Holiday Neptune 2004 Owner's Manual

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MOTORHOME LIMITED WARRANTY

What the Period of Coverage Is:

If you use your Holiday Rambler® motorhome only for recreational travel and

family camping purposes, the Limited Warranty provided by Holiday Rambler

("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. However, the Limited Warranty provided by

Warrantor covers the steel or aluminum frame structure of the sidewalls (excluding

slide outs), roof, and rear and front walls for sixty (60) months from the original

retail purchase date or the first 50,000 miles of use, whichever occurs first.

If you use your motorhome for any rental, commercial or business purposes

whatsoever, the Limited Warranty provided by Warrantor covers your new

motorhome when sold by an authorized dealer for ninety (90) days from the

original retail purchase date or the first 24,000 miles of use, whichever occurs

first. In addition, the Limited Warranty provided by Warrantor covers the steel or

aluminum frame structure of the sidewalls (excluding slide outs), roof, and rear

and front walls for twelve (12) months from the original retail purchase date or the

first 24,000 miles of use, whichever occurs first. A conclusive presumption that

your motorhome has been used for commercial and/or business purposes arises if

you have filed a federal or state tax form claiming any business tax benefit related

to your ownership of the motorhome.

The above Limited Warranty coverage applies to all owners, including

subsequent owners, of the motorhome. However, a subsequent owner must submit

a warranty transfer form by filing the form through an authorized Holiday

Rambler dealer. A subsequent owner's warranty coverage period is the remaining

balance of the warranty coverage period the prior owner was entitled to under this

Limited Warranty. Warranty transfer forms can be obtained by contacting the

Customer Relations Department. There is no charge for the transfer.

NEPTUNE 2004

WARRANTY - LIMITED: 2004 . . . . . . . . . . . . . . . . . . . . . . .1

WARRANTY - LIMITED: 2004 ROADMASTER CHASSIS . . .6

WARRANTY INFORMATION FILE . . . . . . . . . . . . . . . . . . . .10

HOLIDAY RAMBLER

WARRANTY

- LIMITED: 2004

WARRANTY • 1

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Summary of Contents for Holiday Neptune 2004

