Four Winds 2005 Mandalay User manual

OWNER'S MANUAL
07/2004

COMPLETE THIS REGISTRATION CARD WITH THE SELLING DEALER AND KEEP
IT FOR REFERENCE WHEN WARRANTY SERVICE IS REQUIRED

COMPLETE THIS REGISTRATION CARD WITH THE SELLING DEALER AND
RETURN WITHIN 10 (TEN) DAYS OF THE PURCHASE DATE

TABLE OF CONTENTS
MANDALAY LIMITED WARRANTY 1-1
WHAT IS COVERED ....................................1-1
HOW TO GET SERVICE ..................................1-1
WHAT IS NOT COVERED .................................1-2
LIMITATIONS AND DISCLAIMER OF IMPLIED WARRANTIES ..............1-2
LEGAL REMEDIES AND ARBITRATION ..........................1-3
CUSTOMER CARE ROADSIDE ASSISTANCE PLAN 1-4
EMERGENCY ROADSIDE ASSISTANCE .........................1-4
24-HOUR TOLL FREE EMERGENCY MESSAGE SERVICE................1-4
FREE CUSTOMER TRIP ROUTING AND FULL COLOR MAP SERVICE .........1-4
TOLL FREE NATIONWIDE SERVICE APPOINTMENT ASSISTANCE...........1-5
SERVICE ASSISTANCE ..................................1-5
SERVICE NUMBERS FOR OWNER'S REFERENCE....................1-6
OWNER'S PERSONAL PROPERTY RECORD 1-7
OWNER'S INSURANCE INFORMATION 1-8
INTRODUCTION 2-1
TRAVEL PREPARATION 3-1
CHASSIS CHECKS .....................................3-1
RV SYSTEM CHECK ....................................3-2
TANK CAPACITIES CHART ................................3-2
FIRST SHORT TRIPS....................................3-3

CARE & MAINTENANCE 4-1
GENERAL INFORMATION .................................4-1
FIBERGLASS SIDEWALLS .................................4-1
SEALS & ADHESIVES ...................................4-2
EXTRUSIONS & ALUMINUM SURFACES .........................4-3
WINDOWS & DOORS....................................4-3
FRAME ...........................................4-3
TIRES ............................................4-3
ROOF ............................................4-4
TV ANTENNA ........................................4-4
EXTERIOR LIGHTS.....................................4-5
APPLIANCES, SINKS & COUNTERTOPS .........................4-5
PRE-FINISHED PANELS AND WOOD SURFACES ....................4-5
WATER SYSTEM ......................................4-5
ELECTRICAL SYSTEM...................................4-6
ROOF VENTS........................................4-6
ABS PLASTICS .......................................4-6
WINTER PRECAUTIONS..................................4-7
STORAGE PREPARATIONS ................................4-8
MOLD ............................................4-9
PERIODIC MAINTENANCE CHART............................4-11
IDENTIFICATION & SAFETY 5-1
REPORTING SAFETY DEFECTS .............................5-1
RECREATIONAL VEHICLE SERIAL NUMBER DECALS & DATA PLATES ........5-1
MANUFACTURER'S WARRANTIES ............................5-2
SAFETY REGULATIONS FOR LP GAS SYSTEMS & APPLIANCES............5-3
FIRE SAFETY........................................5-4
FIRE EXTINGUISHER ...................................5-5
CARBON MONOXIDE DETECTOR.............................5-6
SMOKE DETECTOR ....................................5-8
SEAT BELTS ........................................5-9
EGRESS EXIT WINDOW .................................5-10

