KZ KZRV User manual

GUIDEBOOKTOENJOYMENTOF
YOURKZRV
RECREATIONALVEHICLE
Maintenance
Manual
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THEPURPOSE OFTHEMAINTENANCEMANUALISTO
PROVIDETHEMOSTUPDATEDMATERIALCONCERNINGTHE
CAREFORALLPRODUCTSBUILTBYKZRV.
AS THEOWNEROFANEWR.V.PRODUCTITISIMPORTANT
TORECOGNIZETHEIMPORTANCEROUTINECAREOFTHIS
COACH DURINGWARRNTYPERIODAND FUTURETIMEIN
YEARSTOCOME.
MAINTENANCEOFYOUR RECREATIONALVEHICLEIS
IMPORTANTTOKEEPINGYOUR COACH INGOOD
CONDITION.FAILINGTOPROVIDEMAINTENANCE,AS
SUGGESTED,COULDRESULTIN LOSS OFWARRANTY
COVERAGE.
FAMILIARIZEYOURSELFWITHTHISMANUALAND USE THE
MAINTENANCECHART INBACKTOKEEPRECORD OFANY
AND ALLREPAIRSNEEDED ,WARRANTYOROTHER WISE.
INCLUDEDISSPACEFORNORMALSCHEDULEDDUTYS,
REQUIRMENTSAND COMPLETIONS.
©2015 KZRV LITHOU.S.A. 01-2015
ConventionalTravelTrailer
FifthWheel
HybridTravelTrailer
ToyHaulerFifthWheel
ToyHaulerTravelTrailer
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KZRV, L.P.
“BUILDINGQUALITYANDFUN FOROVER40
YEARS”
Wecongratulateyouon yourpurchaseofaKZRV,
recreationalvehicle. You havechosen aqualitybuiltRV
whichshouldprovide youwithmanyyearsofcamping
memoriesand fun.
The recreationalvehicleyou havepurchased hasbeen
inspected byourtrainedinspectorsandfullymeetsourhigh
qualitystandards.
Asthe ownerofanewKZRV,RVyoucan restassured that
wewill do all wecan to keepyou a“happycamper”.
Naturally,yourselling dealershipis alwayshappyto helpyou
with anyquestionsyou mayhaveorserviceyoumayneed.
And shouldyouneed assistancewhen traveling,with over
200 KZRV,dealersnationwide, assistanceisusuallyjust
minutesaway.
KZRV
0985 n 900w
Shipshewana, IN 46565
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Maintenance Manual
Thisbooklet hasbeen designed and writtento supplyinforma-
tion regardingmaintenancerequirementsforall makesand models
built byKZRV.
Astheownerof anewKZRVproductit isimportant torecognize
the importanceofperforming routine maintenanceduring the war-
rantyperiod.Justlikeoil changesinyourtowvehicle—ifproper
maintenance isnot performed thewarrantycoverage can be denied;
thisalso appliestoyourrecreationalvehicle.
Onthereverseside ofthecustomerdeliverysheet is the war-
rantycoverage information.Notethetwelve(12)exclusions,espe-
ciallyitemsfour, five, sixand seven, whichare maintenance items.
Familiarizingyourselfwith thismanualandusing themainte-
nancechartinthebackofthe manualwill helpyoumakesurethat
propermaintenanceisperformed. But remember,maintenanceis
routine service and isnot covered bywarranty.
With properandscheduledmaintenanceon yourKZRVwe be-
lieve youwillenjoyyourRVformanyyears to come.
