Custom Tuned DynoMax Chassis ...just one of the reasons those beautiful Country Coach motorhomes are still on the road today

THE CUSTOM TUNED DYNOMAX CHASSIS

Guest Post by Carolyn Gsell, former Customer Care Specialist Extraordinaire with the Country Coach, LLC Sales Dept.

“…Nobody tests a motorhome, and in particular the chassis, the way it was done at Country Coach.”

I was thinking about that this week as some customers were talking in the customer lounge at Premier RV Services in Junction City where I work, and I remembered this great article by my friend Carolyn Gsell authored back when Country Coach LLC was building coaches…It’s still a wonderful look into that DynoMax chassis upon which some of the World’s Finest Motorcoaches were founded…. 

 

The foundation of a Country Coach motorhome (with the exception of Prevost Conversions) was the DynoMax Chassis. A look at the steel structure is telling. The massive framework of welded tubular steel with 8 x 3 frame rails will withstand almost any brute force that it comes up against. But ultimately what owners of a Country Coach experience is the incredible ride and handling attributes when driving down the highway, and its nimbleness when faced with tight turning areas in campgrounds and in-town driving. So how did the engineers at Country Coach marry ruggedness with driveability? The surface answer goes back to the company’s basic engineering principle – Safety, Function, & Design.

…The Chassis designers went to work to develop a steel structure of unsurpassed strength and durability. Utilizing high strength tubular steel they welded together to create the steel cage (the basement, if you will). They next welded the cage to massive 3” x 8” tubular steel frame rails. With this structure in place, Country Coach could utilize the highest horsepower engines on a chassis that could absorb the sheer power and torque that such big engines generate. This meant they chose not to use C channel steel (imagine tubular steel that is missing its widest side, hence the “C” shape). They could have employed an easier, quicker process of bolting the steel together, rather than fusing the steel with high grade welds… but they didn’t. A fiberglass coach has the roof, walls and floors connected somehow to the chassis. CC engineers had to figure a way to integrate these separate house components with the chassis so that it could be fully integrated for the coach to safely travel the road. Chassis engineers built cross bracing into the steel cage structure, properly spaced openings for storage and other components, evenly distributed weight of components, and designed a laminated floor for the house that fully integrated into the chassis structure. The result was a semi-monocoque design where the house came together with the chassis for a motorhome of superior strength and stability.

Another critical aspect of the DynoMax design is the suspension system. Engineers determined that the Independent Front Suspension (IFS) was a crucial component contributing to the smooth drive of a motorhome. From this standpoint, safety and comfort points stack up with the use of DynoMax’s Independent Front Suspension with its double wish-bone construction. The IFS design allows one front wheel to react to an impact independent of the other front wheel; and a major reduction in road stress achieved…The other feature of the suspension was Country Coach’s approach to airbag size and positioning. Country Coach recognized that if they mounted the airbags farther apart, as in outboard mounted airbags, your coach could have the feel of a race car suspension. The DynoMax difference is to mount large volume air bags inboard of the wheels. The size and positioning, in combination with the weight of the coach, provides the luxurious ride that owners love in their Country Coach. Further stabilizing the ride, Country Coach engineers supplied plenty of on-demand air from strategically placed air canisters to the air bags, so that as your coach makes its way around corners and deep curves, the instantaneous delivery of air to one side makes up for movement on the opposing side. Now add the IPD anti-sway bar and all factors add up to one of the best driving motorcoaches ever built.

DynoMax chassis elements that contribute to your personal safety and comfort are numerous.

Note the massive “firewall”, the plate of steel to which your brake and accelerator pedals are mounted, and which also in conjunction with fiberglass dash and fiberglass front cap creates a barrier between you, sitting in the driver and copilot seat, and the world beyond your front bumper.  Notice the wide entry area between the firewall and your co-pilot’s seat.  This distance, in combination with the steel firewall and steel cage structure below, adds monumental protection in the unlikelyevent of a head-on collision.  One testimonial to this, back in 2003 a Country Coach driver was delivering a Country Coach to an industry show. He found himself in the midst of a sandstorm. With his visibility obscured, he ran into a semi truck while traveling at 40 mph. The driver walked away from that accident uninjured and the coach was returned to Country Coach for repairs. Now that is a great testament to safety!

