Mandalay 38A 2004, 38B 2004, 40C 2004, 40B 2004 Owner's Manual

TABLE OF CONTENTS

LIMITED WARRANTY 1-1

WHAT ISCOVERED ....................................1-1

HOW TO GET SERVICE ..................................1-1

WHAT IS NOT COVERED .................................1-2

LIMITATIONS AND DISCLAIMER OF IMPLIED WARRANTIES ..............1-3

LEGAL REMEDIES AND ARBITRATION ..........................1-3

CUSTOMER CARE ROADSIDE ASSISTANCE PLAN 1-4

EMERGENCY ROADSIDE ASSISTANCE .........................1-4

24-HOUR TOLL FREE EMERGENCY MESSAGE SERVICE................1-4

FREE CUSTOMER TRIP ROUTING AND FULL COLOR MAP SERVICE .........1-4

TOLL FREE NATIONWIDE SERVICE APPOINTMENT SERVICE .............1-5

SERVICE ASSISTANCE ..................................1-5

SERVICE NUMBERS FOR OWNER'S REFERENCE 1-6

OWNER'S PERSONAL PROPERTY RECORD 1-7

OWNER'S INSURANCE INFORMATION 1-8

INTRODUCTION 2-1

TRAVEL PREPARATION 3-1

CHASSIS CHECKS ..................................... 3-1

RV SYSTEM CHECK ....................................3-2

TANK CAPACITIES ..................................... 3-2

FIRST SHORT TRIPS.................................... 3-3

CARE & MAINTENANCE 4-1

GENERAL INFORMATION ................................. 4-1

FIBERGLASS SIDEWALLS................................. 4-1

SEALS & ADHESIVES ................................... 4-2

EXTRUSIONS & ALUMINUM SURFACES .........................4-3

WINDOWS & DOORS.................................... 4-3

FRAME ........................................... 4-3

TIRES ............................................ 4-3

ROOF ............................................ 4-4

TV ANTENNA ........................................ 4-4

EXTERIOR LIGHTS..................................... 4-5

APPLIANCES, SINKS & COUNTERTOPS .........................4-5

PRE-FINISHED PANELS AND WOOD SURFACES ....................4-5

WATER SYSTEM ...................................... 4-5

ELECTRICAL SYSTEM ................................... 4-6

ROOF VENTS........................................ 4-6

ABS PLASTICS ....................................... 4-6

WINTER PRECAUTIONS.................................. 4-7

STORAGE PREPARATIONS ................................ 4-8

PERIODIC MAINTENANCE CHART 4-9

IDENTIFICATION & SAFETY 5-1

REPORTING SAFETY DEFECTS .............................5-1

RECREATIONAL VEHICLE SERIAL NUMBER DECALS & DATA PLATES ........5-1

MANUFACTURER'SWARRANTIES ............................5-2

SAFETY REGULATIONS FOR LP GAS SYSTEMS & APPLIANCES............5-3

FIRE SAFETY........................................ 5-4

FIRE EXTINGUISHER ................................... 5-5

CARBON MONOXIDE DETECTOR.............................5-6

CARBON MONOXIDE SAFETY PRECAUTIONS......................5-7

SMOKE DETECTOR .................................... 5-7

SEAT BELTS ........................................ 5-8

EGRESS EXIT WINDOW ..................................5-9

AUTOMOTIVE OPERATIONS & PROCEDURES 6-1

GENERAL INFORMATION ................................. 6-1

NEW VEHICLE BREAK IN .................................6-1

BRAKES........................................... 6-1

WHEEL & TIRES ...................................... 6-1

DAMAGED OR FLAT TIRES ................................6-2

WHEEL NUT TORQUES .................................. 6-2

WHEEL & TIRE BALANCING ................................ 6-2

FRONT SUSPENSION & ALIGNMENT...........................6-3

POWER PLANT & DRIVE TRAIN..............................6-3

ENGINE COOLING SYSTEM................................ 6-3

PROPER LOADING & WEIGHT DISTRIBUTION......................6-4

WEIGHT INFORMATION LABEL ..............................6-5

COMPUTING YOUR LOAD & LOAD DISTRIBUTION ...................6-6

DRIVING .......................................... 6-7

HILLS, DALES & MAKING THE GRADE ..........................6-7

TRAILER TOWING ..................................... 6-8

TOWING PROCEDURE................................... 6-9

EMERGENCY STOPPING................................. 6-10

FUELING YOUR MOTORHOME .............................6-10

CHASSIS FUNCTIONS 7-1

DASH CONTROLS ..................................... 7-1

DASH HEATER/AIR CONDITIONER ............................7-2

FAN SWITCH ........................................ 7-4

ACCESSORY SWITCH ................................... 7-4

EMERGENCY START ...................................7-4

HEADLIGHT SWITCHES ..................................7-4

WIPERS........................................... 7-4

GENERATOR REMOTE SWITCH & HOUR METER ....................7-5

CIGARETTE LIGHTER ................................... 7-5

HEATED MIRROR SWITCH ................................7-5

POWER MIRROR ADJUSTMENT .............................7-5

EXTERIOR OPERATIONS 8-1

ENTRY DOOR ....................................... 8-1

POWER STEP ....................................... 8-2

STORAGE.......................................... 8-2

LADDER & ROOFTOP STORAGE .............................8-3

AWNINGS.......................................... 8-3

GENERATOR SLIDE .................................... 8-3

GENERATOR SAFETY ................................... 8-4

RALLY KIT COMPARTMENT................................ 8-5

WATER AND DRAINAGE 9-1

GENERAL INFORMATION ................................. 9-1

FRESH WATER SYSTEM..................................9-1

EXTERNAL HOOKUP.................................... 9-1

FRESH WATER TANK ...................................9-1

WATER PUMP .......................................9-2

SANITIZING THE FRESH WATER SYSTEM........................9-2

MONITOR PANEL...................................... 9-3

COMMON FIELD PROBLEMS ............................... 9-4

WASTE WATER SYSTEM ................................. 9-4

HOLDING TANKS...................................... 9-5

FAUCETS.......................................... 9-6

TOILET ........................................... 9-7

WATER SYSTEM WINTERIZATION ............................9-7

WATER SYSTEM, MAINTENANCE & TROUBLESHOOTING ...............9-8

ELECTRICAL SYSTEM 10-1

GENERAL INFORMATION ................................10-1