HappyCamping,
KZRV,LP
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I.UNDERCARRIAGE Date Date
WheelBearings Inspected Repacked
LugNutsTorqued Inspected Tightened
Brake Shoes Inspected Adjusted
Shackles
Inspected Lubricated
Steps Lubricated Lubricated
StabilizerJacks Lubricated Lubricated
Coupler Inspected Lubricated
II.EXTERIOR
Metal Washed Waxed
Fiberglass Washed Waxed
Roof Inspected Sealed
RoofSeams Inspected Sealed
CornerMoldings Inspected Sealed
Windows Inspected Sealed
Slide Out Inspected Sealed
RearLowerHinges* Inspected Greased
LPSystems LeakTest
Regulator
LeakTest Adjusted
Plumbing LeakTest
Electrical
Battery Tested Add Water
Lights Inspected Tested
120VBreakers Inspected Tested
GFCI Inspected Tested
IV.APPLIANCES
LPConnections Inspected Tested
Stove Tested
WaterHeater Tested
PlumbingSystem Inspected LeakTest
Refrigerator Tested
MAINTENANCECHART
III.OPERATINGSYSTEMS
SecondYearFirstYear
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TABLEOFCONTENTS
ChapterI—Undercarriage
Frame…………………………………………………………….1
Coupler…………………………………………………………..1
Jacks……………………………………………………………..1
StabilizerJacks……………...………………….…………….2
Jacks………………………………….………………………..2
Tires………………………………………………………………2
Wheels…………………………………………………………...3
Axles..…………………………………………………………....4
Bearings…………………………………………………………4
Brakes...................................................................................6
Springs/Shackles..................................................................9
Steps...................................................................................10
ChapterII—Exterior
Metal...................................................................................11
Fiberglass...........................................................................11
ABSPlastics.......................................................................11
ExteriorRoof.......................................................................11
Extrusionsand Vents.........................................................13
VinylTire Covers.................................................................14
Slide-outs............................................................................14
ToyHaulRearDoors..........................................................15
Tents...................................................................................15
ChapterIII—Systems
Propane System.................................................................17
PlumbingSystem................................................................18
ElectricalSystem................................................................19
ChapterIV—Appliances
Furnace...............................................................................21
WaterHeater.......................................................................22
Winterization HotWaterHeater……………………………..23
Stove, Range, CookTop....................................................23
Refrigerator.........................................................................24
AirConditioner....................................................................26
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ChapterV—Interior
Paneling..............................................................................28
Linoleum/ VinylFloor.........................................................28
Carpet.................................................................................28
CounterTops......................................................................28
SolidSurface CounterTops................................................28
WindowMiniBlinds.............................................................30
DayFabricShades.............................................................30
ABSPlasticComponents....................................................30
Drapes................................................................................30
Cushion Covers..................................................................30
Furniture............................................................................ 30
Windows............................................................................ 31
Smoke-Alarm......................................................................31
Propane and CODetector................................................. 32
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1
YourKZRVrecreationalvehicleisdesignedto beasmaintenance
free aspossible. However,all moveablevehiclesrequiresomecare
to reducethe possibilityofunwanted breakdownsduringtravel.
MaintenanceofyourRVmaynot seemnecessaryat the timeof pur-
chase, yetitisveryimportant tokeep yourcoachinit’sbestcondi-
tionforyourenjoyment. Normalmaintenanceisrequired tomaintain
warrantycoverage, reducewear, and prolong the life of yourcoach.
1. FRAME
The steelframeon yourKZrecreationalvehicleiscleanedwith a
highpressurephosphate spraywashthat removesoils,dirt, and
residue.Aftercleaning the frame isplacedin an ovenat 200°F,high
quality,waterborne paint is then applied. Afinalcuring process is
then applied to producea qualitypaintapplication.
No matterwhat qualityortypeofpaint process isused, wemust
rememberthat duringtravelthe frameisexposed tostones,sand,
road debris,andanyotherobjectsfound onthe road.Theseitems
willcausescratching and chippingofthe paint invitingrustto begin
frommoisture. Yourframeneedsto beinspected and examined
everyyeartotouchuporrepaint asnormalmaintenance. Wesug-
gestthisbe performed eachfall beforestorage toguardagainstwin-
termoisture.
The paintto useisagloss black,ozone safeexteriorpaint with no
fluorocarbon,ina spraycan.
You maywishtopurchaseacommercialrustproofundercoating
treatment, suchas,Ziebart®,etc.However,evensuchhigher
priced treatmentsare subject to roaddebrisand damage.
