April/May 2011 RV Technician

Tow Bar Safety

Getting the most from your

equipment

page 12

December/January

2011

February/March 2011

AApprriill//MMaayy 22001111

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

Storm damage repair tips page 11

Maintaining tow equipment

page 12

5 Repairing Air Conditioners For Profit

11 Storm Repair Tips For Air Conditioners

12 Maintaining The Safety And Value Of Towing Equipment

14 New EPA/CARB Rules For Gas Generator Installations

16 How NOT To Install A Generator

DEPARTMENTS

3 Board of Directors

4 From the Editor

18 New Products

February/March 2011

BODY REPAIR

EXTERIOR REPAIR

HOT PRODUCTS

Diesels

TOP THIS!

Certification

page 20

Air conditioner repair

page 5

New regs for gas generators

page 14

AIR CONDITIONERS

STORM DAMAGE

EQUIPMENT

GENERATORS

TOP THIS!

April/May 2011

Director Tim O'Brien Circle K RVs, Inc. Lapeer, MI (810) 664-1942 [email protected] Director Randy Packard Natl Assn of RV Parks & Campgrounds/Pine Acres Family Camping Resort Oakham, MA (508) 882-9511 [email protected] Director Steve Plemmons Bill Plemmons RV World Rural Hall, NC (336) 377-2213 [email protected] Director Jim Sheldon Monaco RV, LLC Rancho Mirage, CA (760) 883-5556 [email protected] Director Tom Stinnett Tom Stinnett RV Freedom Center Clarksville, IN (812) 282-7718 [email protected] Director Ed Thor Coach-Net Lake Havasu City, AZ (928) 855-2860 [email protected] Director Brian Wilkins Wilkins R.V., Inc. Bath, NY (607) 776-3103 [email protected]

RVDA LEARNING CENTER BOARD OF DIRECTORS

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

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

Director Mick Ferkey Greeneway, Inc. Wisconsin Rapids, WI (715) 325-5170 [email protected] Director Eleonore Hamm RVDA of Canada Richmond, BC (604) 204-0559 [email protected] Director Andy Heck Alpin Haus Amsterdam, NY (518) 842-5900 [email protected] Director Jeff Hirsch Campers Inn of Kingston Kingston, NH (603) 642-5555 [email protected] Director Rick Horsey Parkview RV Center Smyrna, DE (302) 653-6619 [email protected] Director Newt Kindlund Kindlund Investments Winter Park, FL (407) 628-4211 [email protected] Director Matthew Miller Newmar Corporation Nappanee, IN (574) 773-2381 [email protected]

Chairman Jeff Pastore Hartville RV Center, Inc. Hartville, OH (330) 877-3500 [email protected] Vice Chairman Dan Pearson PleasureLand RV Center, Inc. St. Cloud, MN (320) 251-7588 [email protected] Secretary/Treasurer Bill Koster Protective St. Louis, MO (636) 536-5704 [email protected] President Mike Molino, CAE RVDA Fairfax, VA (703) 591-7130 [email protected] Director Bob Been Affinity RV Service Sales & Rentals Prescott, AZ (928) 445-7910 [email protected] Director Randy Biles Pikes Peak Traveland, Inc. Colorado Springs, CO (719) 596-2716 [email protected] Director Debbie Brunoforte Little Dealers, Little Prices Mesa, AZ (480) 834-9581 [email protected]

Page 3

RVDA EDUCATION FOUNDATION STAFF

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

FROM THE EDITOR

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 brand-

new 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

[email protected].

Mary Anne Shreve Editor 3930 University Drive Fairfax, VA 22030 [email protected] (703) 591-7130 x117

Turn Up The Heat On Air Conditioner Repairs

April/May 2011

Page 4

RV Technician Advisory Board

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 self-

contained 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:

* 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.

Air Conditioner Repair

Repairing Air Conditioners For Profit

By Gary Motley, Master Certified Technician

Page 5

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)

Page 6

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.

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.

Page 7

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.

Check condensate drains for clear/open.

When condensation doesn’t drain, it can

build up and run into the RV interior or

ceiling.

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 light-

weight oil in them.

Reinstall exterior shroud and fin cover.

Give everything on the roof a final

inspection and install the shroud.

Inside the RV:

Remove interior coverings, protectants,

and catch bucket. Take care to keep

everything clean.

Torque mounting bolts. The gasket

should be at about half of the original one-

inch 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.

Page 8

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.

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

[email protected].

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 [email protected].

Page 9

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

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.

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.

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.

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.

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.

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 [email protected].

Storm Repair Tips

Storm Repair Tips For Air Conditioners

By Tony Yerman

Page 11

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.

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

Maintaining The Safety And Value Of Towing Equipment

By Ryan Thomas, Blue Ox

Towing Equipment

Page 12

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 [email protected] and at 402.385.3051.

Page 13

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

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. Diesel-

motorized 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

New EPA And CARB Rules For Gasoline Generator Installation

By Tony Yerman

Regulatory Update

Page 14

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.

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 In-

Use, 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 [email protected].

Page 15

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

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 set-

up configuration. The dealer who sold the

new installation told the TV station he was

doing them a big favor by installing this

TOP THIS!

How NOT To Install A Generator

By Tony Yerman

Page 16

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 [email protected].

Send us s stories of your strangest

or most challenging repairs for RV

Technician’s new column, “Top”

[email protected].

