Monaco DIPLOMAT 2004 Owner's Manual

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Diplomat

WARRANTY..............................................................................................3

SECTION 1 • GENERAL INFORMATION ..............................................15

CONTAINS WARRANTY INFORMATION AND KNOWLEDGE FOR THE OPERATION

AND CARE OF THE MOTORHOME.

SECTION 2 • DRIVING & SAFETY ........................................................37

CONTAINS INFORMATION ON DRIVING TIPS, EMERGENCY SITUATIONS, TOWING,

SAFETY DEVICES, WEIGHING THE MOTORHOME AND TIRES.

SECTION 3 • CARE & MAINTENANCE ...............................................111

CONTAINS INFORMATION ON PROPER CARE OF INTERIOR AND EXTERIOR

COMPONENTS AS WELL AS STORAGE TECHNIQUES.

SECTION 4 • APPLIANCES .................................................................159

COVERS OPERATION AND CARE OF VARIOUS APPLIANCES FOUND WITHIN THE

MOTORHOME.

SECTION 5 • EQUIPMENT...................................................................197

COVERS THE BASIC OPERATION AND CARE OF VARIOUS TYPES OF

Equipment.

SECTION 6 • WATER SYSTEMS .........................................................243

CONTAINS INFORMATION AND KNOWLEDGE FOR THE OPERATION AND CARE

OF THE VARIOUS WATER SYSTEMS.

SECTION 7 • LP-GAS SYSTEM...........................................................269

CONTAINS INFORMATION AND KNOWLEDGE FOR THE OPERATION AND CARE

OF THE VARIOUS LIQUIFIED PETROLEUM (LP-GAS) SYSTEM EQUIPMENT.

SECTION 8 • ELECTRICAL SYSTEMS - HOUSE...............................289

COVERS THE BASIC OPERATION OF THE HOUSE ELECTRICAL SYSTEM.

SECTION 9 • ELECTRICAL SYSTEMS - CHASSIS............................327

CONTAINS INFORMATION REGARDING THE CHASSIS ELECTRICAL SYSTEMS

SUCH AS THE BATTERY SPECIFICATIONS, DASH AND ALTERNATOR.

SECTION 10 • CHASSIS .....................................................................357

CONTAINS INFORMATION ON VARIOUS COMPONENTS OF THE MOTORHOME

CHASSIS.

Index....................................................................................................437

Table of Contents

Troubleshooting

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Questions and answers

Kathleen Mason

February 7, 2025

transmission dip stick location on diplomat 2004

1 comments:

Mr. Anderson

February 11, 2025

The transmission dipstick on a Monaco Diplomat 2004 is located in the rear curbside engine service area.

This answer is automatically generated

Charles snell

July 26, 2025

What is the model number

Charles snell

July 26, 2025

What is the model number

MERCEDES SANCHEZ

April 8, 2025

what size and dimensions are in a monaco diplomat 2006 refrigerator?