Page 1 MOTORHOME LIMITED WARRANTY What the Period of Coverage Is: If you use your Holiday Rambler® motorhome only for recreational travel and family camping purposes, the Limited Warranty provided by Holiday Rambler ("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 2 "good will" repairs, which shall not alter the express terms of this limited warranty. Warrantor may use new and/or remanufactured parts and/or components of substantially equal quality to complete any repair. NEPTUNE 2004 2 • WARRANTY...
Page 3 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. WARRANTY • 3 NEPTUNE 2004...
Page 4 SHALL BE DEEMED INDEPENDENT OF, AND SHALL SURVIVE, ANY FAILURE OF THE ESSENTIAL PURPOSE OF ANY LIMITED REMEDY. Some states do not allow the exclusion or limitation of consequential or incidental damages, so the above exclusions may not apply to you. NEPTUNE 2004 4 • WARRANTY...
Page 5 THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS, WHICH VARY FROM STATE TO STATE. 51903 WARRANTY • 5 NEPTUNE 2004...
Page 6 Limited Warranty. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. NEPTUNE 2004 6 • WARRANTY...
Page 7 Warrantor directly in writing of the failure to successfully repair the defect(s) so that Warrantor can become directly involved in exercising a final repair attempt for the purpose of performing a successful repair to the identified defect(s). WARRANTY • 7 NEPTUNE 2004...
Page 8 (See Owner's Manual), damage caused by off road use, Obligation Under collision, fire, theft, vandalism, explosions, overloading in excess of rated capacities, Warranty and odometer tampering shall discharge Warrantor from any express or implied warranty obligation to repair any resulting defect. NEPTUNE 2004 8 • WARRANTY...
Page 9 THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS, WHICH VARY FROM STATE TO STATE. ROADMASTER CHASSIS DIVISION MONACO COACH CORPORATION 91320 COBURG INDUSTRIAL WAY COBURG, OREGON 97408 51903 WARRANTY • 9 NEPTUNE 2004...
Page 10 The foregoing is not a warning. See the Limited Warranty or call (877) 466-6226 for warranty information and limitations. NEPTUNE 2004 10 • WARRANTY...
Page 11: Table Of Contents
Neptune 2004 Sections General Information ~ 1 Driving & Safety ~ 2 Exterior & Interior Care ~ 3 Appliances ~ 4 Equipment ~ 5 Water Systems ~ 6 LP-Gas Systems ~ 7 Electrical Systems - House ~ 8 Electrical Systems - Chassis ~ 9...
Page 13 Section 1 SAFETY SYMBOL LEGEND ........15 INTRODUCTION .............17 CUSTOMER RELATIONS ........18 REPORTING SAFETY DEFECTS......18 TAKING DELIVERY..........18 Holiday Rambler Responsibilities ......18 Dealer Responsibilities........19 Customer Responsibilities.........19 SERVICE SUGGESTIONS ........19 Prepare for the Appointment ......20 Prepare a List ...........20 Be Reasonable With Your Requests ....20 No Looking Over the Technician’s Shoulder ..20...
Page 14 ©Copyright Monaco Coach Corporation. All rights reserved. The Neptune is a trademark of ™ Holiday Rambler. All other trademarks or registered trademarks are property of their respective holders. Brand name products of other companies mentioned in this manual are not endorsed by the manufacturer of the motorhome.
Page 15: Safety Symbol Legend
Manual. Also refers to the WARRANTY INFORMATION FILE, found within the Warranty Information Box inside the motorhome. Indicates a TIP. Information regarding helpful hints and/or suggestion for ease of operation of the motorhome and/or its components. GENERAL INFORMATION --- SECTION 1 • 15 NEPTUNE 2004...
Page 17: Introduction
Try to pick as level a parking spot as possible. All the facilities are fully self-contained and readily available within the motorhome. GENERAL INFORMATION --- SECTION 1 • 17 NEPTUNE 2004...
Page 18: Customer Relations
The necessary forms and required manuals have been placed in the motorhome at the time of shipment to the dealership. 18 • SECTION 1 --- GENERAL INFORMATION NEPTUNE 2004...
Page 19: Dealer Responsibilities
Monday and Friday are busy days for most dealers. Therefore, it makes sense to make a mid-week appointment whenever possible. Ask your dealer if additional time is needed for check in and completion of paperwork. GENERAL INFORMATION --- SECTION 1 • 19 NEPTUNE 2004...
Page 20: Prepare For The Appointment
Check out the service or repair job when you pick up your motorhome and notify Inspect the Work Properly the service manager of any dissatisfaction. If circumstances prevent returning for immediate corrective work, make an appointment as soon as possible. 20 • SECTION 1 --- GENERAL INFORMATION NEPTUNE 2004...
Page 21: Owner's Record
(Located inside refrigerator compartment) Generator Model & Serial Number_______________________________________________________ (Located in outside compartment on generator) Roof Air Conditioner(s) Model & Serial Number__________________________________________ (Located under top cover on air conditioner)_______________________________________________ Inverter Model & Serial Number________________________________________________________ GENERAL INFORMATION --- SECTION 1 • 21 NEPTUNE 2004...
Page 22: Personal Property
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 22 • SECTION 1 --- GENERAL INFORMATION NEPTUNE 2004...
Page 23: Insurance
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ GENERAL INFORMATION --- SECTION 1 • 23 NEPTUNE 2004...
Page 24: Glossary Of Terms
Curbside - This refers to the side of the motorhome which faces the curb when it is parked. Often called the door side or the passenger’s side. 24 • SECTION 1 --- GENERAL INFORMATION NEPTUNE 2004...
Page 25 In most states it is illegal to drain waste tanks anywhere other than at a dump station. Dump Valve - Another name for the T-handle valve used to drain the sewage (black) and waste (grey) tanks. GENERAL INFORMATION --- SECTION 1 • 25 NEPTUNE 2004...
Page 26 Shore Line Plug - The 120/240 Volt outlet allows the motorhome to be hooked up to a campground facility. Stinger - An arm attachment on a tow truck that is used to lift motorhome slightly so that it can be towed. 26 • SECTION 1 --- GENERAL INFORMATION NEPTUNE 2004...
Page 27 Wet Cell Battery - A type of battery that uses liquid as an electrolyte. This type of battery requires periodic maintenance such as cleaning the connections and checking the electrolyte level. GENERAL INFORMATION --- SECTION 1 • 27 NEPTUNE 2004...
Page 28: Vendor List
Carefree 800-343-7357 800-621-2617 www.cummins.com www.carefreeofcolorado.com Energy Management System (Opt.) Axles - Front (WET) Intellitec Westport 800-251-2408 216-431-2000 www.intellitecsve.com www.westportaxle.com Entry Step Axles - Rear Kwikee Dana Spicer 800-736-9961 800-666-8688 www.kwikee.com www.dana.com 28 • SECTION 1 --- GENERAL INFORMATION NEPTUNE 2004...
Page 29 KIB Enterprises Atwood 574-294-1504 800-873-4328 www.kibenterprises.com www.atwoodmobile.com Outside Mirrors Generator Ramco Industries, Inc. Onan 800-321-4819 800-888-6626 www.ramco-eng.com www.onan.com Power Converter Home Theater System (Opt.) Progressive Dynamics Sony 616-781-7802 800-222-7669 www.progressivedyn.com www.sony.com GENERAL INFORMATION --- SECTION 1 • 29 NEPTUNE 2004...
Page 30 Slide-Out Motor - Main & Bedroom Transmission Shiftpad Power Gear Arens Controls 800-334-4712 847-328-6905 www.powergear.com Steering Gear Sony Sheppard 800-222-7669 717-637-3751 www.sony.com www.rhsheppard.com Video Selector Box Television Winegard Sony 800-288-8094 800-222-7669 www.winegard.com www.sony.com 30 • SECTION 1 --- GENERAL INFORMATION NEPTUNE 2004...
Page 31 Water Filters - Flow Pur Flomatic System Inc. 800-461-4406 www.flowmatic.com Water Pump Shurflo 800-854-3218 www.shurflo.com Wheels Simulators Wheel Masters 800-325-9484 www.wheelmasters.com Windshield Wipers Diesel Equipment 800-632-4959 (In State - NC) 800-222-7159 (Out of State) www.dieselequipment.com GENERAL INFORMATION --- SECTION 1 • 31 NEPTUNE 2004...
Page 32 MANUAL ADDENDUMS www.monaco-online.com Click on the Holiday Rambler logo, to enter the main web page. Under SERVICE link, click on MANUAL ADDENDUMS from the drop down menu. TECH TIPS Find current and archived tech tips with answers to frequently asked questions at: www.monaco-online.com...
Page 33: Survey
SURVEY N E P T U N E 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 PLT. #17 MONACO COACH CORPORATION 91320 COBURG INDUSTRIAL WAY COBURG, OR 97408-9908 FOLD LONG OTTED...
Page 35: Warranty Transfer Application
Limited Warranty Transfer Application DEALER IMPRINT Mail Monaco Coach Limited Warranty Transfer Application to: Monaco Coach Corporation Warranty Transfer 91320 Coburg Industrial Way Coburg, OR 97408 Please read terms and representations below before signing. TRANSFER COVERAGE FROM: PRIOR OWNER INFORMATION FIRST NAME INITIAL LAST NAME...
Page 37: Driving & Safety
NEPTUNE 2004 Driving & Safety Section 2 DRIVING & SAFETY ..........39 WEIGHING THE MOTORHOME ........81 Inspections ............39 Weight Label............84 Familiarize Yourself..........39 Four-Point Weighing (Example)......85 Mirror Adjust (Manual) ........39 VIEWS ...............94 Safety Seat Belts ..........40 Front..............94 Driving Tips............43 Rear..............94 PRE-TRIP PREPARATIONS - CHECKLIST ....48 Roadside ..............95...
Page 39: Driving & Safety
Prior to starting out, the mirrors will need to be adjusted. It is recommended an (Manual) assistant be used with these procedures. This will prevent any damage to mirror or motorhome. DRIVING & SAFETY --- SECTION 2 • 39 NEPTUNE 2004...
Page 40: Safety Seat Belts
Pilot and Co-pilot seats must be locked in a forward facing position with seat belts fastened while the motorhome is in motion. Avoid seat rotation while in transit. NEPTUNE 2004 40 • SECTION 2 --- DRIVING & SAFETY...
Page 41 The top of the head must be below the top of the safety seat. Secure safety seat harness straps at or below the shoulders. (See Example 1.) 020231b Example 1: Convertible Seat Facing to the Rear. DRIVING & SAFETY --- SECTION 2 • 41 NEPTUNE 2004...
Page 42 Check for cuts, frays or loose parts. Replace any damaged parts. Do not disassemble or modify the system. Replace the belt assembly if it has been in a severe impact, even if damage is not obvious. NEPTUNE 2004 42 • SECTION 2 --- DRIVING & SAFETY...
Page 43: Driving Tips
Keep in mind, road surfaces may have been repaved or become packed with snow and therefore the actual posted clearance height would not apply in such conditions. DRIVING & SAFETY --- SECTION 2 • 43 NEPTUNE 2004...
Page 44 This will aid in avoiding a premature turn. • Make the turn slowly. • Check mirrors frequently, being aware of necessary clearance and space management of the motorhome, while negotiating the turn. 020181 NEPTUNE 2004 44 • SECTION 2 --- DRIVING & SAFETY...
Page 45 Idle the engine to allow the exhaust and the turbo to cool. While these are cooling, the transmission also cools. Monitor the gauges. DRIVING & SAFETY --- SECTION 2 • 45 NEPTUNE 2004...
Page 46 • Use the mirror heat to keep the mirrors clear. • Remove any ice build-up from the entry step to avoid accidental slipping. NEPTUNE 2004 46 • SECTION 2 --- DRIVING & SAFETY...
Page 47 • Follow the maintenance schedule for the engine, transmission and chassis. Proper maintenance will lead to enhanced fuel economy, motorhome performance, and overall longevity. DRIVING & SAFETY --- SECTION 2 • 47 NEPTUNE 2004...
Page 48: Pre-Trip Preparations - Checklist
• One link kit for ride height control assembly (air suspension OPEN only). GROUND OPEN NUETRAL OPEN HOT HOT/GRD • A spare alternator belt. REVERSE HOT/NEU REVERSE CORRECT • Charge air cooler T-bolt clamp. Polarity Tester NEPTUNE 2004 48 • SECTION 2 --- DRIVING & SAFETY...
Page 49 • Check all fluid levels, oil, antifreeze, transmission, hydraulic fluid and washer fluid. • Inspect belts and hoses for wear. • Inspect wiring for loose, frayed or corroded connections. • Start engine and listen for any unusual noises. DRIVING & SAFETY --- SECTION 2 • 49 NEPTUNE 2004...
Page 50 Additionally, heavy items should be stored as low as possible to keep the motorhome from becoming top heavy. Make sure that every- thing is secure and safe from quick turns, bumps and sudden stops. NEPTUNE 2004 50 • SECTION 2 --- DRIVING & SAFETY...
Page 51: Hitch
Failure to comply with these State and Canadian province requirements may result in fines and/or pose a safety hazard, which may result in an accident. 100198 100198 DRIVING & SAFETY --- SECTION 2 • 51 NEPTUNE 2004...
Page 52: Tow Plug Connection
NOTE: When towing a trailer or vehicle with a two-wire system, a turn signal/brake light converter will be needed to adapt the tow plug wiring to the item being towed. 080420 NEPTUNE 2004 52 • SECTION 2 --- DRIVING & SAFETY...
Page 53: Rear View System
The mounting bolts can be repositioned to the desired angle. Refasten the camera housing cover and seal using an appropriate sealant. DRIVING & SAFETY --- SECTION 2 • 53 NEPTUNE 2004...
Page 54: Backing Up Amotorhome
This type of directional signal is easily discerned in the mirror by the driver. The directional signal given will remain steady until desired movement is completed. NEPTUNE 2004 54 • SECTION 2 --- DRIVING & SAFETY...
Page 55 Start with a wide separation, gradually closing distance of hands, in a rate appropriate to vehicle speed, to indicate amount of distance to the stop point. 5. Closed fists indicate STOP. 020083 DRIVING & SAFETY --- SECTION 2 • 55 NEPTUNE 2004...
Page 56: Set-Up Procedures - Checklist
Check for lateral clearance before extending the slide-out room. NOTE: To operate slide rooms: Ignition must be OFF and the park brake set. Ensure bay doors directly under the slide room are closed. NEPTUNE 2004 56 • SECTION 2 --- DRIVING & SAFETY...
Page 57 • A phone connection port is provided in the service center. Phone utility outlets are placed throughout the motorhome, including a phone line attached to the satellite receiver for Pay-Per-View movies and events. DRIVING & SAFETY --- SECTION 2 • 57 NEPTUNE 2004...
Page 58: Dry Camping Tips
Maneuvering the motorhome into a camp site takes skill and patience. Prior to pulling into a space get out and inspect the area. Check for obstructions and confirm the space has enough room to extend slide rooms and awnings. NEPTUNE 2004 58 • SECTION 2 --- DRIVING & SAFETY...
Page 59 Unscrew one or two bulbs to conserve battery power. • To conserve on energy, turn on the water pump only when in use. Turn it off when not in use. DRIVING & SAFETY --- SECTION 2 • 59 NEPTUNE 2004...
Page 60 • Leave shoes outdoors or at the entry step to avoid tracking in debris. • Get back to nature and still enjoy the comforts of the motorhome. With a little imagination, the ways to conserve available resources while dry camping are endless. NEPTUNE 2004 60 • SECTION 2 --- DRIVING & SAFETY...
Page 61 • One fluorescent dual bulb light has a 2.1 Amp draw. • One halogen ceiling light has a .09 Amp draw. 020034 Battery Voltage: Fully charged with battery at rest for one hour. Battery Charge Voltage chart DRIVING & SAFETY --- SECTION 2 • 61 NEPTUNE 2004...
Page 62: Breaking Camp
• Inspect belts and hoses for wear. • Inspect wiring for loose, frayed or corroded connections. • Start engine and listen for any unusual noises. • Inspect gauges and controls for proper operation. NEPTUNE 2004 62 • SECTION 2 --- DRIVING & SAFETY...
Page 63 Loose rocks, gravel and debris can be thrown from the jack pad and possibly damage the tow car. • Carefully pull forward out of the campsite. If necessary, clean the site and check for forgotten items. 020185B DRIVING & SAFETY --- SECTION 2 • 63 NEPTUNE 2004...
Page 64: Emergency Roadside Procedures
Slowly move to a safe off-road place, which should be a firm level spot. Turn the ignition off and turn the hazard flasher system ON. Save the old tire for possible warranty coverage. 070175 INFORMATION: Goodyear emergency service number is 877-484-7376. NEPTUNE 2004 64 • SECTION 2 --- DRIVING & SAFETY...
Page 65: Running Out Of Fuel
The solenoid is designed for short-term high current intermittent use. Engaging the boost solenoid for an extended period will damage the solenoid. 08349 DRIVING & SAFETY --- SECTION 2 • 65 NEPTUNE 2004...
Page 66 If uncertain about performing a jump-start procedure, contact a professional. Damage and personal injury can occur if this procedure is not performed correctly. NEPTUNE 2004 66 • SECTION 2 --- DRIVING & SAFETY...
Page 67 If a jump-start is necessary, it is recommended to call Roadside Assistance. They will have the equipment necessary to jump-start the motorhome. DRIVING & SAFETY --- SECTION 2 • 67 NEPTUNE 2004...
Page 68: Towing Procedures
Rear frame extensions are not designed to support weight loads imposed by lifting the motorhome from the rear. 020183 020182 NEPTUNE 2004 68 • SECTION 2 --- DRIVING & SAFETY...
Page 69: Tires
To obtain the maximum wear and best service of the tires it is helpful to understand the components and function of the tires. DRIVING & SAFETY --- SECTION 2 • 69 NEPTUNE 2004...
Page 70: Importance Of Air Pressure