Send us stories of your strangest or most challenging

repairs for RV Technician’s new column, “Top This!”

We’d like to share your experiences with other

readers. E-mail the editor at [email protected].

Page 17

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 computer-controlled PowerSafe™ jumper cable

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.

NEW PRODUCTS

Page 18

S

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

Received

7/01/09-04/15/11

$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 ---

Page 19

RV Technician Certification Preparation CourseEvery RV Technician Can Have Access to IndividualSelf‐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• Propane; Electrical; Plumbing; Brakes, Suspension & Towing; Appliances;

Generators; Hydraulics; Exterior; Interior; Expandable Rooms; Miscellaneous (Welding Safety, Customer Care)

• Fulfills 40 hour RVDA RVIA RV Service Technician recertification requirement

Developed by RVIA Available through the RV Learning

Center

• Fulfills 40 hour RVDA-RVIA RV Service Technician recertification requirementPersonal 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

$249 per Technician*

Registration Information

Company:

Address: .

City/State/Zip: .

Phone: Fax: .

In order for the program to function properly, each technician MUST have their own personal e-mail address that only they have access to

per Technician*

*Quantity discounts available when registering four or more technicians at one time. E-mail [email protected] or call 703-591-7130 for details. Note: Registration fee subject to change have their own personal e mail address that only they have access to.

Sign up the following RV technicians from our dealership:

Name: .

E-mail: .

Name: .

E-mail: .

Important:• The RV Technician Certification Preparation course offers RV service technicians the means to prepare for certification through an online, self-study format. A computer with high-speed

without notice.

Name: .

E-mail: .

.Send progress reports to the following supervisor:

Name: Title: .

E-mail: .

p g pInternet 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 The

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

Method of Payment

or higher on the final practice test. The technician should plan for certification testing within the enrollment period as course extensions are not available.

Cardholder’s Name: .Acct. Number: Exp.: .

Cardholder’s Signature: Security Code: .

Billing Address: .

Return completed form to: RVDA I 3930 University Drive I Fairfax, VA 22030 I Ph. (703) 591-7130 I Fax (703) 359-0152www.rvlearningcenter.com I [email protected]

FRVTA–RV Learning Center Partnership$995 per year for each dealership locationOver 40 sessions available, 24 hours aday, seven days a week with full accessto training through July 31, 2011!

The DLN offers your dealership:

• Training at your dealership

• Together as a group

• Without any travel time or expenses

• On a pace determined by your needs

• At times to suit your operation

• For one fixed price of $995 for the subscrip-tion term

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):

q PAY BY CHECK OR MONEY ORDER q 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

Online Training with FRVTA’s

DISTANCE LEARNING NETWORKThe DLN offers online training for:• RV Technicians – An excellent resource for

techs preparing for certification and techsseeking recertification continuing educa-

tion credits.

• Service Writers/Advisors –Useful for new staff and experi-enced personnel preparing for theRV Learning Center’s Service

Writer/Advisor certification.

• Greeters/Receptionists –Emphasizes customer interaction and service.

• Dealers/GMs – Features hot topics, includ-ing Lemon Laws, LP gas licensing issues, andRed Flags.

DEALERSHIP REGISTRATION

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. The 10

th 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.

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: [email protected]

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.

Page 22

RV Learning Center Scholarship Program

Deadline: June 6, 2011. To be considered, all application materials must be received by the deadline. For moreinformation and to download additional applications, visit www.rvlearningcenter.org or e-mail [email protected].

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): $ __________ % to Be Covered by Self/Family: _________%

Are You Employed? No 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 eligibilitycriteria specified for scholarship applicants.

Signature: ________________________________________________________________________________________________

About This ScholarshipThe RV Learning Center’s ScholarshipProgram awards $2,500 scholarships todeserving college undergraduatestudents majoring in business, finance,economics, accounting, or other RVindustry-related subjects. A factor forawarding the scholarship may be anapplicant’s background of RV industryemployment or a desire to work in theRV business after completing post-secondary education. It is madepossible through the generosity of theNewt and Joanne Kindlund Family.

Eligibility RequirementsWe will award the scholarships to RV-related company employees or theirdependents based on a series of factors.Dealer principals and their dependentsare not eligible.

Requirements*• Must be a rising sophomore, junior, or senior college

undergraduate student.

• Must complete an essay on their goals and objectivesfor attending college.

• Must submit a completed Free Application forCollege 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 funda portion of their educational expenses on their own.

• Must be accepted into an accredited four-yearcollege or university as a condition of receiving thescholarship.

• Must have a 2.8 or better cumulative grade pointaverage, and a 1050 minimum SAT score (1575minimum on the 2400 point scale). A minimumACT composite score of 22 is also acceptable.

*All requirements must be met by the application deadline.

Enclose with Application: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 500words on “My Goals andObjectives in College.”

4. A list of extra curricular activities,honors, etc.

5. A copy of your FAFSA form(available at your school or atwww.fafsa.ed.gov).

6. Two photos (digital preferred) forpublicity (only used if candidatereceives scholarship).

FACT SHEET AND APPLICATION: 2011-2012 ACADEMIC YEAR

Submit application packet to: The RV Learning Center3930 University DriveFairfax, VA 22030 or fax to: (703) 359-0152, or by e-mail to [email protected]