. TEMPERATURE RECOMMENDED 0IL Above 90( F. SAE 50 30( F. to 90( F. SAE 30 0° F. to 30° F. SAE 1OW-40, 5W30 Below 0° F. SAE 5W-30 Fill engine with oil through dipstick tube. The oil drain plug is located on the front of the engine. Oil Filter: Change the crankcase oil filter at least every 100 hours of operation. The filter is located on the front of the unit. Remove by turning counter-clockwise with a filter wrench. Before installing new filter, coat the gasket on the filter's base with a light film of new oil. Install by turning clockwise until a light friction is noted, then turn an additional 1/4 to 1/2 turn. DO NOT over-tighten filter, as damage may occur to rubber gasket which will cause filter to leak. Be sure to install sealing ring around filter; this ring is an air seal to prevent cooling air loss. -27- Air Cleaner: Clean screen and cup in a suitable solvent. Refill to Level indicated on cup. Use the same type of oil as used in crankcase. Fuel Pump Filter Element: Every 500 hours or sooner drain the fuel pump and check filter element. Remove fuel pump mounting screws and turn off hex nut on base of pump. If element appears dirty, replace with a new one. Be sure to replace gaskets when reassembling. Carburetor Bowl: Every 500 hours of operating time, clean the screen in solvent. Blow out with low-pressure compressed air and reassemble, making sure the gaskets are in place. Governor Linkage: Every 50 hours of operation, clean the joints and lubricate. Also inspect the linkage for binding, excessive slack and wear. Fuel Sediment: Empty carburetor and fuel filter bowls of any Accumulated sediment. Clean filter screen thoroughly. Reassemble and check for leaks. Brush Replacement: Install new commutator brushes when the old ones are Worn to 5/8" in length. The collector ring brush may be used until worn to 5/16" in length. It is not necessary to remove the brush rig to install new brushes. Remove the end cover to expose the brush rig. Brushes and leads are then easily accessible. Always use the correct brush, never substitute a brush, which may appear to be the same, but may have different electrical characteristics. Be sure to tighten the brush lead terminal nuts. If some brush sparking occurs after replacing brushes, run the power plant at a light load until the brushes wear to a good seat. -28- Spark Plugs: Check, clean, and reset spark plugs every 100 hours of Operating time. Replace spark plugs that show signs of fouling or electrode erosion. It is recommended that spark plugs be replaced at the beginning of each new season. Cooling System: The power plant is cooled by a flywheel blower-fan, Which pulls air over the cylinders and cooling fins. Check and clean the cooling fins every 50 hours of operation. Remove any dust, dirt or oil which may have accumulated. Check compartment air inlet and air outlet for build up of dirt, etc. c. Maintenance Schedules OPERATOR MAINTENANCE SCHEDULE Maintenance Schedule Operational Hours 8 50 100 200 Inspect Plant Generally X Check Fuel Supply X Check Oil Level X Clean Governor Linkage X1 Service Air Cleaner X1 Check Spark Plugs X Change Crankcase Oil X1 Clean Crankcase Breather X Clean Fuel System X Check Battery Electrolyte X X1 - Perform more often in extremely dusty conditions. -29- CRITICAL MAINTENANCE SCHEDULE (Performed Only By Qualified Service Personnel) Maintenance Items Operational Hours 200 500 1000 Check Breaker Points X Clean Commutator & Collector Rings X1 Check Brushes X2 Remove Carbon & Lead X Check Valve Clearance X Clean Carburetor X Clean Generator X Remove & Clean Oil Base X Grind Valves X General Overhaul X X1 - Perform more often in extremely dusty conditions. X2 - Replace collector ring brushes when worn to 5/16" or less. X2 - Replace commutator brushes when worn to 5/8" or less. Warranty Practices: Your auxiliary power plant is warranteed by its original manufacturer. If the above schedule is followed and an accurate hour log is maintained, your warranty will not be voided. 3. External Shore Power The locked shore power utility compartment, located in the left rear of the coach, contains a 25 foot power cord. To make an external power connection, plug the cord into a 11O-volt AC power source. All internal switching will take place automatically. When disconnecting from the external power source, plug into the auxiliary power plant receptacle within the compartment. This will connect the auxiliary power plant to the electrical system. -30- 4. Circuit Breakers Your Revcon's main breaker box contains two or three (depending on your model) 11O-V circuits, each rated to carry 20 or 15 amperes. The circuit breakers located in the left rear closet in the curb side wardrobe) will automatically trip if overloaded on external power. In this event, remove part of the electrical load and reset the breakers. 5. Lighting System The lighting throughout your Revcon operates on a 12-volt system. The switches to the lights are located on the light fixture itself, or from the panel of switches located near the entrance door. The switches on the panel operate the porch light, the entry door courtesy light and the ceiling lights. 6. Fuses The fuse box for engine electrical systems is located beneath the dash board on the left-hand side. Fuse Sizes - Fuse sizes are marked on fuse panel. 7. Fuse box for coach systems is located in the left closet on model 250. B. Plumbing System Your Revcon is equipped with its own self-contained plumbing system. The water tank located under the street side bed. The water pressure pump is located under lavatory pullman in 250 MB models, and is operated by the pump switch from two locations: In the bathroom from the switch the front of the pullman lavatory, and from the galley area control panel. 1. Water Tank: The fresh water filler is located on the external coach in a locked compartment located on street side of the coach. To fill the fresh water tank, remove BOTH caps, screw in garden hose and fill. NOTE: It may be -31- necessary to open the kitchen faucet to clear air from the lines if the water tank has been dry. DO NOT attempt to fill water tank without removing both caps in fill compartment. The air in the tank must be allowed to escape while filling to avoid damage to water tank. To use a park or city water supply, simply hook up a garden hose to the water inlet valve located in the left rear portion of the under belly; this will bypass the water tank. 2. Water Pump: A 12-volt pressure water pump is used to operate the entire water system, and operates off the auxiliary 12-volt battery. The pump is activated by the switch located on the control panels in either the bathroom or galley and is adjusted to hold a line pressure of 20 psi to 30 psi. When initially starting the water pump or if the pump has not been operated for some time, open the kitchen faucet to release line pressure before turning on the switch. When the water tank runs dry, or when the unit will be out of operation for a period of time, the water pump should be turned off. Should problems arise in the water pump system, follow this step-by-step procedure for problem indicated. Pump will not prime (this should be automatic). 1. Check water level in the tank. 2. Check battery power. 3. Check external drains (should be closed). 4. Check for kinks in the inlet hose. 5. Check for air leaks at inlet fittings. 6. Check for clogged line. -32- If pump operates without demand for water: 1. Check faucets and fixtures for leaks. 2. Check lines for leaks. 3. Water Heater: Your Revcon water heater is a 10 gallon electric, 110-volt heat exchanger. Before the power is turned on, make sure the water heater is filled With water. Even momentary operation of the heater without water in it Will burn out the element. NOTE: Always open both the cold and hot water faucets when filling water tank to allow air pockets to be forced out of the heater. When water flows from the heater, close hot water faucet. 4. Sewage & Waste Holding Tanks: Your Revcon is equipped with two separate holding tanks. One for water And another for sewage. Both are insulated to avoid freezing in cold climates. The dump outlet is located on the street side rear of the coach, (on 220 model there are two outlets and are labeled). To drain either tank: a. Remove the cap from the outlet and attach the 3" flexible hose (stores in the storage compartment on the street side) in the same manner as the cap. b. Connect the other end of the hose to a sewage or evacuation system. NOTE: Make sure there are no snags in the hose as this would prevent complete dumping. c. When evacuation is complete, remove and store the flexible hose and replace the cap. -33- NOTE: It is recommended that the sewage tank be dumped first and the water waste second. In this way, the hose is washed free of sewage and helps prevent any lingering odor. 5. Sanitizing Water System: To help assure complete sanitation of your living area water system, it is recommended that the following procedures be followed on a new system, one that has not been used for a period of time, or one that may have become contaminated: a. Prepare a chlorine solution using one gallon of water and 1/4 cup of household bleach (5% sodium hypochlorite solution). With the tank empty, pour chlorine solution into the tank. Use one gallon of solution for each 25 gallons of tank capacity. b. Complete filling tank with fresh water. Open each faucet and drain dock until all air has been released from the pipes and entire system is filled. c. Allow to stand for three hours. d. Drain and flush with potable fresh water. e. To remove any excessive chlorine taste or odor which may remain, prepare a solution of one quart vinegar to five gallons water and allow this solution to agitate in the tank for several days of vehicle motion. f. Drain tank and fill again with potable water. 