AUTOMOTIVE OPERATIONS & PROCEDURES 6-1
DAMAGED OR FLAT TIRES ................................6-2
WHEEL NUT TORQUES ..................................6-2
WHEEL & TIRE BALANCING................................6-2
FRONT SUSPENSION & ALIGNMENT...........................6-3
POWER PLANT & DRIVE TRAIN..............................6-3
ENGINE COOLING SYSTEM ................................6-3
PROPER LOADING & WEIGHT DISTRIBUTION......................6-4
WEIGHT INFORMATION LABEL ..............................6-4
COMPUTING YOUR LOAD & LOAD DISTRIBUTION ...................6-6
DRIVING ..........................................6-7
HILLS, DALES & MAKING THE GRADE ..........................6-7
TRAILER TOWING .....................................6-8
TOWING PROCEDURE...................................6-9
EMERGENCY STOPPING.................................6-10
FUELING THE MOTORHOME...............................6-10
CHASSIS FUNCTIONS 7-1
DASH CONTROLS .....................................7-1
EXTERIOR OPERATIONS 8-1
ENTRY DOOR .......................................8-1
POWER STEP .......................................8-1
STORAGE..........................................8-2
LADDER & ROOFTOP STORAGE .............................8-3
DEEP FREEZE WITH SLIDE-OUT TRAY (OPTIONAL) ..................8-3
AWNINGS..........................................8-3
GENERATOR SLIDE ....................................8-4
GENERATOR SAFETY ...................................8-4
REMOTE AIR FILL .....................................8-5
RALLY KIT COMPARTMENT................................8-6

WATER AND DRAINAGE 9-1
FRESH WATER SYSTEM..................................9-1
WATER PUMP .......................................9-2
SANITIZING THE FRESH WATER SYSTEM ........................9-2
MONITOR PANEL......................................9-4
WASTE WATER SYSTEM .................................9-5
HOLDING TANKS......................................9-6
FAUCETS ..........................................9-7
TOILET ...........................................9-8
WATER SYSTEM WINTERIZATION ............................9-8
WATER SYSTEM, MAINTENANCE & TROUBLESHOOTING ...............9-9
ELECTRICAL SYSTEM 10-1
GENERAL INFORMATION ................................10-1
CONNECTING TO AN OUTSIDE POWER SOURCE ...................10-1
CIRCUIT BREAKERS ...................................10-2
GROUND FAULT CIRCUIT INTERRUPTER .......................10-2
POWER INVERTER ....................................10-3
BATTERY ISOLATOR CONTROLLER ..........................10-3
BATTERY DISCONNECT SWITCHES ..........................10-4
BATTERY CHARGING ..................................10-4
BATTERY MAINTENANCE ................................10-5
SOLAR PANEL ......................................10-6
BATTERY SAFETY ....................................10-6
12 VOLT FUSES......................................10-6
FUSE PANELS.......................................10-8
EMERGENCY MANAGEMENT SYSTEM ........................10-10
LP GAS SYSTEM 11-1
GENERAL INFORMATION ................................11-1
FILLING THE LP GAS TANK ...............................11-2
LP GAS REGULATOR...................................11-3
REGULATOR FREEZE-UP ................................11-4
OTHER COLD WEATHER FACTORS...........................11-4
HOSES, PIPES, TUBES AND FITTINGS .........................11-5
LP GAS LEAK DETECTION SYSTEM ..........................11-5
ABOUT THE LP GAS DETECTOR ............................11-7
LP GAS SAFETY PRECAUTIONS.............................11-8

INTERIOR CONTROLS & OPERATIONS 12-1
REAR VISION TV MONITOR SYSTEM ..........................12-1
LIVING QUARTERS ....................................12-1
CONDENSATION .....................................12-2
OVERHEAD VENTS....................................12-2
CENTRAL VACUUM....................................12-2
HYDRAULIC POWER LEVELERS.............................12-3
AUTOMATIC HYDRAULIC POWER LEVELERS (OPTIONAL) ..............12-4
SLIDEOUTS ........................................12-5
WINDOWS.........................................12-8
DOORS, DRAWERS, AND STORAGE COMPARTMENTS ................12-8
SEATING, TABLES AND ADDITIONAL BEDS ......................12-9