Summary of Contents for Monaco DIPLOMAT 2004

Page 1 Diplomat WARRANTY....................3 SECTION 1 • GENERAL INFORMATION ..........15 CONTAINS WARRANTY INFORMATION AND KNOWLEDGE FOR THE OPERATION AND CARE OF THE MOTORHOME. SECTION 2 • DRIVING & SAFETY ............37 CONTAINS INFORMATION ON DRIVING TIPS, EMERGENCY SITUATIONS, TOWING, SAFETY DEVICES, WEIGHING THE MOTORHOME AND TIRES. SECTION 3 •...
Page 3: Table Of Contents
Warranty WARRANTY LIMITED - 2004 DIPLOMAT ......LIMITATIONS OF IMPLIED WARRANTIES ....... . WHAT THE WARRANTY COVERS .
Page 5 MONACO MOTORHOME LIMITED WARRANTY What the period of coverage is: If you use your Monaco® motorhome only for recreational travel and family camping purposes, the Limited Warranty provided by Monaco ("Warrantor") covers your new motorhome when sold by an authorized dealer, for twelve (12) months from the original retail purchase date or the first 24,000 miles of use, whichever occurs first.
Page 6: Limitations Of Implied Warranties
DIPLOMAT 2004 Limitations of ANY IMPLIED WARRANTIES ARISING BY WAY OF STATE Implied Warranties LAW, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN DURATION TO THE TERM OF THIS LIMITED WARRANTY AND...
Page 7: How To Get Service
DIPLOMAT 2004 Defects and/or damage to interior and exterior surfaces, trim, upholstery and other appearance items may occur at the factory during manufacture, during delivery of the motorhome to the selling dealer or on the selling dealer's lot. Normally, any such defect or damage is detected and corrected at the factory or by the selling dealer during the inspection process performed by the Warrantor and the selling dealer.
Page 8: What The Warranty Does Not Cover
DIPLOMAT 2004 Because Warrantor does not control the scheduling of service work by its authorized servicing dealers, you may encounter some delay in scheduling and/or in the completion of the repairs. What the Warranty This Limited Warranty does not cover: any motorhome sold or registered Does Not Cover outside of the United States or Canada;...
Page 9: Legal Remedies
DIPLOMAT 2004 Legal Remedies THESE WARRANTIES ARE NOT INTENDED TO "EXTEND TO FUTURE PERFORMANCE" AND ANY ACTION TO ENFORCE THESE EXPRESS OR ANY IMPLIED WARRANTY SHALL NOT BE COMMENCED MORE THAN ONE (1) YEAR AFTER THE EXPIRATION OF THE RESPECTIVE WARRANTY COVERAGE PERIOD DESIGNATED ABOVE.
Page 10 DIPLOMAT 2004 Limitations of ANY IMPLIED WARRANTIES ARISING BY WAY OF STATE Implied Warranties LAW, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN DURATION TO THE TERM OF THIS LIMITED WARRANTY AND...
Page 11 DIPLOMAT 2004 Warrantor may use new and/or remanufactured parts and/or components of substantially equal quality to complete any repairs. Defect and/or damage to the Roadmaster Chassis may occur during manufacture at the factory, during delivery of the motorhome to the selling dealer or on the selling dealer's lot.
Page 12 DIPLOMAT 2004 What the Warranty This Limited Warranty does not cover: modifications and alterations to Does Not Cover the Roadmaster Chassis by others; the motorhome that is mounted upon the Roadmaster Chassis, including by way of example the motorhome manufacturer's design, manufacture, assembly and/or installation of the side walls, roof, windows, flooring, electrical system, plumbing system, LP gas system, appliances and slide outs;...
Page 13 DIPLOMAT 2004 Legal Remedies THESE WARRANTIES ARE NOT INTENDED TO "EXTEND TO FUTURE PERFORMANCE" AND ANY ACTION TO ENFORCE THESE EXPRESS OR ANY IMPLIED WARRANTY SHALL NOT BE COMMENCED MORE THAN ONE (1) YEAR AFTER THE EXPIRATION OF THE RESPECTIVE WARRANTY COVERAGE PERIOD DESIGNATED ABOVE.
Page 14: Warranty Information File
WOOD FINISH Monaco Coach Corporation Wood Finish: Because no two trees look alike, authentic woods vary in color and character markings such as streaks, knots and grain patterns. Since the stains may attach differently to these grain patterns,some natural light and dark areas may result.
Page 15 1 SAFETY SYMBOL LEGEND..........17 INTRODUCTION ............18 CUSTOMER RELATIONS..........19 REPORTING SAFETY DEFECTS ........19 TAKING DELIVERY ............19 Monaco Responsibilities..........19 Dealer Responsibilities..........20 Customer Responsibilities ........20 SERVICE SUGGESTIONS..........20 Prepare for the Appointment ........21 Prepare a List ............21 Be Reasonable With Your Requests ......21 No Looking Over the Technician’s Shoulder .....21...
Page 16 The motorhome manufacturer reserves the right to change product specifications, designs and standard equipment without notice and without incurring obligation. ©Copyright Monaco Coach Corporation. All rights reserved. The Diplomat is a trademark of Monaco. All other trademarks or registered trademarks are property of their respective holders.
Page 17 DIPLOMAT 2004 SAFETY SYMBOL LEGEND Indicates a WARNING. Information pertaining to personal safety and/or potential extensive damage to the motorhome. Indicates a CAUTION. Information pertaining to potential damage to the motorhome and/or its components. Indicates electrical DANGER. Information pertaining to danger or caution of potential electrical shock to person(s) or component(s), and/or risk of electrical fire to motorhome.
Page 18 DIPLOMAT 2004 INTRODUCTION This section contains warranty information and knowledge for the operation and care of the motorhome. Not all information may be applicable to your model of motorhome. More detailed information with CAUTION or WARNING instructions, other than what is found in this chapter, can be found in the manufacturer's owner manuals located in the owner information box.
Page 19 However, NHTSA cannot become involved in individual problems between you, your dealer or Monaco. To contact NHTSA you may either call the Auto Safety Hot line toll-free at 1-800-424-9393 (or 1-202-366-0123 in the Washington D.C.
Page 20 DIPLOMAT 2004 Dealer The dealer must perform additional pre-delivery inspections and system Responsibilities checks, assist in the customer’s understanding of the Limited Warranty and assist in completing any necessary forms. They must do a customer orientation to the motorhome, its systems, components and their operation.
Page 21 DIPLOMAT 2004 Prepare for the If you’re having warranty work done, be sure to have your warranty Appointment registration papers with you. All work to be performed may not be covered by the warranty; be sure to discuss additional charges with the service manager.
Page 22 DIPLOMAT 2004 FOR YOUR OWN REFERENCE F O R YO U R O W N R E F E R E N C E OWNER’S RECORD - SERIAL NUMBERS INFORMATION: Many of the serial numbers for various items and components are filed on the Data Card located in the Warranty Information File box.
Page 23 DIPLOMAT 2004 FOR YOUR OWN REFERENCE for your own reference OWNER’S RECORD - PERSONAL PROPERTY Item Serial Number Value _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...
Page 24 DIPLOMAT 2004 FOR YOUR OWN REFERENCE OWNER’S RECORD - INSURANCE Company: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...
Page 25 DIPLOMAT 2004 GLOSSARY OF AC Electricity - Alternating current also known as household power. TERMS Air Compressor - Pumps air to and builds air pressure in an air system. Air Dryer - Cools, filters and dries the air delivered by an air compressor.
Page 26 DIPLOMAT 2004 Current - Alternating (AC) - A current that varies periodically in magnitude and direction. A battery does not deliver alternating current. Also referred to as shore power, utility power, inverter power, generator power, etc. Current - The rate of flow of electricity or the movement rate of electrons along a conductor.
Page 27 DIPLOMAT 2004 Dump Valve - Another name for the T-handle valve used to drain the sewage (black) and waste (grey) tanks. Egress Window - The formal name for the emergency window located in the rear of the motorhome. Egress windows can be easily identified by their red handles.
Page 28 DIPLOMAT 2004 Regeneration - The mild backflow of air through the air dryer and out the purge valve that begins immediately after the purge and lasts normally 10 to 15 seconds. This backflow of air, from the air system and through the air dryer, removes moisture from the desiccant cartridge and prepares the air dryer for the next compressor load cycle.
Page 29 DIPLOMAT 2004 VENDOR LIST Batteries Air Bags Interstate Firestone 800-272-6548 317-818-8600 www.bridgestone-firestone.com www.interstatebatteries.com Air Conditioner Brake-Anti-Lock Brake System SCS/Frigette Eaton 800-545-6341 800-826-4357 www.scsfrigette.com www.eaton.com Air Conditioner - Roof Brakes (Exhaust) Dometic Corp Pac Brake (574) 463-4858 800-663-0096 www.dometic.com www.pacbrake.com Alternator...
Page 30 DIPLOMAT 2004 Engine Generator Cummins Onan 800-343-7357 800-888-6626 www.cummins.com www.onan.com Energy Mangagement System (Optional) Inverter Intellitec Trace Engineering 800-251-2408 (360) 435-8826 www.intellitecsve.com www.traceengineering.com Entry Step Leveling Jacks - Hydraulic Kwikee 800-736-9961 (760)746-5732 www.kwikee.com Liquefied Petroleum Protectors Fan - Bathroom Exhaust MTI Industries, Inc.
Page 31 DIPLOMAT 2004 Television Outside Mirrors Velvac Mirror 877-266-2728 800-783-8871 www.velvac.com www.rca.com Rear Vision System Television Antenna Sony Winegard 800-222-7669 319-754-0600 www.sony.com www.winegard.com Refrigerator Tires Norcold Goodyear Tire & Rubber 800-543-1219 800-399-2772 www.norcold.com www.goodyear.com Satellite Toilet Thetford (401) 847-3327 800-521-3032 www.kvh.com www.thetford.com...
Page 32 DIPLOMAT 2004 Water Filtration Everpure 630-654-4000 www.everpure.com/consumer/rv Water Heater Atwood Mobile Products 800-873-4328 www.atwoodmobile.com Washer/Dryer (Optional) Splendide (503) 655-2563 www.splendide.com MANUAL ADDENDUMS Water Pump Shurflo www.monacocoach.com 800-854-3218 www.shurflo.com Click ENTER to enter the main web page. Then click on the SERVICE link and choose Wheels - Aluminum MANUAL ADDENDUMS from the drop down menu.
Page 33 D I P L O M A T 2 0 0 4 O W N E R ’ S M A N U A L Q U E S T I O N N A I R E Your suggestions are very important to us and we are continually striving to improve the quality of our manuals.
Page 34 FOLD Place Postage Here TECHNICAL PUBLICATIONS MONACO COACH CORPORATION 91320 COBURG INDUSTRIAL WAY COBURG, OR 97408-9908 FOLD LONG OTTED...
Page 35: Limited Warranty Transfer Application
SELLING DEALER SIGNATURE TERMS & REPRESENTATIONS By your signature(s) on this form, and in order to induce Monaco Coach Corporation to transfer its Limited Warranty, you represent the following: 1. That you have received and read a copy of the Limited Warranty.
Page 37 Driving & Safety section 2 DRIVING & SAFETY ............39 WEIGHING THE MOTORHOME ........84 Inspections..............39 Weight Label ............88 Familiarize Yourself ..........39 Four-Corner Weighing (Example) ......89 Mirror Adjust (Manually)..........39 VIEWS ............... 99 Safety Seat Belts .............41 Front ...............99 Driving Tips .............44 Rear..............99 PRE-TRIP PREPARATIONS - CHECKLIST.......49 Roadside.............
Page 39 DIPLOMAT 2004 DRIVING & SAFETY Section two contains information on driving tips, emergency situations,towing, safety devices, weighing the motorhome and tires. 010613 Inspections There are significant differences between a passenger automobile and a motorhome. Always be aware of these differences when traveling. The key to safely operating a motorhome is inspection.
Page 40 DIPLOMAT 2004 Mirror Adjusting: • Tools needed: Allen wrench. • Adjust the driver's seat to the travel position. • Using an "Allen wrench" have the assistant loosen the two 3/16" Allen set screws located at the base of the mirror. (See point "A"...
Page 41 DIPLOMAT 2004 Safety Seat Belts All occupants must be furnished with and use seat belts while the motorhome is moving. The driver’s seat, and all other seats designed to carry passengers while the motorhome is in motion, are equipped with safety seat belts.
Page 42 DIPLOMAT 2004 A child safety seat is required for a child: • From birth to one year, or up to 21 pounds, the child is considered an infant. A (convertible) safety seat for an infant must be secured facing rearward. The top of the head must be below the top of the safety seat.
Page 43 DIPLOMAT 2004 020230 Example 2: High back booster seat facing forward. CAUTION: Installation illustrations are for reference only, and are not to be used as a guide. Refer to the safety seat manufacturer’s guide. WARNING: Because there are many styles of safety and booster seats, refer to the manufacturer’s manual...
Page 44 DIPLOMAT 2004 Seat Belt Care: Keep the belt clean and dry. To clean, use a mild soap and lukewarm water. Never use bleach, dye or abrasive cleaners as they may weaken the belt. Inspect the belts periodically. Check for cuts, frays or loose parts.
Page 45 DIPLOMAT 2004 Driving Cautions: • Avoid getting too close to the edge of the road, a soft shoulder may not support the weight of the motorhome. • Side spacing is best maintained by keeping the motorhome centered in the driving lane.
Page 46 DIPLOMAT 2004 Ascending a Grade: When approaching an uphill grade, try to assess how steep and long it is before beginning to climb. Prepare early for long climbs. Unlike gasoline engines, diesels do not necessarily produce more power by pressing further on the accelerator! A gasoline engine will happily work at full throttle (at least for a short period of time), but a diesel usually just wastes fuel at full throttle.
Page 47 DIPLOMAT 2004 Night Driving: • As always be well rested and alert when driving. If necessary, find a safe stopping place to rest until ready to continue. • Avoid using any interior lights while driving. They can create a glare on the windshield, decreasing visibility.
Page 48 DIPLOMAT 2004 Guidelines to Help Increase Fuel Efficiency: • When starting out, apply the throttle lightly and accelerate gradually, avoid using excessive throttle and accelerating quickly. • Check the tire pressure. A low tire is not only a safety hazard, it also increases rolling resistance which increases fuel consumption.
Page 49 DIPLOMAT 2004 PRE-TRIP PREPARATIONS The following list highlights items that need to be checked on - CHECKLIST the motorhome before traveling. Prior to departing several items will need to be prepared. Some suggestions are listed below. Use the lists as general guidelines when preparing to depart. By doing so, there is a better chance of not facing problems during the trip.
Page 50 DIPLOMAT 2004 Exterior Items: • Check operation of all exterior lights, headlamps, taillights, brake and clearance lights. • Check the battery fluid level of Liquid Lead Acid batteries. • Check all fluid levels on the chassis and generator. (See Chassis Information section and the generator manual for details.)
Page 51 DIPLOMAT 2004 Storing Cargo: Caution must be exercised when opening as cargo may shift during traveling. When closing the bay doors, be sure to keep fingers away from the openings. When opening the bay doors, use thumb at position shown while opening. Cargo may shift while driving.
Page 52 DIPLOMAT 2004 HITCH - When using the rear hitch remember that the motorhome is intended for Using the Rear towing light loads. The motorhome is designed to be used primarily as a Receiver recreational vehicle. Towing will affect durability and economy. Safety and satisfaction require proper receiver use.
Page 53 DIPLOMAT 2004 Tow Car or Trailer: 1. Connect tow car or trailer with light harness to motorhome and perform a light check. 2. Connect safety chains. 3. Check the tow car or trailer and the motorhome before starting a trip and at each rest stop.
Page 54 DIPLOMAT 2004 Tow Plug Connection The motorhome is pre-wired from the factory with an electrical harness for towing. The harness is located on or near the hitch receiver. Convoluted tubing protects the tow harness wires until ready for use. Current draw should not exceed ten amps for each designated light circuit.
Page 55 DIPLOMAT 2004 BACKING UP Whether you are a long time owner of recreational vehicles or just starting A MOTORHOME out, backing up can be a challenge. Following some simple guidelines may help reduce the challenge. When backing up, the driver (pilot) should be comfortable using the mirrors, the back-up camera and the co-pilot’s directions (ground guide)
Page 56 DIPLOMAT 2004 The five directional signals are as follows: 1. Co-pilot uses left hand and arm held horizontal, with forefinger pointing right, to direct rear of motorhome to the right. 2. Co-pilot uses right hand and arm held horizontal, with forefinger pointing left, to direct rear of motorhome to the left.
Page 57 DIPLOMAT 2004 Backing Up Trailers: Trailers have only one pivot point. Trailers may be backed up. Towed vehicles using a tow bar or tow dolly have more than one pivoting point which makes this type of equipment not suitable for backing. If using this type of towing equipment, plan ahead.
Page 58 DIPLOMAT 2004 Follow the procedures and guidelines for “Leveling the Motorhome.” If the motorhome is equipped with hydraulic jacks, be certain the parking surface will accommodate the weight placed on the jacks. CAUTION: Before leveling the motorhome survey the area...
Page 59 DIPLOMAT 2004 • Hook the potable water hose to the city water connection in the service center. Install a water pressure regulator to protect the water hose from excess pressure. Turn the hand valve to “city water.” NOTE: Attach a water pressure regulator between the city water faucet and the potable fresh water hose to protect the hose from swelling or bursting under high city water pressure.
Page 60 DIPLOMAT 2004 By placing a small plastic tub in the sink, gray water can be collected and recycled for use in the toilet. Instead of rinsing dishes under a running faucet, use two plastic sink tubs - one for washing and one for rinsing. When possible, take advantage of campground facilities offering restroom, shower and laundry service.
Page 61 DIPLOMAT 2004 • Place a large flashlight inside the front door for navigating through the coach during the night without having to use interior lights. If interior lighting is needed, use one light in a central location, such as the vanity.
Page 62 DIPLOMAT 2004 Typical Current Draw: • Interior Coach Power requires using a continuous duty solenoid that has a .7 Amp draw. • A 13" TV has a 1.7 Amp draw. • Rope lights (10 ft) are a 1.3 Amp draw.
Page 63 DIPLOMAT 2004 BREAKING CAMP Below is a checklist guide to reference when preparing to break camp. Preparing the motorhome for travel will require several small tasks. Properly securing and storing items will help prevent them from getting lost or being damaged during travel.
