Rexhall Aerbus 1997 How To Operate All Systems PDF: Complete Owner Guide
Operating a 1997 Rexhall Aerbus requires understanding its unique F53 chassis foundation, custom fiberglass bodywork, and integrated coach systems. This comprehensive guide details the precise protocols for managing power grids, climate control, plumbing, and slide-outs to ensure optimal vintage motorhome performance.
Pre-Operation & Equipment Safety Checklist
Mastering a 1997 Rexhall Aerbus begins with validating every foundational system before hitting the road or setting up camp. Built on the Ford F53 motorhome chassis with a robust 460 cubic inch (7.5L) V8 engine or early Ford V10 depending on the mid-year production run, this Class A motorhome relies on a complex network of 12-volt DC and 120-volt AC architecture.
- Essential Tools & Materials: Multimeter for electrical diagnostics, non-contact voltage tester, fresh potable water hose, pressure regulator set to 45 PSI, heavy-duty sewer hose, replacement 15A/20A/30A/50A fuses, and a standard set of SAE combination wrenches.
- Prerequisite Knowledge: Familiarity with dual-battery isolation logic, LP gas detector expiration dates, chassis gross vehicle weight rating (GVWR) limits, and basic plumbing valve positioning.
- Benchmarks: Allow 2 to 3 hours for a complete cold system check and fluid assessment. Budget approximately 100 dollars annually for preventative upkeep on slide-out seals and hydraulic reservoir fluid changes.
Step-by-Step 1997 Rexhall Aerbus System Operation
Step 1: Chassis Engine and Dashboard Instrument Verification
Verify all fluid levels under the front hood access panel, including engine oil, transmission fluid, power steering fluid, and coolant. Insert the ignition key, turn to the ON position, and wait for the dash warning lights to cycle while the fuel pump primes the electronic fuel injection system. Start the engine and monitor oil pressure, alternator charging voltage (targeting 13.5 to 14.2 volts), and pneumatic gauge readings if equipped with auxiliary air suspension helpers.
Warning: Never force the steering wheel to full lock against the mechanical stops for more than a few seconds to prevent overheating the power steering pump on the heavy F53 front axle.
Step 2: 12V House Battery Bank and Converter Management
Locate the main coach battery disconnect switch, typically positioned near the entry stepwell or inside the rear utility bay, and switch it to the ON position. Step inside to the main monitor panel and verify battery state-of-charge for the house deep-cycle batteries. When plugged into shore power, ensure the onboard RV converter/charger is actively outputting voltage to maintain battery health without overcharging.
Pro-Tip: If the house lights flicker when toggling appliances, clean the 12V master solenoid terminals and inspect the inline automatic-reset circuit breakers located near the coach battery tray.
Step 3: Shore Power Hookup and Generator Operation
Turn off all high-draw 120V appliances—such as the roof air conditioners and the microwave—before connecting to shore power. Pull the 30-amp or 50-amp shore power cord from its storage compartment and secure it to the pedestal receptacle. To run the generator (typically an Onan Marquis or Emerald series), prime the unit by holding the dashboard or generator-mounted switch in the STOP/PRIME position for 10 seconds before cranking.
Step 4: LP Gas, Water Heater, and Furnace Startup
Open the primary LP gas tank service valve slowly to prevent triggering the excess-flow safety valve. Light the stove burners briefly to bleed air out of the copper gas lines. Switch on the water heater using either the 120V electric element switch or the LP gas electronic ignition switch located on the monitor panel. For the forced-air furnace, set the wall thermostat to HEAT, adjust the temperature above ambient room temp, and listen for the blower motor to spin up followed by the audible click of the electronic igniter.
Step 5: Fresh Water, Gray, and Black Tank Management
Connect your drinking-water-safe hose equipped with an inline pressure regulator to the city water inlet, or fill the onboard fresh water tank and switch on the 120V/12V water pump. To dump waste tanks at a designated station, pull the black water (toilet waste) valve first, allow it to drain completely, then pull the gray water (sink and shower) valve to rinse residual waste through the sewer hose. Close both valves securely and add a gallon of water mixed with holding tank deodorant down the toilet to re-prime the black tank.