2. COUPLER (Travel Trailers)
Forthe ball on yourhitchusealight amount ofchassisgrease.
Lubricatethe coupler’spivotpointswithsiliconespray.Avoid
grease oroilastheywilldrawdirt, potentiallydamaging thecoupler.
3.JACKS— FORRAISING/LOWERING/SUPPORTS
Numeroustypesofjacksareused inconstructingarecreational
vehicle,suchasstabilizer,tongue ontraveltrailer,landinggear
and formallyon truckcampers.
Eachofthesehave12voltD.C. powermotors available, saving
manuallaborasan option.
Shouldanyframepartsof thesejacksbecomedirtyand rusty,first
clean all partsand then paint asneeded, toimproveappearanceDO
NOTpaint anymoving parts.
ChapterI — Undercarriage
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A. STABILIZERJACKS
On item#4 (illustration),drivescrew,
spraysiliconeisrecommendedtobe
appliedtwoormoretimesperyear.
DONOTuseoil orgreaseasitwill
attractdirtandgritcausing gradual
deterioration.
Alsolubricatepivot pinsattopand
bottom.
Same instructionsforpowerjacks.
B. JACKS
A.Travel Trailers
Tonguejacks,truckcamperand
landinggearjacks,extend tofull
length, clean all partsand spraysilicone lubricanton innertubes.
Onthe topofthe jackisametalcoverattached withawirespring
cliporascrew Removecoverandinspectgears forgrease.Re-
greaseifthereisnonethereorithasdried out. Add onlyifno
greaseisvisible. Somebrandsofjacks haveaholeplacedjustbe-
lowthesegears to insertoilforlubricationoftheramsoitwill move
smoothly,ten to twentydropsannuallywilldothejob.
Alljackslisted abovehave12voltD.C.motors availableasan
optionforthemandneednomaintenance.Allmotors arepre-
lubed and should not be taken apart.
Be-sureto inspectelectricalconnectionsforcorrosion and loose-
ness asloose terminalscause excessiveheat a potentialproblem.
All motors areprotected bya30 ampfuseorcircuitbreakerlo-
cated atvariousplaces.Ifreplacement isrequired, useonlyequally
rated item.
Hydraulicjacks—Ifparked orunusedfor30daysormoreitis
suggested, to lubricate cylinderrodswithsiliconesprayto prevent
rust, oncepermonth, plusoperatethemto lubricantsealsandinter-
nalparts.
4. TIRES
Tiresinstalled on yourRVarematched to the weightofyour
coachaccordingto the rating ofthe tires.The mostimportant item
intiresistoinspectandtestairpressureno less than onceper
week,perhapsdailyduringtravel.CorrectPSIairpressureislisted
on eachtireasperrating. When airpressureisnotmaintainedas
specified tireswillrun hot,especiallyinsummermonths,and blow
outscanoccur.Pressuremustbe alwaysbechecked whentires
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arecold, preferablyinthemorning. DONOTadjustorlowertire
pressurewhenwarmasitwillbetoo lowwhen cool.Alltirepres-
suresrisewhen tiresaremoving onroadway.Atireisconsidered
cold after3 hours ofnot moving.
5. WHEELS
Wheelsare manufactured with steeloraluminummaterialmeeting
the loadrating ofthe tires.Steelwheelsarepowdercoatedpaint
and shouldbe cleaned andpolished yearlytomaintainitspleasing
appearance.Shouldyoufind scratchesorchipsinthe paint, clean
and paint to protect against rust and furtherdamage.
Aluminumwheelsrequirethesametreatment, washwithmild
soap and water.DONOTuseharshsoaporchemicalsastheymay
discolorthe wheel’sfinish.
When changingatireandwheel,alwaysstarttheattachingnuts
byhand beforeusinganypowerwrenchesto avoid cross threading.
Wheeltorque mustbe 85 to 120 maximumfoot lbs,95 lbsispre-
ferred.