Aged tires are also susceptible to sidewall damage. For safety purposes clear the area of people and pets during tire inflation. Inflate the tires using a remote inflation device. NEPTUNE 2004 70 • SECTION 2 --- DRIVING & SAFETY...
Page 71: Tire Pressure Inflation Guideline
When loading a motorhome never exceed the motorhome's Gross Vehicle Weight Rating (GVWR) or the GAWR for each axle. Contact the tire manufacturer for further information concerning proper tire pressure inflation and other tire issues. DRIVING & SAFETY --- SECTION 2 • 71 NEPTUNE 2004...
Page 72: Goodyear Tire Chart
Goodyear Tire Chart NEPTUNE 2004 72 • SECTION 2 --- DRIVING & SAFETY...
Page 73: Inspecting & Pressure
WARNING: Improperly inflated tires can effect handling or Example of Overinflation More wear in center. cause sudden tire failure possibly resulting in loss of vehicle control. Always use an accurate tire pressure gauge when checking tire pressure. DRIVING & SAFETY --- SECTION 2 • 73 NEPTUNE 2004...
Page 74 Aged tires are also susceptible to sidewall damage. For safety purposes clear the area of people and pets during tire inflation. Inflate tires using a remote inflation device. 020161c NEPTUNE 2004 74 • SECTION 2 --- DRIVING & SAFETY...
Page 75: Air Pressure Checklist
NOTE: Air pressure in a tire goes up (in warm weather) or down (in cold weather) 1 to 2 pounds for every 10 degrees of temperature change. 020164 DRIVING & SAFETY --- SECTION 2 • 75 NEPTUNE 2004...
Page 76: Supporting When Leveling
CAUTION: Supporting the tires prevents damage to the sidewall of the tires and does not prevent tire roll. 020063b modified NEPTUNE 2004 76 • SECTION 2 --- DRIVING & SAFETY...
Page 77: Tire Vibration
Have the tire manufacturer inspect the tires for age weathering. DRIVING & SAFETY --- SECTION 2 • 77 NEPTUNE 2004...
Page 78: Tire Care
Damage to the wheel or mounting system could cause a wheel to come off while the recreational vehicle is in motion. NEPTUNE 2004 78 • SECTION 2 --- DRIVING & SAFETY...
Page 79 • If air wrenches are used they must be periodically calibrated for the proper torque output. Use a torque wrench to check the air wrench output and adjust the line pressure for the correct torque. 020086b LUG NUT TIGHTENING SEQUENCE DRIVING & SAFETY --- SECTION 2 • 79 NEPTUNE 2004...
Page 80: Storage Of Tires - Long Term
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 putting the motorhome into service. NEPTUNE 2004 80 • SECTION 2 --- DRIVING & SAFETY...
Page 81: Weighing The Motorhome
The GAWR is the maximum weight for which a single axle is designed. Tires, wheels, axle, the motorhome frame and/or other components of the motorhome, could limit these per axle and total maximum weight ratings. DRIVING & SAFETY --- SECTION 2 • 81 NEPTUNE 2004...
Page 82 The weight load will be transferred on the opposite side from the direction in which the motorhome is cornering. NEPTUNE 2004 82 • SECTION 2 --- DRIVING & SAFETY...
Page 83 Even though an axle or side is not physically on the scale, a definite lean in the motorhome will produce inaccurate scale readings. DRIVING & SAFETY --- SECTION 2 • 83 NEPTUNE 2004...
Page 84: Weight Label
Weight Label NEPTUNE 2004 84 • SECTION 2 --- DRIVING & SAFETY...
Page 85: Four-Point Weighing (Example)
Tire pressure below the minimum inflation pressure can overheat and damage the tire casing leading to premature tire failure or blowout. DRIVING & SAFETY --- SECTION 2 • 85 NEPTUNE 2004...
Page 86 Material lodged between the valve core and internal stem can cause a slow leak resulting in tire failure. NEPTUNE 2004 86 • SECTION 2 --- DRIVING & SAFETY...
Page 87 NOTE: Every load range has a maximum rating as well as a minimum rating. Do not exceed those ratings. • Rated load capacities are listed for individual tires in a Dual or Single position. DRIVING & SAFETY --- SECTION 2 • 87 NEPTUNE 2004...
Page 88 15,000 - 415 14,585 14,585 - 100.8 14,484.2 Next, calculate the Sleep Capacity Weight Rating (SCWR). The manufacturer's designated number of sleeping positions for the motorhome multiplied by 154 pounds. NEPTUNE 2004 88 • SECTION 2 --- DRIVING & SAFETY...
Page 89 Items need to be removed until the weight rating is within specification. WARNING: Further instructions for towing guideline, including auxiliary brake requirements for any towed trailer or towed vehicle, are found in other areas of this manual. DRIVING & SAFETY --- SECTION 2 • 89 NEPTUNE 2004...
Page 90 020254 NEPTUNE 2004 90 • SECTION 2 --- DRIVING & SAFETY...
Page 91 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 DRIVING & SAFETY --- SECTION 2 • 91 NEPTUNE 2004...
Page 92 020255B NEPTUNE 2004 92 • SECTION 2 --- DRIVING & SAFETY...
Page 93 Weight Record Sheet: 020263 DRIVING & SAFETY --- SECTION 2 • 93 NEPTUNE 2004...
Page 94: Views
VIEWS - Front 010725 Rear 010726c NEPTUNE 2004 94 • SECTION 2 --- DRIVING & SAFETY...
Page 95: Roadside
Roadside 010723d Curbside 010724e DRIVING & SAFETY --- SECTION 2 • 95 NEPTUNE 2004...
Page 96: Specifications Chart
NOTE: All tank capacities are estimated based upon calculations provided by the tank manufacturers and represent approximate capacities. The actual "usable capacity" may be greater or less then the estimated capacities based upon fabrication and installation of the tanks. NEPTUNE 2004 96 • SECTION 2 --- DRIVING & SAFETY...
Page 97: Smoke Detector
When testing the smoke alarm it is advised to stand at arms length. CAUTION: Never use an open flame to test the smoke alarm. You may ignite and set fire to the alarm and to the motorhome. DRIVING & SAFETY --- SECTION 2 • 97 NEPTUNE 2004...
Page 98: Maintenance
Butane, like propane, is heavier than air and will settle to the floor level where it will be detected. When this occurs, reset the detector to stop the alert sound. NEPTUNE 2004 98 • SECTION 2 --- DRIVING & SAFETY...
Page 99 The gas detector operates on 12 Volt DC, with a current draw less than 1/10th of one amp. CAUTION: The detector will not alarm during the three minute warm up cycle. DRIVING & SAFETY --- SECTION 2 • 99 NEPTUNE 2004...
Page 100: Testing
15 seconds. The LED will alternately flash red to green and the MUTE switch will not respond to any command. The gas detector must be repaired or replaced. NEPTUNE 2004 100 • SECTION 2 --- DRIVING & SAFETY...
Page 101: Maintenance
Young children and household pets may be the first affected. Other highly sensitive people would include the elderly and people with lung or heart disease or anemia. DRIVING & SAFETY --- SECTION 2 • 101 NEPTUNE 2004...
Page 102: Operation
If the power is on and the connections are correct, but the indicator still does not light, the detector should be returned for service. Do not attempt to fix the detector. NEPTUNE 2004 102 • SECTION 2 --- DRIVING & SAFETY...
Page 103: Alarm
• Engine Exhaust • Portable Grills • Portable Space Heaters • Camp Fires • Gas Stoves and Ovens • Generator Exhaust • Defective Engine Exhaust System • Portable Generators • Other Motorhomes DRIVING & SAFETY --- SECTION 2 • 103 NEPTUNE 2004...
Page 104: Testing
Be sure to replace or recharge the extinguisher immediately after use. NEPTUNE 2004 104 • SECTION 2 --- DRIVING & SAFETY...
Page 105: Egress Exit Window
Living Room Egress Exit Window the rubber seal will tend to stick to the egress window. Occasional operation will help prevent the rubber seal from sticking. 020029 Bedroom Egress Exit Window DRIVING & SAFETY --- SECTION 2 • 105 NEPTUNE 2004...
Page 106 ~ NOTES ~ NEPTUNE 2004 106 • SECTION 2 --- DRIVING & SAFETY...
Page 107: Exterior & Interior Care
NEPTUNE 2004 Exterior & Interior Care Section 3 EXTERIOR CARE..........109 WINDOWS............132 Corrosion ............109 Condensation ..........132 Washing ............109 WINDOW TREATMENTS ........133 Drying ............110 Mini-blinds .............133 Waxing ............110 Day/Night Shades (Opt.) .........134 Tire Care ............111 MOLD & MILDEW..........134 Bright Metal............111 PEST CONTROL...........137 Wheel Simulators ...........112...
Page 109: Exterior Care
Try not to allow the detergent to dry onto the clear coat surface. Use plenty of water when rinsing the surface to remove all detergent residue. EXTERIOR & INTERIOR CARE --- SECTION 3 • 109 NEPTUNE 2004...
Page 110: Drying
These types of products are generally used to correct or flatten a surface by removing high spots or small amounts of material. NEPTUNE 2004 110 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 111: Tire Care
NOTE: When using chemicals to remove road tars, use only automotive type products that are recommended for use on painted surfaces and fiberglass. Observe the warning recommendations and directions printed on the container of any agent being used. EXTERIOR & INTERIOR CARE --- SECTION 3 • 111 NEPTUNE 2004...
Page 112: Wheel Simulators
Cover the area as quickly as possible. Use plastic sheeting and tape, if necessary, so that moisture will not get into the motorhome and damage the interior. NEPTUNE 2004 112 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 113: Roof Care & Seal Inspections
NOTE: Check the tar tape at least twice a year for cracks. Removal of the tar tape is done with a plastic putty stick. Thoroughly clean the surface using 3M adhesive cleaner before applying the new tar tape. EXTERIOR & INTERIOR CARE --- SECTION 3 • 113 NEPTUNE 2004...
Page 114 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. NEPTUNE 2004 114 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 115: Interior Care
Cover all upholstery and make sure window coverings are down to protect from sun damage. Protect the fabric from any unnecessary exposure to moisture. Frequently used items will wear accordingly and may require more attention than those items not regularly used. EXTERIOR & INTERIOR CARE --- SECTION 3 • 115 NEPTUNE 2004...
Page 116: Fabric Cleaning Codes
Avoid products containing Carbon Tetrachloride as it is highly toxic. To help prevent overall soiling, frequent vacuuming or light brushing to remove dust and grime is recommended. NEPTUNE 2004 116 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 117 • Grid Head press for short intervals with minimum steam. Do not lock the head. • Flat bed press dampened drapery using cloth covering. • Avoid prolonged contact with heat. EXTERIOR & INTERIOR CARE --- SECTION 3 • 117 NEPTUNE 2004...
Page 118: Fabric Specifications Chart
Bedspread 48% Polyester, 52% Cotton Dry Clean Remsen 23 Flint Duster, BR Lambriquen 52% Cotton, 48% Polyester LR = Living Room BR = Bedroom FSD = Free Standing Dinette NEPTUNE 2004 118 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 119: Vinyl
Sponge with soapy water containing a small amount of household ammonia. Rinse thoroughly with clean water. Surface Mildew: Wash with diluted bleach and use a soft brush for stubborn growth. Rinse repeatedly with clear, cold water. EXTERIOR & INTERIOR CARE --- SECTION 3 • 119 NEPTUNE 2004...
Page 120 In a well ventilated area, use a cloth saturated with mineral spirits and gently rub the remaining gum. Rinse thoroughly with clean water. NEPTUNE 2004 120 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 121: Leather
NOTE: These are recommended or suggested methods of cleaning. The manufacturer is not responsible for damage incurred while cleaning. Always test the cleaning method in an inconspicuous area first before applying to the entire area. EXTERIOR & INTERIOR CARE --- SECTION 3 • 121 NEPTUNE 2004...
Page 122: Ultraleather
However, this chemical may cause polyurethane to yellow or the back cloth to deteriorate. It is recommended to remove ballpoint pen stains as early as possible with ethanol. For more information, please call: Ultrafabrics, LLC Customer Service: 1-877-309-6648 NEPTUNE 2004 122 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 123: Floors
• If the spot is not completely removed, Soot contact a professional carpet cleaner. Toothpaste Urine 1 4 3 Vomit * While recommended cleaning agents are effective, some stains may become permanent. EXTERIOR & INTERIOR CARE --- SECTION 3 • 123 NEPTUNE 2004...
Page 124 The carpet has been permanently dyed or the carpet yarns have been permanently damaged. NOTE: While the recommended cleaning agents have proven to be effective, some stains may become permanent. NEPTUNE 2004 124 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 125: Vinyl Floor
CAUTION: Abrasive cleaners and scouring pads can scratch and damage the flooring. Never wax, sand or apply lacquer to laminate flooring. NOTE: Any unusual or unique problems can be addressed by contacting Wilsonart at (800) 433-3222. EXTERIOR & INTERIOR CARE --- SECTION 3 • 125 NEPTUNE 2004...
Page 126: Shower
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. Rinse and wipe dry. NEPTUNE 2004 126 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 127 If the stain does not disappear, rinse the soapy area thoroughly with clean water. Mix a solution of 50% water and 50% household bleach. Clean the stained area with the bleach solution. Rinse with clean water. EXTERIOR & INTERIOR CARE --- SECTION 3 • 127 NEPTUNE 2004...
Page 128: Wood Care
Sanding between coats of sealing. Very Fine 280-320 Removing dust spots or mark between finish coats. Extra Fine 360-600 Super Fine Sanding finish to remove luster or surface blemishes. NEPTUNE 2004 128 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 129 With the tip of a rag, a small brush, or even a cotton swab, apply a thin coat of a wipe-on finish. Apply finish to the damaged area only. Several coats may be needed to hide the scratch. EXTERIOR & INTERIOR CARE --- SECTION 3 • 129 NEPTUNE 2004...
Page 130 Once the color is blended, patch the clear finish as described above and apply a wipe-on finish. NEPTUNE 2004 130 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 131: Countertops
NOTE: Do not cut directly on the solid surface. Always run cold water into the Solid Surface sink when pouring boiling water into the sink. EXTERIOR & INTERIOR CARE --- SECTION 3 • 131 NEPTUNE 2004...
Page 132: Laminate
The air flow will warm and ventilate the interior of the storage compartments and the exterior wall surface, reducing or eliminating condensation and preventing the possibility of ice formations. NEPTUNE 2004 132 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 133: Window Treatments
5. Re-install damp shade into window opening. Place a towel directly under the blinds to absorb water that might drip down. 6. Lower shade all the way to allow it to dry completely. EXTERIOR & INTERIOR CARE --- SECTION 3 • 133 NEPTUNE 2004...
Page 134: Day/Night Shades (Opt.)
Many of the synthetic fabrics such as acetate, polyester, acrylic and nylon are mildew resistant. However, soil on these fabrics may supply the nutrients to start mold growth. NEPTUNE 2004 134 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 135 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. EXTERIOR & INTERIOR CARE --- SECTION 3 • 135 NEPTUNE 2004...
Page 136 Limited Warranty coverage period provided. THE MANUFACTURER WILL NOT BE RESPONSIBLE FOR ANY DAMAGES CAUSED BY MOLD THAT MAY BE THE CONSEQUENCE OF OR ASSOCIATED WITH DEFECTS IN THE CONSTRUCTION. NEPTUNE 2004 136 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 137: Pest Control
Prior to operating the motorhome after storage, remove all insect and animal nests that may have developed around vents, engine compartments, the exhaust pipe and in the wheel wells. EXTERIOR & INTERIOR CARE --- SECTION 3 • 137 NEPTUNE 2004...
Page 138 Spraying pesticides will only kill the ants that are away from the colony. To eliminate all ants, the colony must be destroyed. Keep ants away from the sewer hose by spraying the hose ends with a soap and water solution. NEPTUNE 2004 138 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 139 Check references. Explain that you are seeking assistance for a motorhome, as treatments may differ from standard household jobs. EXTERIOR & INTERIOR CARE --- SECTION 3 • 139 NEPTUNE 2004...
Page 140: Lubrication Maintenance - General
Grease containers usually have an approval rating by the SAE (Society of Automotive Engineers), Mil Spec (Military Specification), API (American Petroleum Institute) or by other recognized and accepted organizations. NEPTUNE 2004 140 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 141: Lubricant Classification
Become familiar with the different sounds. If something sounds odd, sounds peculiar or looks unusual investigate the situation. EXTERIOR & INTERIOR CARE --- SECTION 3 • 141 NEPTUNE 2004...
Page 142: Proper Fluid Disposal
Particular care and attention to Chocking the wheels details should be taken when lubricating brake actuating components. Wheel removal may be necessary to access the grease fittings. NEPTUNE 2004 142 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 143 Every effort should be made to lubricate the component, as neglect will only result in premature component failure. 090418 NOTE: Some grease fittings may not be accessible until the steering wheel is turned or the motorhome is moved slightly. EXTERIOR & INTERIOR CARE --- SECTION 3 • 143 NEPTUNE 2004...
Page 144: Storage