CONNECTING TO AN OUTSIDE POWER SOURCE ...................10-1

CIRCUIT BREAKERS ................................... 10-2

GROUND FAULT CIRCUIT INTERRUPTER .......................10-2

POWER INVERTER .................................... 10-3

BATTERY ISOLATOR CONTROLLER ..........................10-3

BATTERY DISCONNECT SWITCHES ..........................10-4

BATTERY CHARGING .................................. 10-4

BATTERY MAINTENANCE ................................ 10-5

BATTERY SAFETY .................................... 10-6

12 VOLT FUSES...................................... 10-6

AUTOMOTIVE 12 VOLT SYSTEM.............................10-7

LP GAS SYSTEM 11-1

GENERAL INFORMATION ................................11-1

FILLING THE LP GAS TANK ............................... 11-2

LP GAS REGULATOR...................................11-3

REGULATOR FREEZE-UP ................................ 11-4

OTHER COLD WEATHER FACTORS...........................11-4

HOSES, PIPES, TUBES AND FITTINGS .........................11-5

CHECKING THE LP GAS SYSTEM FOR LEAKS .....................11-6

ABOUT YOUR LP GAS DETECTOR ...........................11-6

LP GAS SAFETY PRECAUTIONS.............................11-8

INTERIOR CONTROLS & OPERATIONS 12-1

REAR VISION TV MONITOR SYSTEM ..........................12-1

LIVING QUARTERS .................................... 12-1

CONDENSATION ..................................... 12-2

OVERHEAD VENTS.................................... 12-2

HYDRAULIC POWER LEVELERS.............................12-3

SLIDE-OUT ........................................ 12-4

ROOM EXTENSION PROCEDURE ............................12-4

ROOM RETRACTION PROCEDURE ...........................12-5

MANUAL ROOM RETRACTION PROCEDURE......................12-6

WINDOWS......................................... 12-6

DOORS, DRAWERS, AND STORAGE COMPARTMENTS ................12-7

SEATING, TABLES AND ADDITIONAL BEDS ......................12-8

MANDALAY LIMITED WARRANTY

Mandalay

Mandalay

WHAT IS COVERED

The Mandalay, by Four Winds International Corporation (hereafter “Mandalay”), warranty covers this
recreational vehicle (hereafter “RV”), when used only for recreational travel and camping, for three (3) years,
or the first thirty six thousand (36,000) miles of use. In addition, this limited warranty covers the steel or
aluminum frame structure of the floor, sidewalls, roof and rear and front walls for five (5) years or the first sixty
thousand (60,000) miles of use. The warranty period begins on the date that the RV is delivered to the first
retail purchaser by an independent, authorized dealer of Mandalay. In the event that a substantial defect in
material or workmanship, attributable to Mandalay, is found to exist during the warranty period, Mandalay will
repair or replace the defective material or workmanship, at its option, at no charge to the RV owner, in
accordance with the terms, conditions and limitations of this limited warranty.

This limited warranty applies to all owners, including subsequent owners, of the RV. However, all rights and
limitations within this warranty are applicable to all owners, including subsequent owners of the RV, and all
subsequent owners must complete the Warranty Transfer Form contained in the Owner’s Manual and send it
to Mandalay. Any subsequent owner’s warranty coverage period is the remaining balance of the warranty
coverage period that the prior owner was entitled to under this limited warranty.

Mandalay

Mandalay’s obligation to repair or replace defective materials or workmanship is the sole obligation of
Mandalay under this limited warranty. Mandalay reserves the right to use new or remanufactured parts of
similar quality to complete any work. Mandalay makes no warranty as to the future performance of this RV,
and this limited warranty is not intended to extend to the future performance of this RV, or any of its materials,
components or parts. In addition, the RV owner’s obligation to notify Mandalay, or one of its authorized,
independent dealers, of a claimed defect does not modify any obligation placed on the RV owner to contact
Mandalay directly when attempting to pursue remedies under state or federal law.

HOW TO GET SERVICE

To obtain warranty service the owner must do all of the following:

1) Complete and return the Owner Registration Card within ten (10) days of purchase;

2) Notify Mandalay, or one of its authorized, independent dealers, in writing, of any claimed defect within

the warranty coverage period;

3) Provide the notification mentioned in (2), above, within ten (10) days of discovery of the defect; and

4) Promptly return the RV to an authorized dealer for repairs.

For warranty service; contact one of Mandalay’s independent, authorized service centers for an appointment
and then deliver your RV to the service center on the specified appointment date. If you need assistance
contact Mandalay at [phone]. The mailing address is: PO Box 1486, Elkhart, Indiana 46515.

Mandalay 1-1

If two (2) or more service attempts have been made to correct any covered defect that you believe impairs the
value, use or safety of the RV, you must, to the extent permitted by law, notify Mandalay directly, in writing, of
the unsuccessful repair of the alleged defect so that Mandalay can become directly involved in making sure
that you are provided service pursuant to the terms of this limited warranty.

Because Mandalay does not control the scheduling of service work at any service center you may encounter
delays in scheduling and/or the completion of work. All costs associated with transporting the RV for any
warranty service shall be the sole responsibility of the RV owner.

WHAT IS NOT COVERED

This limited warranty does not cover any material, component or part of the RV that is warranted by another
entity, including, by way of example, the automotive chassis and power train, including the engine, drive train,
steering, handling, braking, wheel balance, muffler, tires, tubes, batteries and gauges, generator, hydraulic
jacks, inverter, range, carbon monoxide detector, furnace and roof air conditioner.