Re-torquewheelsat 100 milesand 300 miles.Do thiseachtimea
wheelisremovedand reinstalled.
Trimringsand centercapsmaybe plasticormetal.Both require
cleaning and polishing ,asplasticwill tarnishand metalwillrustif
care isnotperformed.
It isimportanttomaintainpropertorquetoprovidesafeandsecure
attachmentofthewheeltothe hub/drum.Besuretouse wheelnuts
thatarecompatiblewiththecoinofthe wheel. Improperlytorqued
wheelnutscan causethewheeltoseparatefrom the wheelmounting
surfaceduringoperation.Thiscouldresultinpropertydamage,seri-
ous injury, orloss of life.
FASTENER TORQUE
WARNING
!
Tighten eachlugnutin the order showntothe torqueshownin the chart.
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6. AXLE
The axlebeam(tube)itselfrequiresno maintenanceunless ithas
become bent,causing unusualtire wear, camberortoe in/out.Ifthis
occurs the beamneedsto be replaced orrealignedtoprevent con-
tinuoustirewear.Specialalignment equipment isrequired to re-
align an axle beamto correct thiscondition.
A. Bearings
Twotypesofbearing systemsareused
inKZproducts.Beginning in2004 model
yearasecondsystemcalled Ultrulube®has
beeninstalled. ALL wheelbearingsinyour
coacharepre-greased at the point ofassem-
bly.Atsixmonthsor6000milesofuse, in-
spect the bearingsforlubricationandwear.
Thereisno needto liftthe trailerbefore
greasing axlesequippedwith Ultrulube:
1. Remove the rubberplug fromgrease cap
2. Insert greasegun onthegrease fitting..
3. Placethreetofiveshotsof greaseineachgreasefitting. every
3000to5000milesuntilcorrectlyrepacking bearings.Over
greasingwillput grease on brake shoes.
4. Replace rubberplug.
ThissysteminstalledforaquickFridaynight bearinglubrication
and short tripbecauseyouforgot to repackbearingscorrectly.
The Ultrulube®systemDOES NOTremovetheneed torepack
bearingsaslisted below.Werecommend repacking onceeachyear
(everyotheryearmaximum)or12,000 miles.Alsoinspectbearings
and hubsforanydamaged componentswhen you have itapart.
Wheelbearingsrequiremanualinspection, cleaning,repacking,
and inspectingtheoverall condition.
B. Repack Bearings
Beforerepacking bearings,takebearingsoutofhuband washall
oldgreaseand grimout ofbearingsandhubwithsolventcleaner.
Now,usingahightemperatureautomotivetypegrease, youmay
carefullypackbearingsbyhand orusea“bearingpacker.”Grease
mustbe fullyforced intocavitiesbetween rollers,cone,and cage of
bearings.
Useahightemperature,automotivetypewheelbearinggrease
producedbyareputablemanufacturer.The soap typeshouldbe
lithiumcomplexorequivalent. UseNLGIGrade2productwitha
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minimumdropping pointof440°F.
Alwaysreplacebearingsand racesasaset. Install races(new
hub/drumsshouldhaveracesalreadyinstalled)usingamildsteel
driftorbar.Do not usehardened steelorbrass barsastheymay
damage, chiporleavedepositsonthe races.Finalsetting ofthe
raceagainstthe shouldershouldbe checked withfeelergaugesand
be within 0.002”ofthe shoulderinthe hub/drum.
Afterbearingshavebeen packed withgrease, placeinnerbear-
ingsintocorrectposition, seatedinto raceorcup.Placeanewseal
overbearing(neverreusepreviousseal).Useasealdriverorhard
rubbermalletand tapgently.Besuresealisseatedfullyandcom-
pletely.
1. Toget the proper“feel”forbearing clearance, the spindlenut
must turn freelyonthe spindleand the brake must be readjusted
so that thereisnodragon the drum.
2. Whileslowlyturningthe hub/drumtighten the spindlenut to ap-
proximately20ft/lbsthenloosentofirstnotchinnut.Thisis
especiallyimportant ifnewbearing raceshave beeninstalled.
