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KZ KZRV Maintenance Manual

Recreational vehicle
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Maintenance
Manual
GUIDEBOOK TO ENJOYMENT OF
YOUR KZRV
RECREATIONAL VEHICLE
PDF created with pdfFactory trial version
www.pdffactory.com

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Summary of Contents for KZ KZRV

  • Page 1 Maintenance Manual GUIDEBOOK TO ENJOYMENT OF YOUR KZRV RECREATIONAL VEHICLE PDF created with pdfFactory trial version www.pdffactory.com...
  • Page 2 THE PURPOSE OF THE MAINTENANCE MANUAL IS TO PROVIDE THE MOST UPDATED MATERIAL CONCERNING THE CARE FOR ALL PRODUCTS BUILT BY KZRV. AS THE OWNER OF A NEW R.V. PRODUCT IT IS IMPORTANT TO RECOGNIZE THE IMPORTANCE ROUTINE CARE OF THIS COACH DURING WARRNTY PERIOD AND FUTURE TIME IN YEARS TO COME.
  • Page 3 As the owner of a new KZRV, RV you can rest assured that we will do all we can to keep you a “happy camper”. Naturally, your selling dealership is always happy to help you with any questions you may have or service you may need.
  • Page 4 KZRV. As the owner of a new KZRV product it is important to recognize the importance of performing routine maintenance during the war- ranty period. Just like oil changes in your tow vehicle—if proper maintenance is not performed the warranty coverage can be denied;...
  • Page 5 MAINTENANCE CHART First Year Second Year I. UNDERCARRIAGE Date Date Wheel Bearings Inspected Repacked Lug Nuts Torqued Inspected Tightened Brake Shoes Inspected Adjusted Shac kles Inspected Lubricated Steps Lubricated Lubricated Stabilizer Jacks Lubricated Lubricated Coupler Inspected Lubricated II. EXTERIOR Metal Washed Waxed Fiberglass...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Chapter I—Undercarriage Frame…………………………………………………………….1 Coupler…………………………………………………………..1 Jacks……………………………………………………………..1 Stabilizer Jacks……………...………………….…………….2 Jacks………………………………….………………………..2 Tires………………………………………………………………2 Wheels…………………………………………………………...3 Axles..…………………………………………………………..4 Bearings…………………………………………………………4 Brakes...................6 Springs/Shackles..............9 Steps...................10 Chapter II—Exterior Metal...................11 Fiberglass................11 ABS Plastics...............11 Exterior Roof...............11 Extrusions and Vents............13 Vinyl Tire Covers..............14 Slide-outs................14 Toy Haul Rear Doors............15 Tents...................15 Chapter III—Systems Propane System..............17 Plumbing System..............18 Electrical System..............19...
  • Page 7 Chapter V—Interior Paneling................28 Linoleum / Vinyl Floor............28 Carpet.................28 Counter Tops..............28 Solid Surface Counter Tops..........28 Window Mini Blinds.............30 Day Fabric Shades.............30 ABS Plastic Components............30 Drapes................30 Cushion Covers..............30 Furniture................30 Windows................31 Smoke-Alarm..............31 Propane and CO Detector..........32 PDF created with pdfFactory trial version www.pdffactory.com...

  • Page 8: Chapter I-Undercarriage

    1. FRAME The steel frame on your KZ recreational vehicle is cleaned with a high pressure phosphate spray wash that removes oils, dirt, and residue. After cleaning the frame is placed in an oven at 200°F, high quality, water borne paint is then applied.

  • Page 9: Stabilizer Jacks

    A. STABILIZER JACKS On item #4 (illustration), drive screw, spray silicone is recommended to be applied two or more times per year. DO NOT use oil or grease as it will attract dirt and grit causing gradual deterioration. Also lubricate pivot pins at top and bottom.

  • Page 10: Wheels

    are cold, preferably in the morning. DO NOT adjust or lower tire pressure when warm as it will be too low when cool. All tire pres- sures rise when tires are moving on roadway. A tire is considered cold after 3 hours of not moving. 5.

  • Page 11: Axles

    Special alignment equipment is required to re- align an axle beam to correct this condition. A. Bearings Two types of bearing systems are used in KZ products. Beginning in 2004 model year a second system called Ultrulube® has been installed. ALL wheel bearings in your coach are pre-greased at the point of assem- bly.
  • Page 12 CAUTION Over packing the hub results in grease seeping out of the dust cap and wheel seal. WARNING Improper seal or bearing installation or adjustment or insufficient maintenance can lead to wheel bearing failure which could cause the hub/drum and wheel to separate from the axle during operation re- sulting in property damage, serious personal injury, or loss of life.

