April/May 2011 RV Technician

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April/May 2011

Cooling Down Air conditioner repair tips, checklists, and more starting on page 5

Dealership Compliance The effects of new federal regs on RV generators page 14

Tow Bar Safety Getting the most from your equipment page 12


April/May 2011

AIR CONDITIONERS 5

Repairing Air Conditioners For Profit

STORM DAMAGE

Air conditioner repair page 5

11 Storm Repair Tips For Air Conditioners

EQUIPMENT 12

Maintaining The Safety And Value Of Towing Equipment Storm damage repair tips page 11

GENERATORS 14

New EPA/CARB Rules For Gas Generator Installations

Maintaining tow equipment page 12

TOP THIS! 16

How NOT To Install A Generator

DEPARTMENTS 3

Board of Directors

4

From the Editor

18 New Products

Certification page 20

New regs for gas generators page 14


RVDA LEARNING CENTER BOARD OF DIRECTORS

Chairman Jeff Pastore Hartville RV Center, Inc. Hartville, OH (330) 877-3500 jeff@hartvillerv.com

Director Mick Ferkey Greeneway, Inc. Wisconsin Rapids, WI (715) 325-5170 markferkey@greenewayrv.com

Director Tim O'Brien Circle K RVs, Inc. Lapeer, MI (810) 664-1942 t.obrien@circlekrvs.com

Vice Chairman Dan Pearson PleasureLand RV Center, Inc. St. Cloud, MN (320) 251-7588 D.Pearson@pleasurelandrv.com

Director Eleonore Hamm RVDA of Canada Richmond, BC (604) 204-0559 eleonore_hamm@rvda.ca

Secretary/Treasurer Bill Koster Protective St. Louis, MO (636) 536-5704 bill.koster@protective.com

Director Andy Heck Alpin Haus Amsterdam, NY (518) 842-5900 aheck@alpinhaus.com

Director Randy Packard Natl Assn of RV Parks & Campgrounds/Pine Acres Family Camping Resort Oakham, MA (508) 882-9511 opa203@aol.com

President Mike Molino, CAE RVDA Fairfax, VA (703) 591-7130 mmolino@rvda.org

Director Jeff Hirsch Campers Inn of Kingston Kingston, NH (603) 642-5555 jhirsch@campersinn.com

Director Bob Been Affinity RV Service Sales & Rentals Prescott, AZ (928) 445-7910 bobbeen@affinityrv.com

Director Rick Horsey Parkview RV Center Smyrna, DE (302) 653-6619 rhorsey@parkviewrv.com

Director Randy Biles Pikes Peak Traveland, Inc. Colorado Springs, CO (719) 596-2716 rwbiles@pikespeakrv.com

Director Newt Kindlund Kindlund Investments Winter Park, FL (407) 628-4211 newt@kindlund.com

Director Debbie Brunoforte Little Dealers, Little Prices Mesa, AZ (480) 834-9581 dbrunoforte@littledealer.com

Director Matthew Miller Newmar Corporation Nappanee, IN (574) 773-2381 mlmiller@newmarcorp.com

Director Steve Plemmons Bill Plemmons RV World Rural Hall, NC (336) 377-2213 steve@billplemmonsrv.com Director Jim Sheldon Monaco RV, LLC Rancho Mirage, CA (760) 883-5556 jim.sheldo@monacorv.com Director Tom Stinnett Tom Stinnett RV Freedom Center Clarksville, IN (812) 282-7718 tstinnett@stinnettrv.com Director Ed Thor Coach-Net Lake Havasu City, AZ (928) 855-2860 ethor@coach-net.com Director Brian Wilkins Wilkins R.V., Inc. Bath, NY (607) 776-3103 bwilkins@wilkinsrv.com

RVDA EDUCATION FOUNDATION STAFF

Mike Molino, CAE RVDA Education Foundation President Ronnie Hepp, CAE Vice President for Administration Phil Ingrassia, CAE Vice President for Communications Karin Van Duyse Chief, RV Learning Center Mary Anne Shreve Editor

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Chuck Boyd Dealer Services Manager Susan Charter Associate Services Manager Hank Fortune Director of Finance Jeff Kurowski Director of Industry Relations Brett Richardson, Esq., CAE Director of Legal & Regulatory Affairs

Liz Shoemaker Education Coordinator Butch Thomas Field Representative Robin Walker Accountant Tony Yerman RV Service Consultant Isabel McGrath Technician Certification Registrar


FROM THE EDITOR

April/May 2011

Turn Up The Heat On Air Conditioner Repairs It’s the time of year when things start heating up—and breaking down. Warmer weather means people are turning on their air conditioners for the first time in months, and some of them may be getting a rude surprise when, for instance, a critter’s nest prevents the unit from operating. Others might be reckoning with storm damage to their roof-top units this tornado-prone spring and wondering whether repairs are even possible. With this edition of RV Technician, you’ll be equipped to deal with just about any A/C job that finds its way to your service bay. First up is “Repairing Air Conditioners For Profit,” by master certified technician Gary Motley. This article deals with inspecting, cleaning, repairing, and maintaining roof-top units. Accompanying the story is the detailed checklist of operations that Motley performs as part of his comprehensive A/C service. A companion piece, “Storm Repair Tips For Air Conditioners,” by Tony Yerman, describes how even units that appear ripe for retirement may sometimes be repairable. Yerman feels that too many shops are too quick to replace, rather than fix, air conditioners. But if you can save an RV owner’s unit, you’ll not only demonstrate

your value as a crack technician, you’ll also make a customer for life. And A/C repair can be just as profitable for shops as selling a new unit, Yerman says. Thanks also go to Tony for his contribution to this issue’s “Top This!” column. He and his team were tasked with fixing the brandnew but constantly overheating generator in a TV station’s news truck--and fast. They tried all of the usual things and got nowhere. And then Tony noticed that something literally wasn’t measuring up. While we’re on the topic of “Top This,” please send me your stories of unusual repair experiences and how you solved them. I know you’ve had at least one job in your career that made you either laugh or cry. What were the strangest symptoms you ever faced, and what did it take to solve them? E-mail your anecdotes to mashreve@rvda.org.