3. With drumstationary(donot rotate),retightenthe spindlenut to
Overpacking the hubresultsingrease seeping outofthe dustcap
and wheelseal.
CAUTION
!
WARNING
!
Improperbearing adjustmentcan lead towheelbearingfailurewhich
couldcausethehub/drumand wheeltoseparatefrom the axleduring
operation.Thiscouldresult inpropertydamage,serious personal
injury, orloss of life.
WARNING
!
Impropersealorbearinginstallation oradjustmentorinsufficient
maintenancecan lead towheelbearing failurewhichcouldcause the
hub/drumand wheeltoseparatefromthe axleduringoperationre-
sulting inpropertydamage,serious personal injury, orloss of life.
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7ft/lbs(zeroclearance)then backoffone slot(0.001”-0.010”
end play)and align cotterpinhole. Insertcotterpinand bend
both endsoverend ofspindle.Installgreasecap.
7. BRAKES
The brakeson yourcoach are 10”or12”in diameterdepending on
the weightofthetrailer.Theyfunctionfrom12 voltDCpowersup-
plied through brake controlfromyourtowvehicle.
Brakeson models2012
andolderareNOTself-
adjusting. Youwillneedto
adjustbrakesmanuallyas
outlined inthenextseveral
pagesorhaveyourselling
dealerperformthisoperation.
When acoach’sbrakesys-
temisnew,the brakeshoes
and drumarenot completely
meshed together.Thisfirst
adjustment shouldoccurat
200 to1000 milesorwhen
brakeshavebeenengaged
100 times,referred to as
“burnishing.”Afterinitialad-
justment brakesshouldbe
readjusted every3000miles.
Underadjustment can causepoorbraking andthe adjusterwheelto
fall apart,resulting inhaving nobrakesand possibledamage to
othercomponents.Useaqualified technicianto performthismain-
WARNING
!
Improperbrakeadjustmentcan result inreduced brakeperformance
orloss ofbrakes.Reducedbrake performance can leadtoproperty
damage, serious personal injury, orloss of life.
CAUTION
!
Alwaysplace stationaryjackstandsorblocks underframe toguard
againstjackfailure.
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tenance procedure.
TOADJUST
1. Lifttrailer.Donot removethewheels orhub/drumassem-
bly.
2. Locate the adjusting slot atthe bottomofthe backing plateand
remove the protectivecover.
3. Whilespinning the wheel,useastandardbrakeadjusting toolor
the bladeofascrewdriverto rotate the starwheeluntil thereis
a heavybrake drag.
4. Loosenuntilthe wheelturnsfreelyabout 3/4 to one fullturn.
5. Replace the protectiveplugto keep dirt and moisture out.
6. Replace all partsand lowertrailer.
7. Repeat procedureforotherwheels.Neveradjustjustone
brake. It isrecommended that all brakeson the trailer,be ad-
justed at the same time.
Beginningin2013mostmodelshavebrakesthat areself-
adjusting. AsyoudriveforwardORbackwardeachtimebrake,
thesebrakeassemblieswilladjustautomaticallyand keepyour
brake systemat the best stopping ability.
Axlesand brakesystemsarefrom3different suppliers.Besure
partsare fromsamesupplierasoriginalmanufacture.
A. Brake Shoes
Whilethe hub/drumisremovedthebrakeshoesalsorequirefullin-
spectionfor:
1. Normalwear-1/16”isminimum.
2. Cracking fromheat -Hairline heat fissuresarenot uncommon
inbondedshoesandposeno causeforconcern. Ifthereare
anyquestionsconcerning the severityof cracking, consultwith
an expert. Ifthe lining iswornto 1/16”orless,orshowsir-
regularwearorcontaminationfromforeign substances,the
shoesshouldbereplaced with originalparts.Ifcracking is
severe ,replace the shoes.
3. Dirt and othercontaminants.
4. The springsare secureand have goodtension.
WARNING
!