Page 64 DIPLOMAT 2004 Interior Checklist: • If applicable, clear the slide room path, clean the floor, move the driver seat forward and make sure the bay doors are shut. Retract the slide room. When the slide room is fully retracted secure any slide room locks.
Page 65 DIPLOMAT 2004 EMERGENCY If an emergency situation occurs, use the appropriate braking technique PROCEDURES and pull off the roadway a safe distance from traffic (if possible). Set the - ROADSIDE parking brake and turn on the hazard warning flashers, especially when parked alongside traffic lanes.
Page 66 DIPLOMAT 2004 Jump Starting Alternative Starting Procedure: A weak or discharged battery will not supply the amount of CCA (Cold Cranking Amps) necessary to initiate and maintain cranking the engine while supplying the required voltage to start the engine. If the engine fails to crank, or cranks slowly due to a weak chassis battery, there are electrical back-up systems in place that will increase chassis battery voltage.
Page 67 DIPLOMAT 2004 To Use the Solenoid: • With the ignition key off, press and hold the Battery Boost switch for 10 seconds. After 10 seconds, continue to hold the switch down and turn on the ignition. Observe the battery volt gauge on the dash, it should read at least 12 Volts.
Page 68 DIPLOMAT 2004 080350 Jump Starting: • When using an external electrical source to connect to the chassis battery, turn the main battery disconnect switches OFF prior to hooking up the jumper cables. • Hook up the cables then wait several minutes to allow a surface charge to build in the chassis battery before attempting to start the engine.
Page 69 DIPLOMAT 2004 TOWING If calling a towing company for service, it is recommended to use a PROCEDURES lowboy/ landall type of trailer. If a tow truck is used it needs to have a support arm that goes under the motorhome and secures to the front axle.
Page 70 DIPLOMAT 2004 • If the rear wheels are disabled, place the motorhome on a flat bed trailer or use a heavy duty dolly under the rear wheels and tow the motorhome from the front. • The drive shaft must be removed to prevent damage to the transmission.
Page 71 DIPLOMAT 2004 Drum Brake Models: • Place wheel chocks firmly against the wheel before performing this procedure. • Remove the plug from the center of rear brake chamber on the drive axle. • Remove the caging tool from its holder on the brake chamber and insert the tool into hole.
Page 72 DIPLOMAT 2004 TIRES A tire designed for a motorhome is a very technical and precisely engineered product. To obtain maximum wear and the best service out of the tires, it is helpful to understand their function. A tire is a "container" that holds air.
Page 73 DIPLOMAT 2004 Importance of The most important factor in maximizing the life of the tires is Air Pressure maintaining proper inflation. Driving on any tire that does not have the correct inflation pressure for the load of the motorhome is dangerous and may cause premature wear, tire damage and/or loss of control of the motorhome.
Page 74 DIPLOMAT 2004 Tire Pressure Federal law requires that the specifications for the tire’s maximum load Inflation Guideline rating be molded into the sidewall of the tire. The amount of air pressure to use is dependent on the weight of the motorhome when it is fully loaded. The chart within this section indicates the weights that can be properly supported by varying air pressures.
Page 75 DIPLOMAT 2004 Tire Chart - Goodyear The motorhome manufacturer is not the author of this chart and makes no representation or warranty concerning the accuracy of the information disclosed by the chart. The motorhome manufacturer is not responsible for the accuracy of the information disclosed or for any errors within the Tire Inflation Chart DRIVING &...
Page 76 DIPLOMAT 2004 Inspecting & Regularly check the tire pressure. A nail or screw can lodge in a tire and Pressure create a slow leak. The object may eventually be spotted on a front tire or an outside rear dual. However, if there is a slow leak on an inside dual, it will probably go unnoticed.
Page 77 DIPLOMAT 2004 Lower than recommended pressure can cause: • Tire squeal on turns. • Separations. • Rapid and uneven wear on the edges of the tread. • Circumferential Breaks. • Tire container can bruise or rupture. • Higher Risk of Road Hazard.
Page 78 DIPLOMAT 2004 Air Pressure 1. When checking the air pressure, make sure the tires are Checklist cool - meaning they are not hot from driving, even a mile. NOTE: If the motorhome must be driven a distance to get air, check and record the tire pressure first and add the appropriate air pressure when reaching the pump.
Page 79 DIPLOMAT 2004 Supporting When Extreme caution must be taken to ensure that the tires are fully supported Leveling when placing blocks under the tires. The load on the tire should be evenly distributed on the support block. In the case of dual tires, distribute the load evenly on blocks for both tires.
Page 80 DIPLOMAT 2004 Tire Vibration Sudden tire failure or blowout is often preceded by tire vibration. Some other symptoms that can cause tire failure are a bulge in the sidewall or swelling in the tire carcass. Striking an object or large hole in the road surface can damage a tire.
Page 81 DIPLOMAT 2004 Tire Care Road oil will cause deterioration of the rubber. Dirt buildup will help hold chemicals in the air next to the tire and will also cause deterioration. When cleaning any rubber product, proper care and methods in cleaning must be used to obtain the maximum service years out of the tires.
Page 82 DIPLOMAT 2004 • Before installing the wheels, lubricate the hub pilot pads with a drop of oil to prevent galling. Do not lubricate any other wheel or hub surface. • For a hub with intermittent pilot pads, position a pad at the twelve o’clock position to center the wheel and reduce runout.
Page 83 DIPLOMAT 2004 Storage of Tires The motorhome is designed for recreation, not long-term storage. However, - Long Term unless you are living in your motorhome full-time you will have a need to store it. Rubber tires age faster when not being used. A cool, dry, sealed garage is the preferred method of storage.
Page 84 DIPLOMAT 2004 Before removing the motorhome from long-term storage thoroughly inspect each of the tires. This means a close examination of each tire’s tread area and air pressure. If the pressure check indicates the tires have lost air during storage, inflate them to the correct pressure for the current load before...
Page 85 DIPLOMAT 2004 When the actual loaded weight of the motorhome, and the weight on each axle is unknown, follow the recommended tire inflation pressure(s) listed on the federal certification label. When loading a motorhome never exceed the motorhome's Gross Vehicle Weight Rating (GVWR) or the GAWR for each axle.
Page 86 DIPLOMAT 2004 The following is an explanation of commonly used weight abbreviations. • Gross Vehicle Weight Rating (GVWR): Maximum permissible weight of this motorhome. GVWR is equal to or greater than the sum of UVW plus CCC. • Unloaded Vehicle Weight (UVW): Weight of this motorhome as built at factory with full fuel, engine oil and coolants.
Page 87 DIPLOMAT 2004 Scales: Certified public scales are located in a variety of places such as moving and storage lots, farm suppliers with grain elevators, gravel pits, recycling companies and large commercial truck stops. If you are not aware of a nearby public scale, check the local area telephone book yellow pages under "scales-public"...
Page 88 DIPLOMAT 2004 Weight Label 2 • 88 DRIVING & SAFETY...
Page 89 DIPLOMAT 2004 Four Corner NOTE: Following scale readings and Gross Axle Weight Weighing (Example) Ratings are fictitious. Actual scale readings and Gross Axle Weight Ratings will vary with model and options. The motorhome must be weighed fully loaded to obtain accurate scale readings and to determine the proper tire pressure.
Page 90 DIPLOMAT 2004 • Refer to the Tire Chart (Tire size 295/80R22.5). Use the highest actual weight, Scale B or D, line 2. Example 7,100 lbs. Determine the proper tire pressure for each tire using the Load Inflation chart. Example: 115 psi or stamp on the sidewall of the tire.
Page 91 DIPLOMAT 2004 Load and Inflation Tables: The load and inflation table helps to determine the correct inflation for the motorhome tire, after properly weighing the motorhome. All pressures are rated at a cold psi. Cold conditions are defined as early in the morning before the day's ambient temperature, sun's radiant heat or the heat generated while driving have caused the tire pressure to temporarily increase.
Page 92 DIPLOMAT 2004 2 • 92 DRIVING & SAFETY...
Page 93 DIPLOMAT 2004 Cargo Carrying Capacity: When weighing the motorhome it is important to understand that each motorhome, even of the same model year, floorplan and length will weigh different due to options and accessories. The Gross Vehicle Weight Rating (GVWR), Gross Combination Weight Rating (GCWR) and/or Gross Axle Weight Rating (GAWR) must not be exceeded.
Page 94 DIPLOMAT 2004 The 154 pounds (70kg) is the average weight established by the US Federal Government and Transport Canada, and is used to arrive at Cargo Carrying Capacity (CCC). However, actual sleep capacity weight may be greater. The SCWR is not intended to limit the sleeping capacity to a specified weight.
Page 95 DIPLOMAT 2004 020254 DRIVING & SAFETY 2 • 95...
Page 96 DIPLOMAT 2004 6,500 6,500 13,000 5,000 4,000 9,000 13,000 4,000 10,000 10,000 20,000 7,100 6,900 14,000 20,000 6,000 23,000 33,000 10,000 23,000 10,000 9,170 9,087 8,919 8,149 8,149 020255b example 2 • 96 DRIVING & SAFETY...
Page 97 DIPLOMAT 2004 020255b DRIVING & SAFETY 2 • 97...
Page 98 DIPLOMAT 2004 2 • 98 DRIVING & SAFETY...
Page 99 DIPLOMAT 2004 VIEWS - Front 010770 Rear 010771 DRIVING & SAFETY 2 • 99...
Page 100 DIPLOMAT 2004 Roadside 010769 Curbside 010768 2 • 100 DRIVING & SAFETY...
Page 101 DIPLOMAT 2004 SPECIFICATIONS - DIMENSIONS CHART 2004 Diplom at Specifications 36PST 38PBDD 38PST 40PBDD 40DST 40PST 40PST Weights Gross Vehicle Weight Rating 32,000 32,000 32,000 32,000 32,000 32,000 32,000 Gross Combined Weight Rating 42,000 42,000 42,000 42,000 42,000 42,000 42,000...
Page 102 DIPLOMAT 2004 Operation When a 9 Volt DC battery is correctly connected, the smoke alarm is operating. The LED will flash every minute showing the battery is supplying power. A load alarm will sound when a production of combustion is sensed.
Page 103 DIPLOMAT 2004 LP-GAS DETECTOR The LP-Gas detector is required safety equipment in RVs. American National Standards Institute (ANSI) A119.2 - Fire & Life Safety 3-4.8 LP Gas Detectors states " An LP Gas detector must be installed in any RV that contains an LP Gas appliance and an electrical system.
Page 104 DIPLOMAT 2004 Take precautions to be sure one of these nuisances has not masked an actual gas alarm condition. The detector draws less current than one instrument panel lamp. The detector will operate to detect gas until the battery is drained down to 7.0 Volts. The detector must be supplied with a voltage higher than 7.0 Volts, for it to operate properly.
Page 105 DIPLOMAT 2004 Potential Sources of LP Gas Leaks When Operating the Motorhome: • Cooktop Burners • Water heater • Oven • Defective Regulator • Furnace • Defective LP-Gas Connection • Refrigerator • Portable Propane Powered Equipment Alarm Mute: Press the Test-Mute button when the detector is in alarm.
Page 106 DIPLOMAT 2004 CARBON MONOXIDE American National Standards Institute (ANSI) A119.2 - Fire DETECTOR & Life Safety 3-4.6 Carbon Monoxide Detectors states " All RVs equipped with an internal combustion engine or designed with features to accommodate future installation of an internal combustion engine and truck campers shall be equipped with a listed CO detector installed in accordance with its listing."...
Page 107 DIPLOMAT 2004 Operation The detector is equipped with a self-cleaning CO sensor and requires a ten minute initial warm-up period to clean the sensor element and achieve stabilization. During the warm-up period, the green power light will flash ON and OFF. The green power light should be lit when the power is on. If the light is not lit, turn off the power and check all wire connections.
Page 108 DIPLOMAT 2004 Testing Test Procedures: Test the carbon monoxide detector operation after the motorhome has been in storage, before each trip and at least once a week during use. Test the alarm by holding the TEST/RESET button in until the alarm sounds. The alarm will sound 4 beeps and the indicator lamp goes steady red.
Page 109 DIPLOMAT 2004 FIRE EXTINGUISHER The fire extinguisher in the motorhome is located near the main entrance door. Please read the operating instructions that are printed on the fire extinguisher. If there is any doubt on how to operate the fire extinguisher, you and your family should practice using it.
Page 110 DIPLOMAT 2004 ~ NOTES ~ ________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ 2 • 110 DRIVING & SAFETY...
Page 111 Exterior & Interior Care section 3 EXTERIOR CARE ............113 COUNTERTOPS - SOLID SURFACE ......138 Corrosion ..............113 Laminate ...............139 Washing ..............113 WINDOWS ..............139 Condensation ............139 Drying ..............114 WINDOW TREATMENTS..........140 Waxing ..............114 Tire Care ...............115 Mini-blinds ............140 Aluminum Wheels ..........115 Day/Night Shades (Opt.) ........141 Bright Metal............116 MOLD &...
Page 113 DIPLOMAT 2004 EXTERIOR CARE The most common cause of corrosion to the motorhome is the accumulation Corrosion of road salts, grime and dirt. These elements, combined with moisture, may possibly cause early component failure. Salt air and fog from coastal trips can greatly accelerate the corrosion process.
Page 114 DIPLOMAT 2004 Drying Drying chamois cloths come in natural and synthetic materials. Either type is acceptable as long as the surface is clean. Soak the chamois in clean water until all chamois material has absorbed water. Wring excess water from chamois.
Page 115 DIPLOMAT 2004 When selecting a product the container should be marked, “safe for clear coats” or “clear coat safe.” Carefully follow all manufacturer’s application instructions when using a product. Upon first use of a product, try it on a “small test spot” in an inconspicuous area in case an undesired reaction occurs.
Page 116 DIPLOMAT 2004 To maintain the original appearance of the aluminum wheels the following procedures are recommended: 1. After installing new wheels (prior to driving the motorhome) use a sponge, cloth or soft fiber brush to wash the exposed wheel surfaces with a mild detergent/warm water solution.
Page 117 DIPLOMAT 2004 Roof Care & Periodic resealing of the joints and seams is necessary to prevent the entrance of Seal Inspections moisture into the motorhome. Enough emphasis cannot be placed on this issue. Extreme damage from a water leak can occur rapidly. Never leave the vehicle unattended with the slide room extended.
Page 118 DIPLOMAT 2004 Acrylic Foam Tape: Read the following instructions to properly install the 3M Acrylic foam tape. • Clean Surface - Use Pro-Clean to clean the surface of dirt, wax, and any other foreign substances for the best results. • Surface Temperature - The surface where the product is desired should be 75 °F/24°C for proper adhesion.
Page 119 DIPLOMAT 2004 Spray Foam: Used as a sealant where a hole has been made for items such as water lines or wires that are coming through a floor opening. INTERIOR CARE Most fabrics have a designated cleaning code assigned to them. The cleaning - FABRICS code is determined, in most cases, by the content of the fabric.
Page 120 DIPLOMAT 2004 "S/W" - Clean this fabric with the foam only of a water-based cleaning agent or with a pure solvent in a well ventilated room petroleum distillate-based products such as Energine, Carbona, Renuzit, or similar products may be used). Cleaning only by a professional furniture cleaning service is recommended.
Page 121 71% Acrylic 23% Sofa, Living Room Lambrequin Frieze Sandalw ood Polyester 6% Cotton 100% Polyurethane Blend Furniture, Pilot Seat Ultraleather 391-3954 Monaco Sand Ultraleather w / 100% Rayon Backing 100% Polyurethane Blend Pilot Seat Insert Ultraleather Ostritch 333-3958 Tumblew eed...
Page 122 Room & Bedroom Lambrequin Dash Vinyl Tumblew eed Taupe Vinyl Vinyl 100% Polyurethane Blend Furniture, Pilot Seat Ultraleather Monaco Taupe 391-3955 Ultraleather w / 100% Rayon Backing 100% Polyurethane Blend Pilot Seat Insert Ultraleather Ostrich Monaco Taupe Ultraleather w / 100% Rayon Backing 3 •122...
Page 123 Bedroom Pillow , Bedroom 100% Dacron Polyester Lambrequin VisaIntrinsic Krinkle 13 Taupe 100% Polyurethane Blend Furniture, Pilot Seat Ultraleather 391-3955 Monaco Taupe Ultraleather w / 100% Rayon Backing Pilot Seat Insert, Sofa Arm Insert, 100% Polyurethane Blend Ultraleather Ostrich 333-3959 Clay Ultraleather...
Page 124 DIPLOMAT 2004 SOUTH PACIFIC .929 APPLICATION COLOR/PATTERN CONTENT CODE Windshield Pearl Silk 100% Polyester Bedspread, Headboard, Bedroom Millenium Sage 100% Cotton Dry Clean Pillow , Bedroom Lambrequin Bedroom Pillow , Bedspread Accent, Living Room Lambrequin, Macho Sage 100% Avora Bedroom Lambrequin...
Page 125 DIPLOMAT 2004 Vinyl Several areas of the motorhome such as the dash, ceiling and items of furniture may be covered in vinyl. The care and cleaning of these areas are outlined in the Morbern Vinyl section below. Morbern Vinyl: Vinyl requires periodic cleaning to maintain its neat appearance and to prevent the buildup of dirt and contaminants that may permanently stain and/or reduce the life of the vinyl if not removed.
Page 126 DIPLOMAT 2004 Ballpoint Ink: Permanent Marker Ink spots will stain the vinyl permanently. Wipe the stain immediately with rubbing alcohol in a well ventilated area to remove much of the stain. Oil-Base Paint: Use turpentine in a well ventilated area to remove any fresh paint. Dried paint must be moistened using a semi-solid, gel-type stripper.
Page 127 DIPLOMAT 2004 Lipstick, Grease, Oil, Make-Up or Shoe Polish: Apply a small amount of mineral spirits with a cloth. Rub gently. Be careful not to spread the stain by smearing it beyond its original source. Remove shoe polish immediately as it contains a dye which will cause permanent staining.
Page 128 DIPLOMAT 2004 Ultra-Leather Care Instructions: • Spot clean with mild soap and water • Air dry or dry quickly with warm setting of a hair dryer. • For stubborn stains, use mild solvent. • For tougher stains, try Fantastik® brand spray cleaner.