Minor adjustments such as adjustments to the interior or exterior doors, drawers, latches, etc. will be
performed by the dealer during the first 90 days of warranty coverage. Thereafter, such adjustments are the
owners’ responsibility as normal maintenance.

In addition, By way of example, only, this Limited Warranty does not cover any of the following: items that are
added or changed after the motorhome leaves Mandalay; any RV used for rental or other commercial
purposes, normal wear, tear or usage, such as fading or discoloration of fabrics or the effects of condensation
inside the RV; items that are working as designed but that you are unhappy with because of the design;
problems related to misuse, including failure to maintain RV in accordance with the owner’s manual, or other
routine maintenance; damage due to accident, whether or not foreseeable, including any acts of weather or
damage or anything due to the environment, rust, theft, vandalism, fire, or other intervening acts not
attributable to Mandalay; damage resulting from tire wear or tire failure; defacing, scratches, dents, chips on
any surface or fabric of the RV; damage caused by off road use, overloading the RV or alteration of the RV, or
any of its components or parts.

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LIMITATIONS AND DISCLAIMER OF IMPLIED WARRANTIES

The following limitations and disclaimers apply to the original purchaser of the RV, any person to whom the RV
is transferred and any person who is an intended or unintended user or beneficiary of the RV.

ANY IMPLIED WARRANTY ARISING BY WAY OF STATE OR FEDERAL LAW, INCLUDING ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR ANY IMPLIED WARRANTY OF FITNESS, ARE LIMITED IN
DURATION TO THE LENGTH OF THIS LIMITED WARRANTY AND ARE LIMITED IN SCOPE OF
COVERAGE TO THOSE PORTIONS OF THE MOTORHOME COVERED BY THIS LIMITED WARRANTY.
PERFORMANCE OF REPAIRS OR NEEDED ADJUSTMENTS IS THE EXCLUSIVE REMEDY UNDER
THIS LIMITED WARRANTY OR ANY IMPLIED WARRANTY. Mandalay makes no warranty of any nature

beyond that contained in this limited warranty. No one has the authority to enlarge, amend or modify this
limited warranty. The dealer is not Mandalay’s agent, but is an independent entity.

In addition, MANDALAY SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL

DAMAGES THAT MAY RESULT FROM BREACH OF THIS LIMITED WARRANTY OR ANY IMPLIED
WARRANTY. THIS EXCLUSION OF CONSEQUENTIAL AND INCIDENTAL DAMAGES SHALL BE
INDEPENDENT OF ANY FAILURE OF THE ESSENTIAL PURPOSE OF ANY LIMITED WARRANTY, AND
THIS EXCLUSION SHALL SURVIVE ANY DETERMINATION THAT THIS LIMITED WARRANTY OR ANY
IMPLIED WARRANTY HAS FAILED OF ITS ESSENTIAL PURPOSE.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitations of
incidental or consequential damages. Therefore, the above limitations may not apply to you.

LEGAL REMEDIES/ARBITRATION

In consideration for Mandalay providing this limited warranty you agree that, in the event that you become
dissatisfied with the RV, Mandalay or the selling dealership, for any reason, and are unable to resolve your
complaint(s) with Mandalay, then you agree to submit your dispute to binding arbitration. See the Alternative
Dispute Resolution Agreement for details.

Any action to enforce any portion of this express, limited warranty, or any implied warranty, shall be
commenced within one (1) year after expiration of the warranty coverage period designated above. Any
performance of repairs shall not suspend this one-year limitation period from expiring. Any performance of
repairs after the warranty coverage period has expired, or performance of repairs regarding any thing
excluded from coverage under this limited warranty shall be considered “good will” repairs, and they will not
alter the express terms of this limited warranty, or extend the warranty coverage period or this limitation period.
In addition, this warranty is not intended to extend to future performance, and nothing in this warranty, or any
action of Mandalay, shall be interpreted as an extension of the warranty or this limitation period.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS. YOU MAY HAVE OTHER RIGHTS THAT VARY
FROM STATE TO STATE.

Four Winds International Corporation · PO Box 1486 Elkhart, IN 46515

Phone: [phone] Fax: [phone] Website: www.mandalaycoach.com

Mandalay 1-3

Customer Care Roadside Assistance Plan

A special peace-of-mind roadside assistance plan is provided free of charge by Mandalay for the first year of
ownership. (Rental and lease back vehicles are excluded from this program.)

Some companies will tell you customer satisfaction is a nine to five job…

We know better!

When you take delivery of your new Mandalay RV it’s just th e beginning of our exclusive around the clock
Customer Care Roadside Assistance Program.

Our extensive support program provides complete and fully paid roadside assistance, emergency road
service (just show your card and go) and special support benefits that follow you wherever your travels take
you.

Mandalay has teamed up with Coach Net, the largest RV emergency roadside service provider in the country,
to give you immediate access to fast, dependable service when and where you need it. To request service
contact Coach Net at: 800-232-4308.

Our exclusive 24-hour Customer Care Assistance Benefits include:

- EMERGENCY ROADSIDE ASSISTANCE

Simply show your Thor Industries Customer Care Card for payment of covered benefits with no out-of-pocket
expense throughout the U.S. and Canada. (Includes one additional family car!)

- 24-HOUR TOLL FREE EMERGENCY MESSAGE SERVICE

In the event of an emergency, stay in touch with family and friends with no cost emergency message service.
Getting in an accident while traveling in your RV means you’re stuck. We take care of you by paying for a car

rental, meals and lodging. Even helping with a plane ticket home!

- FREE CUSTOM TRIP ROUTING AND FULL COLOR MAP SERVICE

Make your next trip more enjoyable through our partnership with Rand McNally,
the first name in “Getting you there.”