  • Page 13: Brakes

    7 ft/lbs (zero clearance) then back off one slot (0.001”-0.010” end play) and align cotter pin hole. Insert cotter pin and bend both ends over end of spindle. Install grease cap. 7. BRAKES The brakes on your coach are 10” or 12” in diameter depending on the weight of the trailer.
  • Page 14 tenance procedure. TO ADJUST 1. Lift trailer. Do not remove the wheels or hub/drum assem- bly. 2. Locate the adjusting slot at the bottom of the backing plate and remove the protective cover. 3. While spinning the wheel, use a standard brake adjusting tool or the blade of a screw driver to rotate the star wheel until there is a heavy brake drag.
  • Page 15 Brake shoes as a component are subject to daily use absorb nor- mal wear. Shoes are warranted for workmanship but not for normal wear or failure to maintain. WARNING Heavily scored, worn or oversized drums can result in reduced brake performance or loss of brakes.

  • Page 16: Springs/Shackles

    itself to the armature causing the brake to engage with drum sur- face. Inspect the magnet for standard or abnormal wear. Generally a magnet “works” or it is “dead” requiring replacement. Should a magnet be worn on a slant or angle and still works, replace it as it’s life is short.

  • Page 17: Steps

    9. STEPS The step assembly is subject to all types of weather elements and requires the following maintenance: Covering nicks and scratches : 1. Seal any nicks or scratches with an automotive grade primer to prevent rust. 2. Once the nick or scratch has been sealed, cover the damaged area with an automotive grade high-gloss paint.

  • Page 18: Chapter Ii-Exterior

    To clean, use a mild de- tergent and water. Use an automotive type of wax or polish; same as you may use on your tow vehicle. By waxing your KZRV once per year, it retains its nice, new appearance. 2. FIBERGLASS...
  • Page 19 Aluminum material is a smooth mill-finish requiring little care. Wash- ing with soap and water plus rinsing should suffice. There is no hard substrate material underneath and aluminum will show slight waves due to sun and heat causing expansion of the aluminum material. Second, a full roof of fiberglass is used on one model with out any roof seams.

  • Page 20: Extrusions And Vents

    This material can and will also dry and/or crack from weather elements, permitting leakage and eventually major deterio- ration. KZRV advises the owner to remove these extrusions, clean out old putty tape, and replace with new sealant material every five years.

  • Page 21: Vinyl Tire Covers

    7. SLIDEOUTS KZRV uses many variations for slide-out systems, most have power (12 volt) power operation. 1. Below and Above Floor System: This system uses a rack and pinion system which means it runs on a cog track matched to a gear on the motor shaft.

  • Page 22: Toy Haul Rear Doors

    Second type of hinge is all aluminum materials and requires only silicone spray for lubrication. 9. TENT(S) The tent( s) on your KZ hybrid trailer is manufactured with mostly vinyl and polyester fabric laminated, with vinyl exterior in areas where there is vinyl only. Two tendencies that you may dis- cover in any tent assembly are condensation and possible minor leakage on the first several times the tent is used.
  • Page 23 Preventing Leakage During Use • Do not rub against walls, roof or canvas windows when wet or when raining. • Do not place objects against tent walls. • Do not over extend or over stretch your tent. • Do not spray insect repellant or hair spray on fabric as these items may destroy water repellency of this fabric.

  • Page 24: Chapter Iii-Systems

    Chapter III—Systems 1. PROPANE SYSTEM Your system to feed propane fuel thru your piping system needs to be inspected for leakage at least once per year, preferably in the spring before you begin your camping season. The best method to test the system is to use a manometer, an instrument used to measure the operating pressure at 11”...

  • Page 25: Plumbing System

    2. PLUMBING SYSTEM Maintenance to plumbing system is minor, there are several items of importance. 1. Instructions to sanitize your portable water systems are found in your owners manual. This request may not appear to be very impor- tant, yet the longer period of time you don’t use the water tank the more important it becomes.

  • Page 26: Electrical System

    3. ELECTRICAL SYSTEM A. 120 Volt AC Turn off all breakers, plug coach into 120 volt AC, shore power, turn on 30 or 50 amp main breaker and then each breaker following. This procedure indicates your 120V system is working correctly and feeding power throughout your coach unless there is an open circuit somewhere.
  • Page 27 A fully charged battery will measure at 1.265 specific gravity. A discharged battery will measure at 1.120 specific gravity or 11.7 volts DC. A hydrometer is required to measure “specific gravity.” Most batteries with deep cycle rating require water to be added as needed.