Brake shoesshouldalwaysbereplacedinpairs,bothbrakesonthe
sameaxle.Failuretoreplace inpairscanresult inreducedbrake
performanceorloss ofbrakes which couldresult inpropertydam-
age, serious personal injury,orloss of life.
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Brakeshoesasacomponent aresubjectto dailyuseabsorbnor-
malwear.Shoesarewarrantedforworkmanshipbut not fornormal
wearorfailure to maintain.
B. Brake -Hub/Drum
Whilethe hub/drumisremoved forotherserviceworkbe sureto
inspect the drumfor:
1. Cracks in casting, inside oroutside.
2. Rough spots, mayrequire sanding.
3. Heat distortion(bluish color).
4. Out ofround drums(high spots).
5. Deep scoring of0.030”andover.
Items4and 5requireuseofabrakedrummicrometer.Resurfacing
ofthe drummaybe required orreplacement.
Resurfacing the Brake Drum
Astandarddrumlathe maybe used to machine the shoe surface.
Do not exceedthemaximumdiametercastintothebrakedrum.
The drumshouldbereplaced ifitmustbe bored morethan the
maximumdiametercast in the brake drum.
Armaturesurfacemachiningisadifficultprocess with mostdrum
lathesandisnot recommended. Ifitresurfaced itshouldbema-
chinedtoa120microinchfinishandmusthave0.060”abovethe
stud heads. Do not remove more than 0.030”ofmaterial.
Besuretoremoveanymetallicchipsand contamination resulting
fromdrummachining.
C. Brake Magnets
Thiscomponenttransfers the 12 voltpowerintoactionbyengaging
WARNING
!
Heavilyscored,wornoroversized drums can result inreducedbrake
performanceorloss ofbrakes.Thiscouldresult inpropertydamage,
serious personal injury, orloss of life.
FASTENER TORQUE
WARNING
!
Impropertorque can cause componentfailureand theaxles tobe-
come detached from theframe.Thiscouldresult inpropertydamage,
serious personal injury, orloss of life.
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itselftothearmaturecausingthebraketoengagewithdrumsur-
face. Inspectthe magnet forstandardorabnormalwear.Generally
amagnet“works” oritis“dead”requiringreplacement.Shoulda
magnet bewornonaslantorangleandstillworks,replaceitasit’s
life isshort.Each magnet drawsabout 3.0 amps.
8. SPRINGS/ SHACKLES
Allsuspension componentsshouldbevisuallyinspected at least
every6monthsor6,000 miles.Checkforloosefasteners and
torque to propervalues.
A. Springs
Springsthemselvesrequireno maintenanceotherthan inspection
forbreakage orcracks.Paintingspringsandothercomponentsre-
tardsrust, improving the appearance ofthe items.
Ifspring (s) arebroken replaceimmediatelyasdriving willcause
additionalstrain on the othersprings.
B. Shackles
Boltsandshackleplatesneed tobeinspectedoncepertravelsea-
son orif you are travelingmanymiles.
Ontheinside ofshackleboltsthereareserrationsintended for
bolt head not to turnormove. Shouldtheseserrationsbecomedam-
agedorworeflat, boltwillturn,wearing thenylonbushingand then
boltwill wearholesinshacklesinto oblongcondition..Onlysolution
isto replace shackles,boltsand bushings.
When replacing thesepartsbe verysureto,holdboltheadand
turnnutonlyto prevent boltfromturning ,repeating previousprob-
lem.DONOTovertighten, preventingspringfrommoving. Al-
low.050inchspace between spring and hanger.
Fromoriginalparts, thereare two(2)options:
!.Heavydutyshacklekitwith brass bushings—howevertheyMUST
be greased every3000 milesortheywillseize up.
2. Thereisalsoan “EquaFlex” suspension kitavailableto replace
the equalizer,giving yourcampera betterride.
Seeyourdealerfortheseitemsand more information.