Page 129 DIPLOMAT 2004 FLOORS - Carpet Cleaning Spot Removal Procedures: • Act quickly when anything is dropped or A B C D E F G H I spilled. Remove spots before they dry. Use the solution specified in order • Blot liquids with a clean, white absorbent cloth or paper towel.
Page 130 DIPLOMAT 2004 Cleaning Solutions: A. Dry Cleaning Fluid: A nonflammable spot removal liquid, available in grocery and hardware stores. B. Nail Polish Remover: Any acetate, which often has a banana fragrance. Do not use if it contains acetone. C. Detergent Solution: Mix two cups of cold water and 1/8 teaspoon mild liquid detergent (no lanolin, non-bleach).
Page 131 DIPLOMAT 2004 Tile Floors Tile floors vary in porosity and surface irregularities. This can make it difficult to protect and maintain. Regular maintenance is important to keep the tile in the motorhome looking showroom new. Once the slide-out has been extended, keep the tile floor clean to prevent dirt from scratching the tiles prior to retracting the slide-out.
Page 132 DIPLOMAT 2004 Laminate Floors Laminate flooring used in the motorhome provides style, durability and (Optional) ease of maintenance. This high-pressure laminated flooring is designed to be incorporated as a floating floor. Laminate flooring is constructed of three main material components. The surface, similar to many countertops, contains aluminum oxide particles to form an extremely hard, durable outer layer.
Page 133 DIPLOMAT 2004 SHOWER Showers are susceptible to soap build up. Showers should be cleaned weekly to prevent burdensome clean-up. Using the same solution used to clean tile floors will be sufficient for the shower. However, to control mildew growth spray the shower with household chlorine bleach and allow it to stand for five minutes.
Page 134 DIPLOMAT 2004 WALL COVERINGS Time is very important when removing substance from wall coverings that are solvent based or contain color. Do not use abrasive cleaners containing chlorine bleach or solvents. Fidelity and Jolie brands are recommended. Always begin with a mild detergent or soap and warm water. To remove normal dirt clean with a soft sponge.
Page 135 DIPLOMAT 2004 Pencil: Erase as much of the pencil mark as possible. Wipe any remaining marks with rubbing alcohol. Blood, Feces or Urine: Remove these staining substances as quickly as possible. Wash the stained area with a strong soap. If the stain does not disappear, rinse the soapy area thoroughly with clean water.
Page 136 DIPLOMAT 2004 Sanding and Sandpaper: The following table is a general guide to the proper uses, although this may vary from wood type to type.The key to sanding is using the right sandpaper for the repair that is needed. Always sand with the grain.
Page 137 DIPLOMAT 2004 Restoring the clear finish: Check the scratches carefully. If flaking varnish is visible with dark-stained wood underneath, only the clear finish may need to be restored. Rub the loose varnish with fine steel wool or fine synthetic steel wool until you have removed the flaking varnish and slightly roughened a small area of the finish surrounding the scratch.
Page 138 DIPLOMAT 2004 COUNTERTOP The Solid Surface was created for a lifetime of easy care. Just follow the - SOLID SURFACE simple guidelines listed here to the keep countertop surface looking nice. Routine Care: The motorhome countertops are finished with one type of finish: matte/satin.
Page 139 DIPLOMAT 2004 Countertops Clean laminate countertops with a damp cloth or sponge. Use a spray - Laminate cleaner to remove stubborn stains. Avoid using harsh abrasives, scouring powders, peroxides or bleaches as these products may dull or damage the surface. Avoid contact with dyes, bleaches, and indelible inks on food packages.
Page 140 DIPLOMAT 2004 Controlling Moisture Condensation: Reduce or eliminate interior moisture condensation during cold weather by using the following steps: • Partially open the roof vents and windows so that outside air can circulate into the interior. Increase the ventilation when large numbers of people are in the motorhome.
Page 141 DIPLOMAT 2004 • Spot-Cleaning: Spot-clean shades and blinds using a soft cloth or a moistened sponge with lukewarm water. Add mild detergent, if needed. Blot gently to avoid creasing. In a dusty environment, the blinds may need to be cleaned regularly using a sponge or dampened soft cloth.
Page 142 DIPLOMAT 2004 MOLD & MILDEW What is Mold? Mold is a plant belonging to the Fungi group. In short, mold is a type of fungus that occurs naturally in the environment, and is necessary for the natural decomposition of plant and other organic material. Mold spreads by means of microscopic spores borne on the wind, and is found everywhere life can be supported.
Page 143 DIPLOMAT 2004 Standards or threshold limit values for concentration of mold or mold spores have not been set. Currently, there are no EPA regulations or standards for airborne mold contaminants. There is simply no practical way to eliminate all mold and mold spores in the indoor environment. For example, studies have shown that ozone cleaners are not effective at killing airborne mold or surface mold contamination.
Page 144 DIPLOMAT 2004 Whether or not a motorhome owner experiences mold growth depends largely on how the motorhome is managed and maintained. As a manufacturer, our responsibility is limited to things that we can control. As explained in the written warranty, we will repair or replace defects in the...
Page 145 DIPLOMAT 2004 • Seal cracks, crevices, and other gaps especially around doors and windows. Make sure all windows and doors are screened and fit the screens snuggly in their frames. • Many pests need moisture to successfully live and reproduce.
Page 146 DIPLOMAT 2004 Regularly inspect the exterior of the motorhome for signs of a budding wasp nest, and promptly destroy small nests before they become too large. Spiders can be in any structure. Since they are predators and feed on living prey, this would indicate other smaller pests may be found. Immediately remove spider webs.
Page 147 DIPLOMAT 2004 Damage from Pest: On one occasion a motorhome owner, investigating the cause of a failed inverter, discovered that a lizard had crawled in the inverter, shorted out the circuit board and died. Lizards can be captured using glue traps. To remove the lizard from the trap, dissolve the glue with vegetable oil and then release the lizard outside and well away from the motorhome.
Page 148 DIPLOMAT 2004 GENERAL Performing regular scheduled maintenance ensures reliable operation and LUBRICATION optimum service life of the various chassis components. Completed maintenance MAINTENANCE brings peace of mind knowing the various components have received proper service. Failure to follow maintenance guidelines, or perform scheduled maintenance, results in inefficient operation, premature component wear or component failure resulting in breakdown.
Page 149 DIPLOMAT 2004 Grease ratings and their base compounds are especially important when selecting a lubricant type for an intended application. Some grease compounds are manufactured for multi-use application. These are acceptable if the grease rating is in accordance with the manufacturer’s recommended lubricant type and rating.
Page 150 DIPLOMAT 2004 Greasing When preparing to use a high-pressure grease gun, thoroughly clean all Zerk grease fittings before applying new lubricant. Keep paper towels or disposable rags handy when greasing. When lubricating items such as drive shafts and steer axles components, continued grease application is generally required until new grease appears at exit points.
Page 151 DIPLOMAT 2004 Short term storage is defined as storing the motorhome for a period of STORAGE thirty days or less. Properly preparing the motorhome during periods of short - Short Term term storage will make bringing the motorhome out of storage a much easier process.
Page 152 DIPLOMAT 2004 Long Term Long term storage of the motorhome can be defined as leaving a motorhome unattended for a period of thirty days or more. A motorhome requires protection from the elements just as a house or a car would. When...
Page 153 DIPLOMAT 2004 Type of surface to park and store the motorhome on: • The type of surface the motorhome is parked upon will affect how much moisture accumulation occurs on the chassis and flooring. Moisture can eventually seep into the interior.
Page 154 DIPLOMAT 2004 Inspect the motorhome: • Perform a full interior inspection for water leaks every two weeks while the motorhome is in storage. Open all cabinet doors looking for signs of dampness or leaks. Inspect the ceiling areas around roof vents or other roof openings.
Page 155 DIPLOMAT 2004 Winter Storage • Plumbing Lines - Drain and protect by filling with - Checklist approved RV antifreeze. • Fresh Water Tank - Drain. • Body - Clean and wax. Oil locks and hinges. Repair roof seams as needed.
Page 156 DIPLOMAT 2004 Removal from If the motorhome was properly and carefully prepared for storage, Storage removing it from storage will not be difficult. The following checklist pertains to items or areas which should be checked before operating or mov- ing the motorhome. If the motorhome was not properly winterized, extensive freeze damage or other serious deterioration may have occurred.
Page 157 DIPLOMAT 2004 • Open cabinet doors and drawers. Inspect for water leaks at joints or fittings. Repair as necessary. • Operate all 12 Volt lights and accessories. If something does not work there may be a bad 12 Volt circuit breaker or blown fuse.
Page 158 DIPLOMAT 2004 ~ NOTES ~ ________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ 3 •158 EXTERIOR & INTERIOR CARE...
Page 159 Appliances section 4 FURNACE..............181 APPLIANCES - INTRODUCTION ........161 Operating Instructions ...........182 REFRIGERATOR ............161 Using the Furnace..........182 Operating Specifics..........162 Tips...............183 Inverter Mode Operation ........163 If the Furnace Fails to Light........183 Control Panel - Two Door........163 WATER HEATER ............184 Control Panel - Four Door ........164 Before Using the Water Heater .......184 Icemaker (OPT.).............166 Operation ..............185...
Page 161 DIPLOMAT 2004 APPLIANCES This section covers operation and care of various appliances found in the - INTRODUCTION motorhome. The motorhome is equipped with a refrigerator, cooktop range, microwave, furnace, water heater, roof air conditioner and other optional appliances. Many of these appliances operate on AC or DC current, LP-Gas or a combination of all three.
Page 162 DIPLOMAT 2004 Operation • The refrigerator operates from LP-Gas or 120 Volts AC electric. Specifics • DC Voltage must be no higher than 15.4 Volts DC or lower than 10.5 Volts DC. • AC voltage must be no higher than 132 Volts AC or lower than 108 Volts AC.
Page 163 DIPLOMAT 2004 Inverter Mode The ice maker requires 120 Volt AC power from shore power, generator Operation or the inverter to operate. The ice maker will not operate on LP-Gas. For example: If dry camping or 120 Volt AC is not available from the generator or from shore power the ice maker can still operate by using the inverter to supply the 120 Volt AC.
Page 164 DIPLOMAT 2004 Manual Mode: When one of the two manual modes is selected: 1. AC = The refrigerator is operating on AC electric. 2. LP = The refrigerator is operating on LP-Gas. If the LP-Gas does not ignite within 30 seconds, the control changes to a different energy source or the gas safety valve closes and F displays.
Page 165 DIPLOMAT 2004 Manual Mode: When one of the two manual modes is selected: 1. AC = The refrigerator is operating on AC electric. 2. LP = The refrigerator is operating on LP-Gas. Automatic Mode: This feature selects AC over LP-Gas operation. If AC discontinues, the alarm sounds and the refrigerator switches to LP-Gas operation.
Page 166 DIPLOMAT 2004 Icemaker (Optional) The icemaker works from 120 Volts AC only. The icemaker functions only after the freezer temperature is low enough. City water or the water pump must be on and the valve for the water supply line to the icemaker must be on.
Page 167 DIPLOMAT 2004 When storing the motorhome, the refrigerator doors have a storage position that locks the doors partially open. This will help reduce odor from mold and bacteria. A com- pletely sealed refrigerator in storage is a perfect environment for mold and bacteria to grow.
Page 168 DIPLOMAT 2004 Storage • Turn the refrigerator off and remove all items. Leave the drip tray under the cooling fins. • Shorten defrost time by using trays of warm water. Do not use a heating gun, hair dryer or sharp objects to remove frost as these can damage the interior or cooling unit.
Page 169 DIPLOMAT 2004 Microwave Tips: • When the microwave is first powered up, the display will blink. Press Stop/Clear. • Limit microwave use when dry camping. House battery power is quickly consumed. • Turn the oven off before cleaning. • Keep the inside of the oven clean. When food spatters or spilled liquids adhere to oven walls, wipe with a damp cloth.
Page 170 DIPLOMAT 2004 About Cooking: • Food should be arranged with the thickest area towards the outside of the dish. • Monitor cooking times. Use the shortest amount of time required for cooking and add time as needed. For popcorn, follow product instructions and carefully monitor for the duration of popping time.
Page 171 DIPLOMAT 2004 Operation The microwave oven in the motorhome combines the power and convenience of a microwave and a convection oven. The microwave oven is 850 watts microwave oven, with convection temperature range from 100º, 150º and 275º to 450º F, and a 1.2 cubic foot oven capacity. It operates on 110 Volt or 120 Volt AC power sources;...
Page 172 DIPLOMAT 2004 Maintenance The exterior of the microwave is plastic and metal. The interior is metal. Do not use scouring pads, harsh or abrasive cleanser, chemical cleaners or petroleum based thinners as these can damage the finish. Use mild soap and water with a damp cloth or paper towel to remove most stains or spills.
Page 173 DIPLOMAT 2004 Oven Light: 1. Remove the louver as indicated under the charcoal filter. 2. Slide the metal light cover forward and lift upwards. 3. Remove the light bulb and replace only with an equivalent watt bulb. DO NOT EXCEED 30 WATTS.
Page 174 DIPLOMAT 2004 COOKTOP The cooktop uses LP-Gas only as a fuel source. The burners use a piezo type igniter. The cooktop should be used for cooking purposes only and not as a heating source. When the burner valve is opened the fuel source flows through the valve into the mixture tube.
Page 175 DIPLOMAT 2004 Cooktop Cover To Lift Cover: • Lift the cover then fold. The cover will lock into the upright position. CAUTION: Lid is heavy. To Close Cover: • Allow the cooktop to cool to room temperature before closing cover. Raise cover arms from lock position, lower and unfold cover.
Page 176 DIPLOMAT 2004 Operation Tips: 1. A yellow flame is an indication of incorrect fuel/air ratio. Lowered BTU output and carbon build up can occur. 2. Flame appearance may change and BTU output will lower when operating the cooktop at an altitude above 5,000 feet. Allow extra cooking time.
Page 177 DIPLOMAT 2004 Porcelain Enamel: Porcelain enamel, a type of glass fused on steel at a very high temperature, is not extremely delicate but must be treated as glass. Sharp blows, radical surface temperature changes, etc., will cause enamel to chip or crack. Some foods such as vinegar, lemon juice, tomatoes and milk contain acids which can dull the finish of the enamel.
Page 178 DIPLOMAT 2004 WALL THERMOSTAT One comfort control operates the HVAC (Heating, Ventilating and Air Conditioning) system. The comfort control is located in the hallway on the monitor panel. The comfort control will operate roof air conditioner functions and LP-Gas furnace operation. The comfort control uses a liquid crystal display to show the current mode status.
Page 179 DIPLOMAT 2004 NOTE: The air conditioning system freezes moisture in the air. It is recommended to set the blower fan speed to high when operating in high humidity. NOTE: There are ambient air temperature limitations in HEAT PUMP mode. The roof air conditioner will not operate in HEAT PUMP mode with ambient temperatures of 30º...
Page 180 DIPLOMAT 2004 Operating Roof air conditioner operates only when following needs are met. Instructions • 120 Volts AC, from either shore power or the generator, is supplied. • The battery cut-off switch is in the ON position and house batteries are charged.
Page 181 DIPLOMAT 2004 Heat Pump Operation: • Battery cut-off switch must be in the ON position. • Slide the ON/OFF switch to the ON position. • Press the MODE button repeatedly until HEAT PUMP is displayed. • Set desired fan speed by pressing the FAN button.
Page 182 DIPLOMAT 2004 Operating The furnace operates in the following manner: The wall thermostat Instructions sends a signal to the front roof air conditioner circuit board, which closes a relay. Closing a relay sends an electrical signal to the furnace to begin the ignition cycle.
Page 183 DIPLOMAT 2004 Tips • After storage the furnace may produce a musty smell during the first couple of cycles. • Operating the furnace at an altitude above 5,000 feet reduces the BTU output due to air/fuel ratio. • The furnace will periodically need to be serviced by a qualified technician.
Page 184 DIPLOMAT 2004 WATER HEATER The water heater uses two different methods to heat water: (1) 120 Volt AC, supplied either by shore power or the on board generator (2) LP-Gas. The 120 Volt AC uses a heating element similar to the type used in a house water heater.
Page 185 DIPLOMAT 2004 To Purge the Air and Pressurize the System: • Remove the access panel to the back of the water heater. • Turn the water heater Bypass Valve (located at the back of the water heater) to Normal Flow. If necessary replace drain plug.
Page 186 DIPLOMAT 2004 Heating Water with LP-Gas: • Make sure the primary LP-Gas valve is open and the electric LP valve is on. • Turn on the water heater 12 V switch. The indicator light on the switch will illuminate briefly then go out when the burner ignites. The burner will make an audible "roar"...
Page 187 DIPLOMAT 2004 Thermostats Separate thermostats are used for LP-Gas and AC electric. The thermostat controls the power to the module board. At 130° F, the thermostat will open, extinguishing the burner. If the thermostat fails, a High Temperature safety limit switch will open. The safety switch will require manual reset.