MANDALAY LIMITED WARRANTY
WHAT IS COVERED
TheMandalay,byFourWindsInternationalCorporation(hereafter“Mandalay”),LimitedWarrantycovers this
recreationvehicle(hereafter“RV”),whenused onlyforrecreationaltravelandcamping,forthree(3)years,or
the first thirty six thousand (36,000) miles of use, which ever occurs first. In addition, this Limited Warranty
covers the steel or aluminum frame structure of the floor, sidewalls, roof and rear and front walls for five (5)
years or the first sixty thousand (60,000) miles of use, which ever occurs first. The warranty period begins on
thedatethattheRVisdeliveredtothefirstretailpurchaserbyanindependent,authorizeddealerofMandalay.
In the event that a substantial defect in material or workmanship, attributable to Mandalay, is found to exist
duringthewarrantyperiod,Mandalaywillrepairorreplacethedefectivematerialorworkmanship,atitsoption,
at no charge to the RV owner, in accordance with the terms, conditions and limitations of this Limited
Warranty.
ThisLimitedWarrantyappliestoallowners,includingsubsequentowners,oftheRV. However,allrights and
limitations within this warranty are applicable to all owners, including subsequent owners of the RV, and all
subsequentownersmustcompletethe WarrantyTransferFormcontainedintheOwner’sManualandsendit
to Mandalay. Any subsequent owner’s warranty coverage period is the remaining balance of the warranty
coverage period that the prior owner was entitled to under this Limited Warranty.
Mandalay’s obligation to repair or replace defective materials or workmanship is the sole obligation of
Mandalay under this Limited Warranty. Mandalay reserves the right to use new or remanufactured parts of
similar quality to complete any work. Mandalay makes no warranty as to the future performance of this RV,
andthisLimitedWarrantyisnotintendedtoextendtothefutureperformanceofthisRV,oranyofitsmaterials,
components or parts. In addition, the RV owner’s obligation to notify Mandalay, or one of its authorized,
independent dealers, of a claimed defect does not modify any obligation placed on the RV owner to contact
Mandalay directly when attempting to pursue remedies under state or federal law.
HOW TO GET SERVICE
To obtain warranty service the owner must do all of the following:
1. Complete and return the Owner Registration Card within ten (10) days of purchase;
2. NotifyMandalay,oroneofitsauthorized,independentdealers,inwriting,ofanyclaimeddefectwithin
the warranty coverage period;
3. Provide the notification mentioned in (2), above, within ten (10) days of discovery of the defect; and
4. Promptly return the RV to an authorized dealer for repairs.
Forwarrantyservice;contactoneofMandalay’sindependent,authorizedservicecentersforanappointment
and then deliver your RV to the service center on the specified appointment date. If you need assistance
contact Mandalay at [phone]. The mailing address is: PO Box 1486, Elkhart, Indiana 46515.
Iftwo(2)ormoreserviceattemptshavebeenmadetocorrect anycovereddefectthatyoubelieveimpairsthe
value,useorsafetyoftheRV,youmust,totheextentpermittedbylaw,notifyMandalaydirectly,in writing, of
the unsuccessful repair of the alleged defect so that Mandalay can become directly involved in making sure
that you are provided service pursuant to the terms of this Limited Warranty.
Mandalay 1-1