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1997 Rexhall Aerbus System Specifications
| System Category | Component Name | Operational Standard / Rating | Maintenance Interval |
|---|---|---|---|
| Electrical | Chassis Alternator | 13.5V – 14.2V Output | Inspect brushes every 36 months |
| Electrical | House Converter | 30 Amp to 45 Amp multi-stage | Check cooling fan annually |
| Plumbing | Water Pump | 32 PSI to 45 PSI demand pressure | Clean inlet mesh screen bi-annually |
| Climate | Roof Air Conditioner | 13,500 BTU Duo-Therm / Coleman | Clean return air filters monthly |
| Chassis | Transmission Fluid | Mercon V / Dexron III spec | Flush every 30,000 miles |
Common Site Failures and Field Fixes
Symptom: The Onan generator cranks continuously but refuses to start.
- Root Cause: Low fuel level in the main motorhome gasoline tank (generator fuel pickups are deliberately cut short at 1/4 tank to prevent stranding the vehicle) or a vapor-locked fuel filter.
- Actionable Fix: Ensure the motorhome chassis fuel level is above one-quarter tank, prime the generator switch for 15 seconds, and attempt ignition again. If necessary, replace the inline fuel filter under the generator chassis chassis access cover.
Symptom: Roof air conditioner runs, but blows ambient room-temperature air.
- Root Cause: Frozen evaporator coils due to restricted airflow or a failing compressor start capacitor.
- Actionable Fix: Turn the thermostat off and set the fan to HIGH for 30 minutes to thaw the coils. Vacuum the intake filters and inspect the metal fins for debris buildup.
Symptom: The 12-volt interior lights and water pump are completely dead while plugged into shore power.
- Root Cause: The 12V house battery disconnect switch is tripped, or the heavy-duty reverse polarity fuses on the power converter distribution board have blown.
- Actionable Fix: Verify the master disconnect switch is engaged. Inspect the converter fuse panel, replace any blown automotive-style blade fuses, and test the DC bus voltage with a multimeter.
Symptom: Water heater burner lights for three seconds and immediately shuts down.
- Root Cause: Dirty Direct Spark Ignition (DSI) electrode probe or a blocked burner tube infested by spider webs.
- Actionable Fix: Disconnect power, remove the exterior access panel, clean the spark probe with fine sandpaper to restore proper flame sensing feedback, and clear out the burner tube using a bottle brush.
Frequently Asked Questions
Where can I find the exact fuse box locations in a 1997 Rexhall Aerbus?
The 1997 Rexhall Aerbus features two primary electrical centers. The 12V automotive and chassis fuse panel is located under the dashboard near the steering column, while the 120V circuit breaker panel and 12V house fuse block are typically flush-mounted inside a lower cabinet near the bed or beneath the refrigerator.
How do I check and fill the hydraulic leveling jacks?
Park the motorhome on level ground, retract all hydraulic jacks completely, and locate the hydraulic pump reservoir—usually situated behind a dedicated exterior compartment door near the middle or front of the chassis. Check the fluid level with the jacks fully retracted (as extending them lowers the fluid level), and fill with automatic transmission fluid (ATF) or specialized hydraulic fluid as specified on the reservoir decal.
What causes the refrigerator to run on electric power but fail on propane?
Failure to operate on propane typically stems from a blocked burner orifice, a faulty thermistor, or a locked-out electronic control board due to air in the gas line. Turn the refrigerator off and on three consecutive times to clear any lockout faults, and verify that the manual LP shut-off valve behind the exterior refrigerator access panel is fully open.
How do I winterize the plumbing system to prevent freezing damage?
Drain the fresh water tank, gray tank, and black tank completely, then open all low-point drain valves. Bypass the water heater using the onboard winterization valve kit, and either blow out the lines using compressed air at 30 PSI or pump non-toxic RV antifreeze directly through the system using the water pump winterizing suction port.
Mastering your 1997 Rexhall Aerbus ensures decades of reliable cross-country travel and comfortable mobile living. Keep this reference guide handy in your motorhome glovebox for quick diagnostics at every campsite.