Page 188 DIPLOMAT 2004 Pressure The water heater is equipped with a Pressure-Temperature relief valve. Temperature Relief The water heater may discharge from the Pressure-Temperature relief valve Valve during the heating cycle due to thermal expansion of water. The Pressure- Temperature relief valve is designed to open if the water temperature in the tank reaches 210°...
Page 189 DIPLOMAT 2004 Burner Compartment Periodically check the outside service compartment and screen (in the door) for foreign material the can accumulate and prevent the flow of combustion and ventilating air. 010720B Tips • To conserve LP-Gas, turn off the water heater when not in use.
Page 190 DIPLOMAT 2004 Troubleshooting • If water heater fails to light check the mixture tube for obstructions. Spiders may make nests in the burner tube. It is recommended to clean the burner tube with a brush and not compressed air. Compressed air may not fully remove the obstruction.
Page 191 DIPLOMAT 2004 WASHER - DRYER (OPTIONAL) The automatic washer-dryer has a capacity of up to 12 lbs. of dry clothing. It is front loading with an extra large door opening for easier access. Several wash and dry programs are available along with variable water temperature settings.
Page 192 DIPLOMAT 2004 031017 To Conduct the Test Procedure: 1. Set the selector knob to Reset. 2. Set the Dry Timer knob to 30 minutes. Push the On/Off button to On. Wait five seconds. The Auto Dry light should be on and the Status light flashes fast then slow.
Page 193 DIPLOMAT 2004 To begin a wash load: • Sort and pre-treat clothes. • Add the measured amount of detergent suggested by the package directions (maximum two tablespoons). • Load the clothes loosely into the washer. Close the washer door. • Turn the Wash Temperature knob to the desired temperature setting.
Page 194 DIPLOMAT 2004 Winterizing the To Winterize the Washer Dryer with Air Pressure: Washer-Dryer 1. Hook an airline (regulated to 45 psi or less) to the water inlet of the motorhome. 2. Rotate Selector knob to a wash position with the Wash Temp setting on Warm.
Page 195 DIPLOMAT 2004 ~ NOTES ~ ________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ APPLIANCES 4 • 195...
Page 196 DIPLOMAT 2004 ~ NOTES ~ ________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ 4 •196 APPLIANCES...
Page 197 Equipment section 5 SOFA BED EASY BED W/DRAWER......222 EQUIPMENT - INTRODUCTION........199 SOFA HIDE-A-BED CONVERSION ........223 ENTRY STEP ...............199 SOFA BED CONVERSION MAGIC BED (OPT)....223 Operation ..............199 J-LOUNGE W/DRAWER (OPT)........224 Lubrication ............200 ELECTRIC SOFA BED CONVERSION (OPT)....224 STEPWELL COVER............202 STORAGE - UNDER BED ..........225 ENTRY DOOR .............202 STORAGE BAY SLIDE OUT TRAY.........225 Screen Door Maintenance........203...
Page 199 DIPLOMAT 2004 EQUIPMENT This section covers the basic operation and care of various types of - INTRODUCTION equipment found in the motorhome, most of which are provided for entertainment and comfort. More detailed information about specific equipment may be found in that particular manufacturer’s manual.
Page 200 DIPLOMAT 2004 If the step fails to operate: • Verify that the step switch is ON. • Check the main power supply for the step, a 25 Amp fuse is located in the front distribution panel. • A magnetic door jam switch is used to control step operation.
Page 201 DIPLOMAT 2004 030855b • Lubricate pivot points thoroughly with Kwik Lube Spray Grease or equivalent. • Work step several times, allowing lubricant to work into pivot point surfaces. • Repeat as necessary. • Remove excess lubricant. EQUIPMENT 5 • 201...
Page 202 DIPLOMAT 2004 STEPWELL COVER The stepwell cover operates by 12 Volt DC house power. To Operate the Stepwell Cover: 1. Turn on the battery cut-off switch. 2. Press the Step Cover switch to the desired direction. Release the switch to stop movement.
Page 203 DIPLOMAT 2004 • With a 5/8” inch box wrench or socket, loosen the movable strike bolt. Make all adjustments in small increments. Tighten the bolt firmly after making adjustments. The bolts should have slight up and down movement for vibration control in travel.
Page 204 DIPLOMAT 2004 SLIDE OUT The main slide-out room operates by an electric switch which controls OPERATION an electric motor. Slide-out room operation uses many safety features preventing mechanical damage or physical harm. The slide-out room(s) will not operate until all safety requirements are met.
Page 205 DIPLOMAT 2004 Main Room To Extend the Main Slide-out Room: Slide-out • Move the driver seat forward. • Confirm that there is at least five feet of clearance outside the motorhome for the slide-out room to extend. FRONT REAR • Ensure the ignition key is in the OFF position.
Page 206 DIPLOMAT 2004 To Retract the Main Slide-out Room: • Check for sufficient clearance inside the motorhome before retracting the slide-out room. • Clean the floor, if applicable, to ensure there is no dirt or grit that could result in floor damage during operation.
Page 207 DIPLOMAT 2004 If the Slide Room Fails to Operate: Check the fuse and auto-reset circuit breaker on the slide-out relay module located adjacent to the inverter. If the fuses and circuit breakers test okay, it will be necessary to call and obtain mechanical assistance to correct the problem.
Page 208 DIPLOMAT 2004 To Retract the Bedroom Slide-out: • Check for sufficient clearance inside the motorhome before retracting the slide-out room. • Clean the floor, if applicable, to ensure there is no dirt or grit that could result in floor damage during slide-out retraction.
Page 209 DIPLOMAT 2004 Manual Override If the slide-out room does not respond from the switch, check that all the - Bedroom Slide-out safety features are in place. • The ignition key is OFF. • The battery cut-off switch is ON. • The house batteries are fully charged.
Page 210 DIPLOMAT 2004 Slide-out Cover The slide-out cover is automatic. When the slide-out moves in or out, the cover reacts to the slide-out direction. A fixed edge of the slide-out cover is installed into an awning rail, mounted just above the slide-out. A spring-loaded roller with special brackets mounts to the slide-out.
Page 211 DIPLOMAT 2004 AWNINGS - Front Door To Extend the Awning: (Not Available - 40PDT) • Hook the pull strap loop with awning pull rod. • Pull strap until awning is at full extension. With free hand, lever out inner arms.
Page 212 DIPLOMAT 2004 Awning - Patio 030844c To Unlock the Awning: Start with either awning leg and repeat the following steps for each leg. 1. Loosen the black locking knob located on the backside of the awning leg (only about six turns are needed).
Page 213 DIPLOMAT 2004 To Extend the Patio Awning: 1. Locate the awning pull rod. 2. Locate the loop of the pull strap and hook it with the awning pull rod. Draw the awning away from the motorhome to the desired extension.
Page 214 DIPLOMAT 2004 To Retract the Patio Awning: 1. Loosen the strap from the awning leg if it has been stored there. 2. Support the weight of the awning with one hand while opening the extension lock handle and lower the awning until the arms rest on the lower stop bolt.
Page 215 DIPLOMAT 2004 Using the Carport Feature: (Not available with Carefree One Touch Awnings.) 1. Unlock and extend the awning as described under "To Unlock the Awning" and "To Extend Awning." 2. Unlatch the bottom of the rear arm by pushing in on the lock handle on the arm bracket.
Page 216 DIPLOMAT 2004 Awning - Automatic Carefree (Optional) The Carefree One Touch automatic awning requires only “finger tip” operation. A key lock on the One Touch switch pad is provided to prevent accidental deployment of the awning while the motorhome is in motion.
Page 217 DIPLOMAT 2004 To Retract the Awning: • Remove the wind braces. • Verify all persons and objects are clear from the retract path of the awning and related hardware. • Turn the One Touch key to the ON position. • Press and hold the momentary switch to RETRACT. The motor will automatically stop at full retraction.
Page 218 DIPLOMAT 2004 Awning Care & Mildew will not form on the awning material itself, but it may form on the Maintenance dust accumulated on the canopy. A quality vinyl cleaner, such as Carefree Awning Magic, will help keep your awning looking new. Be sure to follow the instructions on the container.
Page 219 DIPLOMAT 2004 Storm Precautions: The warranty does not cover damage caused by acts of nature; therefore, steps should be taken to prevent damage from occurring due to wind, rain or storms. If you are leaving or retiring for the night, close the awning. This takes only a few seconds and it gives the best protection for the awning.
Page 220 DIPLOMAT 2004 Tips: • To keep condensation from accumulating open the vent fan lids slightly to help the air circulate. Condensation occurs naturally from fluctuations in interior and exterior temperatures, humidity and dew point changes, steam from cooking, or boiling large amounts of water on the cooktop.
Page 221 DIPLOMAT 2004 Bathroom Fan The exhaust fan is a three-speed fan with a “0” or OFF position on the (Optional) fan. The exhaust fan requires the presence of 12 Volt DC to operate. There are two basic controls located on the ceiling vent fan. The knurled knob manually opens and closes the dome cover.
Page 222 DIPLOMAT 2004 SLIDING DOOR The sliding pocket door uses two rollers at the top of each door. During the life of the motorhome the sliding door may need adjusting. The sliding pocket door can be adjusted to close tight against the wall.
Page 223 DIPLOMAT 2004 Hide-A-Bed The sofa hide-a-bed will convert easily into a bed. Clear the area of Conversion obstruction and debris. The sofa comes equipped with safety belts to be worn (Not Available if occupied during travel. 36PST & 40PDT) Sofa to Sleeper: •...
Page 224 DIPLOMAT 2004 J-Lounge The J-Lounge provides comfortable seating with extra storage space for w/Drawer small items. The J-Lounge comes equipped with safety belts and these (Optional) should be used if occupied during travel. Not Available 38PBDD & 40PDT Storage Compartment Open: •...
Page 225 DIPLOMAT 2004 Sleeper to Sofa: • Push switch on sofa arm so that back and bottom cushions are in the sofa position. • Push in and down on the bed extension cushion to place cushion in stored position on frame.
Page 226 DIPLOMAT 2004 ENTERTAINMENT The components used to make up the entertainment center are carefully SYSTEMS selected to provide the highest quality in audio and visual enjoyment. There are several pieces of equipment, which encompass the entertainment center. The following paragraphs will discuss the operations and various components.
Page 227 DIPLOMAT 2004 Television Antenna The television antenna is a manual crank up style antenna with built in electronics that use 12 Volts DC to "boost" signal strength. Signals that are weak or fuzzy can be amplified by turning on the TV Ant Power switch on the Video Selector Box.
Page 228 DIPLOMAT 2004 To Lower the Antenna: • Pull down on the directional wheel and align arrows together. • Rotate the crank handle counterclockwise to lower the antenna fully into the cradle. Make an outside visual inspection to ensure the antenna is properly stowed.
Page 229 DIPLOMAT 2004 DVD Player The DVD player is a multi-function component. It plays Digital Video Discs, built in radio and amplifier. The power button on the DVD player must be pushed on to place the system in Stand-by mode. The DVD player will then respond manually or when using the remote control.
Page 230 DIPLOMAT 2004 Operating the To Operate any Component: Components Hook to shore power, start the generator or turn on the inverter. The battery cut-off switch must be in the ON position and the house batteries charged. To View Television using the Antenna or Cable TV: •...
Page 231 DIPLOMAT 2004 To View Satellite Programming (Optional): • Turn ON the Front TV. • Tune the TV to the VIDEO 1 input by pressing TV/VIDEO button on the TV remote control, or by opening the front access panel on the TV and pressing the TV/VIDEO button. VIDEO 1 will display on the TV.
Page 232 DIPLOMAT 2004 To Listen to the DVD Receiver Built-in AM/FM Radio: • Turn ON the DVD Receiver • Press the FUNCTION button on the DVD remote control, or on the front panel of the DVD receiver until TUNER is displayed in the DVD display screen.
Page 233 DIPLOMAT 2004 SATELLITE SYSTEM The TracVision SF is a self-contained stationary, automatic satellite TV (OPTIONAL) system. The TracVision SF automatically acquires and tracks DirecTV®, DISH Network™ and Bell ExpressVu satellite signals throughout the continental United States when the motorhome is in a stationary position.
Page 234 DIPLOMAT 2004 To Turn the TracVision SF Satellite System ON: 1. Park the motorhome. 2. Turn ON the Interior House power using the Battery Cut-off Switch. 3. Turn ON the IRD. 4. Press the Switch Plate’s POWER button. 5. Using the Video Selector Box, press the SAT button above the area marked “Main TV.”...
Page 235 DIPLOMAT 2004 To turn off the TracVision SF system, simply press the switch plate's POWER button WARNING: It is highly recommended that the TracVision SF be turned OFF prior to moving the motorhome. TracVision SF will not track a satellite while the vehicle is in motion.
Page 236 DIPLOMAT 2004 RADIO - DASH The dash radio is a tuner and a compact disc player. It holds up to eighteen preset FM stations and six AM stations. Other features are an attenuate mode; loudness control, clock display and auto seek tuning. The compact disc player features are fast forward and reverse, random track play, repeat and pause.
Page 237 DIPLOMAT 2004 Satellite Radio The Sirius® Satellite Radio is a digital signal decoder and tuner. Signals (Optional) are transmitted from Sirius's ground station to one of three Sirius® satellites that are orbiting over the continental Unites States. The satellite then transmits the signal to the exterior surface-mounted antenna located on the roof of the motorhome.
Page 238 DIPLOMAT 2004 10 Disc CD Changer The 10 disc changer is operated by the dash radio. To load a CD, slide the (Optional) cover to the right, push the CARTRIDGE RELEASE button and remove the cartridge. Load CD’s into the cartridge and reinsert the cartridge into the changer.
Page 239 DIPLOMAT 2004 Function of Features: • ON/OFF POWER BUTTON (PWR) - Press this button to turn the unit on or off. • VOLUME/LEVEL CONTROL (VOL) - To increase the volume level, press the up arrow button. To decrease the volume level, press the down arrow button.
Page 240 DIPLOMAT 2004 • MANUAL UP/DOWN TUNING & AUTOMATIC SEEK TUNING (TUN) - Each time the right arrow button is tapped, the radio will tune one frequency step higher. Similarly, each tap of the left arrow button will tune one frequency step lower. To manually tune in a station, tap the button of the appropriate direction until the desired frequency is reached.
Page 241 DIPLOMAT 2004 • CD PLAY/PAUSE SELECTOR (II) - During disc play, press this button to temporarily stop play of the disc. Press the button again to resume play of the disc from the point at which it was stopped. • REPEAT PLAY SELECTOR (RPT) - During disc play, press this button to repeat the play of the selected track (“RPT”...
Page 242 DIPLOMAT 2004 ~ NOTES ~ ________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ 5 • 242 EQUIPMENT...
Page 243: Water Systems
Water Systems section 6 WATER SYSTEMS INTRODUCTION ......245 MONITOR PANEL (WATER TANK) - MEASUREMENT...245 WATER TANK .............246 Fresh Water Fill (OPT)..........246 WATER TANK - FRESH FILL........247 WATER CITY HOOK-UP ..........247 Fresh Gravity Fill ............248 WATER PUMP.............248 Water Pump Troubleshooting .........249 Galley Filter ............250 WATER SYSTEM - TROUBLESHOOTING......251 WATER SYSTEM - DISINFECTING FRESH WATER ..251...
Page 245 DIPLOMAT 2004 WATER SYSTEMS The Water Systems section contains information and knowledge for the - INTRODUCTION operation and care of the various water system equipment found in the motorhome. The motorhome is equipped with two separate water systems. Optional water equipment will also be discussed, so not all information may be applicable to the motorhome.
Page 246 DIPLOMAT 2004 WATER TANK The convenience of the water hose reel eliminates the need to store a - Fresh Water Fill potable water hose in the bay. Use the hose reel for city water hook-up or to (Optional) fill the fresh water tank. The reel is equipped with a 12 Volt motor that will rewind the hose after use.
Page 247 DIPLOMAT 2004 WATER TANK 1. Check to make sure the fresh water tank drain valve, located on - FRESH FILL roadside in the service center, is in the closed position. 2. Connect the hose labeled for potable water to the water source.
Page 248 DIPLOMAT 2004 Fresh Gravity Fill The gravity fill inlet allows fluids to be introduced directly into the fresh water tank. When dry camping water can be poured directly from a container into the fresh water tank. The gravity fill inlet can be used to pour disinfecting solution into the fresh water tank or when using potable RV antifreeze to win- terize the fresh water system.
Page 249 DIPLOMAT 2004 To turn the water pump on or off: • Momentarily press the water pump switch. The indicator lamp will Indicator Light illuminate when the water pump is turned on. CAUTION: Do not continue water pump operation if the fresh water holding tank is empty.
Page 250 DIPLOMAT 2004 The water pump will not shut-off or runs when the faucet is closed: • Check to see if the fresh water tank fill valve is completely closed. • Check output side (pressure) plumbing for leaks and inspect for a leaky toilet or valves.
Page 251 DIPLOMAT 2004 WATER SYSTEM Water system problems and leaks usually fall into two categories: system - TROUBLESHOOTING problems and problems caused by improper use or lack of attention. These problems result from improper winterizing, poor maintenance, road vibration and campsite water pressure variations. Check all plumbing connections for leaks at least once a year.
Page 252 DIPLOMAT 2004 FAUCET SCREENS • Drain the fresh water tank of the mixed solution. • Fill the water tank with fresh water. Flush hot and cold lines thoroughly with fresh water. Repeat this process until the chlorine bleach smell is no longer detectable in the water system.
Page 253 DIPLOMAT 2004 NOTE: Never dispose of sanitary supplies or other non-dissolving items into the system. Facial tissue, wet strength tissue, paper towels or an excessive amount of toilet tissue can create clogging in the holding tank system. CAUTION: Do not use any products that contain petroleum distillate or ammonia in place of RV odor controlling chemicals.