• A full interior inspection for water leaks should be made bi-monthly, inspecting behind all cabinet doors and drawers. • Start and run the generator at least a ½ hour per month. NEPTUNE 2004 144 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 145: Long Term
NOTE: Batteries in a low state of charge will readily freeze. Freezing will damage the battery. EXTERIOR & INTERIOR CARE --- SECTION 3 • 145 NEPTUNE 2004...
Page 146 • Washing the exterior regularly will help control moss accumulation. The clear coat has UV protective substances. Waxing the motorhome twice a year will augment these substances. NEPTUNE 2004 146 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 147 These items include the roof air conditioners, dash fans, dash blower motor, furnace or Aqua Hot motors, heat exchangers and powered roof vents. EXTERIOR & INTERIOR CARE --- SECTION 3 • 147 NEPTUNE 2004...
Page 148: Winter Storage - Checklist
If the motorhome was not properly winterized, extensive freeze damage or other serious deterioration may have occurred. Consult a dealer or an authorized service center for advice. NEPTUNE 2004 148 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 149 12 Volt circuit breaker or blown fuse. • Install new batteries in battery operated safety detectors or devices. Test the carbon monoxide, LP-Gas and smoke detectors for proper operation. EXTERIOR & INTERIOR CARE --- SECTION 3 • 149 NEPTUNE 2004...
Page 150 • If desired, have the dealer or repair center double check preparation to make any necessary adjustments and/or correct defects. NEPTUNE 2004 150 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 151 ~ NOTES ~ EXTERIOR & INTERIOR CARE --- SECTION 3 • 151 NEPTUNE 2004...
Page 152 ~ NOTES ~ NEPTUNE 2004 152 • SECTION 3 --- EXTERIOR & INTERIOR CARE...
Page 153 NEPTUNE 2004 Appliances Section 4 APPLIANCES INTRODUCTION......155 REFRIGERATOR ..........155 Operating Specifics ........156 Control Panels ..........157 Storing the Refrigerator .........165 MICROWAVE/CONVECTION OVEN .....165 Operation ............169 Maintenace ...........170 COOKTOP ............172 Cooktop Cover ..........172 Lighting Top Burners ........173 Burner Grate ..........174 Cleaning ............174 COOKTOP WITH OVEN (OPT.) ......175...
Page 155: Appliances
With proper care and maintenance, the refrigerator should provide years of trouble-free service. INFORMATION: Refer to the refrigerator manual for detailed operating and maintenance instructions. APPLIANCES --- SECTION 4 • 155 NEPTUNE 2004...
Page 156: Operating Specifics
• The primary LP-Gas valve must be on and the electric gas valve must be on. • The refrigerator AC cord(s) must be plugged in (located outside behind refrigerator access door). 030967b 090967 Non-inverter Models Inverter Models 156 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 157: Control Panels
• When the desired temperature setting shows, release the TEMP SET button. • The temperature setting shows for ten seconds and then the current operation mode of the refrigerator shows. • The number "9" is the coldest temperature setting. APPLIANCES --- SECTION 4 • 157 NEPTUNE 2004...
Page 158 LP GAS shows. - After 10 seconds, the light bar beside LP GAS goes off and only the light bar beside AUTO remains. - The refrigerator is operating on propane gas. 158 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 159 F displays. Turn the refrigerator off then back on. If the gas does not ignite after several attempts, consult a dealer or authorized Norcold service center. APPLIANCES --- SECTION 4 • 159 NEPTUNE 2004...
Page 160 - Number "9" is the coldest setting. 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. 160 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 161 Ice cubes may have contaminates. Do not operate the icemaker without water pressure supplied to the refrigerator. This can cause damage to the icemaker assembly. APPLIANCES --- SECTION 4 • 161 NEPTUNE 2004...
Page 162 Many states have passed laws regarding having the LP-Gas valve open while traveling. Know the laws for the particular state in which you are traveling. 162 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 163 4. Install a GE#214-2 replacement bulb as the replacement bulb. 5. Install the cover. 6. Connect the 12 Volt DC power supply wires to the power board at the rear of the refrigerator. APPLIANCES --- SECTION 4 • 163 NEPTUNE 2004...
Page 164 30 second trial ignition may need to repeated two or three times. • If the burner does not ignite on propane gas after two or three attempts, stop and consult your local dealer or an authorized Norcold Service Center. 164 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 165: Storing The Refrigerator
The microwave offers many features which may include: varied cooking times with different power settings, automatic sensor cooking, a kitchen timer, on screen programming help, childproof lockout, and auto defrost cycles just to name a few. APPLIANCES --- SECTION 4 • 165 NEPTUNE 2004...
Page 166 • Cover food with a microwave-safe paper towel or upside-down plate to keep food spattering to a minimum. Place a paper towel on the turntable to keep clean-up at a minimum. 166 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 167 • If the microwave screen is not lit, plug another electrical appliance into the same outlet as the microwave to verify AC power is present. If the test item works, contact an appliance repair facility to have the microwave checked. microwave food chart APPLIANCES --- SECTION 4 • 167 NEPTUNE 2004...
Page 168 Most food should range between 160º F to 180º F. Never leave the thermometer in during cooking as it can shatter. 168 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 169: Operation
HELP menu. This feature prevents the oven from operating accidentally. To Use this Feature: • Press the CUSTOM HELP label. • Press the number one label. • Press the START/TOUCH ON label. • LOCK will appear in the display area. APPLIANCES --- SECTION 4 • 169 NEPTUNE 2004...
Page 170: Maintenace
4. Remove the louver from the face of the microwave. 5. Remove and replace the charcoal filter ensuring the filter is positioned on the supporting tabs. 6. Replace louver and mounting screws. 170 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 171 • Rinse the filter thoroughly and shake dry. Place the filter back into the opening, tip upward and slide filter to the end of the opening. Lock in place. Do not kink or warp the filter upon installation. APPLIANCES --- SECTION 4 • 171 NEPTUNE 2004...
Page 172: Cooktop
CAUTION: The cover is very 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. 030996 172 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 173: Lighting Top Burners
Open all windows and doors. Do not touch any electrical switches. They may cause a spark which can ignite. Contact a qualified service center to have the problem correctly diagnosed and repaired before resuming operation. APPLIANCES --- SECTION 4 • 173 NEPTUNE 2004...
Page 174: Burner Grate
DO NOT use abrasive cleaners or steel wool. Harsh cleansers like bleach, ammonia and oven cleaner should NEVER be used. The surface burner grate and caps should be cleaned using the same guidelines as the cooktop surface. 174 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 175: Cooktop With Oven (Opt.)
• To extinguish the oven pilot push in the oven control knob and rotate clockwise to OFF. WARNING: Extinguish all pilots when refueling or traveling. Do not block vents in oven with cookware or other objects. 030828 APPLIANCES --- SECTION 4 • 175 NEPTUNE 2004...
Page 176: Wall Thermostat
NOTE: Air conditioning systems will freeze the moisture in the air depending on the humidity content. Under high humidity conditions it is recommended to leave the HIGH/LOW switch to the HIGH position. 176 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 177: Operation
Inside air is drawn into the furnace and blown across the internal heat exchanger. Heated air is then discharged through ducted hoses which can be run throughout the motorhome. APPLIANCES --- SECTION 4 • 177 NEPTUNE 2004...
Page 178: Operation
NOTE: When washing the exterior of the motorhome, avoid a direct stream of water into the outside furnace vents. This can damage the furnace. 178 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 179 NOTE: When washing the exterior of the motorhome, avoid a direct stream of water into the outside furnace vents. This can cause damage to the furnace. APPLIANCES --- SECTION 4 • 179 NEPTUNE 2004...
Page 180: If The Furnace Fails To Light
NOTE: Do not operate the water heater without water in the water heater tank. Damage to the thermostats and electric heating element can occur. NOTE: It is not fuel efficient to use the generator to operate the water heater on 120 Volt AC. 180 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 181: Before Using The Water Heater
"hide" in corners. Liquid propane is highly volatile, explosive and extremely dangerous. Explosion, fire, property damage, injury or death can result. Contact a qualified service center to have the problem correctly diagnosed and repaired before resuming operation. APPLIANCES --- SECTION 4 • 181 NEPTUNE 2004...
Page 182: Operation
• If the burner does not light within six to nine seconds the ignition board will attempt two more ignition cycles. If the burner does not light after the third attempt, the indicator lamp glows steady. 182 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 183: Ignition Module Function
BYPASS stops water from entering the cold water inlet of the water heater. Turn the valve to BYPASS when winterizing. For normal operation, turn valve so that handle points to NORMAL FLOW. 040493c APPLIANCES --- SECTION 4 • 183 NEPTUNE 2004...
Page 184: Pressure-Temperature Relief Valve
The air pocket is re-established and the process does not need to be repeated until the next discharge of water from the Pressure-Temperature valve. If the valve continues to leak, contact a qualified service center to evaluate the valve and make any required repairs. 184 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 185: Burner Compartment
4. Open both HOT and COLD on all faucets. 5. Remove water heater drain plug. 6. Turn the Bypass lever to BYPASS. NOTE: Be sure to refill the water heater with water before resuming operation. APPLIANCES --- SECTION 4 • 185 NEPTUNE 2004...
Page 186: Washer-Dryer Prepared (Opt.)
• If the cabinet or closet in which a washer-dryer is installed does not have vented louvered doors, the manufacturer’s installation instructions may require installation of vented doors or vents to be installed in the doors. This is for sufficient circulation of drying. 186 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 187: Washer-Dryer (Opt.)
• Make sure water lines are secure and water valves are open. • Hook to city water or turn on the water pump. • Hook to shore power or start the generator. APPLIANCES --- SECTION 4 • 187 NEPTUNE 2004...
Page 188 Do not add gasoline, dry cleaning solvents or other flammable or explosive substances to the wash water. Do not use heat to dry articles containing foam rubber or similar textured, rubber-like materials. 188 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 189: Washer-Dryer Maintenance
NOTE: Should the washer-dryer need removal for service, care should be taken as the washer-dryer weighs approximately 170 lbs. Proper accommodations should be made to avoid risk of injury or damage to the cabinetry. 0310176b APPLIANCES --- SECTION 4 • 189 NEPTUNE 2004...
Page 190: Winterizing The Washer-Dryer
4. Any remaining liquid should contain a sufficient amount of antifreeze to be protected from freezing. NOTE: After winter, perform a Test Procedure before washing or drying any laundry to make sure all antifreeze has purged. 190 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 191 ~ NOTES ~ APPLIANCES --- SECTION 4 • 191 NEPTUNE 2004...
Page 192 ~ NOTES ~ 192 • SECTION 4 --- APPLIANCES NEPTUNE 2004...
Page 193 NEPTUNE 2004 Equipment Section 5 EQUIPMENT - INTRODUCTION ........195 ENTRY STEP............195 Operation ............195 Stepwell .............198 ENTRY DOOR ............199 SLIDE-OUT ..............201 Operation ............201 Main Room Slide-out..........202 Bedroom Slide-out..........204 Manual Override - Bedroom Slide-Out ....206 AWNINGS..............207 Slide-out Cover...........207 Patio Awning ............208 Front Door Awning..........211 Awning Care &...
Page 195: Equipment
CAUTION: High curbs can impede step operation. Use care when parked on side streets. EQUIPMENT --- SECTION 5 • 195 NEPTUNE 2004...
Page 196 Mud, snow, road salts and sand quickly breaks down lubricants and corrodes painted surfaces. NOTE: Silicone lubricants and WD-40 are not recommended as they evaporate and are not weather resistant. Moving components are then susceptible to the elements. NEPTUNE 2004 196 • SECTION 5 --- EQUIPMENT...
Page 197 • 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 --- SECTION 5 • 197 NEPTUNE 2004...
Page 198: Stepwell
WARNING: When adjusting the stepwell cover clear the stepwell area of obstructions, pets or persons. Do not adjust the stepwell cover while stepwell area is occupied. NEPTUNE 2004 198 • SECTION 5 --- EQUIPMENT...
Page 199: Entry Door
CAUTION: When operating the entry door ensure the dead bolt latch is fully in the unlock position prior to closing the entry door. Failure to do so can result in damage to the dead bolt and/or entry door. EQUIPMENT --- SECTION 5 • 199 NEPTUNE 2004...
Page 200 • To remove the top half of the screen door for travel, rotate clips and remove the screen. • To store the screen for travel, use the clips provided on the bottom half of the screen door. NEPTUNE 2004 200 • SECTION 5 --- EQUIPMENT...
Page 201: Slide-Out
When retracting the slide-out room, ensure there is sufficient clearance inside the motorhome. Never move the motorhome with any slide-out room extended. CAUTION: Continuous operation of the slide-out room can drain the batteries and damage the motor from overheating. EQUIPMENT --- SECTION 5 • 201 NEPTUNE 2004...
Page 202: Main Room Slide-Out
Continuous operation of the slide-out could cause a drain on the house batteries and damage to the slide-out motor from overheating. CAUTION: Remove lock bar prior to extending slide-out. 030802c NEPTUNE 2004 202 • SECTION 5 --- EQUIPMENT...
Page 203 If the fuses and circuit breakers test okay, it will be necessary to call and obtain mechanical assistance to correct the problem. Double Slide 080429 Triple Slide EQUIPMENT --- SECTION 5 • 203 NEPTUNE 2004...
Page 204: Bedroom Slide-Out
In such conditions, if the slide-out room is extended, clear the awning and ensure free movement prior to operating the slide-out room. NEPTUNE 2004 204 • SECTION 5 --- EQUIPMENT...
Page 205 CAUTION: Continuous operation of the slide-out room can drain the battery and damage the slide-out motor from overheating. Never move the motorhome with the slide-out room extended. EQUIPMENT --- SECTION 5 • 205 NEPTUNE 2004...
Page 206: Manual Override - Bedroom Slide-Out
6. Take the motorhome to an authorized dealer for service. NOTE: The slide out room is heavy and may require several persons to push it into the retracted position. 020079b NEPTUNE 2004 206 • SECTION 5 --- EQUIPMENT...
Page 207: Awnings
The slide-out cover retracts automatically and rolls up to the travel position when the slide-out is completely closed. NOTE: When retracting the slide-out, stop the room approximately halfway. Confirm that the fabric is rolling properly before fully retracting the slide-out. 030924 EQUIPMENT --- SECTION 5 • 207 NEPTUNE 2004...
Page 208: Patio Awning
Push up on tab and swing lock away. 3. Move the brake control (front leg only), to the up/unlock position. 030840 Lower brake control. NEPTUNE 2004 208 • SECTION 5 --- EQUIPMENT...
Page 209 Ensure the awning is straight. 6. Slide the center pull strap to one end of the awning and store it by wrapping the strap around the awning leg. 030841e EQUIPMENT --- SECTION 5 • 209 NEPTUNE 2004...
Page 210 5. Repeat instructions 2 through 4 for the front arm. NOTE: To move the awning out of the carport position reverse the above steps. 030841g 030841d NEPTUNE 2004 210 • SECTION 5 --- EQUIPMENT...
Page 211: Front Door Awning
Slide the strap to rear of awning roll tube and tie to rear arm. • Loosen locking knobs (in equipped) for both arms and extend arms so the canvas will clear door in the open position. 030851 EQUIPMENT --- SECTION 5 • 211 NEPTUNE 2004...
Page 212: Awning Care & Maintenance
Magic, will help keep your awning looking new. Be sure to follow the instructions on the container. NOTE: Allow the awning material to thoroughly dry before rolling the awning up. Metal surfaces should be cleaned with soapy water and thoroughly rinsed. NEPTUNE 2004 212 • SECTION 5 --- EQUIPMENT...
Page 213: Fans
To close the power air vent, push in the power button to stop the fan and close the vent. CAUTION: It is recommended to travel with the vents closed. High winds and vibration can damage the Plexiglass dome. 030842 EQUIPMENT --- SECTION 5 • 213 NEPTUNE 2004...