1-4 Mandalay

-TOLL FREE NATIONWIDE SERVICE APPOINTMENT ASSISTANCE

A “no-hassle” way of arranging a service appointment when and where you travel. We make an appointment
for you; give you directions and the time that fits your schedule best. Want an appointment in a town you’ll be
visiting next week? We’re just a phone call away!

- SERVICE ASSISTANCE

Over 6,800 qualified service agencies throughout North America. A simple phone call gives you expert
direction on where the closest qualified service agency is located.

- FREE DISPATCH OF ON-SITE MECHANICAL SERVICE IN THE EVENT OF A BREAKDOWN

- FREE JUMP STARTS

- FREE TIRE CHANGES

- FREE FUEL DELIVERY

- FREE LOCK OUT SERVICE

For further details and instructions on how to access your Customer
Care benefits, please refer to your Comprehensive Member Benefit

Guide which you will receive in the mail within 30 days from the date
your registration card is received by Mandalay

Or call 888- 890-1738
You may continue your Thor Industries Customer Care benefits in

following years at a special discount rate, as a continued benefit of
the Thor Customer Satisfaction Program.

The Customer Care Roadside Assistance Program is not
available on rental vehicles or lease back vehicles.

Mandalay 1-5

SERIAL NUMBERS FOR OWNERS REFERENCE

Motorhome Serial Number

Motorhome Federal Vehicle Identification Number (VIN)

Door Key Number

Range Model & Serial Number

Microwave Model & Serial Number

Refrigerator Model & Serial Number

Generator Model & Serial Number

Roof Air Conditioner(s) Model & Serial Number

Inverter Model & Serial Number

Misc.

Misc.

Misc.

Misc.

Misc.

Mandalay recommends the customer records the information for future reference. Some of the information
may be found included with Vendor information supplied at time of sale.

1-6 Mandalay

OWNER’S PERSONAL PROPERTY RECORD

ITEM SERIAL NUMBER VALUE

Mandalay 1-7

COMPANY:

POLICY #:

AGENT’S NAME & ADDRESS:

BUSINESS PHONE #:

EMERGENCY PHONE #:

OWNER’S INSURANCE INFORMATION

RENEWAL DATE(S):

NOTES:

1-8 Mandalay

Mandalay

Mandalay

Mandalay

INTRODUCTION

It’s exciting taking ownership of a new purchase as substantial and full of nearly unlimited possibilities for the
future as a motorhome.

Thank you for choosing a Mandalay product.
We take your choice seriously. That’s why we’ve engineered this vehicle to meet and, in many cases, exceed

federal and state regulations and requirements for vehicles of this type. Our primary concern has been to
provide our customers with a beautiful recreational vehicle that is not only dependable and cost effective, but
also safe.

To keep this vehicle at peak performance and to obtain the maximum pleasure from its use over an extended
period, the owner must take a personal interest in its care and operation. Therefore, before operating it, we
suggest that you review the entire contents of this manual. The material within has been prepared in sufficient
detail to be of considerable help when you are getting to know your new recreational vehicle.

That is the purpose of this Owners Manual. It outlines the operation of the unit’s various systems and offers
many helpful hints that will enable you to obtain the most pleasure from this recreational vehicle.

Review both this manual and the chassis manufacturer’s owner’s manual with your dealer. Be sure to ask
them any questions you have at that time. Also make sure to read all warranty and registration information
carefully. Read all component manufacturers’ owner’s manuals, and validate any individual warranties by
completing and mailing individual warranty cards as required.

Refer to the chassis owner’s manual supplied by the chassis manufacture for complete information on the care
and maintenance of the chassis.

COMPLETE THE WARRANTY REGISTRATION CARD IN THIS MANUAL AND RETURN TO US WITHIN 10
DAYS FROM THE DATE OF PURCHASE.

Always keep this owners manual with the recreational vehicle for easy reference, making sure to observe all
notes and warnings associated with the use of this recreational vehicle. A careful owner is the best insurance
against an accident.

THIS OWNERS MANUAL IS AS CURRENT AS POSSIBLE AT THE TIME YOUR RECREATIONAL
VEHICLE WAS PRODUCED. HOWEVER, SINCE OUR PRODUCTS ARE CONSISTENTLY BEING
UPGRADED AND IMPROVED; SOME DIFFERENCES MAY OCCUR BETWEEN THE DESCRIPTION IN
THIS MANUAL AND THE PRODUCT IN THE RECREATIONAL VEHICLE. IF THIS OCCURS FOLLOW
THE COMPONENT MANUFACTURE’S INSTRUCTIONS PROVIDED IN THEIR LITERATURE.

Mandalay 2-1

SOME OF THE PRODUCTS SHOWN IN THIS MANUAL MAY BE OPTIONAL EQUIPMENT NOT
INCLUDED OR AVAILABLE WITH YOUR RV. ANY SPECIAL EQUIPMENT, MODIFICATIONS, OR
ADDITIONS MADE BY OR AT THE REQUEST OF THE CUSTOMER, OR ANY SUBSEQUENT OWNER,
WHETHER MADE AT THE FACTORY OR IN THE FIELD, ARE NOT COVERED IN THIS MANUAL. WE
RESERVE THE RIGHT TO CHANGE THE CONSTRUCTION OR MATERIAL OF ANY PARTS AT ANY
TIME WITHOUT INCURRING THE OBLIGATION TO INSTALL SUCH CHANGES ON DELIVERED UNITS.

Your RV has had a thorough inspection before it was shipped to your dealer. However, to insure your complete
satisfaction, the dealer must perform an inspection of various components and operations based on a
pre-delivery inspection list provided. You should take the opportunity to cover the operation of all components
of your RV with your dealer. This will help make you familiar with the RV and its operation, while at the same
time providing you with the assurance of everything being in proper working order. A road test by the dealer
should be included as part of the pre-delivery inspection. The dealer can then check for and correct any
steering problems before you take delivery of the RV. After this road test has been completed, front end
alignment and/or vibrations will not be covered as part of the new vehicle warranty.