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9. STEPS
The step assemblyissubjectto all typesofweatherelementsand
requiresthe following maintenance:
Covering nicksand scratches:
1. Sealanynicksorscratcheswith anautomotivegrade primerto
prevent rust.
2. Oncethe nickorscratchhasbeensealed, coverthe damaged
area with an automotive grade high-gloss paint.
Lubricating the mechanism(every30to 60 days)
1. Carefullycleantheareaaround the pivotpoints(therivetsin-
volved in the motion ofthe mechanism).
2. Aftercleaning, lubricate thepivotpoints(topinpointthisarea,
locatethewasherbetweentheparts).Anautomotivegrade,
non-staining lubricant isrecommended. Siliconesprayisalso
good, useit monthlyduring traveluse.
Wesuggestlubricatingthemechanismonceeachspring and fall
plusat least once duringsummeruse.
CAUTION
!
To prevent the possibilityofapersonslipping onthe steps:
1.LubricateONLY the pivot points
2.Wipe off anyexcess lubricantand clean the step carefullytobe
sureno excess lubricantison the step assembly.
NOTE:
Paint on axles, springs, etc.hasonlya primercoat. You may
wish torepaintaspartofnormalmaintenance.
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1. METAL
Aluminumskinispre-painted asitarrivespreformed fromsup-
plierwith polyesterautomotivepaint finish. Toclean, useamildde-
tergentandwater.
Usean automotivetypeofwaxorpolish;sameasyoumayuse
on yourtowvehicle.BywaxingyourKZRVonceperyear,itretains
itsnice, new appearance.
2. FIBERGLASS
Fiberglass componentsused inKZRVcoachesareseveraldif-
ferent type:
a. Front andrearcapsarebuiltinamold, using geltype offi-
berglass components.
b. Forsidewalls,therearetwo typesused-“Gelcoat”and
“Lamiplast.”
Cleaning onallfiberglass materials,useamilddetergent and
warmwaterusingasoftbrushorrag. Fortougherstainssuchas
found arounddriprails,awningrails,orwindows,aspecialcleaner
maybe required.
Waxing on Gel CoatMaterial
Asthegelcoatbeginsto loseitsgloss fromconstantexposureto
the naturalenvironment and pollutants,itwillrequiresomespecial
attentiontorestoretheoriginalgloss andcolor.Good polishingwith
a self-cleaningautomotivewaxwillrestoremost oftheoriginalgloss.
Afall and springwaxjob is generallyallthat isneeded to maintain
the originalappearance. Ifthe surfacehasbeenallowed toweather
badly,and cleaning and waxpolishingdoesnot restorethe finish
satisfactorily,then compounding will benecessary.The finishis
totallyimpervioustochemicalsandweathering. Imagine whata
brand newcarcouldlooklikeifallowedto sitoutside foryears with
no coverand no washing orwaxing. With the sameminimummain-
tenanceyouwouldordinarilygiveyournewautomobile’sfinish,your
RVgelcoat finishwillretainitsdepth ofcolorand glossforyears.
3. ABSPLASTICS
OlderFrontierandUltraLitelowerfrontsandfenders willretaintheir
originalcondition with generalwashingand polishing.Thesesur-
facesarenotashardasfiberglass andcanscratch. DONOTuse
abrasive soapsorpolisheson ABSplastics.
4. EXTERIOR ROOF
Three typesofroofmaterialareused on KZRVproducts.
ChapterII —Exterior
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Aluminummaterialisasmooth mill-finishrequiringlittlecare. Wash-
ing with soap and waterplusrinsing should suffice. There isno hard
substrate materialunderneath andaluminumwill showslight waves
dueto sun andheatcausing expansionofthealuminummaterial.
Second, afullroofoffiberglass isused on one modelwithoutany
roofseams.Roofbeginsat front bottom,goesallthe wayacross
roofand endsat rearbottom.Moldingswill screwontop ofmaterial
just like front and backs.