Mary Anne Shreve Editor 3930 University Drive Fairfax, VA 22030 mashreve@rvda.org (703) 591-7130 x117

RV Technician Advisory Board Randy Biles, Pikes Peak Traveland, Inc. Tom Fribley, Fribley Technical Services, Inc. Ellen Kietzmann, Blue Ox Gary Motley, Motley RV Repair Steve Savage, Mobility RV Service Page 4


Air Conditioner Repair

Repairing Air Conditioners For Profit By Gary Motley, Master Certified Technician Servicing rooftop air conditioners is one way to increase average dollars per RO. Rooftop units need to be maintained properly, just like a home air conditioning system. The major difference is that homes generally have a split system, while RV rooftop air conditioners are selfcontained like window units. Manufacturers of rooftop air conditioners warn against breaking into the system to evacuate and recharge. If the system needs recharging, it’s time for a new unit. Dispose of defective units following local and federal EPA regulations. This article will deal with servicing functioning air conditioners. Like a good sales person, a good service advisor should sell air conditioning service. Service advisors do their customers a favor by making them aware of the need for periodic maintenance. After all, what customer wants to be in the middle of Florida in July when the air conditioner conks out? Some ideas to help promote this service:

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* Place a sign at the service desk about the importance of rooftop air conditioner maintenance. * Add the item to your menu. * Include it in your service sales brochure. * Display props such as clean and dirty filters; a copy of the check sheet to show the complexity and details of a proper procedure; and before-and-after pictures of intake and return air separation, evaporator, and return air grill. * Give customers copies of the completed checklist at pickup and tell them the documentation can help increase their RV’s resale value. This must be a team effort between service advisor, techs, and parts department. The parts department needs to have in stock the gaskets, air filters and retainers, and shrouds that might be needed. Refer to the tool and suppy lists on page six for additional materials.


Supply List * Coil cleaner ……………………………….To clean nicotine, grease, etc. from fins; read directions—can damage surfaces * Commercial grade cleaner * Plastic sheet and tape…………………..To protect RV’s interior and controls * Rags………………………………………...For cleaning * Oil …………………………………………..Used on some models to oil the fan motor * Rectorseal or equivalent ……………….To separate intake and exhaust * Expandable foam ………………………...To separate intake and exhaust * Foil tape……………………………………To separate intake and exhaust; used on evaporator compartment * Parts return bags ………………………..For returning old parts to customer * Sealant……………………………………..Used around evaporator lines * Oil can w/ light-weight oil

Tool List * Large square polyethylene bucket * Compressed air * Air wand * Vacuum cleaner * Fin comb * Two calibrated thermometers * Humidistat and wall thermometer * Common hand tools * Ladder * Utility brush assortment (chip brushes)

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Now use the checklist on page 10 to perform the service according to the following instructions. The instructions may vary slightly based on your shop culture and the actual type of air conditioner. These instructions essentially follow the checklist, which is designed to help the tech perform the job quickly and efficiently. Identification. Information on the model and location of the air conditioner unit should be collected and documented any time service is performed on an RV. For this type service it may not be necessary to write down model and serial number. Enter the RV and perform these preliminary steps: Remove interior plenum/grill and inspect. The first step in any job is to inspect the work area for damage or anything improper. These could represent up-sell opportunities for the service advisor. The interior plenum needs to be removed to access the controls and filters and to work on the ducting. Cover/protect interior of RV. Cleanliness should be a top priority. Hang or install interior catch bucket. Hang it under the air conditioner to catch fin cleaner and falling debris. Some fin cleaners have a high acid content and can cause damage. Cover or protect PC boards/control. Remove or cover the control box to protect it from fin cleaner and falling debris. I once had to pay for a replacement control board because I forgot to do this.

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On the roof, inspect and remove the exterior shroud. This may be an up-sell for the service advisor. Be careful not to damage the shroud while removing it, and store the mounting fasteners properly. Take care not to lose or damage any removed items that will be reinstalled. Fin guard installed/ new-style shroud. This is another possible up-sell for the service advisor, since most shrouds without fin guards are old enough to need replacing. Inspect, straighten, and clean condenser fins. A quick visual inspection should determine if the condenser needs more than cleaning. Many experts advise replacing the air conditioner when 70 percent of the fins are damaged. If there’s major fin damage, the service advisor will need to contact the customer and either sell him a new air conditioner or increase the fee for the service. Use compressed air and the air wand to carefully clean fins. Be careful when using coil cleaner: I have seen it drop down the side of an RV and cause damage. Use a fin comb to straighten the fins. Inspect both sides of the condenser and comb out as necessary. Access the evaporator fins: This requires removing the cover over the evaporator fins so they are totally exposed. Inspect, straighten, and clean the evaporator fins. Clean and straighten the evaporator fins as described in the condenser cleaning section. Take care to keep the controls and inside of the RV as clean as possible.


Clean evaporator fin compartment. Use a vacuum cleaner and utility brushes to clean as much of the evaporator compartment as can be reached from the top.

Reinstall exterior shroud and fin cover. Give everything on the roof a final inspection and install the shroud.

Check condensate drains for clear/open. When condensation doesn’t drain, it can build up and run into the RV interior or ceiling.

Remove interior coverings, protectants, and catch bucket. Take care to keep everything clean.