This RV has been designed for short term and recreational use. It was not designed to be used as a permanent
dwelling or as a rental vehicle. If you intend to use your RV as a permanent dwelling or rental vehicle, it could
cause the carpet, drapes, upholstery, and interior surfaces to deteriorate prematurely. This premature wear
caused by long term or permanent residency may, under the terms of the new vehicle warranty, be considered
abnormal and abusive and COULD REDUCE YOUR WARRANTY COVERAGE.

Should a problem develop for which you need assistance, contact your dealer. If the problem is automotive,
the motorhome should be taken either to a chassis manufacturer service center or dealer. If the problem is with
an appliance, check the appliance manufacture’s information supplied with the RV for information regarding
warranty work and/or location of appliance service centers.

If, when traveling, you experience a breakdown or problem while your RV is under warranty, and an authorized
service center or dealer is not available, if possible, contact the dealer you purchased your RV from, or a
Mandalay Technical Service Advisor at [phone] before having any service work performed. By
notifying them, you will know what is covered under the terms of your warranty, as well as making them aware
of your problem. Any parts that require replacement, that are covered under the terms of the warranty
should be retained and returned to your dealer along with your invoice. This way, they are able to check
what has occurred, and also make sure you are properly reimbursed.

Repairs made without prior authorization may be subject to denial or partial reimbursement. Modifications
made to the vehicle without proper authorization can result in reduction or loss of warranty coverage. Please
make sure to contact your dealer before making such changes.

2-2 Mandalay

Mandalay

Mandalay

Mandalay

TRAVEL PREPARATION

Like any vacation trip, pre-planning will pay big dividends. A checklist is often helpful.
In addition to routine trip preparations such as having newspaper delivery stopped and mail held at the post

office, there are now more vehicle-related preparations than there were with the old family car.

CHASSIS CHECKS

As with any vehicle, the RVer needs to check the automotive systems prior to a trip. They include:

Under Hood:

• Fluid levels (oil, power steering, radiator, transmission, windshield washer, etc.)

• Belts (tension and condition)

• Battery (electrolyte level if applicable, connections, charge)

• Hoses (clamps tight, condition, leakage)

• Seals, gaskets (leaks)

Exterior:

• Tire pressure/condition and lug nut torque

• Headlights, running and safety marker lights including brake and turn signal and also any trailer light

connections

• Security of any auxiliary equipment such as TV and CB antennae, awning, etc.

• Windshield wiper blades

• Generator compartment

• Fresh and waste water connections/drains and supplies such as high pressure hose

• Liquid Petroleum Gas compartment/tank

Under Vehicle:

• Drive train condition, specifically leaks (U-joints, differential, transmission)

• Brakes, including lines, pads/shoes, seals

• Engine area for pan gasket or other leaks

• Anything unusual hanging or tangled with road debris such as tree limbs

• Tank condition (gas, fresh water, waste water)

Inside Driver’s Compartment:

• Check operation of all systems, including: Wipers, windshield, horn, brakes, steering, transmission,
heater, defroster, air conditioner, and seat adjustment.

Also idle engine long enough to check cooling system and alternator operation. Be sure to turn on headlights
and climate controls to see if alternator handles the additional drain on the electrical system (should not show
discharge).

Mandalay 3-1

RV System Check:

!

As an RVer you now have the added responsibility to prepare the living quarters for a trip.
Preparations include:

• Filling fresh water tank. In winter make sure that system is freeze protected.

• Check list of food, utensils and clothing needs.

• Check storage of all items, making sure that everything is secured and that heavy items are stored low

so they don’t fall.

• Check operation of stove and refrigerator.

• Check paperwork such as owners registration card, vehicle registration, proof of insurance, driver’s

license and names/phone numbers of individuals you are to contact during the trip, such as ranger
stations.

WARNING: Pay careful attention to where and what type of flammable materials you store.
Certain storage areas are clearly labeled DO NOT STORE COMBUSTIBLE MATERIALS.
Examples of spark producing areas, depending on RV model, are: base kitchen cabinets,
front dinette base, exterior refrigerator service compartment, as well as refrigerator
cabinet. Please use your discretion as to what potentially dangerous products your RV

contains while traveling. Be sure all canisters and bottle tops are secure and leak free.

Tank Capacities - Chart *

Models 38A 38B 40B 40C

Hot Water 10 gal 10 gal 10 gal 10 gal
Fresh Water 110 gal 110 gal 110 gal 110 gal
Black Tank 55 gal 55 gal 55 gal 55 gal
Grey Tank 66 gal 66 gal 66 gal 66 gal
Fuel Tank 100 gal 100 gal 100 gal 100 gal
LP Tank 121.5 lb 121.5 lb 121.5 lb 121.5 lb

* Capacities are approximate and specifications are subject to change without notice.

3-2 Mandalay

FIRST SHORT TRIPS

After becoming familiar with the vehicle’s systems and going through test runs on items such as Liquid
Petroleum Gas (LPG), it is time to take one or two short test trips, including spending the night at a
campground not too distant from your home….. you might want to go back and get something you forgot or
didn’t know you needed.

These short trips could be considered “shake down cruises” or “familiarization flights”. The experience gained
on these short trips will be worth the time and money to you… Time and money spent either needlessly, taking
something that takes up space or the time and money spent trying to obtain an item you hadn’t counted on
needing prior to leaving home base on an extended trip miles from home and in unfamiliar surroundings.

It is understandably upsetting having to purchase a needed item on the road knowing that one is sitting at
home unused.

Not all RVers need the same equipment or supplies. For one thing, North America presents a wide variety of
climates and terrain. For another, personal needs and taste come into play.

Our suggestion is to take a weekend trip to a camp location that is close to home. Be sure to have a note pad
and pen available to write down items you feel will be needed in the future as well as equipment that you may
need to learn more about.