6. Winterizing Procedure: When traveling in cold climates it is recommended that the water tank not be filled until the destination is reached. The water and holding tank system should be drained before leaving for home. -34- When storing the Revcon in below freezing temperatures (without furnace in operation): a. Drain hot water tank by opening petcock in the outside water heater compartment. b. Open the three orange drain valves in the water pump compartment under the sink. The forward valve drains the fresh water tank, the two rear valves drain the water lines. c. Blow compressed air through each faucet (hot & cold). d. Dump approximately one cup of antifreeze into each drain. (Galley, lavatory and tub/shower). C. L.P. Gas System Bottled LPG (Liquid Petroleum Gas) is safe, economical, clean and conveniently available. It operates the galley stove, oven and furnace in your Revcon. The tank is: located on the curb side of the vehicle in the unlocked compartment (on 220 and 250 MB models it is located on the street side) and is accessible only from the exterior of the coach. Propane should be used when making cold weather trips. You may find that in some sections of the Southern part of the country, only Butane is available. Butane will work well at temperatures above 30° F. The filler cap connection is used to replenish the gas supply of gas to all the LPG appliances. When opening the valve to operate the system, open all the way, then close it 1/4 turn. Always refill empty LP gas tank as soon as possible. Appliances will stop working when the gas supply becomes exhausted. When you are not using the gas appliances, shut off the control valve on the tank; this will help prevent moisture from condensing inside the tank. Having a small amount of dry Methyl alcohol put in the tank when you have it filled will help prevent moisture in -35- the tank and help prevent the lines from freezing in the Winter. CAUTION: LP gas is heavier than air and may "pool" in case of leakage. Be sure to thoroughly ventilate coach before attempting to re-ignite appliances. D. Living Area Comfort Features 1. Furnace: Your Revcon is equipped with a 30,000 BTU Suburban Dyna-Trail forced air furnace ducted throughout your coach, with controlled outlets. When the thermostat is adjusted to the desired setting, furnace blower motor is energized immediately. After three to five seconds the main burner will ignite. Following two minutes of burner operation a "snap" will be heard from within the furnace. This is the furnace fan switch changing to its normal run position. After this occurs, and the thermostat is satisfied or turned to a lower setting, the main flame will go out but the blower will continue to run for a short period, then shut off. CAUTION: Blower will turn on even though furnace not lit. Be sure thermostat is in OFF position when not in use. a. Lighting Instructions: 1. Set thermostat, located on the rear wardrobe, to the "OFF" position. 2. Turn the manual valve on the left side of the furnace unit to "OFF" position and wait five minutes. 3. Open manual valve fully. 4. Remove the lighter hole cover. 5. Press reset button and hold. 6. Insert a burning match through the opening so that flame is near the pilot. On the initial lighting, the pilot may not light immediately -36- due to air in the gas line. If such is the case it may be necessary to hold the reset button in for a minute or more before the pilot lights. 7. This new spark igniter has been added to facilitate lighting. It is a solid state device with no outside current required. Depressing the "Ignition Button" operates a lever on the device which, in turn, creates a spark at the igniter tip. Normally the unit will ignite with the first spark. In the event the unit doesn't readily light with the igniter, it's possible the igniter tip may need repositioning -aligning the igniter tip with the pilot gas flow can be accomplished through the lighter hole. On initial lighting, air in the gas line may require several pumps of the "Igniter Button" for ignition. The new igniter does not prevent the lighting by match if desired. 8. When the pilot is burning, continue holding the reset button in for approximately 30 seconds or until the pilot continues to burn when the reset button is released. 9. Replace the lighter hole cover. 10. Set thermostat at desired position. b. Burner Adjustment: After the pilot is lit, the furnace is ready for adjustment and observation of the main burner and pilot flame. To adjust primary air to the main burner, it is necessary to gain access the same way as with lighting the pilot. The small sheet metal cover found just below and to the right of the lighter opening must be removed. Behind the cover is a slotted screw head. With a screwdriver, turn screw head counter- clockwise for less primary air and clockwise for more primary air. A -37- symptom of too much primary air will be a howling or screeching noise when the burner is on. (Reduce air to correct.) A symptom of too little primary air will be sooting on the exterior vent and a distinct yellow and floating flame. (Increase air to correct.) A slight trace of orange should remain at the tip of the burner flame - this is a sign of correct adjustment. c. Shutting Off Furnace: To shut off furnace, set thermostat to "OFF" position and close manual valve. This is a precaution to be used when the furnace will not be in use. d. Furnace Operating Tips: If you experience a lack of heat, it would indicate that the main Burner is out. The most common reason for this is the pilot being out. If this is the case it could be caused by: 1. L.P. tank empty or turned off. 2. Pilot not adjusted properly. 3. Clogged pilot orifice. 4. Malfunctioning micro-switch. 5. Air leakage from combustion chamber or lack of air. If pilot is going out when the burner comes on, it is usually: 1. Not enough primary air. 2. Malfunctioning micro-switch. If pilot is going out two or three minutes after burner comes on: 1. Indicates a shorted fan switch. 2. Be sure thermostat is not set too low and all wires are connected to it. -38- e. Pilot Adjustment: To adjust pilot light, remove lighter cap. Remove pilot adjustment cover. Rotate pilot adjustment screw to where pilot flame just envelopes the thermocouple tip. f. Microswitch: The micro-switch operates in response to the current of air generated by the blower. If for any reason the air from the blower is not sufficient, the switch will not operate. This may be caused by a slow motor due to low voltage, restricted return air, or lint accumulation on the blower wheel. The micro-switch also allows time for the blower to pull sufficient amount of air to support combustion before it engages. Once engaged, the solenoid valve opens, gas flows to burner and ignition occurs. g. Maintenance and Cleaning: The furnace unit does not require any routine maintenance or cleaning. If for any reason the main burner has been allowed to operate with a high yellow flame, a soot formation is sometimes deposited inside the combustion chamber. This carbon deposit may be of quantity that cleaning will be necessary. To clean the combustion chamber, there is an access hole on the front of each radiation chamber. A vacuum cleaner is ideal to clean out any carbon deposit. The furnace is equipped with an oiled, sealed motor and requires no oiling. Warranty Practices: Your furnace is warranteed by its manufacturer. The warranty is enclosed in the warranty packet. Familiarize yourself with its coverage and Limitations. -39- 2. Off Road Air Conditioner Operating Instructions: Your Revcon has a 13,500 BTU roof mounted air conditioner. It operates on 110-V electrical power, which can be supplied by either an outside power source or 110-V auxiliary power plant. All switches and instructions for operation are located on the unit itself. Quick Cooling: To cool a hot vehicle quickly, turn the Temperature Control knob clockwise to its coldest setting and turn Air Control knob to HI COOL. Maintaining a Constant Temperature: Once the vehicle is cool, turn the Temperature Control knob to about one half of its maximum setting. NOTE: Operating the unit with the Temperature Control knob at its maximum or coldest setting after the temperature inside the vehicle has reached a comfortable level will cause the evaporator coil to freeze. When this happens, the amount of air produced by the unit decreases significantly and the temperature of the air will be much warmer. If this occurs, the only remedy is to turn the unit off long enough for the ice to melt from the evaporator coil. b. Maintenance and Protection: Cleaning the return air filters is the only maintenance that needs to be performed. Under normal operating conditions, these filters should be cleaned weekly. The following directions should be followed closely to prevent damage to the return air grills. 