Because Mandalay does not control the scheduling of service work at any service center you may encounter
delays in scheduling and/or the completion of work. All costs associated with transporting the RV for any
warranty service shall be the sole responsibility of the RV owner.
WHAT IS NOT COVERED
ThisLimitedWarrantydoesnotcoveranymaterial,componentorpart of the RV that is warranted by another
entity,including,bywayofexample,theautomotivechassisandpowertrain,includingtheengine, drivetrain,
steering, handling, braking, wheel balance, muffler, tires, tubes, batteries and gauges, generator, hydraulic
jacks, inverter, range, carbon monoxide detector, furnace and roof air conditioner.
Minor adjustments such as adjustments to the interior or exterior doors, drawers, latches, etc. will be
performed by the dealer during the first 90 days of warranty coverage. Thereafter, such adjustments are the
owners’ responsibility as normal maintenance.
Inaddition, by wayof example only,thisLimited Warranty doesnot cover anyof the following: items that are
added or changed after the motorhome leaves Mandalay; any RV used for rental or other commercial
purposes;normalwear,tearorusage,suchasfadingordiscolorationoffabricsortheeffectsofcondensation
inside the RV; items that are working as designed but that you are unhappy with because of the design;
problems related to misuse, including failure to maintain RV in accordance with the owner’s manual, orother
routine maintenance; damage due to accident, whether or not foreseeable, including any acts of weather or
damage or anything due to the environment, rust, theft, vandalism, fire, or other intervening acts not
attributable to Mandalay; cost related to transportation, lodging, loss or damage to personal property, loss of
owner's product, inconvenience, loss of income, rental vehicles; glass breakage; damage from misuse of
equipment used for purposes other than intended design; damage resulting from tire wear or tire failure;
defacing, scratches, dents, chips on any surface or fabric of the RV; damage caused by off road use,
overloading the RV or alteration of the RV, or any of its components or parts.
Itistheowner'sresponsibilitytotakeanynecessarypreventativemaintenancemeasures,asdescribedinthe
Care and Maintenance section of the Mandalay Owner's Manual including periodic maintenance of exterior
caulking and sealers. It is the responsibility of the owner to take necessary measures to prevent secondary
damage from rain water, plumbing leaks, condensation, and the natural accumulation of moisture in the
recreationvehicle.Failuretodosomayresultinstains,damage,separation,andformationofmoldtothefloor,
walls, upholstery, carpeting, furniture, drapes and other components. Mold is a natural growth given certain
environmental conditions and is not covered by the terms and conditions of the Mandalay Limited Warranty.
LIMITATIONS AND DISCLAIMER OF IMPLIED WARRANTIES
ThefollowinglimitationsanddisclaimersapplytotheoriginalpurchaseroftheRV,anypersontowhomtheRV
is transferred and any person who is an intended or unintended user or beneficiary of the RV.
ANYIMPLIEDWARRANTYARISINGBYWAYOFSTATEORFEDERALLAW,INCLUDINGANYIMPLIED
WARRANTY OF MERCHANTABILITY OR ANY IMPLIED WARRANTY OF FITNESS, ARE LIMITED IN
DURATION TO THE LENGTH OF THIS LIMITED WARRANTY AND ARE LIMITED IN SCOPE OF
COVERAGE TO THOSE PORTIONS OF THE MOTORHOME COVERED BY THIS LIMITED WARRANTY.
PERFORMANCE OF REPAIRS OR NEEDED ADJUSTMENTS IS THE EXCLUSIVE REMEDY UNDER
THIS LIMITED WARRANTY OR ANY IMPLIED WARRANTY. Mandalay makes no warranty of any nature
beyond that contained in this Limited Warranty. No one has the authority to enlarge, amend or modify this
Limited Warranty. The dealer is not Mandalay’s agent, but is an independent entity.
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In addition, MANDALAY SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES THAT MAY RESULT FROM BREACH OF THIS LIMITED WARRANTY OR ANY IMPLIED
WARRANTY. THIS EXCLUSION OF CONSEQUENTIAL AND INCIDENTAL DAMAGES SHALL BE
INDEPENDENT OF ANY FAILURE OF THE ESSENTIAL PURPOSE OF ANY LIMITED WARRANTY, AND
THIS EXCLUSION SHALL SURVIVE ANY DETERMINATION THAT THIS LIMITED WARRANTY OR ANY
IMPLIED WARRANTY HAS FAILED OF ITS ESSENTIAL PURPOSE.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitations of
incidental or consequential damages. Therefore, the above limitations may not apply to you.
LEGAL REMEDIES
Four Winds International Corporation participates in the Consumer Arbitration Program for Recreation
Vehicles (CAP-RV). This third-party dispute resolution program is available, at no charge to you, to settle
unresolvedwarrantydisputesforrecreationvehicles.Thisdisputeresolutionprogramreviewseligibleproduct
and service related complaints involving warranty covered components.
To find out more about the program, or to request an application/brochure, please call the Arbitration
Administration office toll-free 800-279-5343.
For recreation vehicles purchased in the State of California: The CAP-RV program operates as a certified
mechanismunderthereviewoftheCaliforniaArbitrationCertificationProgram.Youmustutilizethe arbitration
program before claiming rights conferred by 15 USC section 2310 (Uniform Commercial Code) or Civil Code
section 1793.22(b) (Song-Beverly Warranty Act). You are not required to use the program if you choose to
seek redress by pursuing rights and remedies not created by those laws.
Any action to enforce any portion of this express, Limited Warranty, or any implied warranty, shall be
commenced within one (1) year after expiration of the warranty coverage period designated above or as
required by state law. Any performance of repairs shall not suspend this one-year limitation period from
expiring. Any performance of repairs after the warranty coverage period has expired, or performance of
repairs regarding any thing excluded from coverage under this Limited Warranty, shall be considered “good
will”repairs,andtheywillnotaltertheexpresstermsofthisLimitedWarranty,orextendthewarrantycoverage
periodor thislimitation period. In addition,this warrantyis not intendedto extendto future performance, and
nothinginthiswarranty,oranyactionofMandalay,shallbeinterpretedasanextensionofthewarrantyorthis
limitation period.
THISWARRANTYGIVESYOUSPECIFICLEGALRIGHTS. YOUMAYHAVEOTHERRIGHTSTHATVARY
FROM STATE TO STATE.
Four Winds International Corporation
P.O. Box 1486 Elkhart, Indiana 46515
Phone: [phone] Fax: [phone] Website: www.mandalaycoach.com
Mandalay 1-3