Also, if most of your trips will be made in the summer and your shake down trip is made during some other
season, there will be some adjustments to take into consideration. Talk to other RVers and learn from their
experiences.

If you are an experienced RVer it is still necessary to thoroughly read this manual. New and improved
equipment is coming onto the market every day and, at the same time, not every motorhome manufacturer
builds vehicles the same way.

This manual is packed with detail, however, after you have worked with the various systems during a couple of
shake down trips, you will be capable of conducting a pre-trip check in less time than it takes to read this
manual.

When preparing for your trip always consider vehicle weight when loading the RV.
Because of different RV models Mandalay manufactures and the numbers of options available, your RV may

not include all of the systems in this manual.

Mandalay 3-3

3-4 Mandalay

Mandalay

Mandalay

CARE AND MAINTENANCE

GENERAL INFORMATION

Periodic maintenance and cleaning of your recreational vehicle is necessary to retain the dependability,
safety, and appearance that will provide you with many miles of trouble free operation, as well as protecting
your investment.

Make sure to read and follow all the maintenance tips and schedules that appear in this manual. Keep good
records of maintenance functions performed, and make sure to perform all owner obligations as may be
required by the chassis manufacturer to keep your warranty in force.

It is also important to note that operating conditions will affect service timetables. Driving in extreme conditions
such as heavy dust, continuous short trips, or start and stop heavy traffic means that service durations will be
shortened. Discuss service timetables with both your dealer and chassis service representative. Preventative
maintenance will pay for itself many times over by catching or preventing problems before they occur. Many
repair costs are greatly increased due to the fact a small problem can begin to affect other parts and systems
of the motorhome if left unattended.

If a situation arises involving maintenance or cleaning activity for which you are not sure of the proper
procedure, do not hesitate to contact your dealer, or chassis service representative for information.

Mandalay

FIBERGLASS SIDEWALLS

The exterior painted finish on the motorhome is of the finest quality. Proper maintenance will assure a long
lasting durable finish.

NOTE: DO NOT Wax or polish the exterior for the first 60 days.
NOTE: DO NOT use rubbing compound or other abrasive cleaners on the motorhome exterior. If using a tar

and/or insect remover, insure it is safe for painted surfaces and decals.

Precautionary Measures:

Parking

• Avoid parking under trees or near ocean salt spray.

• Ice or snow should not be scraped from the painted surface: Brush off.

• If the motorhome sets more than 24 hours, remove any front protective covering (bra) while not being

driven.

Washing

• Commercial washes should be avoided.

• Wash with cold water using a mild liquid soap.

• Dry wiping with a dry cloth is not recommended.

Mandalay 4-1

Driving

• Avoid gravel roads.

• Anti-freeze, gasoline, or window solvent spilled on painted surfaces should be rinsed off with water

immediately.

• Rinse off bugs and bird droppings daily with water.

Any exterior finish will deteriorate with time. Dulling and fading can be increased by prolonged exposure to
extreme sunlight, air pollutants, and excessive moisture. Surface weathering of fiberglass will not diminish
structural integrity. Regular monthly washing and waxing of exterior surfaces is the best insurance against
surface deterioration such as fading, yellowing, or chalking. Take care to avoid spraying water directly into
refrigerator and furnace vents when washing the motorhome.

If surface deterioration is apparent, contact a Mandalay dealer for assistance with finish restoration. Physical
damage to the fiberglass, such as cracks, holes, and chips, must be attended to immediately to avoid moisture
from entering and causing problems with interior walls and components. Cover these areas with plastic,
sealing the edges with tape until proper repairs can be made.

SEALS AND ADHESIVES

It is important to maintain the seals and adhesives of your RV to prevent moisture from entering and destroying
your RV components. When washing your RV, inspect the seals for signs of drying out and wear. Be aware
that weather, sun, and road vibration will have an effect on seals, causing them to dry, crack, or separate. If
you are unsure what to look for, have your dealer instruct you, and also show you the correct method for
renewing the seals. All exterior seals should be checked and resealed as needed at least every 6 months. This
also includes your roof components as well. Check with your dealer for the type of caulking required, different
areas require different types of seals. It is especially important to check the seals before and after periods of
extended storage or non-use. Fall and spring inspections are recommended.

NOTE: If your roof should somehow be punctured, cover the puncture to seal out moisture, and have it
repaired as soon as possible.

4-2 Mandalay

EXTRUSIONS AND ALUMINUM SURFACES

!

Clean and wax all extrusions when waxing the RV sidewalls, to help avoid surface pitting. Special aluminum
cleaners are available to restore the original luster to aluminum surfaces. Make sure to follow the instructions
for use as outlined on the product package. Chrome surfaces can be restored with special chrome polish if
regular cleaning methods are not successful. Again, make sure to follow product instructions for use.

WINDOWS AND DOORS

Check the seals around windows at regular intervals. Follow previous instructions for checking the condition of
seals and repairing as necessary. Make sure that the windows remain operative by adjusting and lubricating
latches and moving parts annually. Also check the condition and operation of the door locks, adjusting and
lubricating as necessary. Use powdered graphite or light oil to lubricate moving parts on doors and windows.
Vinyl seals around windows and doors should be cleaned regularly, and kept supple by use of a silicone spray.

Keep screens and window slides clean and free of debris, to maintain proper operation, and avoid component
road damage. Test the operation of all windows occasionally to make sure they are working properly, including
closing flush and locks holding tight. Check with your dealer if you are unsure about the correct methods of
lubrication and adjustment.

NOTE: Be aware that moisture can accumulate in locks and hinges of windows and doors, causing damage or
faulty operation. Do not force the operation of these components in sub-freezing weather.

CAUTION: Failure to maintain seals through regular maintenance can lead to damage of
your motorhome components, and may be considered abusive treatment under the terms
of your RV warranty.

FRAME

Check the condition of the frame regularly. Keep it clean, and repaint as necessary to help avoid rust. It is
especially important to keep underbody components clean, when driving the recreational vehicle in the winter
in areas where road salts are used.