Page 214: Exhaust Fan (Opt.)
Let the fan come to a complete stop before changing the direction of the fan. CAUTION: It is recommended to travel with the vents closed. High winds and vibration can damage the Plexiglass dome. NEPTUNE 2004 214 • SECTION 5 --- EQUIPMENT...
Page 215: Power Shade (Opt.)
• Push the switch down to lower the desired shade. • Push the switch up to raise the shade. NOTE: Do not attempt to move or drive the motorhome with any shade in the lowered position. 080306 EQUIPMENT --- SECTION 5 • 215 NEPTUNE 2004...
Page 216: Sliding Door
This sofa is most commonly called the "Hide-A-Bed." This bed is similar to the ones found in many home guest rooms. The conventional sofa has a spring mattress. The newest addition to this style of hide-a-bed is the Air Coil mattress. NEPTUNE 2004 216 • SECTION 5 --- EQUIPMENT...
Page 217 7. Plug in the pump motor to inflate to a desired firmness. 8. Remove the handheld pump, replace the valve cap and zip the mattress cover. 020260b 9. Place bedding items on the mattress. EQUIPMENT --- SECTION 5 • 217 NEPTUNE 2004...
Page 218: Dinette Booth
NEPTUNE 2004 218 • SECTION 5 --- EQUIPMENT...
Page 219: Dinette Table
AC to operate. Hook to shore power, start the generator or turn on the inverter, if equipped. The video selector box requires 12 Volt DC to operate. Turn on the interior house power using the battery cut-off switch. EQUIPMENT --- SECTION 5 • 219 NEPTUNE 2004...
Page 220 Viewing time of the front TV from the optional inverter depends on the state of charge of the house batteries and any additional 12 Volt DC lighting being used. NEPTUNE 2004 220 • SECTION 5 --- EQUIPMENT...
Page 221 • 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. 130024 EQUIPMENT --- SECTION 5 • 221 NEPTUNE 2004...
Page 222 TV. The VCR will automatically turn on when a tape is inserted. The Audio/Video Input Jacks in the front allows for quick easy connections of additional video equipment. Easy Setup procedures provide the flexibility to quickly adapt the configuration for RV usage. 030880C NEPTUNE 2004 222 • SECTION 5 --- EQUIPMENT...
Page 223 UV stable detachable control panel and electronic tuner. The entertainment center includes 12 Volt DC, 120 Volt AC and Antenna receptacles. The locking cover should be closed and locked when the entertainment center is not in use. EQUIPMENT --- SECTION 5 • 223 NEPTUNE 2004...
Page 224: Component Operation
TV antenna. If picture quality is degraded and you are not using an external power supply, try turning the TV Antenna Power button on the control box OFF and ON. NEPTUNE 2004 224 • SECTION 5 --- EQUIPMENT...
Page 225 CABLE TV button above the VCR section on the switch box. NOTE: To view Cable TV signals, you must be connected to a Cable TV input on the outside of the motorhome. Cable TV inputs are available at many of today's campgrounds. EQUIPMENT --- SECTION 5 • 225 NEPTUNE 2004...
Page 226: Entertainment Center - Exterior (Opt.)
Level Control. Pressing the Select button once will set the unit for volume adjustment ("VOL" will appear on the display panel). Pressing the button additional times will select treble ("TRE" on the display), bass ("BAS"), balance ("BAL"), fader ("FAD") or volume ("VOL"). NEPTUNE 2004 226 • SECTION 5 --- EQUIPMENT...
Page 227 Automatic Seek Tuning function. The radio will seek the next available station and stop at the frequency. Pressing the button again or activating any other tuning function can stop the Seek function. EQUIPMENT --- SECTION 5 • 227 NEPTUNE 2004...
Page 228 • REPEAT PLAY SELECTOR (RPT) - During disc play, press this button to repeat the play of the selected track ("RPT" will appear on the display panel). Play of the track will continue to repeat until the button is pressed again. NEPTUNE 2004 228 • SECTION 5 --- EQUIPMENT...
Page 229 Grasp the released side and pull it off the chassis. To reattach the panel position the right side of the panel in place first and then press the left side of the panel until the mechanism locks it into place. EQUIPMENT --- SECTION 5 • 229 NEPTUNE 2004...
Page 230: Systems Control Center
10. Energy Management Remote Panel - Optional item used only with the Energy Management System. 11. Inverter Remote Panel - This is an optional item used only with an Inverter. 060158l NEPTUNE 2004 230 • SECTION 5 --- EQUIPMENT...
Page 231 ~ NOTES ~ EQUIPMENT --- SECTION 5 • 231 NEPTUNE 2004...
Page 232 ~ NOTES ~ NEPTUNE 2004 232 • SECTION 5 --- EQUIPMENT...
Page 233 NEPTUNE 2004 Water Systems Section 6 WATER SYSTEMS INTRODUCTION......235 MONITOR PANEL - WATER........236 WATER SERVICE CENTER ........237 WATER TANK............238 Fresh Fill............238 City Water Hook-up ..........239 WATER PUMP ............239 Troubleshooting the Water Pump ......240 WATER FILTER ............241 FAUCETS ...............242 SHOWER - EXTERIOR..........242 WATER SYSTEM............242...
Page 235: Water Systems Introduction
A pressure regulator is attached to the city water/tank fill connection. After each hose. use, attach the end cap to keep debris and insects out of the hose. 040487c Typical Domestic Water Layout NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 235...
Page 236: Monitor Panel - Water
• Red lamps indicate full or empty ranges (depending on the scale), which are in the critical range. Located in the Service Center. 030446e Located in the Main System Control Center. 030446e 236 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 237: Water Service Center
040503 NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 237...
Page 238: Water Tank
Return to the service center. When the fresh water tank is full water will come out an overflow vent. 6. Turn off water supply. 7. Return fill valve handle to "City." 238 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 239: City Water Hook-Up
(i.e. overnight or longer) be sure that the city water and all water pumps have been turned off. Damage from neglect will be the responsibility of the owner, not the manufacturer. 040487h NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 239...
Page 240: Troubleshooting The Water Pump
• Check for proper voltage with the pump operating. • Look for debris in the pump inlet/outlet valves or dry/swollen valves. • Check the pump housing for cracks or loose drive assembly screws. 240 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 241: Water Filter
Even when a decreasing water flow does not demand the cartridge be replaced, it is recommended the filter be replaced at least once a year for continued reliable performance from the purification system. 040383 NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 241...
Page 242: Water Systems
If the system continues to leak take the motorhome to an authorized dealer for service. NOTE: A small water leak can cause severe water damage. Shut off the water supply and have the leak repaired. 242 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 243: Disinfecting Fresh Water
• 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. • Install new water filter. NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 243...
Page 244: Waste Water Systems
CAUTION: Do not use any products that contain petroleum distillate or ammonia in place of RV odor controlling chemicals. Petroleum distillate or ammonia will damage the ABS plastic holding tanks and seals. 244 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 245: Waste Drain & Sewage Tanks
Lay the hose inline between the termination outlet and the shore fitting. Restrain the hose to prevent movement during use. Wear protective and/or disposable gloves when handling the sewer hose. 040422 NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 245...
Page 246: What To Put In Holding Tanks - Black Tank
Do not use any products that contain petroleum distillate or ammonia in place of RV odor controlling chemical. Petroleum distillate or ammonia will damage the ABS plastic holding tanks and seals. 246 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 247: What To Put In Holding Tanks - Grey Tank
Use the tank flush system each time the holding tanks are cycled. Failure to routinely use the flush system will result in a clogged spray nozzle. Turn off the water supply when finished flushing the tank. NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 247...
Page 248: Toilet
• To operate the hand held sprayer, press and hold the pedal until water begins to flow into toilet. Press lever on hand held sprayer. 040466 NOTE: Holding the flush pedal longer than necessary results in excess water use. 040467 248 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 249: Cleaning & Maintenance
NOTE: If the motorhome is in storage for six months, it is a good idea to spray silicone on the ball valve. Perform this maintenance monthly (silicone will evaporate in about 30 days). NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 249...
Page 250: Drain Traps & Auto Vents
The tank heater pad(s) will protect the fresh water tank. A bay heater with a “Snap Disc” thermostat is used to heat the water control bay. 250 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 251: Storage - Cold Weather
NOTE: Icemakers, water filters, water purifiers and water heaters all use domestic water and should be drained and stored in accordance with the manufacturer’s recommendation for winterization. NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 251...
Page 252: Winterizing
8. While the air is on, hold the spray nozzle (located right next to the toilet) open until the water has quit running. Hold the toilet flush pedal or handle up until the water has stopped running. 9. Unhook the air hose. 252 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 253 12. If the motorhome is equipped with an icemaker in the refrigerator, remove the ¾" fitting and flush antifreeze through the water line. 13. Disconnect the power supply line affecting water pump operation. NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 253...
Page 254: Tank Capacities Chart
NOTE: All tank capacities are estimated based upon calculations provided by the tank manufacturers and represent approximate capacities. The actual "usable capacity" may be greater or less then the estimated capacities based upon fabrication and installation of the tanks. 254 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 255 ~ NOTES ~ NEPTUNE 2004 WATER SYSTEMS --- SECTION 6 • 255...
Page 256 ~ NOTES ~ 256 • SECTION 6 --- WATER SYSTEMS NEPTUNE 2004...
Page 257 NEPTUNE 2004 LP-Gas Systems Section 7 LP-GAS SYSTEMS ............259 LP-GAS DETECTOR ............260 Testing..............261 Alarm..............262 Maintenance ............262 LP-GAS TANK STATUS MONITORING......263 LP-GAS EMERGENCY PROCEDURES - CHECKLIST..263 LP-GAS TANK...............264 Tank Capacity ............264 Tank Filling..............264 LP-Gas Tank Operation..........265 LP-GAS FUNDAMENTALS ..........266 LP-GAS REGULATOR ...........268 LP-GAS HOSE INSPECTION .........271...
Page 259: Lp-Gas Systems
All fitting tested should be thoroughly rinsed and dried after testing. Only qualified service personnel should perform any maintenance or repair to the LP-Gas system. NEPTUNE 2004 LP-GAS SYSTEMS --- SECTION 7 • 259...
Page 260: Lp-Gas Detector
NOTE: The LP-Gas detector only indicates the presence of propane gas at its sensor. Combustible levels of propane gas may be present in other areas. This detector is intended for the detection of LP-Gas ONLY. 260 • SECTION 7 --- LP-GAS SYSTEMS NEPTUNE 2004...
Page 261: Testing
The red LED will flash and the alarm will sound whenever a dangerous level of propane or methane gas is detected. The detector will continue to alarm until the gas clears or the Test/Mute switch is pressed. NEPTUNE 2004 LP-GAS SYSTEMS --- SECTION 7 • 261...
Page 262: Alarm
2. Do not spray cleaning agents or waxes directly onto front panel. This may damage the sensor, cause an alarm or cause a detector malfunction. 262 • SECTION 7 --- LP-GAS SYSTEMS NEPTUNE 2004...
Page 263: Lp-Gas Tank Status Monitoring
• Contact a qualified service technician to find the source and repair the gas leak. WARNING: A fire or explosion from ignited gas or gas fumes can seriously injure person(s) or cause death. NEPTUNE 2004 LP-GAS SYSTEMS --- SECTION 7 • 263...
Page 264: Lp-Gas Tank
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. 050269 264 • SECTION 7 --- LP-GAS SYSTEMS NEPTUNE 2004...
Page 265: Lp-Gas Tank Operation
• Hand-tighten the primary valve only. Do not use a wrench or pliers, as this will over-tighten the valve. The primary valve is designed to be closed by hand, over-tightening may permanently 050267c damage the valve seat. NEPTUNE 2004 LP-GAS SYSTEMS --- SECTION 7 • 265...
Page 266: Lp-Gas Fundamentals
27.7 in. Water Column = 1 lb. per sq. in. pressure. The above capacities allow for 20% vapor space on each cylinder. Data taken from the National Fire Prevention Association (NFPA). Pamphlet #58-1998. 266 • SECTION 7 --- LP-GAS SYSTEMS NEPTUNE 2004...
Page 267 NOTE: The above information is not a complete guide for the use of LP-Gas tanks or appliances. In cold climates keep fuel levels above 50% in order to keep vaporization of LP-Gas at the highest level. NEPTUNE 2004 LP-GAS SYSTEMS --- SECTION 7 • 267...
Page 268: Lp-Gas Regulator
100º F. the liquid quickly vaporizes with tank pressure, about 200 psi. Vapor pressure must remain relatively consistent regardless of temperature so that appliance heat output remains stable. Vapor pressure regulation is performed by the regulator. 268 • SECTION 7 --- LP-GAS SYSTEMS NEPTUNE 2004...
Page 269 This is why it is important to have the LP-Gas pressure checked for proper pressure and accurate regulation during appliance operation. Erratic pressure regulation dramatically effects refrigerator operation on LP-Gas. NEPTUNE 2004 LP-GAS SYSTEMS --- SECTION 7 • 269...
Page 270 Do not operate any LP-Gas appliance until the LP-Gas pressure is checked and a leak down test is performed! 050260 Manometer Gauge for Testing Type 1 Typical Testing Layout 050259e Manometer at Rest Type 2 270 • SECTION 7 --- LP-GAS SYSTEMS NEPTUNE 2004...
Page 271: Lp-Gas Hose Inspection
The motorhome manufacturer recommends following these guidelines to assure continued safety and dependable use. NEPTUNE 2004 LP-GAS SYSTEMS --- SECTION 7 • 271...
Page 272: Lp-Gas Distribution Lines
INSPECTION: Inspect the rubber flexible lines, twice a year, for abrasions, tears, kinks or other signs of damage. If a gas leak is suspected, get the system inspected and repaired by a qualified service technician as soon as possible. 050257l 272 • SECTION 7 --- LP-GAS SYSTEMS NEPTUNE 2004...
Page 273: Lp-Gas Consumption
Improper LP-Gas regulator adjustment will affect the performance of LP-Gas operated appliances. Incorrect flame or explosion can occur. Only qualified personnel should perform any maintenance or repair to the LP-Gas system. NEPTUNE 2004 LP-GAS SYSTEMS --- SECTION 7 • 273...
Page 274: Lp-Gas Safety Tips
(one of the most important items). There is a required 12 year re-qualification. The final piece of information is for the Dip Tube (DT) length. This is part of the overfill protection and maximum liquid allowance in the cylinder. 274 • SECTION 7 --- LP-GAS SYSTEMS NEPTUNE 2004...
Page 275 • Never use gas ranges or ovens for heating purposes. • Always have pot handles turned inward. • Ensure children understand never to turn or play with the knobs on the front of the propane gas range. NEPTUNE 2004 LP-GAS SYSTEMS --- SECTION 7 • 275...
Page 276 ~ NOTES ~ 276 • SECTION 7 --- LP-GAS SYSTEMS NEPTUNE 2004...
Page 277: Electrical Systems - House
NEPTUNE 2004 Electrical Systems - House Section 8 HOUSE ELECTRICAL - INTRODUCTION ....279 BATTERIES...............298 AC System 120/240 Volt ........279 How They Work ..........298 Shore Power ............279 Starting Batteries..........298 Generator ............280 Deep Cycle Battery..........299 Converter ............280 Battery Maintenance..........299 Inverter (Opt.) .............280 Testing the Battery..........300...
Page 279: House Electrical - Introduction
NOTE: In instances when 50 Amp shore service is not available, care will have to be used when operating the appliances and using the outlets so the shore power service will not be overloaded. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 279 NEPTUNE 2004...
Page 280: Generator
Some are federal mandate items, such as the LP detector. If the motorhome will not be used, or will be stored for more then 48 hours, it is recommended to turn the batteries off. 060003b NEPTUNE 2004 280 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 281: Battery Cut-Off Switch
If there is no power to the motorhome inform the park manager. It is the park manager's responsibility to fix any problems with the park's shore hook up. 020125 ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 281 NEPTUNE 2004...