  • Page 28: Chapter Iv-Appliances

    Chapter IV—Appliances 1. FURNACE The furnace in your KZRV does need some normal maintenance attention, preferably once each spring, just before you begin your summer camping season. It’s best to have your selling dealer or a qualified service techni- cian perform such an inspection. Your dealer may have a “spring special”...

  • Page 29: Water Heater

    the furnace under this condition could lead to serious insufficient operation. If soot is observed on the vent, immediately shut the furnace down and contact a qualified service agency. 2. WATER HEATER Since this appliance has burner and pilot assemblies located in an exterior chamber, they are subject to insects and moisture con- tacts.

  • Page 30: Winterization Hot Water Heater

    WARNING DO NOT replace the anode rod with any non– Suburban accessory part, such as an “add-on” electric heating element. Items such as these are not approved to be installed in Suburban products. They could cause an unsafe condition and will also void all warranties. Photo shows what a new and full rod should be plus a 75% deteriorated rod now requiring it...

  • Page 31: Refrigerator

    WARNING Be sure all controls are turned off and cooled down before cleaning to avoid burns. During the usage of your stove and oven it is important to keep your equipment clean for beauty, longer lasting appearance, and operational condition. 1.
  • Page 32 After turning off the refrigerator for the winter, remove all food and allow time for defrosting. Then remove any water from the refrigerator using pots, pans and towel from defrosting. 2. Clean Now wash the refrigerator completely to a nice clean condition. You may wish to allow the door to remain open slightly to com- plete the drying process and to prevent any mildew or mold to grow.

  • Page 33: Air Conditioner

    1. Reconnect the 12 volt DC battery, deep cycle suggested, and make sure it is fully charged. 2. Plug in 120 volt AC plug into receptacle. 3. Door seal should always be tight and not leak air. Place a piece of paper (or a dollar bill) between the door gasket and frame.
  • Page 34 DO NOT operate the air conditioner without the filter in place. Cleaning and/or changing the filters: 1. Disengage the two 1/4-turn fasteners that secure the ceiling assembly grille to the ceiling assembly (see figure). 2. Lower the grille and filters from the ceiling assembly. 3.

  • Page 35: Chapter V-Interior

    Chapter V—Interior 1. PANELING Wall panels in your KZRV are manufactured with vinyl glued to luan panels. To clean, use a mild solution of soap and water with a sponge or soft cloth. DO NOT use any abrasive cleaner as scratching of vinyl could occur, causing dull colors and scratches.
  • Page 36 For the sink bowl, use a beach-water solution, using 1/4 to 1/2 cup of bleach with sink filled to top with water. Let stand for 15-30 minutes. Sink has a different surface and you may use an abrasive cleaner, such as Comet. For difficult problems: CLEANING ALL FINISHES Moist dirt &...

  • Page 37: Window Mini Blinds

    6. WINDOW MINI BLINDS (Kitchen Window) Blinds and rails are made of pre-painted aluminum metal. Clean these blinds by using a soft damp cloth or sponge to remove dust. Blind can be removed from mounting brackets for additional or ex- tensive washing.

  • Page 38: Windows

    12. WINDOWS On window (s) which have opening sliders or awning panel, there are “weep or drain” holes at lower sections of frame extru- sions, generally at the end of each movable panel. Dirt, debris, in- sects, etc. can and will accumulate, potentially plugging up these weep holes.

  • Page 39: Propane And Co Detector

    • Replace you Smoke Alarms at least every 10 years. This includes models with 10-year batteries (SA-668LL and SA-668SLL). Manu- factured date code is on the back of the alarm. 14.PROPANE AND C.O. DETECTOR—COMBO: HOW TO TAKE CARE OF YOUR ALARM This CO/Propane Gas Alarm is designed to be as maintenance free as possible.
  • Page 40 TEST PROCEDURE WARNING TO REDUCE THE RISK OF CARBON MONOXIDE POISONING OR PROPANE GAS EXPLOSION, TEST THIS ALARM’S OPERA- TION AFTER THE RV HAD BEEN IN STORAGE, BEFORE EACH TRIP AND AT LEAST ONCE PER WEEK DURING USE. WARNING DO NOT USE A CIGARETTE LIGHTER TO TEST THE CO/ PRO- PANE GAS ALARM.

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