Check that evaporator lines are sealed into compartment. The factory-installed sealant where the refrigerant lines come into the evaporator compartment sometimes shrinks, allowing outside air into the evaporator compartment. When this happens, the evaporator can freeze up or cause more condensation. It may be necessary to add more sealant or adjust the factory sealant. Replace evaporator cover and seal thoroughly. Check all joints so no outside air can get into the evaporator compartment. Use foil tape and sealant to completely seal the evaporator compartment. Little gaps can let outside air into the compartment or cool air out. Spend a couple of extra minutes checking this thoroughly and repair as needed to increase the efficiency. Inspect base pan for cracks and damage. This happens infrequently, but check to make sure. Oil the fan motor at oil ports. Occasionally the oil ports on the fan motor will be clearly visible. Put some lightweight oil in them.

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Inside the RV:

Torque mounting bolts. The gasket should be at about half of the original oneinch thickness. (This means the gasket should be torqued to about ½ inch.) Some air conditioners have a tab built onto the base pan to indicate how tight to torque the mounting bolts. There may be an opportunity to sell a gasket and installation if you feel a new one is needed. Separate and seal intake/return air. This is a crucial step. The intake and return air often don’t get separated when air conditioners are installed, creating major inefficiency. Inspect this very carefully and use expandable foam, foil tape, and rector seal to separate them. With ducted models, make sure the cold air is going into the ducts, not the ceiling. Seal the ducting off as necessary to insure the air is directed properly. Inspect the base pan and inside plate for holes that may allow cold air to go into the ceiling or mix with the return. Wire holes in this area can also allow cold air to escape. Inspect direct discharge models and correct fluttering ducts. This step may take a few minutes. Replace or clean intake filter(s). It’s a judgment call whether to replace or clean the filters. I’ve seen new filters included in the price of an air conditioner service.


If you clean them, do that job first so they’ll be dry when you’re ready to reinstall them. Clean interior ceiling and plenum. Assemble and install interior plenum, grill, controls. Put the interior pieces of the air conditioner back where they belong. The controls portion refers to direct discharge models. Clean work area and do a final visual inspection. Next comes taking temperature/amperage readings. Ambient temperature and relative humidity: Attach the humidistat and thermometer to the wall in the shop for easy access and visibility. Cool: intake/return Delta: With the fan speed on high, use two calibrated thermometers to determine the air temperature going into the return and coming out of the air conditioner at the closest outlet. Delta is the difference between the two. After 20 to 30 minutes, there should be about a 20-degree difference. High humidity and high ambient temperatures can cause the Delta to be less than 20 degrees. When the ambient temperature gets below 75 degrees, the compressor won’t work as efficiently. Heat: intake/return Delta: Turn the heat pump on and take readings in the same way as described in the COOL section. The heat pump won’t operate below 40 to 45 degrees ambient temperature.

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Amp draws: Using an amp meter, record the amp draws when the air conditioner is in the high cool and high heat modes. Be sure to turn off all other electrical draws in the RV if taking the amp draw at the main power cord. Determine the proper amp draw for the air conditioner you’re testing. This should be between 8 and 14 amps. The voltage in your supply should be nominally 115 volts. Low voltage will increase the amps. Technician notes: Make notes of anything of concern or interest. This is a very thorough rooftop air conditioner service, with a suggested flat rate of two to two-and-a-half hours, based on the culture of the shop. On the following page is the checklist I use when performing this air conditioner service. Feel free to contact me if you have questions or ideas. My email address is rvrepairs@aol.com.

Gary Motley is owner of Motley RV Repair in Oklahoma City. He is a master certified RV technician and a member of the RV Technician advisory board. He can be contacted at rvrepairs@aol.com.


A/C Service Checklist Customer ______________________ Coach______________________________ Date_______ A/C brand_________________ Model____________________ Serial_____________________ Ducted__________Direct discharge____________ Location in RV_________________________

* Remove interior plenum/grill and inspect

______

* Cover and protect interior of RV as needed

______

* Hang or install interior catch bucket * Cover and protect PC boards/control

______

* Inspect and remove exterior shroud

______

* Fin guard installed/ new-style shroud

______

* Inspect, straighten, clean condenser fins (advise if major)

______

* Access evaporator fins

______

* Inspect/ straighten/clean evaporator fins (as needed)

______

* Clean evaporator fin compartment as needed

______

* Check condensate drains for clear/open

______

* Check that evaporator lines are sealed into compartment

______

* Replace evaporator cover and seal thoroughly

______

* Inspect base pan for cracks/damage

______

* Oil fan motor at oil ports as needed

______

* Reinstall exterior shroud and fin cover

______

* Remove interior coverings/protectants/catch bucket

______

* Torque mounting bolts to ½ original thickness (use crush tabs) * Separate/seal the intake/return air * Replace/clean intake filter(s)

qty ______

____ ______

price ______ea______

______

* Clean interior ceiling and plenum as needed

______

* Assemble and install interior plenum/grill/controls

______

* Clean work area and do final visual inspection

______

Temperature/amperage readings Readings are taken on HIGH after approximately 20 minutes. Ambient temperature _______ F Relative humidity _______% A/C air temps Cool Intake ______ F Return ______° F Delta______ F Amp draw______Amps Heat Intake ______°F Return ______°F Delta______◦F Amp draw ______Amps NOTE: Acceptable temperature differential in A/C mode is 16 to 20 degrees; ambient temp and relative humidity affect differential.

Technician notes: ______________________________________________________________________ Page 10


Storm Repair Tips

Storm Repair Tips For Air Conditioners By Tony Yerman

I get a lot of calls at this time of year from customers wanting to know if their hail or storm-damaged air conditioner can be repaired. Many retail customers--including insurers--are concerned that air conditioners too often are replaced instead of repaired. I have some suggestions to address that concern and make a shop look like a real value to a customer.