TIRES

In areas where hot sun constantly beats down on the recreational vehicle, shading the tires by covering can
reduce tire sidewall cracks from forming.

Mandalay 4-3

ROOF

!

!

Inspection of roof components at least twice a year is very important to make sure seals are not cracked or
worn. Proper maintenance of seals is necessary to keep moisture from entering and causing severe damage
such as rot, mold, or mildew. If you encounter drying, cracked, or weathered seals, make sure to reseal as
necessary. Check with your dealer for the type of caulking required for roofs and correct methods of resealing.
Special sealers are also required for the skylights.

CAUTION: It is especially important to check the seals before and after periods of extended
storage or non-use. Fall and spring inspections are recommended.

WARNING: Some products may contain hazardous materials which require special
handling. Read labels carefully. Follow all of the product manufacturer’s safety
requirements.

NOTE: If your roof should somehow be punctured, cover the puncture to seal out moisture, and have it

repaired as soon as possible (check with your dealer).

TV ANTENNA

To lubricate the elevating gear, apply a liberal amount of silicone spray lubricant to the elevating gear with the
lift in the down position. Run the lift up and down a few times to distribute the lubricant over the gears.

If rotating the antenna becomes difficult, normal operation can be restored by lubricating the bearing surface
between the rotating gear housing and the base plate. Any spray type silicone lubricant may be used.

Elevate the antenna and remove the set screw from the rotating gear housing (see illustration). Spray lubricant
into hole and around the edges of the gear housing. Rotate the gear housing until the lubricant coats the
bearing surfaces and the antenna rotates freely.

4-4 Mandalay

EXTERIOR LIGHTS

Make sure to check the operation of all exterior lights often. Check identification, clearance, turn signal, brake,
and backup lights to make sure they are working correctly. Replace burnt out bulbs as soon as possible.

APPLIANCES, SINKS AND COUNTERTOPS

Clean with hot soapy water or a good liquid cleaner. Avoid using abrasive cleaners. Never use steel wool on
stainless steel, since the steel particles left in the sink can rust and become unsightly. Also, when cleaning
stainless steel with a mild cleanser, rub gently with the grain, and rinse well. Rinse after each use and wipe
dry.

Be sure to remove all food and ice from the refrigerator at the end of each trip. Prop the door open slightly to
keep the interior dry, and free of mold, mildew, and odors.

Make sure to read all literature provided with each of the appliances, and follow the maintenance instructions
included. Pay particular attention to any cautions or warnings included. Also read the rest of this manual,
following the instructions for the care and use of appliances.

Do not place hot pans directly on countertops, because they can loosen or scorch surface.

PRE-FINISHED PANELS AND WOOD SURFACES

Treat cabinetry and wood surfaces as you would any fine furniture product in your home. Proper care and
maintenance of wood products will keep them looking like new for many seasons of use.

Clean pre-finished panels with a spray-type furniture polish. Avoid getting wood surfaces wet. Wipe off and
dry immediately if you do get wet. Do not use abrasive cleansers around wood finishes. Clean regularly with a
soft cloth and cleaner designed for wood products such as lemon oil or any oil based wood cleaning product.
Avoid constant exposure to direct sunlight which can cause fading and drying of wood surfaces.

WATER SYSTEM

Check all hoses, fittings, and connections regularly for leaks and signs of wear. Make sure to keep the system
sanitized, and take care to winterize during cold weather (see instructions elsewhere in this manual). Do not
allow water to remain in system for extended periods or after a trip.

Mandalay 4-5

ELECTRICAL SYSTEM

The electrical system requires minimal maintenance under normal circumstances. Most electrical
maintenance in the recreational vehicle involves the chassis and auxiliary batteries. Keeping the batteries
properly maintained will help to eliminate many frustrating electrical problems. Make sure to refer to the index
for the location of electrical and battery maintenance information elsewhere in this manual.

The generator is another area in which simple preventive maintenance can “head off” problems before they
happen. Read the manual supplied with the generator for the care and maintenance required on a regular
basis. The first scheduled maintenance should be at 50 hours, followed thereafter with regular service
intervals of 150 hours.

If you experience electrical problems with your recreational vehicle, make sure to have it checked by a
qualified electrician.

ROOF VENTS

Check roof vents regularly for debris that may block air flow or jam the cranking mechanism. Lubricate the
cranking mechanism with light oil.

ABS PLASTIC

Many components of the recreational vehicle are constructed of strong, lightweight ABS plastic. Sometimes, it
may be necessary to remove stains, or generally clean. A mild solution of soap and water will clean many
stains and should be used initially. Tougher stains may require stronger cleaners, but be sure to read the label
to determine if the product is recommended for use on plastics.

Avoid abrasive cleanser (even the liquid and cream types), alcohol based products, and solvents such as
acetone and MEK. Gasoline and kerosene should not be used because of the damaging effect they have on
the plastic surface, as well as the fire hazard they present. Often the damage caused by solvents, alcohol, and
oil based products may not be immediately noticeable, but the plastic is made weaker, and prone to stress
cracking.

4-6 Mandalay

WINTER PRECAUTIONS

!

SPECIAL TIPS FOR WINTER USE

Water Systems – If the fresh water storage tank is located inside the coach, the normal heating of the coach

during cold weather should be enough to insure its not freezing. In severe cold weather (40°F or Lower)
however, it is wise to monitor the water temperature in the tank, and take appropriate steps to drain and
winterize if necessary. In severe cold it may be necessary to open lower cabinet doors at night in both the bath
and kitchen areas to keep warmer air circulating around water fixtures.

If you are going to leave the coach unheated for any length of time in severe cold conditions, it is best not to
keep water in the fresh water tank. It may work best to carry cooking and drinking water with you in plastic jugs
instead.