1. Turn the unit off. 2. Remove the return air grills and filters. Use a smooth flat object, such as a table knife. Insert this object between the center of the switch or label end of the grills and using a twisting action, gently -40- pry the grill until the mounting pins on the grill are free of their mounting holes in the plenum assembly. 3. Wash the filters and grills with warm soapy water; DO NOT use solvents. 4. Rinse the filters and grills with fresh water and dry. 5. Replace filters and grills in unit. When replacing the grills, be sure to install them with their notched side up toward the switch label plates. NOTE: You can damage the compressor by causing it to cycle off and on again immediately. Once the compressor has been turned off, wait several minutes for the pressure in the refrigeration .system to equalize before starting the system again. Warranty Practices: Your air conditioner is warranteed by its manufacturer. The warranty is enclosed in the warranty packet. Familiarize yourself with its coverage and limitations. E. Galley Area 1. Range and Oven: Your Revcon is equipped with an LPG operated range and oven. Any time the range/oven is in operation, the power vent fan should be operating to help ensure proper ventilation. Be sure the gas supply is turned on at the LP gas tank before using stove or oven. a. Top Burner Operation: Your range/oven has a top burner lighter pilot; this control has no preset positions but the flame can be adjusted to any desired height between full and off. To light top burners, turn the control knob counter-clockwise to full "ON" position. From the full "ON" position the flame may be lowered by turning the knob clockwise. -41- b. Oven Operation: The oven is controlled by a low temperature thermostat. This thermostat has no bypass setting and will cycle off and on at all temperature settings except broil ("B"). No bypass adjustment is necessary. c. Lighting Instructions: 1. Be sure all valves are in the "OFF" position. The oven thermostat dial should be in the "PILOT OFF" position. 2. Turn on main gas supply to the range. 3. Lift main cook top panel and light top burner lighter pilots with a match. 4. To turn on oven pilot, depress and turn the thermostat dial to the "OFF" position. 5. Open oven door and light oven pilot with a match. A small flame will be noted at the top of the pilot burner. d. Shutdown Instructions: When oven cooking is finished, turn the thermostat dial to the "OFF" position; the oven standby pilot flame will remain lit. When the coach is not in use, or while traveling, turn the thermostat dial to the "PILOT OFF" position and turn off the main gas supply. e. Thermostat Operation: Depress and turn thermostat dial counter- clockwise to the desired temperature setting. There is a delay of about 45 seconds before the amin burner ignites. This is normal and there is no gas escaping during this delay. It is also normal for the oven burner flame to cycle off and on at all set temperatures except broil. This maintains a constant temperature in the oven. -42- f. Pilot Adjustments: To adjust the top burner lighter pilot, raise main top and turn adjustment screw with a screwdriver. The top pilot flame should be about 1/8" above the lower edge of flash tube. NOTE: DO NOT use the pilot adjustment screw as a shutoff valve. g. Power Vent Switch: The power vent switch operates automatically when the upper compartment is opened on eye-level oven model. The bottom switch inside the compartment selects the fan speed. On under-counter model, the switch is on the hood. Stove Light: Is operated from the switch on the light fixture itself. Warranty Practices: Your stove/oven is warranteed by its manufacturer. The warranty is enclosed in your warranty packet. Familiarize yourself with its coverage and limitations. 2. Dual Voltage Refrigerator/Freezer a. Operation If your Revcon is equipped with a dual voltage refrigerator, it is operable on either 12-V DC or 115-V AC. Unlike the absorption type refrigerator which requires a constant heat source for efficient operation, your refrigerator operates on the same principle as the standard domestic refrigerator. That is, it has an electrically operated compressor and uses freon as its refrigerating medium. A single thermostat controls operation of the refrigerator on AC or DC. This thermostat is mounted at the rear of the freezer compartment. The knob is marked "OFF", 1 , 2, 3, 4 and 5. The nearer the dial is set to "5" the colder the temperature becomes in the cabinet. There is no need to re-adjust the setting of the thermostat for dual operation. Once the desired temperature is reached, the thermostat will control the cabinet -43- temperature equally well on either voltage supply. Before operating the refrigerator for the first time, check to see that the AC and DC supply connections are correct and that the thermostat is turned to the "OFF" position. Connect the vehicle to the external power supply of 115-V AC. Turn the thermostat knob to the number "3" setting. The unit should be operating. Allow the unit to operate on AC until it cycles or shuts itself off. This indicates the thermostat is operating and that the refrigerator is cooling on AC operation. Disconnect the AC supply and open the refrigerator door so that the cabinet interior will warm up and allow the thermostat to demand cooling. As soon as the unit compressor begins to operate, close the door, allowing the unit to run. It should shut off or cycle within 10 to 20 minutes indicating the DC operation is correct. Operating Tips: The following operating suggestions will serve as a guide in operating your unit efficiently during the 12-V DC (battery) operation. 1. Set the thermostat knob at the lowest setting that will provide adequate refrigeration. This will reduce the running time of the refrigerator and draw less current from the battery. A setting of "3" is normal. 2. Operate the unit with 120V AC source (shore power) whenever available. 3. Frost buildup (1/4" or more) should be avoided since it decreases the overall cooling capacity and increases power consumption. Warranty Practices: Your dual-voltage refrigerator is warranteed by -44- its manufacturer. The warranty is enclosed in your warranty packet. Familiarize yourself with its coverage and limitations. Gas/Electric Refrigerator: If your Revcon is equipped with a gas/electric refrigerator it will operate on LP gas or 12-V DC current. The unit is the continuous absorption type, which operates by the application of a small amount of heat. No moving parts are employed. Leveling: Park your coach as level as possible. The unit must be leveled back to front and side to side. There are two freezer plates inside the deep freeze compartment and when determining levelness of the freezer plates a small level must be used on either of the two plates to assure levelness. This level should be no longer than 3-1/2" to enable you to place it directly on the plate and not on the extending side rails. DO NOT place a long level over both freezer plates at the same time. The right freezer plate is slightly elevated over the left one. Operation: The normal start-up time is eight to 12 hours. There will be no Immediate refrigeration noticeable upon lighting the gas burner or operating your refrigerator on electricity. It is recommended that the door be opened from time to time during the first 12 hours of operation as thorough ventilation helps to improve the cooling power. For most economic ice cube production the ice cube trays should be Placed on the metal freezer plates. This refrigerator is equipped with a safety shutoff device, which will Cut off the gas supply should the burner flame extinguish for any -45- reason. However, it is recommended that all gas connections should be checked regularly for gas leaks with a soapy liquid. Gas Starts: The electric toggle switch must be in the "OFF" position to prevent simultaneous operation of the gas and electric energy source. 1. Level refrigerator in both directions (side to side and front to back). 2. Turn manual gas valve lever to horizontal position "ON". 3. Turn gas thermostat knob clockwise until stop, which is coldest or maximum position. 4. Push ignition push-button valve until stop and hold lit match. 5. Do not release the ignition valve for at least 30 seconds. 6. Observe burner flame in the mirror mounted beside the burner by looking in the direction of your ignition tube trickle flame. 