Remove any debris and check that the fan motor moves freely. Late model units no longer have ports for oil or lubrication, so any resistance from bearings may require a motor replacement. Check the wiring next, making sure connections are good and that it hasn’t been chewed on or separated. Take a look at the capacitors for leakage or severe deterioration.

In most cases, a storm-damaged unit can be repaired. I know that the initial reaction is to simply replace it, since there’s profit in selling a new A/C. But there’s also profit in repair, and repairing things is what a shop is supposed to do. The profit margin can be just as good and even better for repairing as opposed to replacing.

Condensers are a hot topic (no pun intended). Hail wreaks havoc on them, smashing the fins. But smashed fins don’t mean the end of an air conditioner. Several tool suppliers offer a fin straightening tool to repair the damage. I’m sure some old timers have just pulled a comb out of their pocket and used it for the same thing. Does the repair look perfect? Not always, but then, I’ve seen a lot of brand-new A/C units with damaged condenser fins right out of the factory-packaged box. Occasionally the fins get a little damage during installation, but they can be straightened.

On the roof, look for obvious external damage such as smashed shrouds (plastic covers) or condensers. Shrouds are easy to replace and available from air conditioner manufacturers and even some aftermarket suppliers. If a mounting bolt or screw breaks, drill it out and replace it. It’s a good idea to apply a little penetrating oil on fasteners whenever you can before trying to remove them. After removing the shroud, inspect the workings for nests--mud daubers, birds, and even some rodents can get in and build nests that prevent the fan from turning. Sometimes they even use wiring or insulation from the unit to build their nests.

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Fix damaged air conditioners and maintain them for your customers and you’ll be demonstrating real value that will keep them coming back.

RVDA Service Consultant Tony Yerman is an Ohio-based master certified technician, repair specialist, and the author of the RV Damage Repair Estimator. He can be contacted at tyerman@rvda.org.


Towing Equipment

Maintaining The Safety And Value Of Towing Equipment By Ryan Thomas, Blue Ox

Flat towing is a quick and popular way to take a car when RVing. Most RV owners are so conscientious about maintaining their units that they rarely exceed their oil change schedule by more than a few miles. Taking care of a tow bar is just as important--and just as potentially costly if ignored.

The first step is the initial setup. Proper height alignment and connections are crucial to the performance and life of a tow bar and baseplate. The tow bar can’t be more than four inches higher on the motorhome side and never lower on the RV than the towed vehicle. If an extension is added for, say, a bike rack, it’s even more important that the tow bar not be at a severe angle. It’s all geometry and physics--the farther back you move the pivot point of the tow bar from the rear axle of the coach, the more vertical movement you get and the more leverage is applied to the receiver hitch, tow bar, and baseplate. It’s important to run the safety and electrical cables under the tow bar. Crossing the safety cables underneath the tow bar is the recommended method; should the tow bar become disconnected, the crossed cables will keep the vehicle straight and catch the tow bar rather than allowing it to drop and drag on the ground.

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Inspect the pins attaching the tow bar to the baseplate to make sure they’re in good condition. Pull them out and feel the surface to insure they’re not wearing. Check the retainer pins holding the main pin in place--make sure they still have a good strong resistance when you snap them in place to secure them. Don’t forget to also check the 5/8” pin that holds the tow bar to the motorhome receiver hitch. Replacement parts are cheap, so replace worn pins with genuine factory parts. Cleanliness is another important part of maintaining tow bars, which pick up a lot of dirt and road grime that can cause premature wear. If you use a lubricant such as WD-40 on the outside of the tow bar, you’ll pick up lots of road grime. Some customers think their tow bar is too stiff for them to use and spray down the joints and legs with a lube or grease. In most cases, doing this causes much more harm than good. The lubricant leaves a residue that acts like glue when driving down the road, and you’ll pick up more grime than if the


tow bar had just been left dry. If the bar needs lubrication, it’s best to use dry silicone spray and nothing petroleum-based. It’s also a good idea to wash the tow bar when washing the motorhome. Check to ensure collapsible tow bar legs latch properly and adjust them according to the manufacturer instructions. The two biggest contributors to premature wear on tow bars are loose bolts, which allow excessive movement between mating parts, and miss-adjusted leg latches, which allow too much fore/aft movement while towing. Some tow bars have a rubber boot that protects the inside legs from dirt and water. If a tow bar is “sticky” or the legs don’t slide in and out easily, follow these steps: Remove the small cable ties holding the rubber boots on the legs and slide the boots back. Wipe clean each inside leg and apply a light coat of multipurpose grease to insure smooth operation. Secure each boot back in place with an 8-inch nylon cable tie.

Tow bars with exposed legs require a closer watch, since dirt and grime can get into the latches and actually cause them not to latch properly. Clean these legs regularly to maintain proper function. Make these steps part of your regular maintenance schedule and you’ll get the most use and life from your tow bar.

Ryan Thomas is a service technician at Blue Ox. He performs tow bar service and installations at the company’s factory in Nebraska and at races and rallies nationwide. He also does onsite dealership service and sales training. He can be reached at ryanthomas@blueox.com and at 402.385.3051. Page 13


Regulatory Update

New EPA And CARB Rules For Gasoline Generator Installation By Tony Yerman

Starting this year, the Environmental Protection Agency (EPA) and the California Air Resources Board (CARB) have issued new regulations and requirements for evaporative fuel systems on gasoline engines. The regs cover Class 2 engines larger than 225cc. As of January 1, 2012, Class 1 engines smaller than 225cc will be included. The main purpose of the regulation is to have any gasoline engine, installed in any RV, equipped with the same type of evaporative systems found in larger automotive applications. All gasoline engines pose a threat to the environment, no matter what their size. RV on-board generators are affected How does the regulation affect RV dealers and service centers? Though it covers all gasoline engines, the concern in our industry is mainly with the on-board gasoline generator and the fuel system that feeds it. Generator and RV manufacturers are required to comply by obtaining an Executive Order/Evaporative Certificate, supplied by CARB and EPA. This means that new generators installed