If you will be using your recreational vehicle when conditions fall below the freezing level, it will be necessary to
protect the drainage system components from damage by the addition of an approved antifreeze solution as
outlined on the product directions. Drain lines which are exposed outside the recreational vehicle are
especially susceptible to freezing, and steps should be taken to protect them from damage.

Food Storage – In the event the recreational vehicle is left for a period of time without the furnace in operation,
canned goods and other foods packed in water should be stored as high as possible, since heat rises. They
might also be stored in the refrigerator as insulation against the cold. Store dry foods, and other items that are
not damaged by freezing, in the lower storage areas.

LP Gas System – Make sure to use an LP gas that will vaporize properly in the colder temperatures. Check
with your LP gas representative for the proper fuel, and reread the information on LP gas selection in the LP
Gas section of this manual (check the Index for the location).

NOTE: It is important to remember that heating with LP consumes gas rapidly, so refill tank
immediately when low, to avoid running out completely.

Heating – Use ONLY the furnace to heat the recreational vehicle. It is properly vented to the outside.

WARNING: NEVER USE THE RANGE FOR HEATING - ASPHYXIATION COULD RESULT.

Condensation – Cooking produces large amounts of moisture. Not just as steam from pots and pans, but
also as a product of combustion. Make sure to use the exhaust vents and open a window slightly to control the
humidity. At night, leave a roof vent and/or a window slightly open.

Mandalay 4-7

STORAGE PREPARATION

When storing the recreational vehicle for the winter (or other extreme conditions), certain precautions need to
be made to protect it until you open it again for use. Make sure to talk with your local dealer concerning any
special requirements for storage in your particular geographic area. The following steps are general, and your
dealer can help you choose those that are most appropriate for your needs.

1. Make sure to park the recreational vehicle on a level surface.

2. Make sure to winterize the chassis as outlined in the chassis owner’s manual, and also the 110V

generator (if so equipped) as outlined in the generator’s owner’s manual.

3. Clean the recreational vehicle thoroughly, both inside and out, as previously outlined, including the
refrigerator.

4. Make sure all electrical switches and appliances are turned off.

5. Close all the drapes and curtains, and protect the curtains from sun fading by placing foil, or paper

between the windows and the screens.

6. Make sure all windows, doors, and vents are closed securely. Cover exterior vents on appliances to
prevent moisture and insects from entering during storage.

7. Check the interior of the recreational vehicle periodically while in storage to make sure leaks have not
developed, or condensation formed that can cause damage to interior components. Condensation
can most readily be observed as moisture accumulation on windows and mirrors. To reduce
condensation, make sure to air the recreational vehicle out occasionally during storage.

8. Be sure that both the chassis and coach batteries have the proper electrolyte level and that they are
fully charged (specific gravity of 1.260). A discharged battery will freeze and crack the case, ruining
the battery. In storage, a battery will lose charge gradually over a 30 to 45 day period, even when
disconnected by use of the battery disconnect switch. We recommend that at least monthly the
batteries be checked for charge. If the charge is 80% (specific gravity of 1.235) or less, it must be
recharged.

You may wish to remove the batteries from the recreational vehicle and store them in a heated area.
However, even when warm, the battery charge level must still be maintained. A warm battery accepts
charge much more readily however, than a cold one.

Make sure to follow all precautions associated with battery care and maintenance outlined in the
electrical section of this manual.

9. Store with as much fuel as possible in the fuel tank to limit condensation buildup.

10. Check engine coolant, making sure antifreeze is sufficient for local temperature extremes.

11. Make sure the tires are inflated to correct pressures.

12. Store the windshield wiper arms and blades inside the motorhome.

13. Let the engine run for a period of time until it is warm. Change the oil and oil filter.

14. Run the air conditioner during this final engine warm up to make sure the compressor seal is

lubricated.

15. If snow accumulates on the recreational vehicle, try to remove it as often as you can.

16. A primary concern when winterizing the recreational vehicle is to make sure the water systems are

protected against damage caused by freezing. Follow the water system winterizing procedure
outlined in the Water and Drainage section of this manual (check the index for location).

Be sure to read the rest of this manual, and follow any additional information on storage, cleaning and
winterizing procedures.

4-8 Mandalay

PERIODIC MAINTENANCE CHART

Ea.

ITEM

Ea. Mo3Mo6MoEaYrAs

Trip

Req

PROCEDURE

Fiberglass Exterior

X Wash with warm water & mild detergent

X Wax with liquid or paste wax

Roof & Roof
Components

X Check vinyl seals when washing exterior

Windows & Doors

X Inspect & re-seal as needed

X Lubricate roof vent mechanism w/light oil & clean completely

X Check seals for damage & repair as needed
X Lubricate door hinges & step components with WD40

X Adjust & lube window latches with powdered graphite or light oil
X Lube door locks & strike pocket, incl. ext. storage & access drs

Seals & Adhesives X Inspect & reseal as necessary

LP Gas System

X Check for leaks & road damage

X Have qualified serviceman check pressures & complete system

X Check hoses, fittings & connections for leaks & signs of wear

X Check drainage system for leaks & road damage

Water Drainage

X Sanitize system

X Winterize system depending on local seasonal conditions

X Check GFCI circuits

Electrical System

Appliances

Safety Equipment

X Remove food & ice from refrigerator after each trip

X Clean fan blades & wash filter on range exhaust hood
X Check for obstructions & dirt on exterior appliance vents

X Test smoke detector operation

X Check fire extinguisher pressure & condition

X Vacuum after each trip

X Perform maint. on generator as outlined in generator manual
X Check & service batteries

X Clean smoke detector components

Carpeting

X Clean

Wood Surfaces X Clean pre-finished panels & wood

Seats

X Lubricate all mechanisms & inspect for proper operation
X Check all seat belt buckles, release mechanisms & belt webbing

Chassis & Components X Follow chassis lubrication & maint procedures & schedules
Weight & Distribution X Be sure unit is within specified load limits & weight distribution

Mandalay 4-9