Once the entire frame with axle assemblies was welded together, the chassis was taken to a special paint booth where rust inhibitive paint was applied around every bit of steel that makes up the structure. While the process is important to protecting the steel, Country Coach took this one step further. Most chassis manufacturers utilize an assembly line approach, with the paint application being the final step. At Country Coach, builders took the time to pull the frame out of its station, take it to the paint booth, and then move it into another short assembly line where the drive train was installed. Open up the engine access doors of a competitor’s product and you may see paint overspray on the engine, transmission or hose lines. By taking the time to paint the frame prior to installing drive train components, it’s unlikely you’d ever see this on a Country Coach.

Note: As a special note regarding the special black rust inhibitor applied to the chassis, sheet metal and angled iron used at that time was not available from the suppliers with the zinc oxide process. So these areas are more susceptible to rust (wheel wells, battery bay, propane bay, service center). A preventative care step is to give a good thorough power washing of the coach undercarriage after each trip to help prevent rusting in those susceptible areas. Now...back to the chassis info.

After the chassis frame is painted, it was moved to the drive train assembly area. Installers and assemblers with engine/transmission hoists installed the power plant that makes your coach move down the road. When it comes to engines and transmissions, Country Coach utilized only the most powerful power plants on the road. The line-up of heavy duty engine/transmission combinations boasts horsepower and torque curves that gave each motorhome the boost needed for climbing hills or navigating our nation’s superhighways.

While the engine installation was in progress, the wire harnesses, brake fluid lines, heater hoses and air lines were laid down in the channel between the two main frame rails. To prevent chaffing of hoses and conduit against metal, strips of neoprene line the rails upon which the wires and hoses rest. This procedure greatly reduces the amount of friction and assures the integrity of the lines. So that your bays look clean and attractive, the lines are covered with removable cargo panels so that they are accessible for any possible trouble shooting or repairs. Batteries on convenient pull-out trays, filters, air tanks, brake and accelerator pedals – basically everything necessary to the function and maintenance of the chassis, are installed and hooked up at this time. The initial set up for the plumbing bay was also started in this area. The insulated floor was installed, and the holding tanks were mounted in place.

And speaking of heavy duty, weight distribution plays a key roll in how comfortable you feel when driving your coach, and also plays into safety. An unbalanced load would make driving a motorhome challenging at best. Country Coach engineers paid close attention to creating the right balance at the basement level of your coach, through careful placement of holding tanks, the fuel tank and other chassis components. The fuel tank is located directly rearward of the front wheels, and spanning curbside to driver side, with the bonus convenience of allowing diesel fuel to be pumped on either side of the coach in most Country Coach chassis designs. Just forward of your drive wheels is one large bay for all the fresh, black and gray holding tanks – again, weight balanced side to side. With the lower weight distributed in accordance with axle carrying capacities, engineers designed the bay storage in between the front and rear so that you, the owner, can load up your provisions knowing that the proper weight balance has already been 98% achieved by the inherent design and placement of the chassis bays.

DynoMax chassis are rated for towing. With high tow weight ratings, owners have a wide range of options for what they may choose to tow, without the limitations other RV’s put on their towing capacities.

CC engineers went the extra mile in this chassis design by adding a layer of neoprene, which acts as a vibration dampening material, on the underside of the engine deck floor, with continuous strips of this same material being applied forward of this area on the upper side of all the chassis steel rails. Most other RV manufacturers choose not to take the time to add this material. It is another of the differences that you’ll find in the Country Coach build process that makes Country Coach stand out ahead of every other motorcoach in its class.

These chassis features add up to create the luxurious smooth ride that one experiences driving a Country Coach. One testimonial on that smooth ride was shared in a 2005 issue of CC Destinations. An owner of a 2002 Affinity once rested a pocket knife curved side down on the belt molding of the driver side slide room. Not remembering he had left it there, he and his wife departed from the campground complete with speed bumps, navigated a steep grade and large chuckhole, and then traveled another 128 miles where they stopped at another RV park. The next day, the coach owner found his knife still sitting in the same exact location where he had left it (that story, “The Little Kershaw Knife that Could”, appeared on page 64, Autumn 2005 Destinations Magazine).

Ask a manufacturer of a motorcoach how they test their chassis and they may describe the initial design and testing when the chassis model was first designed, or describe the road test performed on their newly manufactured units. Nobody tests a motorhome, and in particular the chassis, the way it was done at Country Coach. Before each chassis was put into production, it was taken to the Dynocenter, where the chassis was chained down and the engine hooked up to a Dynomometer. Before the Dyno Test began, quality auditors closely inspected welds, wiring, hose connections and bolt torques to insure that every chassis component was correctly assembled. Once done, with the use of 7000 lbs of water delivering force to steel drums that allowed the drive wheels to work against a load, the chassis was “started” from an enclosed room overlooking the test area. By putting the drive train through the paces, Country Coach evaluated the data to make sure horsepower output of the engine matched the manufacturer’s specifications. If anything came up, it was immediately corrected and if necessary, the chassis was “dyno’d” again. The Dyno program was in place from 2001 until the company closed in 2009. The rigorous Dyno process helped ensure quality and integrity of your DynoMax chassis.