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in new units must comply via the generator manufacturer and OEM. At present, LP vapor and diesel generators are not required to follow the regulation. Most gasoline-powered motorized units comply automatically, as the chassis fuel system is already compliant. A compliant generator must be installed. Dieselmotorized units with gasoline generators must have a generator and fuel system that is compliant. Fuel delivery systems must also comply The big issue is towable units and, more specifically, toy haulers or sport utility type vehicles. Many of these trailers are outfitted with an on-board generator as well as a fuel station for other equipment, like ATVs. The regulations cover the fuel station as well. The generator manufacturer and the OEM must be certified to install generators and fuel systems, but how about RV dealers who install generators that they purchase from an aftermarket distributor? A dealer or service center doesn’t need to be certified but is responsible for


installing a certified system. Most generator manufacturers do not make fuel tanks or fuel delivery systems, and every component of the generator and fuel delivery system must be compliant with no conflicts between systems or components. If one part of the system is non-compliant, the whole system is non-compliant. Most new generators sold today are compliant with EPA/CARB regs and any additional equipment needed is readily available through the supplier. Check your aftermarket distributor catalog. You may have to look a little harder to find fuel tank manufacturers. Transfer Flow and ECI Metal Fabricators are a couple that supply compliant tanks. If you don’t comply, you face fines of more than $30,000 per installation.

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For more information Go to EPA’s site at www.epa.gov and look for Code of Federal Regulations (CFR) 40, Subchapter U, part 1060, Control of Evaporative Emissions from New and InUse, Non-Road and Stationary Equipment. For CARB regulations, go to http://www.arb.ca.gov/msprog/offroad/sore/ sorectp/sorectp.htm. This link takes you directly to the applicable regulations. Don’t take chances. To be completely certain of what you need to do, have your attorney look into the matter. RVDA Service Consultant Tony Yerman is an Ohio-based master certified technician, repair specialist, and the author of the RV Damage Repair Estimator. He can be contacted at tyerman@rvda.org.


TOP THIS!

How NOT To Install A Generator By Tony Yerman

The brand new generator would overheat and shut down after 15 minutes. But everything—electrical connections, settings, voltage and frequency outputs—checked out. Then the tech noticed something odd about the housing box…

I once got a call from a local TV station representative who said that a new generator installed in one of the news vans kept shutting down after running for about fifteen minutes. The rep had taken it back to the installing shop, which claimed the problem had to be the way the TV station was using the generator. I told the rep to bring it to me.

The TV station folks brought the truck over and were very concerned about how long it would take to get it back. Apparently, the installing dealer had kept the truck for quite some time and claimed there was nothing wrong. I told them I couldn’t say how long until I knew what we were up against. I put a “unit down, rush” on it and sent it back to my service department. Boxed in At first look, everything seemed normal. The generator was the kind that comes in its own box and had been packed into a very small compartment in the side of the van. Our tech first checked the oil and all electrical connections, incoming and outgoing. We then got out the unit’s manual and started the unit up to check settings and measurements. The unit seemed to run smoothly, and voltage and frequency Page 16

outputs were normal. We applied a load, which the unit handled well, and let it run for a bit, since the complaint was that the unit would work for about 15 minutes and then shut

down. Sure enough, after fifteen minutes it died. It had overheated. Sizing up the situation The first thing I do in these cases is to ensure all venting is correct and unobstructed. It was then that I noticed something peculiar--there was an outlet vent, but it wasn’t very big. Referring to the installation manual, I realized that not only was the outlet too small, but the entire housing box was smaller than the book claimed it should be. At this point, I had to call the TV station to tell them what we found and what we thought needed to be done. And it wasn’t going to be a simple fix. The van’s original generator was a different brand with an entirely different style and setup configuration. The dealer who sold the new installation told the TV station he was doing them a big favor by installing this


more efficient, quiet, and compact unit. The problem was, the new unit didn’t fit the original unit’s compartment in the van. Instead of resizing the compartment, the shop resized the generator. This was not a good idea. Changing the box configuration and size altered the cooling system. It was an air-cooled unit and relied on an adequate air flow. Without proper cooling, the generator would overheat and shut down. Out of warranty The first thing that had to be done was to replace the generator box. The generator manufacturer wouldn’t take the unit back, nor would they warranty the unit because of the improper installation. There was also a question about the dealer’s generator dealer status. It looked as though it would take a court order to get any action from the selling dealer. The TV station was losing money without the unit and needed to remedy the situation in the fastest and least expensive way possible. The original generator was no longer available and any replacement unit would require compartment modification. We decided to rebuild the new generator and modify the compartment. This wouldn’t be simple, as there were other pieces of equipment mounted in the vehicle that would have to be relocated and remounted.

Taking a different route The entire generator box was ordered and shipped overnight. While waiting for parts, work began on the truck and the compartment. About twelve labor hours later, the compartment and van were ready for the new generator box. The generator had been removed from the modified box and now awaited its new housing. Once the parts arrived, we went to work rehousing the generator and installing it in the van. The next problem was routing the engine exhaust and creating a duct to route the heat exhaust from the unit and around the springs and jack under the van. Ignorance can be expensive The entire repair cost the TV station around $3,500 and took about three days. This would not have been necessary if the dealer who sold and installed the generator had read the installation guide and made modifications to the van instead of the generator. Get educated, or pay the price. The original dealer eventually lost in court and had to pay for repairs and to reinstate warranty coverage. RVDA Service Consultant Tony Yerman is an Ohio-based master certified technician, repair specialist, and the author of the RV Damage Repair Estimator. He can be contacted at tyerman@rvda.org.