CUSTOMER CARE ROADSIDE ASSISTANCE PLAN
A special peace-of-mind roadside assistance plan is provided free of charge byMandalay for the first year of
ownership. (Rental and lease back vehicles are excluded from this program.)
Some companies will tell you customer satisfaction is a nine to five job, we know better!
When you take delivery of your new Mandalay RV it’s just the beginning of our exclusive around the clock
Customer Care Roadside Assistance Program. Our extensive support program provides complete and fully
paid roadside assistance, emergency road service (just show your card and go) and special support benefits
that follow you wherever your travels take you.
MandalayhasteamedupwithCoachNet,thelargestRVemergencyroadsideserviceproviderinthecountry,
to give you immediate access to fast, dependable service when and where you need it. To request service
contact Coach Net at: 888-890-1738.
EMERGENCY ROADSIDE ASSISTANCE
SimplyshowyourThorIndustriesCustomerCareCardforpaymentofcoveredbenefitswithnoout-of-pocket
expense throughout the U.S. and Canada. (Includes one additional family car!)
24-HOUR TOLL FREE EMERGENCY/MESSAGE SERVICE
Intheevent of anemergency,stayin touch with familyandfriends with no costemergencymessageservice.
Gettingin anaccident while travelingin your RVmeans you’restuck. We takecare of youby paying foracar
rental, meals and lodging. Even helping with a plane ticket home!
FREE CUSTOM TRIP ROUTING AND FULL COLOR MAP SERVICE
Member Services provides trip routing with detailed full color maps.
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TOLL FREE NATIONWIDE SERVICE APPOINTMENT ASSISTANCE
A “no-hassle” way of arranging a service appointment when and where you travel. We make an appointment
foryou;giveyoudirectionsand the time that fits your schedule best. Want an appointmentinatownyou’llbe
visiting next week? We’re just a phone call away!
SERVICE ASSISTANCE
Over 6,800 qualified service agencies throughout North America. A simple phone call gives you expert
direction on where the closest qualified service agency is located.
•Free dispatch of on-site mechanical service in the event of a breakdown
•Free jump starts
•Free tire changes
•Free fuel delivery
•Free lock-out service
SERVICE NUMBERS FOR OWNER'S REFERENCE
For further details and instructions on how to access your Customer Care Benefits, please refer to your
Comprehensive Member Benefit Guide which you will receive in the mail within 30 days from the date your
registration card is received by Mandalay, or call 888-890-1738.
You may continue your Thor Industries Customer Care Benefits in following years at a special discount rate,
as a continued benefit of the Thor Customer Satisfaction Program.
NOTE: The Customer Care Roadside Assistance Program is not available on rental vehicles or lease back
vehicles.
Mandalay 1-5

Motorhome Serial Number
Motorhome Federal Vehicle Identification Number (VIN)
Door Key Number
Range Model & Serial Number
Microwave Model & Serial Number
Refrigerator Model & Serial Number
Generator Model & Serial Number
Roof Air Conditioner(s) Model & Serial Number
Inverter Model & Serial Number
Misc.
Misc.
Misc.
Misc.
Misc.
Mandalayrecommendsrecordingthisinformationforfuturereference.Someoftheinformationmaybefound
included within vendor literature supplied at the time of sale.
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SERIAL NUMBERS FOR OWNERS REFERENCE

ITEM SERIAL NUMBER VALUE
Mandalay 1-7
OWNER’S PERSONAL PROPERTY RECORD