These days are exciting times too....as Ron Lee and Country Coach Corporation are at work on a new generation of Country Coach motorcoaches. The first one is being built this year. Pop over to www.countrycoach.com to learn more about that. 

Seven Things for Motorhome Owners To Do List in 2015!

7 Things for the Motorhomers' Must Do List in 2015!

 ...some call them resolutions...or bucket list items...I call them just plain fun ideas!

Just Do It! Have you been dreaming of a certain RV trip you’ll one day take? There’s no time like the present! Make 2015 the year you do it!

Get off the beaten path. Find the unusual, unique and less known attractions in every state you visit! The largest ball of twine, or the line of cadillacs that form a roadside artwork in Texas…RoadsideAmerica.com is a great website to visit to learn about some of the attractions in states you’ll be visiting this year.

America’s Got Talent. Love snapping photos of your travel adventures? How about taking a photography class? Enjoy writing notes on every destination visited? Start a blog! For an easy to use blogspot, one to consider is found at https://support.google.com/blogger/. Is cooking your passion? Consider taking a couple’s cooking class. Or, cook up a dish that is a specialty to each region you visit this year! Texas BBQ, Dakota Pheasant Dinner, New York Style Pizza…

We Like to Move it Move it! Every kid loves to sing that song from Madagascar. Have you been thinking about getting moving more this year…focusing on fitness among your goals? Let’s resolve to get moving this year…Take a Hike! Skip rocks at a creek. Get out of the coach more and enjoy the beauty of nature wherever you happen to be parked.

Connect more!  Friendship is just what this mobile lifestyle is about--new places, new faces...lifelong friends in the making. Stroll through the resort / campground and make at least two new acquaintances. Strike up a conversation. You may just meet your new bestie this year!

Joy in the Journey, not just the destination. Instead of your usual route to the destination, try changing up the course a bit to see what’s round that next bend. Who knows you might just discover a new “favorite destination.”

Does the barn need painting, er…make that the RV? Well, give it a good facelift this year with a new exterior paint job…or a new full tile floor inside…or a work area modification for your office on the move. Renovate! Rejuvenate! The coach, that is.

Come to Oregon in 2014 www.Come2Oregon.com   Junction City Oregon in the beautiful Pacific Northwest is a motorcoach owners’ mecca when it comes to a concentration of the world’s finest service centers, dealers, aftermarket suppliers, and amazing sites and attractions to enjoy. 

Winter RVing in an older motorhome

Winter RVing

authored  by Dennis Wasserburger, former CC, Inc service team member and motorhomer

Back in 1999 a very seasoned RVer and then director of customer relations Dennis Wasserburger shared timely information on enjoying your motorhome during the cold winter months. Many of those Country Coaches are still out there on the road today so we share his insights on winter RVing again for those who enjoy traveling during the winter.

 Winter traveling means less crowds, a choice of RV parking spaces at most campgrounds open in the colder months, and as an added bonus usually lower overnight stay prices as it is the “off season”. If you have ever ridden a snowmobile through Yellowstone National Park you can appreciate the grandeur of the sights which are not as dramatic during the hectic summer months.

Be Prepared. The key to winter RVing is preparation, attentive coach maintenance, and a weather conditions. The coach components that should receive special attention pre-trip follow:

Batteries: If your coach batteries and engine cranking batteries are left in a discharged state during inclement weather they will freeze. This will render your batteries useless. Even when they thaw they will not accept and hold a charge after being frozen only one time. To prevent freezing batteries, 1) keep all batteries components tight and free of corrosion; 2) keep the water at the proper level with liquid batteries, and 3) keep your batteries fully charged as much as possible. While hooked up to shore power, Country Coaches have automatic charging. While dry camping, your onboard generator will be required to maintain an adequate charge level. The charging process should start when batteries drop to the 12.00 volt DC level. Solar panels will assist in keeping batteries charged. During cold weather, the drain on the domestic batteries which run your heating system is too great for solar panels to keep up with the demands placed on them.