Send us stories of your strangest or most challenging Send us s stories of your strangest repairs for RV Technician’s new column, “Top This!” or most challenging We’d like to share your experiences with other repairs for RV Technician’s new column, “Top” readers. E-mail the editor at mashreve@rvda.org. hreve@rvda.org. Page 17


NEW PRODUCTS

New RV Buffing Compound When an RV's wheels and chrome shine, the entire rig looks brand new. Shurhold's Buff Magic is formulated with jeweler's rouge to be a metal polish and a buffing and polishing cream. With each pass of a buffer or hand polishing, the proprietary abrasives break down smaller and smaller, creating a compound that can work a finish from very dull to ultra glossy. Additionally, the elimination of switching products saves users time and money. Buff Magic is also an ideal metal cleaner and polisher for steel, aluminum, brass, bronze, copper, gold, and other precious metals. It's formulated to be user-friendly, whether buffing by machine or hand. Shurhold is dedicated to helping owners maintain their RV’s value. It manufactures specialty care items and accessories to clean, polish and detail.

Computer-controlled Jumper Cables Energy Safe Technologies, Inc. has expanded its line of computercontrolled PowerSafe™ jumper cable

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systems to include a suite of 25-foot professional-grade cables that fit the connectors used on many tow and service trucks. The jumper cables are the world’s first to use a computerized control module that prevents surges, short circuits, and spark-induced explosions that can occur when a vehicle is jump-started. They increase/decrease current flowing through the cables during a jump-start, preventing surges that can cause extensive damage to on-board electronics. In addition, the built-in computer prevents power from flowing through the cables until they’ve been connected correctly. The cables can be connected backwards or the leads can touch each other or another metal object, and electricity will not flow until the error has been corrected. The computer module informs operators of the error.

Tongue Weight Capacity Increased Cequent Performance Products’ new Reese brand receiver hitches, class III and above, will carry an increased capability for tongue weight ratings. The increased capacity will also be extended to select existing receiver hitches. The Reese improvements have raised the capacity from 10 percent to 15 percent of GTW, a 50 percent improvement.


The RVDA Education Foundation proudly recognizes the following

CONTRIBUTORS: Additional/New Contributions Received 7/01/09-7/01/11 Ace Fogdall, Inc. Affinity RV Service Sales & Rentals All Seasons (CA) Alpin Haus Altmans Winnebago American RV Best Value RV Bill Plemmons RV World Bill Thomas Bill Thomas Camper Sales, Inc. Blue Ox Byerly RV Center Camperland of Oklahoma, LLC Campers Inn of Kingston Candys Campers Capital R.V. Center, Inc. Carolina Coach & Camper Carpenter’s Campers, Inc. Circle K RVs, Inc. Coach-Net Crestview RV Center Curtis Trailers, Inc. Diversified Insurance Management, Inc. Dixie RV Superstore Bill & Kristin Fenech Ron & Lisa Fenech Foundation Floyd's Recreational Vehicles Folsom Lake RV Center Greeneway, Inc. (Route 66 Dealer) Hayes RV Center Hemlock Hill RV Sales, Inc. Ronnie Hepp Hilltop Trailer Sales, Inc. Holiday World of Houston Horsey Family Memorial Fund J. D. Sanders, Inc. Jamatt RV Sales Jayco, Inc. La Mesa RV Center, Inc. Lloyd's I-10 RV Center, Inc. Manteca Trailer & Camper Maxxair Vent Corporation MBA Insurance, Inc. McClain's RV Superstore Craig Mellor Mike Molino Momot Trailer Sales Rose Zella Morris Motley RV Repair Myers RV Center, Inc. Newmar Corporation Noble RV, Inc. Northern Wholesale Supply, Inc. Open Range RV Company Pan Pacific RV Centers, Inc. Paul Evert's RV Country, Inc. PleasureLand RV Center, Inc. PPL MotorHomes Protective RCD Sales Company, Ltd. Redex Reines RV Center, Inc. Rich & Sons Camper Sales Rivers Bus & RV Sales RV World Recreation Vehicle Center RVDA of Canada RV's Northwest, Inc. Sonny's RV Sales, Inc. Spader 20 Group #20 Stag Parkway Steinbring Motor Coach Tacoma RV Center Tarpley RV The Trail Center Tiffin Motor Homes, Inc. U-Neek RV Center United RV United States Warranty Corporation Wilkins R.V., Inc. Winnebago Industries, Inc. The Kindlund Family Scholarship Endowment

Page 19

Received 7/01/09-04/15/11

S

$5,200 $2,000 $49 $4,000 $10,000 $250 $1,000 $2,550 $500 $500 $1,870 $16,000 $500 $2,000 $50 $1,000 $100 $1,000 $500 $10,417 $1,000 $1,000 $2,200 $5,000 $10,000 $25,000 $250 $2,500 $13,300 $1,350 $2,000 $250 $41 $5,000 $13,500 $250 $500 $2,500 $10 $50 $500 $250 $1,100 $5,000 $100 $150 $250 $25 $1,600 $1,750 $5,000 $150 $250 $2,250 $500 $3,570 $5,350 $100 $33,817 $1,000 $3,000 $4,500 $2,000 $1,000 $500 Cdn $25,000 $50 $1,000 $1,700 $5,250 $250 $500 $250 $100 $2,500 $200 $1,000 $1,000 $4,200 $1,000 ----