7. When refrigerator has not been used for a long time, ignition operation may have to be repeated, thus caused by air in the gas supply lines. 8. When stable refrigeration conditions have been attained, turn thermostat knob counter-clockwise to a lower position or to the temperature desired. Electric Starts: 1. Level refrigerator in both directions (side to side and front to back). 2. Make certain that refrigerator electric supply cord is plugged in to the receptacle. 3. Turn manual gas valve lever to vertical position "OFF". -46- 4. Flip electric toggle switch to "ON" position and turn electric thermostat knob clockwise to coldest or maximum position. 5. The red electric pilot or indicator light should be lit. 6. When stable refrigeration conditions have been attained, turn thermostat knob counter-clockwise to a lower position or to the temperature desired. Maintenance: Heavy frost accumulation on the freezer plate results in poor refrigeration efficiency. It is therefore recommended that you defrost your refrigerator whenever the frost layer reaches approximately 3/8". To defrost, simply turn off the energy source either by turning off the manual gas valve or the electric toggle switch. You can accelerate the process by opening the refrigerator door. While you defrost it is recommended that you clean the inside with a lukewarm detergent solution and wipe the interior completely dry after cleaning, including the freezer plates. Never use any hot water, heating appliances or strong abrasives and detergents to force the defrosting process. This could cause severe damage to the refrigerator and would not be covered by the warranty. Warranty Practices: Your gas/electric refrigerator is warranteed by its manufacturer. The warranty is enclosed in your warranty packet. Familiarize yourself with its coverage and limitations. 3. Sink Area: a. Sink The stainless steel double sink is equipped with a hand spray to conserve water and increase efficiency in washing dishes. To operate -47- the spray; turn on water tap, depress handle on spray and hold while using. Water will come through spray as long as the lever is depressed. When finished simply release lever. b. Water Purifier The water purifier is located below the galley sink or the stove. This purification system provides you with water safe from harmful bacteria, virus and cysts, in addition to removing the dirt, tastes and odors. You received your purifier without its cartridge installed to assure you that the cartridge is a fresh one. You will find the cartridge under the sink or in a drawer. Install it following the instructions on the wrapper. A new cartridge is needed only when collected dirt blocks the ultra-fine filter pores so much that flow from the faucet is too slow for your convenience. Normally, the cartridge will last about 1,000 gallons, or a full season. For additional water safety and since the water purifier services the galley faucet only, it is advisable to chlorinate your water in the tank. Chlorinate with liquid household laundry bleach. Fill the chlorine disinfectant dispenser (Chlor-Pack) with liquid bleach and add 1/6 ounce (I teaspoonful) to each 10 gallons of water filled. This dosage quick-kills harmful bacteria and slime- forming organisms. 4. Electrical Outlets The control panel switch contains: a. TV antenna jack receptacles, (additional receptacles are in the bedroom and dinette.) The coach is not equipped with a TV antenna, however, a lead-in wire extends from the jack to the compartment over the refrigerator. -48- b. Water Pump Switch - to activate the water pump which supplies water pressure throughout the coach. c. 12-V DC outlet - any 12-V appliances can be plugged in to these outlets. (DO NOT exceed 12 amps.) d. 110-V AC outlets - any normal home appliance may be used with these outlets. The power is supplied by the auxiliary power plant or by shore power. NOTE: DO NOT exceed wattage capacity of your power plant when using 110-V appliances. F. Dinette Area All of the dinette configurations can easily be converted into a bunk, using the seat and back cushions for the mattress. 1. "L" Shaped Dinette on 350 DT and 220 Models To convert this dinette seating into a double bed, remove the table top, post, bolsters and teak wood moulding. Remove the detent pin under the inside seat bolster. Pull both platforms toward the aisle; release leg lever and leg will drop into place. Unfold the double bolster and place in position along with the back bolster. 2. "L" Shaped Dinette on 250 D Models Again remove table top, post bolster and teak wood moulding. Lift floor pedestal lid into vertical position and lock into place with slide bolt. Place table top on bunk brace plate and fit into niche of mouldings. Place the back cushion on the table top with the holding straps snapped into place to prevent the cushion from sliding. Place the small bolster (stored under the bed/couch shelf) between bolsters. Remove the end cushion and fold down shelf by releasing slide bolts on each end. -49- 3. "Magic Couch" To convert the couch into a double bed, again remove table top and post and end bolsters. Lift the underside of the front of couch and pull. Fold back seat cushion. 4. Goucho Dinette To convert the face to face dinette to a bed, remove the teak moulding from the front of both seats. Pull forward seat out to meet the facing seat and your bed is ready. G. Bedroom Area To convert the couch in the bedroom into a full size double-bed, remove detent pin under the front edge of the cushion. Lower shelf by releasing toggle bolts at both ends. Slide the bed frame toward the aisle and replace bolt to hold the frame in position. Place back bolster on the frame and you are ready for the sheets and blankets. 1. Double Bed Conversion a. Pull ring under front edge of cushion. b. Slide the bed frame toward you into position and replace pin to hold in place. c. Remove back cushion and place it on frame. d. Release slide bolts under each end of back shelf and allow shelf to drop against side of coach. 2. Gaucho Conversion - same as double bed. 3. Bunk Bed Conversion a. While holding bunk in place against ceiling, release slide bolts at each end. -50- b. Allow bunk to drop into sleeping position. c. Lock into position with slide bolts. 4. Vanity Area The vanity pullman is available in the 250 D model Revcon and offers, in place of the single bed of the 250 DT, counter space, four drawers and a wardrobe. Vanity The vanity area has two directional lights in the upper corners. The Switch knobs are on each individual light. To open the drawers, lift up on the handle slightly before pulling. Closets are opened by "pinch-pull" catch latches. H. Bathroom 1. Toilet The sanitation system used in your Revcon allows you to be away from public utilities with workable, convenient comfortable sanitation equipment. It provides a clean effective toilet system, a means of retaining waste, and a clean efficient way of disposing of waste. To operate the automatic flush and refill, depress the foot pedal until the rinse completely cleanses the bowl, then release. If you wish to add water into the bowl without flushing, depress the small, right-hand pedal until desired water level is reached, then release. Cleaning of the toilet bowl can be accomplished by using any high grade, nonabrasive cleaner. Highly concentrated or high acid content cleaners might damage rubber seals. -51- The toilet dumps directly into the sewage holding tank, therefore it is recommended that the tank be drained at regular intervals to avoid over- filling. Operating Tips a. Do not put facial tissue, automotive type anti-freeze, coffee grounds, laundry bleach or highly concentrated or high-acid content household cleaners in your holding tank or toilet systems as they may damage plastic or rubber parts in the system. b. Special nontoxic, non-flammable deodorizing chemicals can be added to holding tank, but are not required. Follow directions on container. c. Most toilet tissues are usable in system, however, special tissues designed to break down readily are available. d. Keep your holding tank drain valve closed when parked and connected to a sewer system. By doing this, enough fluids are put into the holding tank to entirely wash away the waste when drain valve is opened. 2. Lavatory Your Revcon is equipped with a stainless steel lavatory sink with hot and cold water taps and the "water saver". Press the "water saver" button before using the hot water. This will clean the line of cold water, returning it to the water tank, and fill the line with hot water, thereby conserving water. The swivel-mirror lights are operated by the switch beneath the right-hand fixture. -52- To open glass and soap holder, push on edge of the front plate and it will turn into position. 