Page 282 Use the inverter or start the generator if AC power is needed. NOTE: The three types of shore power outlets most commonly used are shown in the illustration below. 060121B NEPTUNE 2004 282 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 283 30 Amp shore cord to a 20 Amp shore power outlet. 060174 30-20 Amp adapter. Adapts the 30 Amp shore cord to a 20 Amp shore power outlet. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 283 NEPTUNE 2004...
Page 284: Transfer Switch
HALF LOAD FULL LOAD lb/h (kg/h) lb/h (kg/h) lb/h (kg/h) 60Hz 2.6 (1.2) 4.5 (2.0) 7.3 (3.3) 50Hz 2.2 (1.0) 3.4 (1.5) 5.1 (2.3) *LP-Gas weighs 4.2 lbs. per gallon. NEPTUNE 2004 284 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 285: Volt Ac Diesel (Opt.)
Before Starting the Generator: • People and animals must be clear of hazards of electrical shock and moving parts. • All appliances and other large AC electrical loads must be off. 020159b ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 285 NEPTUNE 2004...
Page 286: Starting The Generator
This will allow the engine to cool. Push and hold the control switch in the STOP position, the engine will stop. Release the switch. NEPTUNE 2004 286 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 287: Powering The Equipment
No Load Half Load Full Load NOTE: The motorhome manufacturer does not cover damage to the generator caused by fuel contamination, or to appliances due to erratic AC voltage. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 287 NEPTUNE 2004...
Page 288: Resetting The Circuit Breaker
50 Amp MAIN breaker first, followed by power being fed to the individual branch circuit breakers. The panel label describes the breaker layout and the item, outlet or appliance to which they pertain. NEPTUNE 2004 288 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 289 OFF position, then back to ON. Should the breaker trip again after the load is reapplied it may indicate a fault with that particular load. Do not continue to reset breaker until the problem has been diagnosed and corrected. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 289 NEPTUNE 2004...
Page 290: Circuit Breakers
1370 watts. Divide that by the operating voltage of 115 Volts which equals 11.913 Amps. Use this formula to calculate the amount of load to the available power supply. NEPTUNE 2004 290 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 291: Gfci Breakers & Outlets
The breaker or outlet will not trip if AC power is not present at the device. If power is present and the device will not trip, replace it before using that circuit. NOTE: One mil is 1/1000 of one amp. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 291 NEPTUNE 2004...
Page 292: Energy Management System - 50 Amp (Opt.)
120 Volt AC 30 Amp shore power the EMS attempts to keep the total 120 Volt current draw to less than 30 Amps. 060082b With 50 Amp Input. NEPTUNE 2004 292 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 293 The load meter will indicate the Amps load. 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. 060082 With 30 Amp Input. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 293 NEPTUNE 2004...
Page 294 If the system is in the averaging mode the decimal point at the lower right corner of the load meter display on the display panel will illuminate. NEPTUNE 2004 294 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 295 20 Amp mode when 20 Amp service is available. The service select button allows the current threshold to be set to either 30 Amps or 20 Amps to match the incoming service. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 295 NEPTUNE 2004...
Page 296: Distribution Panel - House 12 Volt Dc
Shorting a battery cable to ground with a battery at a reasonable state of charge can result in a fire or serious personal injury from a burn. 060086b ATO Fuse NEPTUNE 2004 296 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 297: Tools Of The Trade
If the fuse repeatedly blows after replacing it do not continue to replace it. Have the problem diagnosed and corrected by a qualified technician. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 297 NEPTUNE 2004...
Page 298: Batteries
This allows a very high starting current but lets the plates warp when the battery is deep cycled (discharged). Battery with cover. Battery with cover removed. The plastic cover must be cut to be removed. NEPTUNE 2004 298 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 299: Deep Cycle Battery
Carefully hook the cables back to the battery. Coat the terminals with petroleum jelly or an anti- corrsion grease. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 299 NEPTUNE 2004...
Page 300: Testing The Battery
Note the reading Hydrometer (Cylinder Type). 030816b for that cell. Complete the same test for the rest of the cells on that battery bank. NEPTUNE 2004 300 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 301 Never add acid to a battery once the battery has been placed in service. Doing so may result in hazardous splattering of electrolyte. tools.eps2 ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 301 NEPTUNE 2004...
Page 302: Reasons Why Batteries Fail
Clean off all corrosion, especially around the battery terminals and on the top of the battery. Prevent accumulation by coating the terminals and the exposed metal cable connectors with high temperature grease. NEPTUNE 2004 302 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 303: Battery Voltage & Current
Think of siphoning water from a bucket. As the level of the water drops, the volume of water exiting the siphon slows down. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 303 NEPTUNE 2004...
Page 304: Battery Charge Time & Consumption Rate
Commercial type batteries bridge the gap of deep cycle and engine batteries. Commercial batteries release medium amounts of current over a longer period of time but they are not designed to cycle their charge capacity. NEPTUNE 2004 304 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 305 Observe the battery condition with hydrometer and voltage readings. Use only distilled water when filling batteries. To achieve the highest quality of battery performance and longevity keep batteries in their proper operating range. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 305 NEPTUNE 2004...
Page 306: Battery Specification Charts
Specific Gravity State of Charge Depth of Charge 12.66 1.265 100% 12.45 1.225 12.25 1.190 12.05 1.145 11.90 1.100 100% Voltage Reading: Battery fully charged at rest for one hour. NEPTUNE 2004 306 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 307: Converter - 60 Amp (Units Without Inverters)
060157 settings. To Turn the Inverter On: • Press the switch marked INVERT on the remote panel. 060158l Press to Turn Inverter On ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 307 NEPTUNE 2004...
Page 308: Battery Charging
The remote panel monitors the inverter status and is used to change variable Remote Panel settings. The panel uses LED lights to monitor values when hooked to shore power, inverting or in the set-up mode. Remote panel in set-up mode. 060169 NEPTUNE 2004 308 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 309: Battery State Indicator
Two branch circuit breakers are located on the front of the inverter. One of the branch circuit breakers supplies AC power to various receptacles. The other breaker supplies AC power to the microwave. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 309 NEPTUNE 2004...
Page 310: Stand-By Mode
The charging cycle is initiated each time the inverter is disconnected or reconnected to AC power. Repeated charging cycles in succession can lead to boiling of the batteries. NEPTUNE 2004 310 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 311: Pass-Through Relay
Press the INVERT button to change the settings. Battery Capacity: Setting the proper battery capacity tailors the internal charger to optimum values. The Factory setting is 400. Press the CHARGE button to change the settings. ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 311 NEPTUNE 2004...
Page 312: Lights - Interior Halogen
CAUTION: Do not touch halogen lighting while on. They can cause a burn. Do not touch replacement bulbs. Oil in the hands can cause a "hot-spot" to occur. If the bulb is touched, clean bulb with alcohol. NEPTUNE 2004 312 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 313 ~ NOTES ~ ELECTRICAL SYSTEMS - HOUSE --- SECTION 8 • 313 NEPTUNE 2004...
Page 314 ~ NOTES ~ NEPTUNE 2004 314 • SECTION 8 --- ELECTRICAL SYSTEMS - HOUSE...
Page 315: Electrical Systems - Chassis
NEPTUNE 2004 Electrical Systems - Chassis Section 9 CHASSIS ELECTRICAL - INTRODUCTION...317 Chassis Electrical Overview......317 CHASSIS BATTERY DISCONNECT ......318 CHASSIS BATTERY ..........318 BATTERY SPECIFICATIONS CHARTS....319 FUSES & CIRCUITS ...........320 Front Distribution Panel .........320 Relays ............320 ALTERNATOR .............323 Alternator Testing Procedure ......323 STEERING COLUMN...........325...
Page 317: Chassis Electrical - Introduction
5. Disconnect the wiring from the alternator. 6. Do not connect welding cables to electronic control components. 7. Attach the welding ground cable no more than two feet from the part to be welded. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 317 NEPTUNE 2004...
Page 318: Chassis Battery Disconnect
Perform a charging system and current draw check if the battery is exhibiting abnormal hydrometer readings. NOTE: Replacement batteries should have the same cold cranking amp (CCA) rating. 060003b NEPTUNE 2004 318 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 319: Battery Specifications Charts
Voltage Reading: Battery fully charged at rest for one hour. CUMMINS ENGINE - COLD CRANKING AMP REQUIREMENTS 1110 12 VOLTS CCA Ratings are at 0° F. These are the minimum requirements. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 319 NEPTUNE 2004...
Page 320: Fuses & Circuits
Another indicator to the type of relay is the post or legs. Turn the relay over and look at the post. Each post is numbered. It is important to note these differences listed: 080406 080405C 080405b NEPTUNE 2004 320 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 321 NOTE: When there is power applied to the coil, the coil sets up a magnetic field in the windings. When the power is removed, the field collapses. A momentary high voltage discharge will occur. This is how an ignition coil works. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 321 NEPTUNE 2004...
Page 322 080388B 080387B Located in the fuse bay, below the driver window. Located in the Inverter/Converter compartment - curbside. 080427B NEPTUNE 2004 322 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 323: Alternator
NOTE: Excessive loads applied to the inverter/converter could actually drain both chassis and house batteries during operation ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 323 NEPTUNE 2004...
Page 324 NOTE: Remember the alternator is not a battery charger, but designed to maintain proper electrical system voltage. A battery with a low state of charge, or a dead battery, may overheat and damage the alternator. NEPTUNE 2004 324 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 325: Steering Column
ON. Hazard Flasher Button (located on Steering Column): • Pull out on flasher button to turn four way flasher on. • Push button inward to shut off flasher. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 325 NEPTUNE 2004...
Page 326: Shift Tower Console
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. 080386b 060097 NEPTUNE 2004 326 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 327 NOTE: There should be an audible click from the engine compartment when the solenoid engages. CAUTION: The Batt Boost switch should not be held for more than 30 seconds. Damage to the boost solenoid may occur from overheating. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 327 NEPTUNE 2004...
Page 328 12. ICC FLASH: The Upper clearance and Rear Marker lights will blink when switch is pressed. NOTE: The Headlight switch must be on to operate the ICC FLASH switch and circuitry. NEPTUNE 2004 328 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 329 A wooden clothes pin clasped at the base of the shaft will work. 15. Level Sight Glass Bubble: Used during leveling procedures. The bubble indicates high part of the motorhome. 020076 ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 329 NEPTUNE 2004...
Page 330: Dash
Inspect the serpentine belt. 6. Ant Up: TV antenna is not resting flat in the storage cradle. 7. Left Turn: Left turn indicator circuits active. NEPTUNE 2004 330 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 331 Lamp when air tank is drained. 14. Check Trans: Alerts of problems related to the Allison Transmission. 15. Stop Engine: Alerts of severe out of range condition within the engine protection circuits. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 331 NEPTUNE 2004...
Page 332: Gauges
NOTE: Fuel mileage varies with driving style and road conditions. Always average more than one tank of fuel to obtain a more accurate figure. NEPTUNE 2004 332 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 333: Switches
Tailights and clearance lights are not illuminated when the DRL module is activated. The headlight switch will deactivate the DRL module resuming normal headlight/taillight operation. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 333 NEPTUNE 2004...
Page 334 Release the switch after the generator has started. To Stop the Generator: Momentarily press the switch to Stop. It is not necessary to hold the switch until the generator has stopped. 080357 NEPTUNE 2004 334 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 335 14. Stor Light: Provides power to cargo storage compartment lights. 15. Step Light: Turns on and off stepwell lights. 16. Pass Shade: Operates the power sun visor on the passenger side. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 335 NEPTUNE 2004...
Page 336: Air Conditioners & Heater Controls
This switch directs air flow by opening or closing damper doors. Use the Mode Control Switch to direct airflow where it is needed to maximize comfort in the cockpit area. 080221 Blower Speed Control Temperature Control Mode Control Switch NEPTUNE 2004 336 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 337 OFF to dehumidify the air. Rotate the temperature control switch to set discharge air temperature. • Set the Mode Control Switch to the desired position. • Set the Temperature Control Switch to the red zone. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 337 NEPTUNE 2004...
Page 338 This will avoid sudden high speed activation resulting in damage from lack of internal compressor lubrication. • The dash A/C and heater system should be used monthly to keep the compressor lubricated. NEPTUNE 2004 338 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 339 8. Compressor Clutch is inoperative, will not engage. 9. Expansion Valve is faulty or frozen. 10. Thermostat control is faulty. 11. Mode control switch is faulty. 12. Compressor is faulty. 13. Loss of refrigerant. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 339 NEPTUNE 2004...
Page 340 5. Check the mode switch. 6. Check wiring. 7. Check for a pinch in the vacuum line leading to the vacuum motor that operates the damper door in question. NEPTUNE 2004 340 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 341 This forced air will ensure continuous vaporizing of the R134a. Relays and Switches - Both electronic and vacuum switches are used in the control and operations of the system. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 341 NEPTUNE 2004...
Page 342 On a fully charged system the expected pressure that should be seen on the HIGH-SIDE gauge will be around 200 PSIG. NOTE: All systems are charged at the factory with 4.0 lbs of R134A. NEPTUNE 2004 342 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 343 The amount of heat required to raise or lower the temperature of one pound of water by 1º F equals one British Thermal Unit (BTU). The BTU is the standard measurement of an air conditioner system. ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 343 NEPTUNE 2004...
Page 344 • The discharge air outlets should have hot air. • Rotate the temperature control to full cold position. • Allow 10 minutes for the temperature to stabilize. • The discharge air outlets should have cold air. NEPTUNE 2004 344 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 345: Diagnostic Plug Location
The Engine Diagnostic Plug is located in the Power Engine Oil engine compartment area. Steering Dipstick Reservoir & Filter Engine Diagnostic Plug ABS Plug .tif Diagnostic Plug .tif ELECTRICAL SYSTEMS - CHASSIS --- SECTION 9 • 345 NEPTUNE 2004...
Page 346 ~ NOTES ~ NEPTUNE 2004 346 • SECTION 9 --- ELECTRICAL SYSTEMS - CHASSIS...
Page 347 NEPTUNE 2004 Chassis Information Section 10 CHASSIS - INTRODUCTION........349 OIL RECOMMENDATIONS -ENGINE ......384 AIR SUPPLY SYSTEM..........351 Oil Maintenance..........386 Air Governor............352 Cold Weather - Oil ..........386 Air Storage Tanks ..........352 ENGINE SHUTDOWN ..........387 Air Fittings............352 Extended Shutdown..........387 AIR SPRINGS ............353 COOLANT ..............387 Air Spring Inspection - Checklist......354...