Total Received $36,600 $6,000 $37,049 $15,500 $50,500 $5,925 $1,000 $5,050 $500 $20,500 $12,750 $16,000 $3,350 $27,422 $1,050 $6,000 $100 $2,000 $5,500 $199,917 $1,500 $7,000 $10,000 $15,000 $50,000 $50,000 $250 $7,000 $13,300 $5,100 $6,000 $300 $1,540 $25,000 $66,000 $2,250 $500 $17,500 $3,510 $15,050 $4,000 $2,250 $12,100 $30,000 $100 $10,736 $750 $25 $7,940 $2,000 $115,000 $150 $750 $2,500 $36,500 $25,000 $75,350 $100 $87,845 $1,250 $3,000 $20,025 $2,000 $15,850 $1,800 Cdn $150,000 $9,050 $2,000 $1,700 $32,100 $250 $500 $4,500 $1,100 $16,000 $200 $1,000 $3,250 $12,100 $26,000 $270,000

Last Contribution Received 11/1/2010 8/30/2010 7/10/2010 9/30/2010 1/19/2011 1/25/2011 12/3/2010 10/20/2010 10/26/2010 10/26/2010 4/22/2010 12/20/2010 7/2/2010 7/12/2010 8/18/2009 12/7/2010 3/31/2011 12/7/2010 10/21/2010 11/24/2009 12/17/2010 12/7/2010 5/19/2010 8/18/2010 7/29/2010 6/16/2010 10/19/2010 12/23/2009 12/3/2010 1/28/2011 9/16/2010 10/20/2010 6/23/2010 8/24/2010 10/19/2010 7/21/2009 12/3/2010 2/19/2010 12/30/2010 7/27/2009 6/21/2010 6/25/2010 10/19/2010 6/23/2010 10/25/2010 10/18/2010 7/1/2009 10/25/2010 12/7/2010 12/16/2010 12/8/2010 10/18/2010 7/7/2009 4/6/2011 10/21/2010 4/12/2011 2/10/2011 8/12/2010 12/7/2010 6/16/2010 12/29/2009 12/20/2009 11/5/2009 9/28/2010 12/10/2010 10/13/2009 7/6/2009 12/17/2009 3/30/2011 11/12/2010 10/14/2010 7/6/2010 9/9/2010 10/29/2010 3/4/2010 3/17/2010 9/9/2010 8/24/2010 12/03/2010 1/7/2011 ---


RV Technician Certification Preparation Course Every RV Technician Can Have Access to Individual Self‐Study Training and Certification Preparation Interactive-Multimedia, Online Format • Combines text, audio, graphics, and video, with mentor-led technician community forum – all content is online (no extra books or handouts needed)

Corresponds to RV Certification Test Sections

Developed by RVIA Available through the RV Learning Center

• Propane; Electrical; Plumbing; Brakes, Suspension & Towing; Appliances; Generators; Hydraulics; Exterior; Interior; Expandable Rooms; Miscellaneous (Welding Safety, Customer Care) • Fulfills 40 hour RVDA-RVIA RVDA RVIA RV Service Technician recertification requirement

Personal Progress Tracking • Automatically tracks individual’s progress • Quizzes after each chapter and section with immediate feedback • 205 question assessment that is similar to the RV technician certification test

Registration Information

per Technician*

Company: Address:

.

City/State/Zip:

.

Phone:

$249

Fax:

*Quantity discounts available when registering four or more technicians at one time. E-mail info@rvda.org or call 703-591-7130 for details. Note: Registration fee subject to change without notice.

.

In order for the program to function properly, each technician MUST have their own personal e e-mail mail address that only they have access to to. Sign up the following RV technicians from our dealership: Name:

.

Important:

E-mail:

.

Name:

.

E-mail:

.

Name:

.

E-mail:

.

• The RV Technician Certification Preparation course offers RV service technicians the means to prepare for certification through an online, self-study format. A computer p with high-speed g p Internet is needed to access the course. • Visit www.rvtechnician.com for information about the RVDA-RVIA RV Service Technician certification program. The certification testing fee is not included in the course registration fee. • Registration gives the technician 365 days to complete the course by achieving 80% or higher on the final practice test test. The technician should plan for certification testing within the enrollment period as course extensions are not available.

.Send progress reports to the following supervisor: Name:

Title:

.

E-mail:

.

Method of Payment All registrations must be pre-paid in U.S. funds.

□ Check Enclosed: Make Check Payable to: The RV Learning Center □ Send Invoice (RVDA Members Only) □ VISA □ MC □ AMEX □ DISCOVER C Cardholder’s Name: Acct. Number: Cardholder’s Signature: Billing Address:

Page 20

. Exp.:

.

Security Code:

. .

Return completed form to: RVDA I 3930 University Drive I Fairfax, VA 22030 I Ph. (703) 591-7130 I Fax (703) 359-0152 www.rvlearningcenter.com I info@rvda.org


Online Training with FRVTA’s

DISTANCE LEARNING NETWORK FRVTA–RV Learning Center Partnership

The DLN offers online training for:

$995 per year for each dealership location Over 40 sessions available, 24 hours a day, seven days a week with full access to training through July 31, 2011!

• RV Technicians – An excellent resource for techs preparing for certification and techs seeking recertification continuing education credits. • Service Writers/Advisors – Useful for new staff and experienced personnel preparing for the RV Learning Center’s Service Writer/Advisor certification.

The DLN offers your dealership: • Training at your dealership • Together as a group • Without any travel time or expenses

• Greeters/Receptionists – Emphasizes customer interaction and service.

• On a pace determined by your needs • At times to suit your operation • For one fixed price of $995 for the subscription term

• Dealers/GMs – Features hot topics, including Lemon Laws, LP gas licensing issues, and Red Flags.