Third, Asoftfabricisgluedonto asubstrateOSBboard, whichis
attachedroofframework.Three typesofmaterialhavebeen
used:EPDMfullrubbercover,TPO(ThermoPlasticOlefins) and
SUPER FLEXsystem,
The propercare, cleaning and maintenanceofyourSUPER
FLEXANDTPOroofing isquitesimplebecauseofthebasicproper-
tiesand longevityofthe materialitself.
Periodiccleaning isthe primarymaintenance.AlphaSystems
suggestsusing Murphy’s Oil Soap, Top Job, orSpicandSpanwith
asoftnylonbrushorsponge.DONOTUSEsolidorgranulated
cleaners, astheywillmarthe naturalfinish.
DONOTUSE Armor-All orotheroil/solvent basecleaners as
theywillleave a slicksurface.
Agood thorough cleaningwith someelbowgreaseandthe sug-
gestionsaboveshouldkeep yourrooflooking goodand remove
moststains.Formorestubbornstains,youshouldcontactyourau-
thorizeddealer.
Ifyou keep yoursoftfabricroofclean, youwillbe performing the
primarymaintenancenecessarytokeep itlooking good andextend
itslongevity.
Annualinspectionoftheroofissuggested. Checkthe mem-
brane forpossibledamage and checkthe caulk/lap sealant usedin
all termination ventareas,aroundroofventsand anyotherattach-
ments.Besuresealantisfullyattachedtoroofmembraneandnot
coming loose.
RoyalTuff-PlyandSuperFlexareUVresistant. It willnot re-
tainodors orrot.
Thereareone ortwoseamson top ofthe roof,front and rear,
attachingthefront and/orrearpaneltotheroofmaterial.Aputty
tape sealsthe seam,whichiscovered withaflat extrusion plusroof
sealant, to be inspectedandresealed asrequired. Thisneedsto be
donetwiceperyear, spring and fall.
Sealant to useisAlpha Systems1010 overseamswhichisre-
quired forfull sealing seams.
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Periodicinspectionofthe roof,during cleaning, isrequired.Inspect
the membrane forsignsofdamage forpunctures,sealant loose,
missing, cracking and voids.Membrane can be patchedifonly
small punctures.
Perform inspectionseachspring and eachfall beforestoring forwin-
ter.
5. EXTRUSIONSAND VENTS
Allcomponentsinstalledon the exteriorofyourcoachhave
sometypeof“puttytape”placedbetween the mounting flangeor
surface to guardagainstwaterentryand leakage.
Additionalsealant,referred to as“cap seal”isused to protect
along theedgesofextrusionsorbe asecondarysurface sealant.All
ofthesesealantsaresubjectto weatherelementssuchasUVrays
fromthe sun,rain, snow,cold,heat,airpollution,frostandotherex-
posurescausing dry-out, shrinkage and possible cracking.
Cap sealMUSTbe examined eachyear,preferablyeachspring
and fall,forlooseness,cracking, and separation fromanyattached
surface. Ifuponinspectionyou find theaboveconditions,repairs
mustbe made. Theseconditionswillpermitwatertoenterslowly
and eventuallycause majordamage to yourKZRV.
Cornerandroofextrusionshaveputtytape sealant between the
components.Thismaterialcan and willalsodryand/orcrackfrom
weatherelements,permitting leakage and eventuallymajordeterio-
ration.KZRVadvisesthe ownerto removetheseextrusions,clean
out oldputtytape, and replacewith newsealant materialeveryfive
years.
Windows,entrancedoors,andcargodoors useablackclosed
cell foamtape,forsealant needs,plusaninsidebutyltape. These
sealantsmayalsodeteriorate overtime, looseitsmemory,shrink
with weatherconditions, etc., overa period offiveyears
CAUTION
!
Atleastonce peryear,inspectall roofseams;front, rearand around
all vents.Removeanyloose sealantand resealtheseareas.Use
self-levelingsealant, “AlphaSystems #1010 or1021atplasticitems,
anon-hardening sealant. Failuretoinspectand correctas needed
will voidthewarrantycoverage, classed asnegligence.
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