Page 349: Chassis - Introduction
5. Disconnect the wiring from the alternator. 6. Do not connect welding cables to electronic control components. 7. Attach the welding ground cable no more than two feet from the part to be welded. CHASSIS INFORMATION --- SECTION 10 • 349 NEPTUNE 2004...
Page 350 The suspension control arms attach to the frame through bushings, which require no lubrication. The preset suspension ride height automatically maintains proper suspension height throughout the load range. 350 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 351: Air Supply System
NOTE: The air tank(s) should be drained manually every 30 days. Open the manual drain on the bottom of the tank until all air escapes. Leave valve(s) open an additional five minutes allowing excess moisture to drain. CHASSIS INFORMATION --- SECTION 10 • 351 NEPTUNE 2004...
Page 352: Air Governor
• Push hose into fitting. • Push release ring down against locking ring portion of the fitting body. • While holding the release ring down, pull hose away from Splice fitting. fitting. 090445 090466 NEPTUNE 2004 352 • SECTION 10 --- CHASSIS INFORMATION...
Page 353: Air Springs
5. PISTON: Provides a lower mounting arrangement for air spring. Controls characteristics of spring under changing pressure loads. 6. PISTON BOLT: Attaches piston to bellows. Sometimes extended as a means of attaching spring to vehicle suspension. CHASSIS INFORMATION --- SECTION 10 • 353 NEPTUNE 2004...
Page 354: Air Spring Inspection - Checklist
The approved cleaning method is to use soap and water, methyl alcohol, ethyl alcohol and isopropyl alcohol. Unapproved cleaning methods include all organic solvents, open flames, abrasives and direct pressurized steam cleaning. NEPTUNE 2004 354 • SECTION 10 --- CHASSIS INFORMATION...
Page 355: Ride Height Valves
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. CHASSIS INFORMATION --- SECTION 10 • 355 NEPTUNE 2004...
Page 356: Adjusting Ride Height
This is usually characterized by a severe "listing" of the vehicle, or one end of the motorhome sitting unusually low or high. In the event this occurs, it is not advisable to drive as body or suspension damage may result. NEPTUNE 2004 356 • SECTION 10 --- CHASSIS INFORMATION...
Page 357: Brake System
Gravity flow bleeding requires only one person and NO pressure bleeder. Each caliper has a bleeder valve for removing any air in the system. CHASSIS INFORMATION --- SECTION 10 • 357 NEPTUNE 2004...
Page 358: Maintenance & Troubleshooting
The system should be flushed whenever any repair has been performed, ensuring clean and uncontaminated fluid in the system. NOTE: Do not reuse brake fluid that has been drained as the fluid may be contaminated. 358 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 359: Abs System (Anti-Lock Brakes)
ABS indicator light remains illuminated, normal braking is not affected. However, the ABS system may not function correctly in a panic stop. It is recommended to drive with caution and obtain service on the ABS system as soon as possible. CHASSIS INFORMATION --- SECTION 10 • 359 NEPTUNE 2004...
Page 360: Parking Brake & Emergency Brake System
When the exhaust brake is activated, the amount of engine braking power developed is related to engine speed (RPM). When an exhaust brake application is made, the engine braking affect increases with higher engine RPM. NEPTUNE 2004 360 • SECTION 10 --- CHASSIS INFORMATION...
Page 361: Axle
Use EP-SAE 90 gear oil or any good equivalent petroleum base or synthetic lubricant. CAUTION: Do not mix petroleum based oil with synthetic based oil. This could cause an oil seal failure. CHASSIS INFORMATION --- SECTION 10 • 361 NEPTUNE 2004...
Page 362 Use NLGI #2 Lithium soap base lubricant for all steering linkage and brake components. INSPECTION: Wheel bearings should be inspected for wear whenever the hubs are removed from the front axle. 362 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 363: Alignment
This is machined into the axle when manufactured and is not adjustable. • “Positive” camber is an outward tilt of the wheel at the top. • “Negative” camber is an inward tilt of the wheel at the top. 090267 CHASSIS INFORMATION --- SECTION 10 • 363 NEPTUNE 2004...
Page 364 “near zero toe-in” can be achieved when the vehicle is in motion. Incorrect toe settings, where toed-in or toed-out, can have a significant affect on tire wear. The toe setting is adjusted by lengthening or shortening the cross tube. 090265 364 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 365: Steering System
This movement of the sector shaft is then transferred to the front axle and tires through the steering linkages. CHASSIS INFORMATION --- SECTION 10 • 365 NEPTUNE 2004...
Page 366: 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 Steering Component Layout 366 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 367: Steering Gear
Greasing interval is yearly or every 30,000 miles. Slip Yoke LUBRICATION POINTS 090349 CHASSIS INFORMATION --- SECTION 10 • 367 NEPTUNE 2004...
Page 368: Drag Link
Greasing interval is every six months or 5,000 miles. GREASE FITTINGS CENTER LINK 090354 (BOTTOM VIEW) NEPTUNE 2004 368 • SECTION 10 --- CHASSIS INFORMATION...
Page 369: Steering Spindles
For this reason, it is important that maintenance be performed on the axle as required to avoid premature wear of the gears and bearings in the axle. 090416 Ring and Pinion Gears CHASSIS INFORMATION --- SECTION 10 • 369 NEPTUNE 2004...
Page 370 • Re-install the fill plug and tighten to 35 ft. lbs. NOTE: When checking the lube level also check the housing breathers. Clean the breathers if dirty or replace them if damaged. 370 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 371 NOTE: It will be necessary to move the motorhome forward or backward to access all fittings on the drive shaft. CHASSIS INFORMATION --- SECTION 10 • 371 NEPTUNE 2004...
Page 372 Rotating shafts can snag clothes, skin, hair, hands, etc. causing serious injury or death. Do not work on or near a shaft “with or without a guard” when the engine is running. 090341 372 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 373: U-Joint Angles, Phasing & Driveline Balance
Among the most common causes of U-joint and slip joint damage is lack of lubrication. To keep the motorhome operating smoothly and economically, the driveline must be carefully checked and lubricated at regular intervals. 090336 mod CHASSIS INFORMATION --- SECTION 10 • 373 NEPTUNE 2004...
Page 374: Shock Absorber
The system also features a remote control location from the driver seat. The torsion stress is significantly reduced during proper operating procedures. Damage resulting from improper procedures can range from windshield damage to entry doors jamming. 374 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 375 The control panel will not activate until these safety features are in place. • Turn the ignition switch to the Run position. • Place the transmission in Neutral. • Apply the parking brake. CHASSIS INFORMATION --- SECTION 10 • 375 NEPTUNE 2004...
Page 376 Incrementally extend jacks rather than over-extending a single jack. Damage resulting from improper leveling procedures and excess twist/stress can range from windshield damage to jamming of the entry door. 376 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 377: Manual Operation
Damage to the jacks may occur. DO NOT use jacks to raise wheels off the ground. Damage to the motorhome may occur. CHASSIS INFORMATION --- SECTION 10 • 377 NEPTUNE 2004...
Page 378: Retracting Leveling Jacks
NOTE: Do not move the motorhome until the jacks are fully retracted. A visual check of the jacks is recommended to ensure full retraction. Do not rely solely on the lights and alarms. NEPTUNE 2004 378 • SECTION 10 --- CHASSIS INFORMATION...
Page 379: Manual Retract Valves
An indication of a system needing fluid is the bong alarm intermittently sounding when turning corners or the pump whining or gurgling. Use Dexron III ® automatic transmission fluid to fill the reservoir. CHASSIS INFORMATION --- SECTION 10 • 379 NEPTUNE 2004...
Page 380: Engine
The equipment owner and operator is responsible for safe operation of engine. INFORMATION: Consult your engine authorized repair location for future information. NEPTUNE 2004 380 • SECTION 10 --- CHASSIS INFORMATION...
Page 381: Chassis Information
The motorhome should be shut down as soon as safely possible and remain shut down until the fault can be repaired. CHASSIS INFORMATION --- SECTION 10 • 381 NEPTUNE 2004...
Page 382: Starting Procedure
If the CHECK TRANS fails to illuminate, or remains on after starting, refer to the Transmission Operator’s Manual for corrective action. 5. The WAIT TO START light should illuminate, then go out. NEPTUNE 2004 382 • SECTION 10 --- CHASSIS INFORMATION...
Page 383: Cold Weather Starting
6. Start out slowly with the motorhome to allow the transmission and axle lubricants time to circulate and warm before putting them under full load. CHASSIS INFORMATION --- SECTION 10 • 383 NEPTUNE 2004...
Page 384: Oil Recommendations -Engine
The use of synthetic oils should not be used to extend drain intervals. Extended oil change intervals can decrease engine life and possibly affect the engine warranty. NEPTUNE 2004 384 • SECTION 10 --- CHASSIS INFORMATION...
Page 385 All synthetic based oils must meet the API category III classifications and SAE viscosity grades. NOTE: Synthetic oils and petroleum based oils should never be mixed. CHASSIS INFORMATION --- SECTION 10 • 385 NEPTUNE 2004...
Page 386: Oil Maintenance
10º F (6º C) lower than the ambient temperature in which the motorhome operates. INFORMATION: Refer to the Operations & Maintenance Manual for more detailed information. NEPTUNE 2004 386 • SECTION 10 --- CHASSIS INFORMATION...
Page 387: Engine Shutdown
The coolant fluid freeze point should be checked with every oil change interval at 15,000 miles, 500 hours or six months, whichever comes first. The coolant should be drained and flushed at 6,000 hours or two years of service, whichever comes first. CHASSIS INFORMATION --- SECTION 10 • 387 NEPTUNE 2004...
Page 388 (50/50 mix of water and antifreeze). 5. Always use antifreeze. In addition to freeze protection, antifreeze is essential for overheat and corrosion protection. 6. Freeze point should be measured every 15,000 miles/6 months. 388 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 389: Coolant Hoses
The CAC performs the same function as a radiator, cooling air instead of liquid. Ambient air passing through the CAC will cool the engine's intake air charge. CHASSIS INFORMATION --- SECTION 10 • 389 NEPTUNE 2004...
Page 390: Transmission
“Adaptive Shifting.” A wide variety in shifting under varied conditions is required before optimizing the shift quality. Generally, five typical shifts of a shift type are needed for shift calibration. NEPTUNE 2004 390 • SECTION 10 --- CHASSIS INFORMATION...
Page 391 Allison Service center. The transmission is not actually in third gear. This is only a reference point so the transmission will optimize engine-braking efficiency. CHASSIS INFORMATION --- SECTION 10 • 391 NEPTUNE 2004...
Page 392 If warning beeper sounds, the Shifter has shifted the transmission to Reverse. If it does, proceed to the next step. If it doesn't, go to the Electrical Troubleshooting Section. 392 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 393 Assembly on the left side of the transmission. One is on a pigtail, and the other is plugged directly into the position sensor. Ensure both connectors are in good condition (no pushed out pins or damage) and properly connected. CHASSIS INFORMATION --- SECTION 10 • 393 NEPTUNE 2004...
Page 394: Transmission Check Light
Check the condition of the electrical harnesses regularly. Check the engine cooling system occasionally for evidence of transmission fluid which would indicate a faulty oil cooler. Report any abnormal condition to the Allison dealer. NEPTUNE 2004 394 • SECTION 10 --- CHASSIS INFORMATION...
Page 395: Importance Of Proper Fluid Levels
Local conditions, severity of operation or duty cycle will dictate more or less frequent service intervals. Contact an authorized Allison Service center for change intervals. CHASSIS INFORMATION --- SECTION 10 • 395 NEPTUNE 2004...
Page 396: Transmission Fluid Level - Cold Check
If the readings are not consistent check to be sure that the transmission breather is clean and not clogged. If the readings are still not consistent, contact the nearest Allison distributor or dealer. NEPTUNE 2004 396 • SECTION 10 --- CHASSIS INFORMATION...
Page 397: Fuel Requirerments
Routine Maintenance Recommendations: 1. Change the fuel filter at every oil change interval. 2. Change the fuel-water separator filter every six months or every 15,000 miles. CHASSIS INFORMATION --- SECTION 10 • 397 NEPTUNE 2004...
Page 398: Fuel Filters
• Turn key to on for approximately 30 seconds and then off again. This may need to be repeated several times before the system is purged of air. • If unable to start, contact nearest Cummins Center or phone 1-800-343-7357 for Cummins Customer Assistance Center. 398 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 399: Fuel Sending Unit
• Full Adjustment: The full adjustment can be used to correct for slight differences between fuel meters. During installation, it has been calibrated for your meter and should not need readjustment. CHASSIS INFORMATION --- SECTION 10 • 399 NEPTUNE 2004...
Page 400 NOTE: Sending units are calibrated by length from the manufacture. If replacing a sending unit and the sender needs cut, the empty setting will require being set first. 400 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 401: Hydraulic System
The oil dipstick fill is located on top of the reservoir in the rear compartment. The oil level should be kept between the full and add 090391 marks on the dipstick. If adding of fluid is required, use only Dexron-III® Automatic Transmission Fluid. CHASSIS INFORMATION --- SECTION 10 • 401 NEPTUNE 2004...
Page 402: Hydraulic Filter
4. After replacing the filter assembly, reverse the process to re-assemble the reservoir. 5. When attaching the cover plate in the rubber cover seal, check for any damage. 090391c NEPTUNE 2004 402 • SECTION 10 --- CHASSIS INFORMATION...
Page 403: Air Filter Minder
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. 090317c CHASSIS INFORMATION --- SECTION 10 • 403 NEPTUNE 2004...
Page 404: Lubrication Points Chart
250,000 or 3 Years Keep to Full Mark 6 Months Brake Master Cylinder ABS Module Inspect 6 Months Park Brake Assembly Inspect 12 Months Before Each Trip/Daily Enroute Fuel Tank Inspect NEPTUNE 2004 404 • SECTION 10 --- CHASSIS INFORMATION...
Page 405 20 miles bi-monthly. It is important to remember the generator maintenance interval is based on hours of usage. Consult the OEM manual for the generator service interval. CHASSIS INFORMATION --- SECTION 10 • 405 NEPTUNE 2004...
Page 406: Parts - Common Solenoids & Senders
Water Temperature/High Water Temp Dual Post Sending Unit: • One post water temperature. • ISB 300 engines, the sending unit is located in the engine block. • One post alarm. 090259 NEPTUNE 2004 406 • SECTION 10 --- CHASSIS INFORMATION...
Page 407 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 CHASSIS INFORMATION --- SECTION 10 • 407 NEPTUNE 2004...
Page 408: Filters & Belts
NOTE: All tank capacities are estimated based upon calculations provided by the tank manufacturers and represent approximate capacities. The actual "usable capacity" may be greater or less then the estimated capacities based upon fabrication and installation of the tanks. NEPTUNE 2004 408 • SECTION 10 --- CHASSIS INFORMATION...
Page 409 22 qts (MH 2,000) Transmission Oil (With Service) 19 qts with filter Radiator Coolant (Initial Amount) 11.5 gal A/C Refrigerant (Initial Amount) 4.0 lbs of 134A Rear End Capacity 16 qts (approx) CHASSIS INFORMATION --- SECTION 10 • 409 NEPTUNE 2004...
Page 410: Tire Chart
TIRE CHART 410 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 411: Metric/U.s. Conversion Chart
METRIC/U.S. CONVERSION CHART CHASSIS INFORMATION --- SECTION 10 • 411 NEPTUNE 2004...
Page 412: Maintenance Records
Checks and Services” or “Periodic Maintenance” can be added on the following record pages. In addition, retain all maintenance receipts. The owner information portfolio is a convenient place to store them. 412 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 413 CHASSIS INFORMATION --- SECTION 10 • 413 NEPTUNE 2004...
Page 414 414 • SECTION 10 --- CHASSIS INFORMATION NEPTUNE 2004...
Page 415 CHASSIS INFORMATION --- SECTION 10 • 415 NEPTUNE 2004...
Page 416 James Magee - OR Fran Weisenstein - IN TECHNICAL ILLUSTRATIONS Judie Pressler, Kelly Stroble, Rena Koffler, Wes Bogan, Aaron Graham Neptune 2004 Technical Writer Robert Buckholtz Neptune 2004 Layout & Cover Design Kelly Stroble PRINTING Holiday Graphics - IN ONLINE CORPORATE SITE www.monaco-online.com...