3. Shower-Tub The exclusive moulded shower-tub combination is designed for your comfort and convenience and to conserve the use of water. Before using hot water, activate the water pump and water saver. The shower head and flexible hose mount to a bracket on the shower wall. The hot and cold water handles on the bottom of the shower unit may be used to get desired temperatures. The On-Off valve on the showerhead may be used intermittently. Remove the shower head from holder by lifting up and removing it from the holding pin. To use the shower curtain, unsnap it from its folded position, pull across shower opening, and fasten into the snap on the wall by the shower unit. 4. Power Vent Operates from either the control panel switch plate or from the fan itself. The switch on the control panel must be on before switch on fan unit can be operated. I. Entry Step 1. Pullout step-simply pullout to extended position. 2. Electric Step (optional) - operates automatically. J. Windows The windows throughout your Revcon are operated by squeezing the latch and sliding the window to the desired position. The screens are easily removable for window cleaning. NOTE: Emergency evacuation of your coach can be accomplished by removing any screen. -53- K. Ceiling Vents The purpose of the ceiling vents is to allow warm air to escape that may accumulate at ceiling level when the vehicle is parked in the sun. Opening of a ceiling vent will aid in removing condensation from the windows. The vents are crank operated from inside the coach. In rainy weather it is possible to leave the ceiling vents open slightly for ventilation without entry of water into the living area (this is dependent upon the magnitude and direction of the rain, however). NOTE: All windows, drapes and roof vents must be tightly closed when operating the air conditioner or furnace to obtain maximum cooling or heating. L. Light and Power Switches 1. Overhead Lights: A light switch control plate is located inside the entry door. The top switch operates the overhead light fixtures in the center aisle of the coach. In addition, each overhead fixture has its own switch. The main switch must be in the "ON" position before either of the overhead light fixtures will operate. 2. Entry Light (Porch Light): Operates from the switch plate at the entry door only. 3. Step Light: The step light is located on the inside entry step and is operated by the switch plate at the entry door. M. Decor Features 1. Carpet: The carpeting used in your Revcon is nylon, and complies with the Federal Safety Standards. Cleaning of the carpet can be done with the use of any NONFLAMMABLE commercial carpet cleaners. -54- 2. Draperies: The drapes throughout the coach are operated by unsnapping the tie-back strap and sliding the drapes across the track. Should the drape disattach for any reason, simply re-insert the slide button into the track. For best results the drapes should be professionally dry cleaned. -55- IV. DRIVE TRAIN SERVICE & MAINTENANCE A. Engine Access Easy access to the Revcon drive train may be obtained from inside the driver's compartment. Swivel the passenger seat to the side and pull the chrome ring in the carpet next to the driver's seat. A hinged access cover lifts to reveal a portion of the engine for checking transmission fluid and engine oil. By sliding this cover up and to the rear you can lift the complete hatchway out of the front compartment, fully exposing the engine and making maintenance or repairs an easy job. Front engine access is provided by unlocking the front outside access door. Items that can be checked or serviced through the front access are coolant level, brake fluid, windshield washer and engine oil fill. Be sure to secure the access door after servicing to prevent the hatch from opening after the vehicle is in motion. Refer to the "Vehicle Maintenance Schedule" for service intervals and lubricant recommendations. Required checking and adjusting of the engine components is covered later in this section. B. Hoisting Instruction A twin post hoist of sufficient capacity and with proper adapters and/or fitting must be used. Front hoisting position is the front engine cross-member. Rear hoisting must be done at the rear suspension brackets. If an "I" beam type adapter is used, it should be approximately 82 inches in length to gain adequate support at suspension brackets. If the coach is to be placed on safety stands for maintenance or repairs, the hoisting points should be used. C. Lube & General Maintenance 1. Chassis At four month or 6,000 mile intervals, lubricate all fittings in front -56- and rear suspension and steering linkage. Also lubricate transmission shift linkage, brake pedal spring, parking brake cable guides and linkage. 2. Fluid Levels Check level of fluid in brake master cylinder, power steering pump, radiator, all batteries, engine, differential, final .drive, transmission and windshield washer. Distilled water should be used in all batteries. Clean battery cable terminals and hold down bracket every 12 months with a solution of ammonia water, and flush with clean water. The engine coolant should be checked for proper level and freeze protection to at least 32° F. NOTE: Any significant fluid loss in any of these systems or units could mean that a malfunction is developing and corrective action should be taken. A low fluid level in the brake master cylinder front reservoir could also be an indicator that the disc brake pads need replacing. 3. Engine Oil Change every three months or 3,000 miles, whichever occurs first. 4. Air Conditioning Check condition of air conditioning system hoses and refrigerant charge. Replace hoses and/or refrigerant as the need is indicated. Adding refrigerant may be necessary during the summer months. 5. Engine Oil Filter Replace at the first oil change and every other oil change thereafter. 6. Automatic Transmission Fluid and Final Drive Lubricant Under normal driving conditions transmission fluid and filter should be -57- changed every 12 months or 12,000 miles. Under unusual conditions such as hot weather, trailer pulling, etc., change should be made every 6,000 miles. It is important that the transmission fluid level be maintained at the fill mark and not overfill. Fluid level in the Final Drive should be maintained at the fill level line, with 1051022 or 1050081 fluid. For sustained high speed driving or trailer hauling it is recommended the fluid be changed at least every 12,000 miles. 7. Cooling System At 12 month or 12,000 mile intervals wash radiator filler neck and cap with clean water, pressure test system and radiator cap for proper pressure holding capacity. Tighten hose clamps and inspect condition of all cooling and heater hoses. Replace hoses every 24 months or 24,000 miles or earlier if checked, swollen or otherwise deteriorated. Every 12 months or 12,000 miles, clean exterior of radiator core and air conditioning condenser. Every 24 months or 24,000 miles, drain, flush and refill the cooling system with a new coolant solution. 8. Wheel Bearings Clean and repack rear wheel bearings with a high melting point wheel- bearing lubricant 1051344 every 12 months or 12,000 miles. 9. Final Drive Axle Boots & Output Shaft Seals Check for damaged, torn or leaking boots on drive axles and for leaking output shaft seal. Replace defective parts as necessary. 10. Wheels and Tires Have wheel-nut torque checked (450 lbs.) after first 500 miles and 500 miles after every wheel replacement thereafter. To equalize wear, rotate -58- tires and check tires for excessive wear, nails, glass, cuts or other damage. Make certain wheels are not bent or cracked. 11. Brakes & Power Steering Check lines and hoses for proper routing, leaks, cracks, chafing, deterioration, etc. Any questionable parts noted should be replaced or repaired immediately. 12. Exhaust System Check complete exhaust system and nearby body areas of engine and power plant systems for broken, damaged, missing or miss-positioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes to seep into the passenger compartment-. 13. Engine Drive Belts Check belts, driving fan, power steering pump, power plant and air conditioning compressor for cracks, fraying, wear and tension. Adjust or replace as necessary. NOTE: It is recommended that belts be replaced every 24 months or 24,000 miles, whichever occurs first. 14. Suspension and Steering Check for damaged, loose or missing parts, or parts showing visible signs of excessive wear or lack of lubrication in front and rear suspension and steering system. Questionable parts noted should be replaced by a qualified mechanic without delay. 