Page 254 DIPLOMAT 2004 To Attach the Hose: 1. Remove sewer hose from carrier. 2. Remove termination cap. Align coupler tangs with termination tabs. Twist coupler clockwise 90º locking coupler to termination outlet. 3. Attach the other end of the hose to the drain service.
Page 255 DIPLOMAT 2004 What to Put in The grey water waste tank stores the sink, shower and clothes washer Holding Tanks - Grey drain water. No chemical is required in this holding tank; however, a waste Water Tank holding tank can produce odors. A reduced mixture of chemicals can help with odor control.
Page 256 DIPLOMAT 2004 10. If preparing for travel, close both the valves. Undo any restraining devices from the hose. Disconnect the hose from the termination outlet by rotating the fitting counterclockwise 90º. 11. Raise hose and drain using hand over hand method working hose towards shore fitting.
Page 257 DIPLOMAT 2004 TOILET The toilet operates from either the fresh water tank or city water supply. - THETFORD The water pump must be turned on or the city water connected. The toilet OPERATING flushes directly into a sewage holding tank (black water).
Page 258 DIPLOMAT 2004 Troubleshooting Wiring: • The toilet is wired to a 10 Amp Fuse in the house distribution panel. • The toilet has a 4 Amp 3 Ag “slow-blow” in-line fuse located in the back of the toilet. Leaks: • Back of toilet: check water supply line connection.
Page 259 DIPLOMAT 2004 TOILET - The Hydro-Vac toilet operates on a simple principle of accelerating pressured HYDRO-VAC water through a Venturi jet to create a vacuum. City water supply or the water OPERATING pump and an accumulator tank can be used to supply the pressurized water. The INSTRUCTIONS venturi jet water macerates and discharges waste to the black holding tank.
Page 260 DIPLOMAT 2004 Troubleshooting PROBLEM POSSIBLE CAUSES Toilet will not flush. • System not pressurized. • Debris stuck in flush valve Toilet flushes continuously. diaphragm. Bowl fills up while flushing. • Holding tank is full. • Holding tank is not adequately ventilated.
Page 261 DIPLOMAT 2004 TOILET - SEALAND OPERATING The toilet operates from either the fresh water tank or city water supply. INSTRUCTIONS The water pump must be turned on or the city water connected. The toilet flushes directly into a sewage holding tank (black water).
Page 262 DIPLOMAT 2004 Cleaning Cleaning: The toilet should be cleaned regularly for maximum sanitation and opera- tional efficiency. Clean the toilet bowl with a mild bathroom cleaner. Do not use chlorine or caustic chemicals, such as drain opening types, as they will damage the seals.
Page 263 DIPLOMAT 2004 Drain Traps & Auto Vents Sinks, shower and clothes washer drains incorporate a water trap or "P-trap" and auto vents to prevent waste water holding tank odor from entering the motorhome. These P-traps are usually within 54" of a vent tee. These traps must have water in them to block odors.
Page 264 DIPLOMAT 2004 System Heat Operation: 1. Turn the Systems Heat switch ON to supply power to the snap disc thermostat. 2. When the bay temperature reaches 40ºF (+/- 6ºF), the snap disc thermostat will close. The bay heater and the systems heat Active light will turn on.
Page 265 DIPLOMAT 2004 Winterizing Using Air Pressure: To use air pressure to winterize the motorhome you will need access to an air compressor and an adapter to connect the air line to the water system. Adapters can be found at any RV supply store. When hooked to the water lines the pressure should not exceed 40 psi.
Page 266 DIPLOMAT 2004 Winterizing with antifreeze: Ten gallons of FLA approved RV antifreeze will be required to winterize the motorhome. 1. Empty and flush the holding tanks. 2. Remove the water filter element from the galley spigot and reassemble with diverter cap.
Page 267 DIPLOMAT 2004 TANK CAPACITIES - CHART Tank Capacities 36 PST 38PBDD 38PST 40BDD 40DST 40PST 40PDT Water Heater (Atwood) 10 gal. 10 gal. 10 gal. 10 gal. 10 gal. 10 gal. 10 gal. Grey Tank (Amerikart) 60 gal. 60 gal.
Page 268 DIPLOMAT 2004 ~ NOTES ~ ________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________ 6 • 268 WATER SYSTEMS...
Page 269 LP-Gas System section 7 LP-GAS SYSTEM............271 LP-GAS DETECTOR .............272 Testing ..............273 Alarm ..............274 Maintenance............274 MONITOR PANEL (LP TANK) MEASUREMENT ....275 LP-GAS EMERGENCY PROCEDURES - CHECKLIST..276 LP-GAS TANK..............276 Tank Capacity............276 Tank Filling ............276 LP Tank Operation ..........278 LP-GAS FUNDAMENTALS ...........278 LP-GAS REGULATOR ..........280 LP-GAS HOSE INSPECTION ........283 LP-GAS CONSUMPTION..........284 LP-GAS DISTRIBUTION LINES ........285...
Page 271 DIPLOMAT 2004 LP-GAS SYSTEM The LP-Gas System section contains information and knowledge for the operation and care of the various Liquefied Petroleum (LP-Gas) system equipment found in the motorhome. The motorhome is equipped with several appliances and various equipment which are capable to operate on LP-Gas.
Page 272 DIPLOMAT 2004 LP-GAS DETECTOR The LP-Gas detector is required safety equip- ment in RVs. American National Standards Institute (ANSI) A119.2 - Fire & Life Safety 3-4.8 LP Gas Detectors states " An LP Gas detector must be installed in any RV that contains an LP Gas appliance and an electrical system.
Page 273 DIPLOMAT 2004 The LP-Gas detector is not tested to detect other types of gas. However, other volatile gases (nuisance gases), most of them flammable in various concentrations, may cause the detector to alarm. Some products that may cause the detector to alarm are alcohol, liquor, kerosene, gasoline, deodor- ants, colognes, propellants used in spray cans and cleaning solvents.
Page 274 DIPLOMAT 2004 Alarm Procedures to Take During an Alarm: 1. Turn off all gas appliances, (stove, heaters, furnace), extinguish all flames and smoking material. Evacuate, leave doors and windows open. 2. Turn off the primary valve on the LP tank.
Page 275 DIPLOMAT 2004 MONITOR PANEL (LP TANK) - Measurement 060158D 060158D Use this switch to test tanks. Momentary push & hold. 060158D Tank Measurement: To measure level of a tank simply push button on display panel corresponding to tank you wish to measure. Observe the gauge.
Page 276 DIPLOMAT 2004 LP-GAS EMERGENCY If you smell gas (a rotten egg or sulfur smell) at any time, perform the fol- PROCEDURES lowing steps immediately: - CHECKLIST • Shut off gas appliances. • Manually turn off the primary shut-off valve at the LP-Gas tank.
Page 277 DIPLOMAT 2004 NOTE: Actual filled liquid capacity is 80% of full tank capacity. WARNING: Extinguish all sources of heat, sparks, flame and smoking materials within a 50-foot radius during the fueling process. 1. Turn off the electric gas valve at the remote tank fill, pilot lights, all appliances and the engine.
Page 278 DIPLOMAT 2004 LP Tank Operation • Manually open the primary shut-off valve located on the LP-Gas tank. • Turn on the electric valve to allow gas to flow to the appliances. • Turn off the electric valve and primary valve on the LP-Gas tank when the tank is being filled, in between trips and when in storage.
Page 279 DIPLOMAT 2004 LP-Gas Statistics: Pounds Per Gallon 4.24 Specific Gravity of Gas 1.50 Specific Gravity of Liquid .504 Cubic Feet Gas Per Gallon of Liquid 36.38 Cubic Feet Gas Per Pound 8.66 BTU Per Gallon 91,502 BTU Per Pound 21,548 Dew Point in Degrees Fahrenheit - 44°...
Page 280 DIPLOMAT 2004 LP-GAS LP-Gas is compressed into liquid form in the tank. Only the vapor is used REGULATOR during combustion by an appliance. As vapor is removed from the tank, the remaining liquid will vaporize to maintain pressure that is removed dur- ing consumption.
Page 281 DIPLOMAT 2004 The regulator is the heart of the LP-Gas system. The regulator reduces vapor pressure so that it is safe to use. The regulator on the motorhome is a two-stage regulator. The first stage of the regulator reduces tank pressure to a range of 10 to 13 psig (pounds per square inch gauge).
Page 282 DIPLOMAT 2004 Manometers: The manometer is the best way to accurately determine LP-Gas pres- sure. There are two different styles of manometers, a gauge and a U-tube. Gas pressure is measured in Inches of Water Column. This is the amount of pressure applied to one side of a U-shaped tube half filled with water.
Page 283 DIPLOMAT 2004 LP-GAS HOSE It is suggested by the hose manufacturer that the Liquid Propane Gas (LP- INSPECTION Gas) supply hoses, used on the motorhome, be subject to regular inspec- tion. As a guideline, we suggest that all flexible LP lines connecting the slide-out, appliances, or tanks be inspected in the spring and fall of each year by a qualified RV technician.
Page 284 DIPLOMAT 2004 LP-GAS Each gallon of LP-Gas produces 91,502 BTU’s of heat. One 27 gallon CONSUMPTION tank produces two million BTU’s. Total consumption depends on the rate of usage by each appliance and the operating time. The stove and heating systems typically use the most gas.
Page 285 DIPLOMAT 2004 A primary manifold black steel pipe running throughout the LP-GAS motorhome distributes LP-Gas to secondary lines. All secondary lines DISTRIBUTION LINES leading to gas appliances are made of copper tubing with flared fittings. If any lines rupture do not attempt to splice them. Always run a new line. We recommend gas distribution work be performed by an authorized dealer or an authorized service technician.
Page 286 DIPLOMAT 2004 LP - GAS Liquid Propane gas is one of the safest and most reliable fuels available SAFETY TIPS on the market if it is handled properly. LP-Gas, however, does have a great explosive “potential" if handled improperly. Danger is minimized by becom- ing familiar with and following a few safety precautions, and by learning how to properly operate LP-Gas appliances.
Page 287 DIPLOMAT 2004 Maintenance and Safety Tips for the LP-Gas Refrigerator: • Have the refrigerator, furnace and venting inspected annually by an authorized service center. • Before firing up the refrigerator, or using the propane gas fur- nace for the first time each season, have the venting system checked for blockage.
Page 288 DIPLOMAT 2004 ~ NOTES ~ ___________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ 7 • 288 LP-GAS SYSTEM...
Page 289 Electrical Systems - House section 8 ELECTRICAL HOUSE - INTRODUCTION.......291 DISTRIBUTION PANEL (50 AMP) ........307 Shore Power............291 Circuit Breakers .............308 Generator ..............291 Energy Management System (Opt.) .......309 Inverter/Converter ..........292 Fuses ..............311 BATTERY DISCONNECT - HOUSE........292 GFCI Breakers & Outlets ........312 BATTERY CUT-OFF SWITCH........293 Tools of the Trade..........313 SHORE POWER HOOK-UP...........293...
Page 291 DIPLOMAT 2004 ELECTRICAL HOUSE - The motorhome 120/240 Volt AC system can be operated from three differ- INTRODUCTION ent power sources: shore power, the on-board generator or the inverter/charger. Shore power is the most efficient and should be used whenever possible. The on board generator can be used when shore power is unavailable.
Page 292 DIPLOMAT 2004 Inverter/Converter The inverter/converter can be used for silent AC power if shore power is not available, and using the generator is not going to be selected as a secondary power source. This device has limited AC power output, measured in watts.
Page 293 DIPLOMAT 2004 The battery cut-off switch is located inside next to the entry door. This BATTERY CUT-OFF SWITCH switch controls the 12 Volt DC power to the interior 12 Volt panel and select front distribution panel circuits. The switch locks into the center position preventing interior DC power from being accidentally turned on or off.
Page 294 DIPLOMAT 2004 Power Supply: Different amperage supplies vary greatly in the amount of available current. • The continuous amount of current through a breaker or fuse is only 80% of its rated capacity. • 50 Amp 220 Volt AC shore power service consists of two power supply conductors, a neutral and a safety ground.
Page 295 DIPLOMAT 2004 After connecting the motorhome to shore power, wait approximately one minute for the inverter/charger or converter to "stabilize" charging of the bat- teries before starting air conditioners or other large AC loads. In the instance 50 Amp service is not available, use caution not to overload the supplied shore service breaker.
Page 296 DIPLOMAT 2004 CAUTION: Avoid the risk of electrical shock or component damage by disconnecting from shore power during electri- cal storm activity. Use the inverter or start the generator if AC power is needed. NOTE: Three types of shore power outlets most commonly used are shown in the illustration below.
Page 297 DIPLOMAT 2004 GENERATOR The standard generator for the motorhome is a 6.5 kW LP - 120 AC LP - GAS generator. This generator provides 6500 watts of power. This power is 120 AC Volts at 60-Hertz Frequency with 54.2 Amps of current.
Page 298 DIPLOMAT 2004 GENERATOR The generator is located in the front compartment of the motorhome. The 120 AC DIESEL generator can be started from the following locations: • The generator remote switch on the dash. • The generator control panel located on the generator.
Page 299 DIPLOMAT 2004 Pre-Start Checks Prior to the first start of the day perform a general inspection including oil and coolant levels. Keep a maintenance log on number of hours in operation since the last service. Perform any service or maintenance that may be due.
Page 300 DIPLOMAT 2004 Starting the Push and hold control switch in START position until the generator starts. Generator Release switch. On diesel models the control switch may flash up to 15 seconds, indicating engine preheat. NOTE: Diesel models may require priming. Hold control switch in the OFF position for one minute.
Page 301 DIPLOMAT 2004 Powering the The AC output of the generator powers the motorhome air conditioners, Equipment the AC inverter/converter charger, all appliances and items plugged into the electrical outlets of the motorhome. The number of electrical appliances that can be operated at any given time depends upon how much power is available from the generator.
Page 302 DIPLOMAT 2004 Generator Fuel When refueling there is always a possibility the fuel may be contaminated. Contamination of fuel affects the performance of the generator. Diesel fuel may contain water or a microbe growth (black slime). Propane, due to the refining process, may contain lightweight oil. Any contamination of fuel greatly reduces the total output of the generator and may cause erratic AC output.
Page 303 DIPLOMAT 2004 Generator Exercise If use of the generator is infrequent, “exercise” the generator once a month by operating it at approximately half the maximum rated output for two hours. This “exercise” will help promote better starting, more reliable operation and longer engine life. This procedure drives off moisture, relubricates the internal engine parts and replaces the old stale fuel with a fresh supply.
Page 304 DIPLOMAT 2004 Battery Charging The inverter will automatically begin charging when AC power is supplied from shore service or the generator. The charger uses a three-stage cycle to charge the batteries. If desired the charger may be turned off. To turn the charger OFF or back ON: •...
Page 305: Circuit Breakers
DIPLOMAT 2004 Battery State Indicator The battery state indicator performs two functions. When not hooked to shore power the Battery State indicator displays the approximate state of charge of the house batteries. When connected to shore power or operating from the generator, the lamps indicate what part of the charge cycle the inverter is in.
Page 306 DIPLOMAT 2004 Power Share Setting the Power Share amps can limit the amount of AC power available to the internal charger. Battery charger draw can exceed 20 AC Amps. When hooked to anything less than 50 Amp service it may be necessary, depending on other AC loads, to adjust the Power Share amps to avoid overloading the shore power breaker.
Page 307 DIPLOMAT 2004 Temperature The inverter uses a battery temperature sensor to adjust charge Sensitive Charging voltage. When the battery temperature rises the sensor sends this information to the inverter to decrease charge voltage. Voltage compensation with temperature variation is necessary to keep charge voltage at optimum values.
Page 308 DIPLOMAT 2004 WARNING: This panel contains high voltage which can cause serious injury or death. Before beginning any work or testing procedures involving the electric panels, or any of the branch cir- cuits, be sure the motorhome is unplugged from shore power and the generator is not running.
Page 309 DIPLOMAT 2004 Energy The Energy Management System is easily identified by the remote Management display panel located inside motorhome. System The 50 Amp Smart EMS consists of two elements: the display panel and (Optional) the bedroom distribution panel. The distribution panel, located in the bedroom, is a completely self-contained 120/240 Volt power distribution and energy management system intended to be used in recreational vehicles.
Page 310 DIPLOMAT 2004 If 120 Volt AC is present at the distribution panel L1 and L2 inputs the system will assume that 120 Volt AC, 30 Amp shore power is available and the energy management feature will be enabled. If only 20 Amp service is available the user must select the 20 AMP service mode by momentarily pressing the 20/30 Amp select switch on the Control Panel.
Page 311 DIPLOMAT 2004 Display Panel: The display panel connects to the distribution panel located in the bedroom. Six power status LED’s indicate power is applied to those loads. These LED’s are on when the power is applied. The load meter has a two digit display to indicate the amount of current actually being drawn by all the appliances in the motorhome.
Page 312 DIPLOMAT 2004 GFCI Breakers & A ground fault circuit interrupter “GFCI” can be found in two different Outlets types of applications. One type is incorporated in a breaker used in 120 Volt AC breaker panels, the other is incorporated in an outlet. The GFCI, whether it is a breaker or an outlet, offer two types of protection.
Page 313 DIPLOMAT 2004 Tools of the Trade One of the most widely used tools for testing a 12 Volt problem is the test light. Test lights come in a host of varieties, such as a light bulb with a probe and ground clip, to the more elaborate electronic ones that measure a wide scale of voltages and perform a variety of functions.
Page 314 DIPLOMAT 2004 BATTERY Batteries come in different sizes, types, amp hours, voltages and How It Works chemistries. There are nearly as many descriptions of battery types and how they should be used as there are people willing to offer advice on them.
