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This document provides instructions for novice RV owners to perform simple maintenance and repair tasks themselves. It outlines how to save money by doing repairs like replacing roof bungee cords, fixing basic electrical issues, and servicing wheel bearings and brakes. The document gives step-by-step guidance on inspection, part replacement, cleaning, lubrication, and adjustment for various components and systems. Tasks are kept simple without requiring many specialized tools.
This document provides instructions for novice RV owners to perform simple maintenance and repair tasks themselves. It outlines how to save money by doing repairs like replacing roof bungee cords, fixing basic electrical issues, and servicing wheel bearings and brakes. The document gives step-by-step guidance on inspection, part replacement, cleaning, lubrication, and adjustment for various components and systems. Tasks are kept simple without requiring many specialized tools.
This document provides instructions for novice RV owners to perform simple maintenance and repair tasks themselves. It outlines how to save money by doing repairs like replacing roof bungee cords, fixing basic electrical issues, and servicing wheel bearings and brakes. The document gives step-by-step guidance on inspection, part replacement, cleaning, lubrication, and adjustment for various components and systems. Tasks are kept simple without requiring many specialized tools.
From simple to moderate Many routine repair & maintenance issues can be done by owners. Most involve simple tools you may have at home already. $ you save on professional labor can pay for needed tools. Why DIY? Save money. Some repairs are primarily labor costs; materials are of minimal expense. See the job is done right the rst time. If you break down, you know better how to x it or have it xed. You can do repairs when YOU want to have them done. Develop greater self-condence. Better able to deal with RV repair personnel when you are knowledgeable. None of this is rocket science ! Tasks well cover 1. Simple items needing lubrication 2. Roof bungee cords/straps: ! Inspection & replacement 3. Simple electrical issues 4. Axles & wheel bearings 5. Brake system 1. Simple items needing lubrication Trailers hitch latch mechanism: use light oil 1. Simple items needing lubrication Trailers hitch latch mechanism: use light oil 1. Simple items needing lubrication Trailers hitch latch mechanism: use grease & light oil 1. Simple items needing lubrication Door hinge & latch: use light oil 1. Simple items needing lubrication Roof panels where guide rides: use silicone spray Spray both interior EDGE & TOP of aluminum extrusion s i l i c o n e s p r a y 1. Simple items needing lubrication Slide-out step: use light spray oil or silicone spray on any contact points 2. Roof bungee cords Bungee cords keep roof panels attached to each other. Without bungee cords the roof panels would swing past their apex (point of connection) and damage the roof panels. 2. Roof bungee cord inspection Look for irregular appearance of bungee cords: Thin sections Lumps or bumps Dry-rot exterior covering Tears / breaks 2. Bungee Cord replacement Bungees are multiple rubber bands together in a common, woven sleeve of fabric. They dry out like rubber bands. I prefer to purchase bungee cord material from the trailers manufacturer. Factory keeps fresh stock due to manufacturing demands. 2. Bungee Cord replacement (continued) Take several digital photos of the existing bungee system; used later for reassembly. Most A-frame folding trailers use aluminum pop- rivets to secure bungee brackets. Some may use sheet metal screws. Replace the fastener with the same type. Most times I replace the pop-rivets with 3/16 diameter aluminum pop-rivet. *Buy a little more bungee cord than you think youll need. 2. Bungee Cord replacement (continued) Replace both bungees. Do one side at a time. Check the tension of the old bungee before disassembly. Put proper tension on new bungee before riveting. *When you pull the bungee to adjust tension, it may be easier to install longer bungee during assembly, then cut o! excess after installation. 2. Bungee Cord replacement (continued) Make sure that the contact point between the bungee cord and the fastening xture is smooth or cushioned so as to not cut, wear or abrade the bungee due to rubbing or chang. Test your rst bungee installation before doing the second bungee: erect roof several times. Check for cord being too loose or too tight. 3. Simple Electrical Issues Youll be shocked at how much you can do! 12VDC lighting & wiring You wont get a shock, its only 12 volts. But a direct short to the battery can cause: sparks; re; component damage; burnt wiring Always install wiring circuits w/ fuses (12 VDC, flat blade fuse is best; or connect to fused converter Wire nuts work well; easy disconnect for repairs Use braided wire for 12VDC circuits. It can bend with trailer vibration and not crack or fracture. 12VDC lighting & wiring Grounding 90% of 12VDC trailer problems are bad ground. When installing new circuits, or repairing problem circuits, install ground wire back to converter or to trailers frame with bolt/screw and star washer. Check ground wire from trailer frame to converter. Install another if needed. 