Coolant. All the manufacturers of diesel engines in Country Coach motorcoaches (Caterpillar, Cummins, and Detroit Diesel) recommend that the coolant be maintained at a 50/50 mixture of low silicate anti-freeze and water. This will give freeze protection down to -34 degrees F. This is about as cold as most of us will encounter and colder weather should be left to the polar bears. If you insist on colder temperature use, a stronger mixture of anti-freeze and water may be required. Check with your engine manufacturer if you expect colder climates. Caution: Straight anti-freeeze should never be used since cooling and freeze protection require water mixed with the anti0freeze for proper circulation.) Annually, your engine coolant additives should also be checked and maintained at the proper levels. The engine manufacturer’s dealer service network can check the additive level and contamination levels of your coolant. This is a very easy test that is accomplished with a sample of coolant taken from your cooling system surge tank.

The same anti-freeze and water mixture is used in the hydronic heating system that is used to heat the interior of many Country Coaches. An added benefit of the hydronic interior heating system is that it can also be used to pre-heat your main diesel engine while heating the interior of your coach.

Don’t forget the onboard diesel generator’s cooling system. This system should be serviced using the same guidelines as above. You will definitely be using your generator during cold weather for battery charging purposes, so proper surfacing of your onboard generator is a must. Unfortunately, many owners tend to forget the generator until they need it and discover that lack of proper service has made it inoperable.

Engine Belts and Hoses. Any seasoned traveler knows you should always carry an extra set of engine belts with your coach. Cold weather can make rubber very  brittle and cause a worn belt to break. Any sign of cracking or fraying on any engine belit is the sign to replace them. Some models of Country Coaches have more than one belt driven accessory. A good rule of thumb is to replace all engine drive belts at the same time so they are all the same age and you do not have to remember which one you replaced last. Some of these drive belts, if broken will disable the engine (i.e., water pump, alternator). With a minimum of hand tools the drive belts can be changed. For this reason all owners should carry an extra set of engine drive belts. Hoses should be replaced if they have cracks appearing on the outside or if they feel spongy or brittlwe. Most radiator hoses will laast up to five years if not contaminated with fuel or oil spills which are allowed to remain on them. All hoses should be checked annually for signs of deterioration and be replaced as needed.

Engine Oil. Today’s engine oil technology has advanced in leaps and bounds. The multi-viscosities and additives in engine oil along with advances in engines has eliminated the need to let your engines run all night as some truckers still do. The fear in cold weather was if you shut your engine off it would not start after a cold night. The 15W40 engine oil recommended by Cat, Cummins, and Detroit Diesel eliminates this fear.

The 15W40 viscosity is recommended for all but the most severe weather conditions and can be used year round. Engine oil becomes contaminated from the combustion process and condensation during normal operation. Oil and filter changes are recommended by the engine manufacturer for this reason. Engine oil is inexpensive when compared to engine oil related repairs on an engine. A good rule of thumb is change the engine oil and oil filter at the beginning of summer and winter. Again, don’t forget your onboard generator.

Diesel Fuel. The fuel supply in your coach in most cases is diesel. This requires some special attention during cold weather operation. Unlike gasoline, diesel fuel will begin to gel at approximately 10 degrees F. If this gelling or clouding becomes too severe it can clog your fuel filter and stop your engine. Diesel fuel companies recognize this problem and produced Diesel #1 or “winterized” fuel. It may not give you as much power or the mileage as the Diesel #2 you are used to burning but it has all but eliminated the gelling problem except in extreme conditions.

Additives are available that can be added to your present fuel supply to prevent this problem until your fuel tank can be filled with the cold region winterized fuel. Speaking of filling your fuel tank, it is a good idea to keep your tank as full as possible. This will eliminate the air space in the tank that will allow condensation to form in your fuel tank. Moisture and diesel fuel don’t mix and will stop you cold, if allowed to enter your engine. Country Coach diesel pusher motorhomes are equipped with a fuel filter/water separator to stop water from entering the engine. Since you never know when you may pick up water-contaminated diesel fuel, you should always carry a spare fuel filter/water separator, and acquire the knowledge on how to replace this filter. Due to the volume of diesel fuel they sell, large truck stops usually have fresher, less contaminated fuel. They are also the first fuel supply locations to receive the winterized fuel in the cold regions of the country. Fuel heaters for fuel filters and tanks are available aftermarket. If you use the winterized diesel fuel and keep your fuel tank as full as possible, these heaters should not be required except in extreme conditions.