Page 315 DIPLOMAT 2004 Deep Cycle Batteries: Deep cycle batteries are best suited for use with 12 Volt operated lights, appliances and inverters. These are available in many sizes and types. The most common is a non-sealed, liquid electrolyte battery. The non-sealed types have battery caps.
Page 316 DIPLOMAT 2004 Temperature and recent battery activity (charging or discharging) affect the hydrometer readings. It is best to check the battery when it has been “at rest” for at least three hours, although readings taken at other times will give a “ballpark” figure. When using the hydrometer, draw the electrolyte solution up into the tube.
Page 317 DIPLOMAT 2004 Battery Maintenance At a minimum, the battery electrolyte level should be checked at least once a month. Check the level sooner if the battery is frequently used. The level should be above the top of the plates, but not overfull.
Page 318 DIPLOMAT 2004 Reasons Why 1. Physical Condition: Batteries Fail Active material flakes off the plates and falls to the bottom of the cell. This is normal, but sediment accumulation under the plates can short out a cell. The plate separators fail to insulate positive and negative plates in a cell and the cell becomes shorted, ruining the battery.
Page 319 DIPLOMAT 2004 7. Overcharging: Overcharging rapidly converts water to gas and decreases the elec- trolyte’s water content as the water evaporates. The electrolyte level drops and becomes more acid in content. This subjects the plates to a higher concentration of sulfuric acid and results in early battery failure.
Page 320 DIPLOMAT 2004 When the tank is full it is capable of feeding more “pressure” to the pump inlet due to gravity, and the pump always has enough water available to maintain its rated pressure and volume. However, if the water tank gets low the pump will not have enough water volume coming in to maintain 12 psi at 15 GPM.
Page 321 DIPLOMAT 2004 period equals the rated 100 Ahr. capacity. These discharge figures are calcu- lated with the battery starting at 100% state of charge with the battery at 80º F when the discharge cycle begins. However, increasing the discharge load applied to the battery from five amps to ten amps on a 100 Ahr battery does not yield 10 hours of discharge time.
Page 322 DIPLOMAT 2004 BATTERY SPECIFICATION - HOUSE RC (25A @ 80° F) Application Ah (20hr) CCA† minutes 12 Volt Chassis* 180 X 2 = 360 Group 31p - LHD (2 each) 6 Volt Domestic** 75Amp@ 80º F. = 230 Min. U2200 (4 each) *Batteries connected in parallel.
Page 323 DIPLOMAT 2004 SOLAR PANEL The system consists of one roof-mounted solar panel and a charge con- (Optional) troller located in the battery compartment. The solar panel is a laser-grooved, buried-grid panel that is capable of delivering about two or three amps of charge per hour in full sunlight (usually between 9:30 a.m.
Page 324 DIPLOMAT 2004 Solar Panel Care: A critical part of maintaining the solar powered battery charging system is keeping the panels clean. The amount of power that a panel will produce is directly related to the intensity of sunlight that reaches the internal crystals. A dirty panel will allow less light to reach the crystals resulting in reduced power output.
Page 325 DIPLOMAT 2004 Electrical Layout 060191B ELECTRICAL SYSTEMS - HOUSE 8 • 325...
Page 326 DIPLOMAT 2004 ~ NOTES ~ ___________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ ELECTRICAL SYSTEMS - HOUSE 8 •326...
Page 327: Electrical Systems
Electrical Systems - Chassis section 9 ELECTRICAL CHASSIS - INTRODUCTION....329 BATTERY DISCONNECT - CHASSIS......329 BATTERY - CHASSIS...........331 BATTERY SPECIFICATIONS - CHASSIS .......331 DASH ................332 Indicator Lamps ............332 Gauges..............334 Parking Brake ............336 Switches ...............336 Controls ..............340 AIR CONDITIONER & HEATER CONTROLS ....341 About Refrigerants..........346 STEERING COLUMN............350 Tilt &...
Page 329 DIPLOMAT 2004 ELECTRICAL A majority of the lighting and appliances are designed to operate from 12 CHASSIS Volt DC (direct current) power. This is why batteries play such an important - INTRODUCTION role in the function of the motorhome. There are exceptions with appliances such as the microwave or television;...
Page 330 DIPLOMAT 2004 NOTE: The solar panel (optional) will charge the batteries with the disconnect switch off. WARNING: When the frame or other welding is involved for motorhome repair, or modification, the following pre- cautions are required to protect electronic components in the motorhome chassis: 1.
Page 331 DIPLOMAT 2004 The chassis battery operates only chassis and engine functions. The BATTERY chassis battery is a crank type battery, producing the high amperage needed - CHASSIS to start the engine. Engine starters initially require a large amount of current to crank an engine.
Page 332 DIPLOMAT 2004 DASH 13 12 11 Indicator Lamps 1 14 5 10 15 6 16 080239F 1. Ant Up: TV antenna is raised. Lower antenna before moving coach. 2. Low Coolant: Coolant level in the overflow tank is below acceptable level.
Page 333 DIPLOMAT 2004 8. Check Trans: Alerts driver of problems related to the Allison Transmission. The light should momentarily illuminate when the ignition is switched ON. When starting the lamp will extinguish indicating the circuits are working properly. If the lamp fails to illuminate or remains on, the transmission needs to be checked immediately.
Page 334 DIPLOMAT 2004 Gauges 080246E 1. TURBO BOOST: Boost pressure produced by the engine turbocharger. 2. OIL PRESSURE: Indicates oil pressure, not the amount of oil in the engine. Please refer to manufacturer’s instructions for specific pressure recommendations. NOTE: When operating the engine cold, the pressure will be considerably higher due to increased viscosity (thickness) of the oil.
Page 335 DIPLOMAT 2004 NOTE: Fuel mileage varies with driving style and road conditions. Always average more than one tank of fuel to obtain a more accurate figure. The diesel Generator uses fuel from main tank and will affect fuel mileage figures. Diesel Generators will not operate below 1/4 tank to ensure there is enough fuel to run main engine.
Page 336 DIPLOMAT 2004 9. ODOMETER/TRIP METER: Used to toggle between the odometer and trip meter. Holding the button down for two seconds will reset the trip meter. 10. Trans Temp: Shows Temperature of transmission fluid. Normal transmission operating temperature is 160-250° F. The maximum transmission to cooler oil temperature is 300°F.
Page 337 DIPLOMAT 2004 BATT BOOST: In the event the motorhome chassis battery has been drained and cannot start the engine, this switch momentarily “jumps” the domestic battery to the motorhome chassis battery to assist in starting the engine. ATC SYSTEM: The ATC system improves traction on slippery or unstable surfaces by preventing excessive wheel slip (see Section 10 for detailed information).
Page 338 DIPLOMAT 2004 GEN START: The generator automatically initiates a preheat cycle when the switch is pressed to START. The preheat cycle cycle is indicated by the light on the switch flashing rapidly. Depending on ambient temperature the preheat cycle may last up to 15 seconds.
Page 339 DIPLOMAT 2004 RADIO: Applies power to the dash radio. This will allow the radio to be turned ON and OFF, independent of the main radio switch. FANS ON/OFF (Not on all units): Operates driverside windshield fan. FANS ON/OFF (Not on all units): Operates passenger side fan.
Page 340 DIPLOMAT 2004 Controls MIRROR ADJUST: To adjust the rear view mirror the small selector in the middle of the switch must be placed in the desired side. The middle position is to prevent accidental bumping of the switch and changing the mirror position. The outside mirrors have been placed so that they can be easily adjusted with the Allen wrench.
Page 341 DIPLOMAT 2004 The system is designed to only provide heating, cooling and defrost for AIR CONDITIONER & HEATER the pilot and co-pilot area. The system is not capable of heating or cooling CONTROLS the entire motorhome. Blower Control Switch: This switch controls the four speeds of the blower motor. This is one of the best and most effective ways of controlling temperature.
Page 342 DIPLOMAT 2004 FLOOR - Fresh air is drawn in and discharged through the floor louvers. A small amount of air discharges through the defrost vents. MIX - Fresh air is drawn in and discharged through the floor and defrost louvers. The A/C system operates to dehumidify the discharged air.
Page 343 DIPLOMAT 2004 Operating Tips and Hints: • Air intake and discharge temperatures are greatly effected by ambient temperature and relative humidity. • A large amount of cooling capacity is used to dehumidify air as well as cool it. After three to five minutes of A/C compressor operation, the discharged air temperature should be approximate- ly 30º...
Page 344 DIPLOMAT 2004 No Cooling: 1. Check blower is operating, A/C switch is in A/C or Max position, temperature control is turned to Max cooling (blue area). 2. System fuses are not blown. 3. Condenser fan is operating. 4. Check power supply to unit and grounding of system.
Page 345 DIPLOMAT 2004 Air Conditioner Refrigeration Components: Compressor - The compressor is belt driven from the engine through the compressor and electronic clutch pulley. The compressor will pump freon from a low pressure gas into a high pressure, high temperature gas. This is the start of the refrigeration process.
Page 346 DIPLOMAT 2004 About Refrigerants Chemical Stability: The air conditioning system life and efficient operations depends upon the chemical stability of the refrigeration system. The refrigeration system is made of Refrigerant-R134a and Polyakylene Gycol (PAG) synthetic lubricant. It is very important that all materials contained within the refrigerant system be chemically compatible.
Page 347 DIPLOMAT 2004 psi gauge_temp R-134a Refrigerant: R-134a is classified non-explosive, non-flammable and non-corrosive. There is hardly any odor and it is much heavier than air. R134a is ozone friendly; however, it is not technician friendly. Proper care in handling and adequate ventilation must be observed.
Page 348 DIPLOMAT 2004 Safety and Handling of 134A and Pag Oil: • When working with any refrigerant system wear eye protection and hand protection. • Pag Oil irritates the skin. Flush with water immediately if in contact with any body part.
Page 349 DIPLOMAT 2004 Functional Test: • Start and operate the engine until the water reaches normal operating temperature. • Set the HVAC temperature control to the full hot position. • The discharge air outlets should have hot air. • Rotate the temperature control to full cold position.
Page 350 DIPLOMAT 2004 STEERING COLUMN Tilt and Telescope Steering Wheel Control Lever: Located on the Tilt & Telescope Steering Column. • To tilt the steering wheel pull the lever up. Tilt the steering wheel where desired. Releasing the lever will lock the steering wheel in the new position.
Page 351 DIPLOMAT 2004 The front electrical panel is located in the outside roadside front FUSE & CIRCUITS - Front Distribution compartment and contains the fuses, self resetting manual reset supply circuit Panel breakers, solenoid and relays. The automotive fuses are located in the front electrical panel. The fuses are the standard plug-in type (ATM).
Page 352 DIPLOMAT 2004 080427B Fuse label chart inside cover of distribution panel. 9 •352 ELECTRICAL SYSTEMS - CHASSIS...
Page 353 DIPLOMAT 2004 ALTERNATOR The Leece-Neville alternator with integral rectifier, regulator and remote voltage sensor is designed for reliable output throughout the engine operating range. When traveling, keep an eye on the voltmeter in the dash area. Normal readings should be between 13 to 14.5 Volts. Voltage indications higher or lower indicate a problem with the charging system.
Page 354 DIPLOMAT 2004 Specifications: • 160 Amp standard • The integral rectifier system utilizes 12:50 Amp diodes mounted in multiple aluminum heat sinks for efficient heat dissipation during high-output operation. • Aluminum housings • Bi-directional fan • Front bearing: 305 cartridge type •...
Page 355 DIPLOMAT 2004 ~ NOTES ~ ___________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ ELECTRICAL SYSTEMS - CHASSIS 9 • 355...
Page 356 DIPLOMAT 2004 ~ NOTES ~ ___________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________ 9 •356 ELECTRICAL SYSTEMS - CHASSIS...
Page 357 Chassis Information section 10 Manual Retract Valve ..........394 CHASSIS - INTRODUCTION.........359 Maintenance............395 AIR SUPPLY SYSTEM ..........360 ENGINE - GENERAL INFORMATION ......395 Air Governor............361 STARTING PROCEDURE ..........398 Air Storage Tanks Remote Drains......361 Normal Starting .............398 Air Charging System (External) ......362 Cold Weather Starting..........398 Air Coupler ............363 OIL RECOMMENDATIONS ...........399 BRAKE SYSTEMS............364...
Page 359 DIPLOMAT 2004 CHASSIS This section contains knowledge and information on various components - INTRODUCTION of the motorhome chassis. Following the guidelines and procedures will help you to understand and operate your motorhome. Complete instructions for engine and transmission are located in their respective operators manual included in the Owner’s Information File box.
Page 360 DIPLOMAT 2004 AIR SUPPLY The air compressing system on the motorhome is comprised of several SYSTEM items: an air compressor, air governor, air dryer, a front air tank and a rear air tank. The compressed air system operates several items, some of which include brakes, suspension, air horns, air gauge.
Page 361 DIPLOMAT 2004 The pneumatically operated items are divided into two categories: brakes and accessory air. Brakes have full use of supplied air pressure. Accessory air items, such as air horns, receive air through pressure protection valves (PPV). The PPV will not allow compressed air flow until approximately 60 psi.
Page 362 DIPLOMAT 2004 Air Drains Air system tank drains are located in the generator compartment and in the rear engine compartment. The air tanks should be drained at least once a month or more often in areas of high humidity and where temperature fluctuates 40º...
Page 363 DIPLOMAT 2004 Air Coupler Provided for convenience is a remote air supply coupler located in the generator compartment. This female fitting will accept type C automotive. This auxiliary air fitting may be used to inflate tires, air mattresses or other pneumatic items.
Page 364 DIPLOMAT 2004 BRAKE SYSTEMS The motorhome is equipped with air brakes using the same efficient - Air Brakes system as over the road trucks. Proper maintenance and lubrication is the key to keeping the brake system in proper working order. The brake system on the motorhome is designed to accommodate the weight of the vehicle and towing loads.
Page 365 DIPLOMAT 2004 Park & Emergency The park and emergency brake systems are combined and apply to the Brake Systems rear drive axle only. These are called spring brakes. When the park brake is applied, air is released from the rear brake chambers, allowing the large spring in each rear brake chamber to manually push the brake pads against the drum.
Page 366 DIPLOMAT 2004 Brake Adjustment The motorhome is equipped with automatic slack adjusters. As brake /Slack Adjuster lining wears, the slack adjusters will automatically ratchet on the return stroke as needed. This ratchet action will keep the brake lining at proper adjustment.
Page 367 DIPLOMAT 2004 Accessory air items are other pneumatically operated items such as the air horns. The accessory air items operate only when air tank pressures exceed 65 psi. This is done with pressure protection valves. Should an accesso- ry air item fail, the pressure protection valve (PPV) reserves the remaining air pressure of 65 psi for braking.
Page 368 DIPLOMAT 2004 Maintenance The exhaust brake system, used routinely at normal exhaust operating temperatures, is virtually maintenance free. There are contributing causes which can result in failures with the exhaust brake, including moisture, dirt, carbon, and improper usage. Starting the engine and idling for short periods of time is not recommend- ed.
Page 369 DIPLOMAT 2004 AIR DRYER The air dryer is located underneath the motorhome next to the transmission. The air dryer removes moisture from the compressed air system. This is important because if air contains moisture it can freeze and prevent operation of brakes or other pneumatic operated items.
Page 370 DIPLOMAT 2004 Air Dryer Components: 1. Purge Valve: A valve located on the bottom of the air dryer base that remains open during a compressor unload cycle. The purge valve allows collected moisture, condensation and contamination to be expelled from the air dryer during the purge cycle.
Page 371 DIPLOMAT 2004 Desiccant Cartridge 1. The replacement kit contains one cartridge and one O-ring. 2. Loosen and remove the old cartridge. Use a strap wrench, if necessary. 3. Remove and discard the O-ring from the dryer base. 4. Inspect and clean the seal seat. Repair any minor damage.
Page 372 DIPLOMAT 2004 Desiccant-Type 1. Warm, humid air from the compressor condenses into either Air Dryer water or water vapor before entering the air dryer. 2. A desiccant-type air dryer protects the motorhome air brake system by drying moisture-laden air before it passes through the air reservoirs and into the brake system.
Page 373 DIPLOMAT 2004 AIR SPRINGS Air ride springs are available in single, double and triple convolution types plus reversible sleeve models for virtually every conceivable heavy-duty vehicle suspension application. 1. STUD: Manufactured as a permanent part of bead plate assembly for maximum strength and durability. Used to attach spring to the vehicle's suspension.
Page 374 DIPLOMAT 2004 • The leveling valves (or height control valves) play a large part in ensuring that the total air spring system works as required. Clean, inspect and replace if necessary. • Make sure to check shock absorbers for leaking hydraulic oil and worn or broken end connectors.
Page 375 DIPLOMAT 2004 NOTE: Drive shaft angle is affected by the suspension ride height. Improper drive shaft angle can damage suspension or shorten the life of universal joints. Shock absorbers and air springs are in travel centers at proper ride height.
Page 376 DIPLOMAT 2004 ABS/ATC SYSTEM The motorhome is equipped with an anti-lock braking system (ABS) and (Anti-lock automatic traction control system (ATC). The ABS system monitors wheel Brakes) rotation speeds by using a 100-tooth magnetic tone ring mounted to the hub.