15. Safety Checks to be performed by Owner Listed below are the safety checks that should be made by the owner. These checks should be made every four months or 6,000 miles, whichever occurs first, or more often when the need is indicated. Any deficiencies -59- should be brought to the attention of your service outlet. a. Steering Column Lock - Check for proper operation. Key should turn to LOCK position only when transmission control is in the "PARK" position, and should be removable only in "LOCK" position. b. Seat Belts - Check belts, buckles, retractors and anchors for cuts, fraying or weakened portions, loose connections, damage and for proper operation. c. Steering - Be alert to any changes in steering action. d. Windshield Wipers and Washers - Check operation of wipers and washer as well as condition and alignment of wiper blades. e. Defroster - Check performance by moving control to "ON" position and noting amount of air directed against the windshield. f. Wheel Alignment and Balance - In addition to abnormal tire wear, the need for wheel alignment service may be indicated by a pull to the right or left. The need for wheel balancing is indicated by vibration of the steering wheel or seat while driving at normal speeds. g. Brakes - Be alert to illumination of the brake warning light or changes in braking action, such as repeated pulling to one side, unusual sounds when braking or increased brake pedal travel. h. Parking Brake - Check parking brake holding ability by parking on a fairly steep hill and restraining the vehicle with the parking brake only. NOTE: DO NOT attempt to test the holding ability of the "PARK" position on the transmission, the vehicle could become locked in this position. -60- i. Lights and Buzzers - Check all instrument panel illumination, warning lights, ignition key buzzer, interior lights, license plate lights, side marker lights, headlights, parking lights, brake lights, turn signal and back up lights, hazard warning lights and clearance lights. j. Fluid Leaks - Check for fuel, water, oil or other fluid leaks by observing the ground beneath the vehicle after it has been parked for awhile. (Water dripping from the automotive air conditioner system after use is normal.) If gasoline fumes or fluid are noticed at any time, the cause should be determined and corrected without delay. k. Engine & Power Plant Exhaust System - Be alert to any change in the sound of the exhaust system, power plant, or smell of fumes which may indicate a leak. l. LP Gas System - Check that all vents and LP gas operated components are clean and operating properly. If LP gas fumes are noticed at any time the cause should be corrected without delay. 16. Disc Brakes Check brake pads and condition of rotors while wheels are removed during tire rotation. 17. Drum Brakes and Parking Brake Check drum brake linings and other internal brake components at rear wheels. Parking brake adjustment also should be checked whenever drum brake linings are checked. NOTE: More frequent checks should be made if driving conditions result in frequent brake application. A check should also be made without delay, if vehicle pulls to one side or an abnormal sound is heard during braking. -61- 18. Throttle Linkage Check for damaged or missing parts, interference or bindings. Any deficiencies should be corrected without delay. 19. Headlights Check for proper aim. Correct as necessary. D. Emission Control Maintenance 1. Thermostatically Controlled Air Cleaner Inspect air cleaner to make certain that all hoses and ducts are intact and correctly installed. Check valve for proper operation. 2. Carburetor Choke Check choke mechanism for free operation. A binding condition may have developed from petroleum gum formation on the choke shaft or from damage. 3. Timing Points (Dwell), Idle Speed, Distributor Adjust ignition timing, dwell and carburetor idle speed accurately at the first six month or 6,000 miles of operation, then at 12 month or 12,000 mile intervals. Adjustments must be made with test equipment known to be accurate. Replace distributor points every 12 months or 12,000 miles and replace cam lubricator every 24 months or 24,000 miles. Also carefully inspect and clean the interior and exterior of the distributor cap at 24 months or 24,000 mile intervals to prevent misfiring and deterioration. Proper functioning of the carburetor is particularly essential to control of emissions. Correct mixtures for emission compliance and quality have been preset by the manufacturer. Plastic idle mixture limiters have been installed on the idle mixture screws to -preclude unauthorized adjustment. These idle limiters are not to be removed unless some major carburetor -62- repair or replacement which affects the idle screw adjustment has been necessary. 4. Carburetor Mounting Torque carburetor-attaching bolts to 15 foot-pounds to compensate for compression of gasket at first four months or 6,000 miles of vehicle operation only. 5. Spark Plugs Replace at 6,000 mile intervals (when operating with leaded fuels) or at 12,000 mile intervals (when using unleaded fuel). Use of leaded fuels result in lead deposits on spark plugs and can cause misfiring at mileages less than 12,000 miles. Where misfiring occurs prior to 6,000 miles, spark plugs in good condition can often be cleaned, tested, and reinstalled in an engine with acceptable results. 6. EGR Valve Check system operation at 24 month or 24,000 mile intervals (12 month or 12,000 miles with leaded gasoline). Also clean valve and EGR passages in intake manifold as required. 7. Thermal Vacuum Switch and Hoses Check for proper operation. A malfunctioning switch must be replaced. Check hoses for proper connection, cracking, abrasion 'or deterioration and replace as necessary. 8. Carburetor Fuel Inlet Filter Replace filter at 12 month or 12,000 mile intervals or more frequently if clogged. A clogged carburetor fuel inlet filter will restrict fuel flow. -63- 9. Idle Stop Solenoid Check the idle stop solenoid to assure that it permits the throttle plate to close further when the ignition switch is turned "OFF". An inoperative solenoid should be replaced. 10. Positive Crankcase Ventilation System Check the PCV system for satisfactory operation at 12 month or 12,000 mile intervals, using a tester, and clean filter. Replace the PCV valve at 24 month or 24,000 mile intervals and blow out PCV valve hose with compressed air and replace the filter. The PCV valve should be replaced at 12 month or 12,000 mile intervals when the vehicle is used in operations involving heavy dust, extensive idling, trailer pulling or short trips in freezing temperatures. 11. Engine Compression Test engine cranking compression. If a problem exists, have correction made. Minimum compression recorded in any one cylinder should not be less than 10% of the highest cylinder. 12. Evaporation Control System Check all fuel and vapor lines and hoses for proper connections and correct routing as well as condition. Remove canister(s) and check for cracks or damage. Replace damaged or deteriorated parts as necessary. Replace filter in lower section of canister at 24 month or 24,000 mile intervals. 13. Air Cleaner Element Replace the carburetor air cleaner element under normal operating conditions every 24,000 miles. Operation of vehicle in dusty areas will necessitate more frequent element replacement. -64- 14. Fuel Cap, Fuel Lines and Fuel Tanks Inspect the fuel tank cap and lines for damage, which could cause leakage. Inspect fuel cap for correct sealing ability and indications of physical damage. Replace any damaged parts. 15. Spark Plug Wires Inspect spark plug wires for evidence of checking or cracking of exterior insulation and tight fit in the distributor cap and at the spark plugs. Exterior of wires should be cleaned, any evidence of corrosion on ends removed and wire replaced if deteriorated. 16. Coolant Level & Protection Check coolant for proper level regularly and every six months or 6,000 miles for freeze protection to at least 32 F. or the lowest temperature expected during the period of vehicle operation. Proper engine coolant also provides corrosion protection. -65- V. EMISSION CONTROL SYSTEMS A. Federal Clean Air Act The Clean Air Act requires the engine manufacturer to furnish, with each new engine installed or to be installed in a motor vehicle, such written instructions for the maintenance and use of the engine or vehicle as are reasonable and necessary to assure the proper function of emission control devices and systems installed on the engine or vehicle by Oldsmobile Division - General Motors Corporation. The following is being provided to Revcon owners in compliance with the law. B. Normal Vehicle Use The owner's maintenance instructions that follow are based on the assumption that your vehicle will be used as designed: 1. To carry passengers and cargo within the weight limitations indicated on the GVW (gross vehicle weight) plate or tire placard affixed to vehicle. 2. On reasonable road surfaces within legal operating limits. 3. On daily basis, as a general rule, for at least several miles. 