12VDC lighting & wiring Exterior lighting: wiggle the light xture Interior lighting: wiggle xture; check loose wires Check behind converter inside trailer: loose wire nut Use correct size wire nuts (color); consult chart (search Internet) If too many wires, run a pig tail See sparks? Pull fuse! Then repair! converter Quick Splice Connectors Blue = 16-14 gauge wire White = 18-14 Red = 22-18 Beige = 18-14 to 12-10 Yellow = 12-10 Installation of Quick Splice 1. Align wires 2. Compress tab into connector 3. Snap cover into place 4. Pray it works Testing for 12VDC problems Buy or build a 12VDC test light Check switch; is it on ? Check fuse; if fuse blows you have a short Circuits must have a load or device to operate. A short means part of circuit is going around the device and blowing the fuse. Shorts: bare wire touching ground; bad device Loose connection Testing for 12VDC problems With power on check for power Buy decent volt-ohm test meter with buzzer to hear continuity Continuity = connection across entire circuit Connect continuity meter to each end of wire (NO power one!) and listen for tone = continuity Converter functions & parts Converts 120VAC to 12VDC Manages 120VAC & 12VDC via fuses 120VAC breakers 12VDC protection* 12VDC power circuit fuses rear of converter inside converter 120VAC: Household current AC, outlets, converter input, appliances, etc. Connecting to shore- power (nautical term) NO POWER in trailer 1. Plug fully inserted in campground outlet? 2. Breaker switches on at campsite power box? 3. Trailers breaker switches on? (inside converter) 1 2 3 120VAC: Household current AC, outlets, converter input, appliances, Check GFIC outlet. Push TEST button, then RESET button. Outlets can also be daisy-chained with one GFIC outlet protecting others downline. 1 2 3 120VAC: Household current AC, outlets, converter input, appliances, Microwave ovens and wall A/C units may have their own GFI module on the end of the power cord. Locate the GFI module (plugged into a 120VAC outlet). Push TEST button, then RESET button. If no module on end of cord, check GFI outlet somewhere else in trailer & reset there. test & reset buttons A simple, e!ective x Even very light corrosion can cause electrical problems. Spray with electronic tuner cleaner and lube Around $15-$20 per 11oz. aerosol can Inspection Replacing Cleaning & repacking Adjusting 4. Axles & Wheel Bearings Whenever trailer needs to be jacked-up off the ground Support with jack stands, not just jack Use steel stands, NOT concrete blocks or lumber piles! Shake the trailer rmly before you go under it! Stabilizers are NOT jacks! Inspection: Roller bearings Worn, grooved, cracked, burnt race Bent, worn, cracked cage Loose bearings when under load race or cup Replacing wheel bearings View of YouTube.com Only di"cult part is driving out the race or cup Wear eye protection Use a at-nose punch, drift pin, bar of brass (steel) Drive out carefully; dont jam race cockeyed Drive new race in straight until seated; do NOT chip it ! Cleaning & Repacking Wash good bearing in solvent (mineral spirits, etc.) Wipe dry or blow dry with compressed air BUT DO NOT spin the bearing (itll explode!) Pack with high-speed wheel bearing grease. Check axle seal: grease beyond axle ange? Replace especially with brakes! Repacking w/ grease gun Straight steel nozzle works easily; rubber hose OK Pump grease in until it comes around side of bearing then stop; do not overll Carefully wipe out excess grease with pinky nger. Caution SHARP EDGES! Excess grease expands & can blow o! dust cap; lose grease causing bearing failure! grease bearings Replacing bearing seal Seals are inexpensive Be sure to install them STRAIGHT into hub Seals only on backside Double-check against axle for exact t prior to installation Use 2x2 scrap & mallet or hammer to install Adjusting bearing tension Run nut down rmly; back-o! & spin drum/ hub; tighten until drag. Pull hub/drum out at 12 & 6 oclock & feel for play (thump). Tighten just until no thump. Cotter pin curves internally; not straight Cold chisel: mark slots Adjusting bearing tension (continued) Cut o! excess cotter pin one side, bend over other end of spindle. This is all the extra grease you need; dont overll. Drive dust cap on straight; make sure its seated properly or it may fall o! (grease loss = bearing failure) 5. Thems the breaks brakes! But you can easily x them Download AL-KO Owners Manual: 500 lbs - 7,000 lbs. Axles, Brakes, Hubs and Drums www.al-ko.us http://www.al-ko.us/download/ ALKO_Owner_Man._2-7K__05_2014.pdf Brake system components Brake drum Brake assembly driving stopping Inspection Remove dust cap Remove cotter pin Remove nut Remove outer bearing Pull o! hub/brake drum Check inner (axle) seal Check bearings, races, etc. Inspection (contd) Inspect brake lining Check magnet wear Check wiring Replace seal if needed Clean brake drum w/ spray brake cleaner uid Pull magnet arm to conrm brake actuation Repair (contd) Consider replacing entire brake assembly ($60 per side); just 4 bolts; all new parts Replace component parts: $brake shoes, $springs, $magnet clip or spring, etc. Check all brake wires & connections for continuity Repair & adjust Carefully reinstall hub/ drum; do not drag & tear new seal Re-torque spindle nut; install new cotter pin Spin each drum with same approximate force. Do they spin evenly? Inspection (contd) Determine direction to tighten / loosen brakes Alternate methods: Spin, tighten, spin, etc. until even spinning both brakes; brake spin 1 rev. Tighten until drum stops; back o! 5 clicks. Listen for light friction / rubbing Inspection (contd) Most laws require a breakaway switch on trailers w/ brakes. If the trailer separates from the pull vehicle, a cable will activate the switch and SLAMS* on the trailers brakes. Pull the cable to listen for the brakes to activate BUT immediately reinsert the key to shut o! the brakes. *Applies full voltage = excessive drain on trailers battery. Test drive Increasing brake shoe drag reduces fuel economy, but increases stopping power because the magnet can only swing so far. More drag = less distance for magnet to swing to make more brake shoe contact. Find the happy medium. HAPPY CAMPING ! !
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