DEALERSHIP REGISTRATION Company Name: ____________________________________________________________________________________________ Address: ____________________________________________ City:________________________ State: ____ Zip: __________ Phone: ______________________________________________ Fax: __________________________________________________ Mentor Name: ________________________________________________________ Phone: ______________________________ E-mail (at dealership) : __________________________________________________ Fax: ________________________________

**High speed internet access required. RVIA Service Textbooks not included** _____ location(s) at $995 each = payment due: $__________________ (select payment method below)

PAYMENT METHOD

(complete lower section & mail or fax to):

PAY BY CHECK OR MONEY ORDER

PAY BY VISA, MASTERCARD

Florida RV Trade Association, 10510 Gibsonton Drive, Riverview, FL 33578, (813) 741-0488, Fax: (813) 741-0688 Name on Credit Card: ______________________________________________________________________________________ Card Number: ________________________ Security Code: _________ Expires: ______________________________________ Card Billing Address: ________________________________ City:________________________ State: ____ Zip: __________ Card Holder Signature: ______________________________________________________________________________________

For more information, call (386) 754-4285 or go to https://www.fgc.edu/rv-institute.aspx Page 20


10th Edition Service Management Guide (Flat Rate Manual) The expanded Service Management Guide offers over 100 pages of average work unit times for the most basic service functions performed by competent RV technicians. th

The 10 Edition of the Service Management Guide offers extensive updates and additions provided by dealers, service managers, and technicians.

It also offers all new Service Check Sheets that provide a valuable reference for service managers and technicians.

It is a great tool for the service department when working with extended service contracts.

The Service Management Guide is also available in CD-ROM.

The Service Management Guide is designed to provide reasonable guidance relative to the time required for competent technicians to complete assigned tasks. It is an important part of the service management system, but it is not intended to be the sole determinant of prices or rates charged in that sale of service. Manual or CD-ROM: RVDA Members $164.95

Non-Members: $330.00

Manual and CD-ROM: RVDA Members $275.00

Non-Members: $550.00

Order Online at http://www.rvlearningcenter.com - prices are subject to change without notice

Order Form – 10th Edition Service Management Guide (Flat Rate Manual) Name:____________________________________________________________________________________________ Company Name:___________________________________________________________________________________ Address:_________________________________________________________________________________________ City:__________________________________________State:________Zip Code:______________________________ Phone:___________________________________Fax:______________________E-mail:________________________ ___RVDA Member

___Non-RVDA Member Manual - # of Copies:___ CD-ROM - # of Copies:____

Method of payment (Please check one) ___Check enclosed (Made Payable to The RVDA Education Foundation) ___Send an invoice (members only) Credit Card: __Visa __Master Card __American Express Card Number:____________________________________________Expiration Date:___________________________ Name on Card:_____________________________________Signature:______________________________________ Billing Address:_________________________________________________________Billing Zip:_________________

RVDA, 3930 University Dr, Fairfax, VA 22030 (703) 591-7130, Fax (703) 359-0152, Email: info@rvda.org Page Page 22 22


RV Learning Center Scholarship Program FACT SHEET AND APPLICATION: 2011-2012 ACADEMIC YEAR About This Scholarship

Requirements*

Enclose with Application:

The RV Learning Center’s Scholarship Program awards $2,500 scholarships to deserving college undergraduate students majoring in business, finance, economics, accounting, or other RV industry-related subjects. A factor for awarding the scholarship may be an applicant’s background of RV industry employment or a desire to work in the RV business after completing postsecondary education. It is made possible through the generosity of the Newt and Joanne Kindlund Family.

• Must be a rising sophomore, junior, or senior college undergraduate student.

1. An official copy of your most recent college transcript. 2. A copy of your SAT/ACT scores. 3. An essay of not more than 500 words on “My Goals and Objectives in College.” 4. A list of extra curricular activities, honors, etc. 5. A copy of your FAFSA form (available at your school or at www.fafsa.ed.gov). 6. Two photos (digital preferred) for publicity (only used if candidate receives scholarship).

Eligibility Requirements We will award the scholarships to RVrelated company employees or their dependents based on a series of factors. Dealer principals and their dependents are not eligible.

• Must complete an essay on their goals and objectives for attending college. • Must submit a completed Free Application for College Student Aid (FAFSA) form. The form is available at: www.fafsa.ed.gov/fotw1112/pdf/PdfFafsa11-12.pdf, or may be completed online at: www.fafsa.gov. • Must demonstrate the ability and willingness to fund a portion of their educational expenses on their own. • Must be accepted into an accredited four-year college or university as a condition of receiving the scholarship. • Must have a 2.8 or better cumulative grade point average, and a 1050 minimum SAT score (1575 minimum on the 2400 point scale). A minimum ACT composite score of 22 is also acceptable. *All requirements must be met by the application deadline.

Submit application packet to: The RV Learning Center 3930 University Drive Fairfax, VA 22030 or fax to: (703) 359-0152, or by e-mail to info@rvda.org

Applicant’s Name: ________________________________________________________________________________________ Address: ____________________________________________________________________________________________________ Phone: ______________________________________________ E-mail: ______________________________________________ Sponsoring RV-related Company: ________________________________________________________________________ Address: ____________________________________________________________________________________________________ Phone: ______________________________________________ E-mail: ______________________________________________ High School:__________________________________________________ Year Graduated: __________ SAT/ACT Score: ____ Address: __________________________________________________________________ Phone: __________________________ College Attending in 2011-2012: __________________________________________________________________________ Address:__________________________________________________________________ Major: __________________________ Have You Been Accepted?: ______ If No, When Do You Expect to Be? ____________ College Credits Completed: ________ College GPA: ______ Estimated College Expenses (One Year): $ __________ Are You Employed? No

% to Be Covered by Self/Family: _________%

l Yes l Employer: ________________________________________________________________

How Long/When?____________________________________________________________________________________________ By signing below, I indicate that I have read the fact sheet that accompanied this application and that I meet the eligibility criteria specified for scholarship applicants. Signature: ________________________________________________________________________________________________ Deadline: June 6, 2011. To be considered, all application materials must be received by the deadline. For more information and to download additional applications, visit www.rvlearningcenter.org or e-mail info@rvda.org. Page 23


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