4. On unleaded or low lead fuel. Unusual operating conditions will require more frequent vehicle maintenance as specified in the Emission Control Maintenance Schedule that follows. C. Maintenance Source and Evidence The required owner maintenance operations presented may be performed at the owner's option, by any qualified service outlet regularly performing such services. NOTE: Receipts covering the performance or regular maintenance should be retained in the event questions arise concerning maintenance. These -66- receipts should be transferred to each subsequent owner of the vehicle. D. Recommendations for Required Maintenance Service Replacement Parts The emission control systems on your new Oldsmobile engine were designed, built and tested using genuine General Motors parts and the vehicle is certified as being in conformity with federal regulations implementing the Clean Air Act. It is recommended that any replacement parts used for maintenance or repairs of emission control systems be new, genuine G.M. parts. Use of replacement parts which are not of equivalent quality may impair the effectiveness of such systems. EMISSION CONTROL MAINTENANCE SCHEDULE WHEN TO PERFORM SERVICES ITEM SERVICES NO. OWNER SERVICE LOG (Months or miles, Insert month and day whichever comes first) in mileage square closest to the mileage when serviced. Every 3 months or Engine Oil 3,000 miles At first oil change then Engine Oil Filter every second Every 6 months or 6,000 Coolant level and Miles protection Every 6,000 miles Spark plugs-using Every 12,000 miles leaded fuel. Spark Plugs-using unleaded fuel At first 6 month or 6,000 Thermostatically Miles - then at 12 month/ Control Air 12,000 mile intervals Cleaner Engine Drive Belts Carburetor Choke Timing, Dwell, Cart. Idle Sp. & Distributor At 6 months or 6,000 miles Carburetor Mounting -67- WHEN TO PERFORM ITEM SERVICES OWNER SERVICE LOG SERVICES NO. Every 12 months or Cooling System 12,000 miles Carburetor Filter Positive Crankcase Ventilation System Spark Plug Wires Automatic Transmission Every 24 months or Engine Compression 24,000 miles Evaporation Control System Air Cleaner Element Fuel Cap, Tank and Lines E. Emission Control Systems Warranty for Heavy Duty Engines Oldsmobile Division, General Motors Corporation warrants to the original and each subsequent owner of a recreation vehicle powered by an Oldsmobile heavy duty gasoline engine that the Oldsmobile engine at time of sale to the vehicle manufacturer (I) was designed, built and equipped so as to conform, at the time of sale, with applicable regulations of the Federal Environmental Protection Agency, and (2) is free from defects in materials and workmanship at the time of sale which will cause the engine to fail to conform with applicable Federal Environmental Protection Agency regulations for a period of use of 50,000 miles or five years, whichever occurs first. The five year/50,000 mile engine emission control systems warranty period shall begin on the date the vehicle is delivered to the first retail purchaser or, if the vehicle is first placed in service as a demonstrator or company vehicle prior to a sale at retail, on the date the vehicle is first placed in such service. This warranty does not cover: -68- 1. Malfunctions resulting from misuse, negligence, alteration, accident or lack of performance of required maintenance services. 2. The replacement of expendable maintenance items, which are spark plugs, ignition points, positive crankcase ventilation valve, filters, hoses, belts, wires and coolant made in connection with required emission control maintenance services. 5. Loss of time, inconvenience, loss of use of the vehicle, or other consequential damages. 4. Any vehicle on which the odometer mileage had been altered and the vehicles actual mileage cannot be readily determined. 5. Any vehicle registered and normally operated outside the United States. Oldsmobile Division's responsibility in respect to claims is limited to making or causing repairs to be made on recreational vehicles qualifying under this warranty be obtained from the servicing facilities of the vehicle manufacturer or any other qualified service outlet which regularly performs such repairs, in some cases, the owner may be required to pay for the repairs and obtain paid receipts covering the work performed. A statement of the circumstances relative to the warranty work, along with the paid receipts, should then be provided to 1he vehicle manufacturer for reimbursement in accordance with the manufacturer's published procedures covering warranty repair. -69- VI. EXTERIOR MAINTENANE The best way to preserve the exterior finish of your Revcon is to keep it clean. Normally, only frequent washings are required to maintain its original beauty. Wash the vehicle with either cold or warm water, not in the direct rays of the sun and not while the surface is hot. Do not wipe dirt from dry surface as this may scratch the finish. Wash all bright metal parts frequently to alleviate the destructive forces of salt, calcium chloride, salt air and exhaust gasses. Use lukewarm water and mild soap, not with a strong alkali solution and rinse thoroughly. DO NOT use metal polishes which may contain harmful abrasives. Even though the acrylic enamel on your Revcon is durable, it is advisable to wax or polish your coach to provide added protection. Nicks and chips in painted surfaces should be touched up before weathering action begins. The best time is immediately after the coach has been washed. Touch up paint is available from Revcon, Inc. or at Ditzier distributors throughout the United States. When ordering Revcon touch up paint, use the following Ditzler codes: White Gloss Automotive Enamel - LA-42474 Light Tan Gloss Automotive Enamel - LA-42473 Brown Gloss Automotive Enamel - LA-42475 -70- VII. EMERGENCY EQUIPMENT Fire extinguishers are standard equipment in all Revcon models. It is located just inside the main door. Instructions for its operation are printed on the cartridge. NOTE: It is advisable to make a periodic check of the chemical level and operation of your extinguisher. Recharging instructions are included in your appliance packet. Additional emergency equipment should include: 1. Flashlight. 2. First Aid Kit. 3. Emergency road flares and/or reflectors. 4. Extra fuses and lamps. 5. Shovel. 6. Basic Tool Kit including hammer, pliers, screw drivers and wrenches. -71- XI. LOADING YOUR REVCON A. Weight and Distribution Your Revcon is designed to take advantage of all available space for storage. Weight and distribution of the load are your most important factors to keep in mind. Therefore, care should be taken to: 1. Select only items essential to your travels. 2. Keep heavy items to a minimum. 3. Stow heavy items as low as possible and as close to the rear axle as possible. At no time should your load exceed the GROSS VEHICLE WEIGHT RATE (GVWR), the weight that your model Revcon is designed to handle including the vehicle itself, and all items added to it, on it and in it, including passengers. A GVWR plate is located under the lower left side of the dashboard which indicates the total GVWR for your model and the GVWR for both the front and rear axles. NOTE: The sum of the front and rear axle capacities is greater than the total GVWR, so DO NOT load both axles to maximum capacity at the same time. Actual total weight and front and rear axle weights can be determined at highway weigh stations. CAUTION: Exceeding the GVWR can void your warranty. B. Outside Storage A locked storage compartment with interior and exterior access is located on the curb side of your coach, just to the rear of the main entry door. Remember to store heavy items near the bottom. It is a good idea to limit the weight in this compartment to 100 lbs. C. Telescoping Rear Bumper Revcon's specially designed telescoping rear bumper is ideal for bicycles, -72- motor bikes, lawn chairs and other light equipment. To extend the bumper, remove the detent pins, pull out bumper to second set of holes and reinsert detent pins. NOTE: Be careful not to overload the rear bumper, keeping in mind proper weight distribution. Caution should be taken to balance and secure the load properly. Rack, straps and hardware are available from your recreational vehicle dealer or supplier. D. Interior Storage All of Revcon's interior storage compartments are designed for the security of your belongings. All cabinet and closet doors have a "pinch-catch clasp", pinch to open - push to close. Overhead lockers are secured with spring loaded hinges that stay closed while traveling. All drawers stay closed due to the "drop-in" groove - lift slightly before opening. NOTE: Avoid storing heavy, loose items in overhead lockers. They may fall and cause injury when locker is opened. Galley Area: Your galley area has ample storage compartments for dishes, cooking utensils and food. Stow heavy items such as canned goods in low areas. Commercial stack racks are ideal for glasses and dishes; trays are ideal for flatware and sharp utensils. Pots, pans and the like are best accommodated in lower compartments. When loading the refrigerator, stow heavy items low, but not in the door. Plastic containers are suggested rather than glass or cardboard. Never store any items in the oven. NOTE: Be sure that refrigerator and oven doors are secured before traveling. Bedroom Area: Overhead lockers are ideal for light articles such as clothing and bedding. When considering clothing for your travels, keep in mind the storage limitations. -73- Bathroom: Your bathroom is equipped with a clothes hamper, flush medicine cabinet with adjustable shelves and a linen closet. Here again, plastic containers are suggested to eliminate glass bottle breakage. NOTE: Do not store loose items in the bathtub. It can cause damage requiring costly repairs. E. Towing The towing capability of the Revcon is limited to a maximum of 2,000 pounds gross weight and to 750 pounds tongue weight. CAUTION: The power train warranty is voided if these specifications are not adhered to. If for any reason you find it necessary to have your Revcon towed, tow with the front wheels off the ground if possible. If the coach must be towed with all four wheels on the ground or with just the front wheels on the ground, tow with the transmission selector in neutral ("N") position and DO NOT EXCEED 35 MPH. -74- XII. PRE-TRAVEL CHECK LIST A. Exterior Check 1. Clean windows, mirrors and lights. 