Block Heaters. Country Coach supplies an electric block heater on current model diesel coaches. This is especially useful to preheat your engine when 110 volt AC power is available from campground hook ups or from your onboard generator.

Although this electric block heater can be used all night if conditions require, it should never be used when the engine is running. On Country Coaches equipped with hydronic heating there is an added advantage in that when you are operating your hydronic heating system with the diesel fired furnace, you are also heating the coolant in your coach diesel engine. This makes cold starts much easier and the electric block heater becomes a back up system only.

Thermal Pane Windows. Coaches equipped with dual pane windows in all the openings except the windshield conserve heat in the winter and cool air in the summer months. An added benefit of the thermal pane windows option is the amount of sound deadening that is gained over the standard, single pane side windows.

Windshield Washer. Reservoirs should be filled with winter premix solutions (20/10 or equivalent). Don’t forget to run your windshield washers long enough to purge any non-winter solution from the hoses going to your wipers. This will prevent freezing in the entire windshield washer system. You will be glad you followed this simple procedure the first time your windshield is sprayed with slush and salt from oncoming traffic. Also carry extra solution to replenish your reservoir. You will be surprised how quickly you can go through a gallon of winter windshield solution during heavy use.

Water Pumps & Holding Tanks. Country Coach placed the water pumps, resh water storage tank, and black and gray holding tanks in one plumbing bay. This plumbing bay is heated by a radiant heater on hydronic heating system coaches and by a forced air heating duct on forced air LP heating system. The freeze protection in the plumbing bay is automatic and operational when the interior furnace is operating. The black or gray dumping valves should never be left open during cold weather camping. They should only be opened during the actual dumping procedure—black tank first, followed immediately by the gray tank. Failure to follow this procedure will result in frozen sewer lines and a real mess when they do thaw out. Black holding tank chemicals can also be used in the gray holding tank during cold weather camping.  The use of such chemicals will aid in breaking down solids that may enter either holding tank and promote complete dumping.

Locks. Exterior locks can present a problem by freezing and becoming inoperable. Once the lock is frozen, about the only things that will work to free it are the old heated key trick or a commercial deicer. NEVER throw hot water on a frozen lock. This will only cause it to have more moisture to refreeze later. You should also never wash your coach at the end of the day when freezing temperatures are expected at night, unless you have the ability to blow the moisture out of the locks, with compressed air before it can freeze. Parking your coach so direct sunlight will be on locks during the day is a good way to dry out the locks and conserve fuel needed to heat the interior.

Traction. Country Coach diesel pusher motorhomes have excellent traction due mainly to the weight on the rear drive axle. This weight is created by the large rear mounted diesel engines and heavy duty automatic transmissions. This added traction will assist you in most conditions of moderate snow. In icy conditions, studded snow tires and/or chains are required. Cable type chains are best for motorhome use due to the smaller tire to fender clearances. You may never need to use your cable chains. After you purchase them to carry along for safety reasons, always do a trial fit to insure proper operation in case you are required to use them in the future. Traction with reference to going is one thing, but traction with reference to stopping is something else. The weight factor of a motorhome (this is such a plus going) become a large minus when stopping. To stop a motorhome on icy road surfaces, increase your stopping distance dramatically. Depending on road speed which should be very slow on icy roads, your breaking distance may need to be extended by ten times. Your tow car also needs to be considered when judging extended braking distance, especially if you are towing a vehicle or trailer without independent braking capabilities.

Be Flexible, Hang Loose, Enjoy the Trip! Wiinter operation of your coach should always be done on a very loose schedule. If you plan on being a certain place a certain day you may not allow yourself the luxury of being able to hold up in a campground during severe storms with impassable roads. A more relaxed schedule allows you to wait out storms in the comfort of your coach. With a little planning, you could be in a campground with full hook ups enjoying hot chocolate and watching the storm pass by on TV.

If driving during inclement weather, especially snowstorms, go slow. Remember yoru increased braking distance and take frequent breaks. Driving snow has a somewhat hypnotic effect which can cause fatigue before you recognize it. Frequent breaks will eliminate any lasting effects of this problem and help ensure your safety as you continue on down the road.

Night driving should also be avoided during a snowstorm due to the drastic reduction in visibility. During a clear day you may be able to see for miles. At night that distance is reduced to a few yards, while your braking and stopping distance remains the same.

Winter RVing for the fun of it! Operating your coach in cold climates is rewarding with nothing to fear. Correct preparation and a little caution and you will be telling snowbird friends how much fun you had last winter. They will be wondering why they have not tried this aspect of coach ownership. Travel safely.