Holiday Neptune 2004 Owner's Manual

Sections

Driving & Safety

Driving & Safety

Pre-Trip Preparations - Checklist

Hitch

Rear View System

Backing up Amotorhome

Set-Up Procedures - Checklist

Dry Camping Tips

Breaking Camp

Emergency Roadside Procedures

Towing Procedures

Tires

Weighing the Motorhome

Views

Specifications Chart

Smoke Detector

Lp-Gas Detector

Carbon Monoxide Detector

Fire Extinguisher

Egress Exit Window

Exterior & Interior Care

Exterior Care

Exterior Maintenance

Fabrics

Interior Care

Floors

Shower

Ceiling

Wall Coverings

Wood Care

Countertops

Windows

Window Treatments

Mold & Mildew

Pest Control

Lubrication Maintenance - General

Storage

Appliances

Appliances Introduction

Refrigerator

Microwave/Convection Oven

Cooktop

Cooktop with Oven (Opt.)

Wall Thermostat

Air Conditioner - Roof

Furnace

Water Heater

WASHER-DRYER PREPARED (Opt.)

WASHER-DRYER (Opt.)

Equipment

Equipment - Introduction

Entry Step

Entry Door

Slide-Out

Awnings

Fans

Power Shade (Opt.)

Sliding Door

Sofa Bed

Dinette Booth

Storage - under Bed

Entertainment Systems

Dinette Table

Entertainment Center - Exterior (Opt.)

Systems Control Center

Water Systems

Water Systems Introduction

Monitor Panel - Water

Water Service Center

Water Tank

Water Pump

Water Filter

Water System

Faucets

Shower - Exterior

Waste Water Systems

Toilet

Cold Weather Use