2. Check inflation and condition of all tires, including spare. A fully loaded Revcon, traveling at an average speed of 70 mph, should carry 60 psi in each tire. 3. Check propane tank level and secure fill door. 4. Check water storage tank level and fill cap. In the winter months it is recommended that the water tank not be filled until your destination is reached. This will eliminate the possibility of frozen water. 5. Empty waste and sewage holding tanks and check dump valve caps. 6. Secure storage compartment door. 7. Check rear bumper load. 8. Check operation of auxiliary power plant. 9. Check oil level in auxiliary power plant. 10. Check for clearance in all areas surrounding your coach. NOTE: This is a good opportunity to survey your campsite to make sure that all litter has been picked-up. B. Interior Check 1. Secure entrance door. To lock from the outside, turn key in counter-clockwise direction. To lock from the inside, simply push button in. NOTE: When locked, the door latch mechanism is inoperative, preventing inadvertent opening of the door. Always lock door while traveling for greater security for those inside and from those outside. 2. Position all windows and vents suitable for travel. 3. Secure all doors and drawers. -75- 4. Check that all stowage is secured properly. 5. Clear all tables, shelf and counter tops of all items. NOTE: Even small items can cause injury in case of sudden stops or accidents. 6. Turn off all LP gas controls on furnace, range and oven. 7. Turn off all lights and switches not needed for travel. 8. Adjust inside and outside rear-view mirrors. Inside mirror is equipped with "night-day" lever. 9. Position driver's and passenger seats, making sure position and swivel mechanisms are locked in place. 10. Adjust seat belts. Never use the same belt for more than one person. 11. Be sure you understand your Revcon and how to operate it and its systems. C. Automotive Check 1. Check gasoline level. 2. Check oil level. 3. Check fluid level in all batteries. 4. Check windshield wipers and washer reservoir. 5. Check radiator coolant level. 6. Check transmission fluid level. 7. Check power steering fluid level. 8. Check brake operation. 9. Check lug nuts on wheels (450 lbs. torque). 10. Check operation of all exterior lights. 11. Check vehicle maintenance schedule to make sure that all periodic maintenance and safety checks have been performed. -76- XIII. DRIVING TIPS 1. Your Revcon is 9' 8" high, with roof air conditioner, so watch for low hanging branches, bridges, overpasses and service station overhangs. Remember you have 20 to 25 feet of Revcon behind you, so swing wide around corners. And since your Revcon is 7' 6" wide, be sure you have ample clearance on both sides. 2. The Revcon power-to-weight ratio is lower than that of the average automobile. It is essential to compensate for less acceleration when moving into traffic or when passing another vehicle. 3. Give yourself more road room. This is as basic as it is simple. Since you have a bigger, heavier vehicle to handle, maintain a greater distance between you and the other guy. Tailgating is out. Slam-stops are out. Abrupt wheel swings are out. Extra maneuvering space is in - always. 4. Keep out of freeway "packs". The need for breathing space becomes even more ' apparent out on the big roads where the going gets fast. Allow more room all around, and more reaction time up ahead. Since a motor-home has more bulk, it doesn't like sudden surprises, evasive maneuvers or high-speed jockeying for position. Veteran drivers say, "Stay out of the wolf-packs. Ride alone." 5. Reign in on hot left turns. The turn to watch with special care is the tight left curve on any road that has a high center crown. Such roads, naturally, are banked to throw you the wrong way. Right turns are usually banked to let you lean into the turn, and are easier to take. 6. Keep good tires all around. You know how often you see the drivers of tractor-trailers out walking around their rigs inspecting their tires at service stops. Well, tires are pretty important for motor-homes too. Don't ever make the mistake of running on bald or near-bald tires. All drivers today should know that threadbare tires can be as slippery as grease on a -77- rainy road. With that extra weight pushing you around and possibly a higher center of gravity to contend with, a bad skid is a spooky experience. Of course, there is also more weight to bang down and possibly pop a worn tire if you hit a chuckhole. 7. Watch the pavement edge. It isn't easy for a motor-home to recover from a "drop-off" as it is for a car. So - run with a sharp eye on the edge whenever the pavement drops a couple of inches or the shoulder slopes away toward the ditch. If you should drop two wheels off the pavement, hold your steering wheel firmly so that a soft or sloping shoulder won't drag you to the right. And, as with a car, let your speed drop a good deal before trying to regain the pavement. 8. Use your right side mirror. When passing, it helps to watch the other vehicle until you are sure that you have plenty of room before pulling back in front of it. But you can also use that mirror as a means of getting cooperation from the other driver. Drivers today are learning to watch for the truck driver's face in the right side mirror. When you are ready to begin your pullback, let the driver you are overtaking see your face. Let him know you are watching him. When the other driver sees this, he may give you a quick flash of the headlights letting you know it is alright to pull back in lane. 9. "Pass the message back." John 0. Moore, Safety Programs Coordinator for New York State's Motor Vehicle Department, offers this tip. In even most light trucks, you have a big advantage over car drivers - you can see over their roofs. You can scan what's happening much farther ahead. At the same time, you may be blocking the view of cars in back of you. "The car drivers down there behind you don't have the chance you do to see problems ahead. So give them advance notice whenever you can. Tickle your brakes a few times to light up your brake lights. You can put your better vision to work to help the -78- other fellow, and many will appreciate it." 10. Don't wave cars around you. If you ever find yourself going slower than the flow of traffic and see a chance to help other vehicles get ahead of you, you may be tempted to wave them on by hand. This is a courtesy much appreciated by drivers behind you, but it is a serious risk. You might wave him right into trouble. He may collide with another vehicle, say one that suddenly turned onto the road. 11. Know how to outfox the wind. A strong, gusty wind is a real smart enemy. Never underestimate the wind's fighting punch. Its been known to upset high-sided vehicles. If you begin to feel wind-buffeting, there's only one thing to do - slow down. And if you see one of those vicious black thundersqualIs sweeping toward you, it's wise to get off the road into a safe parking place until the powerful wind subsides. The trouble isn't only that the wind can shove you around, it's in the danger that wind may blow other vehicles against yours on a slippery road. 12. Look out for wind shock from big trucks. There are three times to be careful. One, when you overtake a fast moving tractor-trailer in a steady crosswind. Wind comes around the front of a big rig, or bounces off the tractor with lots of force. It's probably wise if you not overtake a tractor-trailer at speeds over 50 mph if you are feeling any effects of crosswinds. The second time is when a tractor-trailer is overtaking you at high speed. You may feel a wind-jolt, followed by an "undertow" sensation. Your Revcon may feel pulled backward and the speed may actually drop a mile or two. In close proximity to any fast moving tractor-trailer, expect an "undertow" just as the tractor section pulls ahead of you. Third, use care when you meet an oncoming big rig on a narrow two-lane road at high speed. Again, you will feel a heavy wind blast which may make your -79- vehicle hard to control. So - prepare in advance. The smart thing to do is reduce your speed. Since this takes time, you should watch for these big rigs at least a half mile ahead. 13. Finally, never let yourself get too sleepy at the wheel. Drivers just starting or returning from vacations sometimes try to travel too far. -80-