Page 377 DIPLOMAT 2004 ABS Warning Lights: The ABS will perform a dash indicator lamp check and self-diagnostic test each time the ignition is switched to the on position. • When the ignition is turned on, the ABS indicator illuminates momentarily (2.2 seconds), verifying the self-diagnostic test. If the...
Page 378 DIPLOMAT 2004 Reading Configuration Codes: 1. Turn the ignition key to ON. 2. Apply and release brakes once before proceeding. 3. Press and hold the diagnostic button for two seconds and release, immediately press the diagnostic button a second time for two seconds and release.
Page 379 DIPLOMAT 2004 Automatic Traction The ATC system improves traction on slippery or unstable road surfaces Control System by limiting excessive drive wheel slip. This is accomplished by limiting engine torque to the drive wheel or engaging a brake to the spinning drive wheel.
Page 380 DIPLOMAT 2004 ATC Switch: Activating the ATC switch reduces ECU control over engine torque. Momentarily pressing the ATC switch allows the ECU to increase the amount of engine torque applied to the drive wheel in an ATC event. The amount of engine torque applied to the drive wheel will vary with the amount of drive wheel slip versus road speed.
Page 381 DIPLOMAT 2004 While driving the motorhome, be aware of any changes in the feel of steering and have the system checked if there are any apparent differences. It is normal to hear some hydraulic noise from the steering, especially when the steering is at maximum or while turning the wheel when the motorhome isn't moving.
Page 382 DIPLOMAT 2004 Toe Setting: The toe setting represents different distances between the front and rear of the tires (measured at the vertical center line of the tires). Toe-in: Occurs when the tire front distance is less than the tire rear distance.
Page 383 DIPLOMAT 2004 Caster Adjustments: Caster is the fore and aft tilt (toward the front or rear of the motorhome) of the steering kingpin as viewed from the side of the motorhome. “Positive” caster is the tilt of the top end of the kingpin toward the rear of the motorhome.
Page 384 DIPLOMAT 2004 Steering Components Steering Components.eps Axle Beam Steering Box Steering Driveline Universal Joints Slip Yoke Ball Joint Steering Column Steering Wheel Steering Spindle Spindle Kingpin Centerlink Pitman Arm Drag Link TYPICAL 10 • 384 CHASSIS INFORMATION...
Page 385 DIPLOMAT 2004 Steering Column The steering wheel connects to the steering box using a driveline. Service the steering drive shaft universal joints and slip yoke every 30,000 miles or annually. Remove the steering column cover to access the upper universal joint and slip yoke.
Page 386 DIPLOMAT 2004 Center Link The center link is located on the backside of the steer axle. The center link attaches the two wheels together causing the right front to track with the left front. Greasing interval is every six months or 5,000 miles.
Page 387 DIPLOMAT 2004 Front Brakes The slack adjuster and camshaft need to be lubed periodically to ensure proper brake operation. Lubricate every 10,000 miles or annually. 090350 Typical Air Drum Brakes - Lubricate until new grease appears at exit points. DRIVE AXLE &...
Page 388 DIPLOMAT 2004 During lubricant change, fine metal particles will be observed clinging to the magnetic fill and drain plugs of the axle. These particles are normal wear particles from the axle components, but will cause faster than normal wear of the axle components if allowed to circulate through the lubricant.
Page 389 DIPLOMAT 2004 To Drain and Replace Lubricant: With vehicle parked on a level surface and rear axle warm, place a large container under axle. 1. Remove drain plug and allow axle to drain completely. 2. Dispose of oil properly. 3. Clean the drain plug and test (replace the drain plug if needed).
Page 390 DIPLOMAT 2004 Drive Shaft: The drive shaft transfers the power produced by the engine to the drive axle. A worn or out of balance driveline causes chassis vibration that generally increases in intensity with road speed. NOTE: It will be necessary to move the motorhome forward or backward to access all fittings on the drive shaft.
Page 391 DIPLOMAT 2004 U-Joint Angles Correct U-joint working angles U-joint phasing, and driveline balance is vital Phasing & to maintaining a quiet-running drivetrain and long life of drivetrain components Driveline Balance (including driveline components). When in phase, the slip yoke lugs (ears) and tube yoke lugs (ears) are in line.
Page 392 DIPLOMAT 2004 SHOCK ABSORBER The shock absorber by definition is a hydraulic device used to dampen suspension/body movement. Road surface irregularities are compensated for by the shock absorber. The roadmaster chassis incorporates the "Monroe" shock in the design of the exclusive air glide suspension system. This shock absorber is a telescopic, mono tube unit filled with nitrogen gas and hydraulic oil.
Page 393 DIPLOMAT 2004 CAUTION: If blocking up a rear jack pad to gain added clearance while the motorhome is on a slope, place a chock at the opposite set of rear wheels to prevent the motorhome from rolling. WARNING: Using an improper leveling process can result...
Page 394 DIPLOMAT 2004 • Place the gear selector in PARK. • Apply the parking brake. • Turn the ignition switch to the ON position. • Switch the main jack control power switch ON. • To extend a particular jack, push the appropriate rocker switch to extend position and hold it until the desired extension is reached.
Page 395 DIPLOMAT 2004 Maintenance Occasionally, while the jacks are fully extended, wipe dirt from the jack rod. This will help lengthen the life of the jacks. This can vary from the amount and type of usage of the jacks. Dexron III will serve as a solvent as well as a lubricant.
Page 396 DIPLOMAT 2004 WARNING: Do not operate a diesel engine where there are or can be combustible vapors. Vapors can be drawn through the air intake system and cause engine acceleration and over-speeding, resulting in fire, explosion and extensive property damage.
Page 397 DIPLOMAT 2004 Diagnostic Fault Codes: The engine ECM will record three types of fault codes; Electronic Control System Faults, Protection System Faults and Maintenance Indicators. All faults recorded will be ACTIVE or INACTIVE. Not all faults will light an indicator when they are ACTIVE.
Page 398 DIPLOMAT 2004 STARTING The engine is equipped with an intake manifold grid heater. The grid heater PROCEDURE helps engine starting in cold weather. Intake manifold air temperature is - Normal Starting monitored by the Electronic Control Module (ECM) on the engine. If intake manifold temperature is below specified level (approximately 40º...
Page 399 DIPLOMAT 2004 1. When operating below 32º F, an engine block heater or other means to warm the engine can enhance engine starting. This will ease cranking and help prevent engine misfiring and white smoke during starting. 2. Always follow the recommended oil, fuel, and coolant specifications as outlined in the OEM Engine Manual.
Page 400 DIPLOMAT 2004 Low viscosity oils, used for winter operations, will aid in starting. Synthetic oils, or oil with adequate low temperature properties used for Arctic operations where the engine cannot be kept warm when shut down, will aid in starting.
Page 401 DIPLOMAT 2004 Viscosity: Viscosity is simply a measure of resistance of molecule layers moving relative to an adjacent layer. All fluid viscosity is affected by temperature. A multigrade lubricating oil tends to be less sensitive to temperature changes due to formulation. Lubricating oils are generally selected for use with viscosities appropriate for the expected operating temperature.
Page 402 DIPLOMAT 2004 Allow time for the oil to drain into the sump and start the engine. Observe the engine for proper oil pressure. Run the engine at low idle for three minutes while observing engine and filter for leaks. Stop the engine and allow the oil to settle for five minutes.
Page 403 DIPLOMAT 2004 Extended Engine When the motorhome has been sitting for extended periods, 30 days or Shutdown more, verify all the fluid levels are correct. Follow the normal starting procedures. If the oil pressure gauge does not register within 15 seconds, shut off the engine immediately to avoid damage.
Page 404 DIPLOMAT 2004 Keypad Functions: • Select the REVERSE gear by pressing R. • Select NEUTRAL by pressing N. The area around the N button has a raised ridge so the driver can orient his hand to the push buttons by touch, without looking at the display.
Page 405 DIPLOMAT 2004 Transmission The electronic control system of the transmission is programmed to inform Check Light the operator of a problem with the transmission system and reacts automatically to protect the operator, motorhome and transmission. When the Electronic Control Unit (ECU) detects a DO NOT SHIFT (DNS) condition the ECU restricts shifting, turns on the CHECK TRANS light in the instrument panel and registers a fault code.
Page 406 DIPLOMAT 2004 Diagnostic Codes: The diagnostic codes are numerical representations of malfunctions in the transmission operations. Each code is a two digit main code and a two digit sub code. The codes, when detected, are logged in the ECU memory. These codes will fall in two classes: active and inactive.
Page 407 DIPLOMAT 2004 The Importance of Proper Fluid Levels: Transmission fluid cools, lubricates and transmits hydraulic power. Proper fluid levels must be maintained at all times. If fluid level is too low, the converter and clutches do not receive an adequate supply of fluid. If fluid level is too high, the fluid can aerate.
Page 408 DIPLOMAT 2004 To Exit Oil Level Sense Mode: • Press Neutral, Reverse or Drive. NOTE: Reading between the Oil Level Sensor and the dipstick may not agree because the OLS compensates for fluid temperatures. NOTE: To correctly check the transmission fluid level using the dipstick, the transmission fluid must be at operating temperature.
Page 409 DIPLOMAT 2004 Fluid Levels Cold Check - Manual Check Procedures: - Cold Check The concept of a cold check is to determine adequate fluid level for safe operating until hot check can be performed. To Check the Fluid When Cold: •...
Page 410 DIPLOMAT 2004 Fluid Levels • Fluid level rises as temperature increases. Fluid must be hot to - Hot Checks ensure an accurate check. • Be sure fluid has reached normal operating temperature (160º - 200º F /71º - 93º C). If a transmission temperature gauge is...
Page 411 DIPLOMAT 2004 The charge air cooler, cools the intake air for the engine after it has passed through the turbocharger. This is necessary due to the heat generated as the intake air is pressurized, and subsequently heated, as it passes through the turbocharger.
Page 412 DIPLOMAT 2004 Coolant Fully formulated antifreeze or coolant containing a precharge of Supplemental Coolant Additives (SCA) is recommended. The use of either will significantly simplify coolant system maintenance. The difference between a fully formatted antifreeze and a fully formatted coolant is the percentage of water.
Page 413 DIPLOMAT 2004 Engine Coolant Reservoir: A “see-through” plastic reservoir, similar to the familiar windshield washer jar, is connected to the radiator by a hose. As the motorhome is driven, coolant is heated and expands. A portion of fluid displaced by this expansion flows from the radiator into the reservoir tank.
Page 414 DIPLOMAT 2004 Coolant Fully formulated products contain SCA and are Additive (SCA) required to protect the cooling system from fouling, solder blooming and general corrosion. The cooling filter is required to protect the coolant system from abrasive materials, debris and precipitated coolant additives.
Page 415 DIPLOMAT 2004 Maintenance When performing maintenance, it is also necessary to inspect other Procedures components of the cooling system. Have an inspection performed of the surge tank cap seal and have the cap pressure tested, and also replace the thermostat, gasket and seal. The charge air cooler and radiator also requires an inspection for cracks, broken welds, secure mounting, and general cleanliness.
Page 416 DIPLOMAT 2004 Coolant Overheated: If the engine is overheated, never pour cold coolant into a hot engine. The sudden change in temperature may crack the cylinder head or block. If the engine is hot, fill slowly to prevent rapid cooling and distortion of engine castings.
Page 417 DIPLOMAT 2004 CHARGE AIR COOLER The diesel engine uses compression to ignite the fuel/air charge. To increase compression inside the combustion chamber (resulting in increased power output) a turbocharger is added to the engine. The turbocharger is a paired housing assembly with impellers inside each housing connected by a common shaft.
Page 418 DIPLOMAT 2004 FUEL SYSTEM The fuel tank, fuel lines, fuel/water separator, secondary fuel filter, fuel transfer pump, and fuel injectors are primary components of the fuel system. When the fuel transfer pump is operating, fuel is drawn from the fuel tank through the fuel supply hose to the primary water/separator.
Page 419 DIPLOMAT 2004 Any fuel additives product should show supporting data for performance and benefits. Engine failures caused by incorrect fuel are not covered under warranty. Maintenance of the fuel system is important, as it supplies the energy with which the engine requires to run efficiently. Poor maintenance of the fuel system can result in poor performance, premature failure of components, and unexpected breakdowns.
Page 420 DIPLOMAT 2004 Adjustments: The "Centroid" sender has two adjustments: • EMPTY: Adjusts for length of sender. It has been set at the factory, covered with a sealant and should not be changed. • Full Adjustment (FULL): The full adjustment can be used to correct for slight differences between fuel meters.
Page 421 DIPLOMAT 2004 Fuel Filters The primary and secondary fuel filters have drains located at the bottom of the filters. The primary filter has a clear fuel/water separator bowl located at the bottom of the filter. Water (by weight) is heavier than fuel and will collect in the separator bowl. Water can accumulate in the fuel from condensation in the fuel tank or contamination upon refueling.
Page 422 DIPLOMAT 2004 Fuel Line & Hoses Make a visual check for fuel leaks at all engine-mounted fuel lines and connections and at the fuel tank pick-up and return lines. Leaks in this area may best be detected by checking for accumulation of fuel under the tank.
Page 423 DIPLOMAT 2004 Checking the Fluid Level: 1. Start the engine and allow it to reach normal operating temperature. 2. While the engine is at idle, turn the steering wheel left and right several times. 3. Shut the engine off. 4. The easy grip handle is rotated counterclockwise to remove the dipstick.
Page 424 DIPLOMAT 2004 AIR INTAKE & CHARGE AIR SYSTEM The air intake and charge air system supply the engine with clean air for proper combustion and performance. Air entering the system is cleaned through a replaceable filter element and monitored with an air filter restriction indicator.
Page 425 DIPLOMAT 2004 Changing Air Filter To replace air cleaner remove screws and cover from air cleaner body. Remove air cleaner cartridge and discard. Install new air cleaner cartridge and secure with cover and screws. WARNING: Do not start the engine with the air cleaner removed and do not remove it while the engine is running.
Page 426 DIPLOMAT 2004 PARTS - COMMON SOLENOIDS & SENDERS Rear Bag Dump Solenoids: • Only used for the hydraulic leveling. • Dumps air in the rear bags. • Two air bag solenoids, one for each side. • Location - Open rear the engine...
Page 427 DIPLOMAT 2004 Link Assembly: • Located on ends of connecting rod between axles and ride height valve. • Secures connecting rod with hose clamp. • Type Hadley Products HPB450-3. • MP# 2057. 090333D House Disconnect Solenoid: • 110 Amp solenoid controlled log switch at entry door.
Page 428: Lubrication Charts
DIPLOMAT 2004 LUBRICATION CHARTS 070168B COMPONENT ACTION WHEN CODE - REFER TO CHART 1 Engine Oil Fill/Dip Stick Keep To Full Mark Before Each Trip 2 Engine Oil Filter Replace Refer to OEM 3 Transmission Oil Check Keep To Full Mark...
Page 429 DIPLOMAT 2004 070169c LUBRICATION CODE CHART CL-4 U-Joints located inside the coach under the steering cover Engine oil as recommended by engine manufacturer OEM Refer to Equipment Manufacturers Manual AP GL-5 or MT-1 type gear lubricant - Penzoil Gear Plus SUPER-ew 75w-90,...
Page 430 DIPLOMAT 2004 SPECIFICATIONS DIMENSIONS CHART 2004 Diplom at Specifications 36PST 38PBDD 38PST 40PBDD 40DST 40PST 40PST Weights Gross Vehicle Weight Rating 32,000 32,000 32,000 32,000 32,000 32,000 32,000 Gross Combined Weight Rating 42,000 42,000 42,000 42,000 42,000 42,000 42,000 Front Gross Axle Weight Rating...
Page 431 DIPLOMAT 2004 ENGINE SPECIFICATIONS - CUMMINS ENGINE ISC 330 Engine Size / Cummins 8.3 Liter Allison Transmission MH 3000 Torque (lbs. - ft. Max. Net at 1,400 RPM) - 330 HP Cubic Inch Displacement - 300 HP 504.5 Alternator / Leece Neville...
Page 432 DIPLOMAT 2004 10 • 432 CHASSIS INFORMATION...
Page 433 DIPLOMAT 2004 MAINTENANCE RECORD After scheduled services are performed, record the date, odometer reading and who performed the service in the boxes provided after the maintenance interval. Any additional information from “Owner Checks and Services” or “Periodic Maintenance” can be added on the following record pages. In addition, retain all maintenance receipts.
Page 434 DIPLOMAT 2004 Lubrication Service Record 10 • 434 CHASSIS INFORMATION...
Page 435 DIPLOMAT 2004 Battery and Tire Record CHASSIS INFORMATION 10 • 435...
Page 436 Fran Weisenstein - IN Wes Bogan - IN TECHNICAL ILLUSTRATOR Judie Pressler - IN Additional Illustrations Kelly Stroble, Rena Koffler The Diplomat 2004 Technical Writer & Cover Design Wes Bogan The Diplomat 2004 Layout Design Julie Slagle PRINTING Holiday Graphics - IN ONLINE CORPORATE SITE www.monaco-online.com...
Page 437 Diplomat INDEX...
Page 439 DIPLOMAT 2004 How It Works ....... . 314 Reasons Why Batteries Fail ....318 ABS/ATC System .
Page 440 DIPLOMAT 2004 Coolant System ......410 Emergency Procedures ....65 Coolant .
Page 441 DIPLOMAT 2004 Generator 120 AC Diesel ....298 Generator Access ......298 Fans .
Page 442 DIPLOMAT 2004 Leveling System ......392 Oil Recommendations ....399 Hydraulic Leveling .
Page 443 Main Room Slide-out ......205 Monaco Responsibilities ......19 Manual Override - Bedroom Slide-out .
Page 444 DIPLOMAT 2004 Toilet - Sealand Limitations of Implied Warranties ....6 What the Warranty Covers ..... . . 6 Operating Instructions.
Page 445 DIPLOMAT 2004 Water Pump ......248 Galley Filter ......250 Water Pump Troubleshooting .

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