DIY Repair and Maintenance
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Transcript of DIY Repair and Maintenance
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DIY: Novice Maintenance & Repair
You really CAN do it!
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From simple to moderate
Many routine repair & maintenance
issues can be done by owners.Most involve simple tools you mayhave at home already.
$ you save on professional labor canpay for needed tools.
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Why DIY?
Save money.
Some repairs are primarily labor costs;
materials are of minimal expense.
See the job is done right the first time.
If you break down, you know better how tofix it or have it fixed.
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You can do repairs when YOUwant to have them done.
Develop greater self-confidence.
Better able to deal with RV repair
personnel when you are
knowledgeable.None of this is rocket science !
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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
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1. Simple items needing lubrication
Trailers hitch
latch
mechanism:use light oil
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1. Simple items needing lubrication
Trailers hitch
latch
mechanism:use light oil
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1. Simple items needing lubrication
Trailers hitch
latch
mechanism:
use grease &
light oil
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1. Simple items needing lubrication
Door hinge
& latch:use light oil
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1. Simple items needing lubrication
Roof panels
where guide
rides:usesilicone spraySpray both
interior EDGE
& TOP of
aluminum
extrusion
silic
one
spray
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1. Simple items needing lubrication
Slide-out step:
use light sprayoil or silicone
sprayon any
contact points
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2. Roof bungee cords
Bungee cords keep roof panels
attached to each other.Without bungee cords the roofpanels would swing past their apex
(point of connection) and damagethe roof panels.
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2. Roof bungee cord inspection
Look for irregular
appearance of bungee
cords:
Thin sections
Lumps or bumps
Dry-rot exterior covering
Tears / breaks
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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. Factorykeeps fresh stock due to manufacturing
demands.
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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 thinkyoull need.
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2. Bungee Cord replacement (continued)
Replace both bungees. Do one side at a time.
Check the tension of the old bungee beforedisassembly.
Put proper tension on new bungee beforeriveting.
*When you pull the bungee to adjust tension, it
may be easier to install longer bungee duringassembly, then cut o!excess after installation.
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2. Bungee Cord replacement (continued)
Make sure that the contact point between thebungee cord and the fastening fixture is smoothor cushioned so as to not cut, wear or abrade thebungee due to rubbing or chafing.
Test your first bungee installation before doingthe second bungee: erect roof several times.
Check for cord being too loose or too tight.
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3. Simple Electrical IssuesYoull be shockedat how much you can do!
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12VDC lighting & wiring
You wont get a shock, its only 12 volts.
Buta direct short to the battery can cause:
sparks; fire; component damage; burnt wiring
Always install wiring circuits w/ fuses (12 VDC, flatblade fuse is best; or connect to fused converter
Wire nuts work well; easy disconnect for repairs
Usebraidedwire for 12VDC circuits. It can bendwith trailer vibration and not crack or fracture.
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12VDC lighting & wiring Grounding
90% of 12VDC trailer problems are bad ground.
When installing new circuits, or repairing problemcircuits, install ground wire back to converter or
to trailers frame with bolt/screw and starwasher.
Check ground wire
from trailer frame toconverter. Installanother if needed.
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12VDC lighting & wiring
Exterior lighting: wiggle the light fixture
Interior lighting: wiggle fixture;check loose wires
Check behind converterinside 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
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Quick SpliceConnectors
Blue= 16-14gauge wire
White = 18-14
Red= 22-18
Beige= 18-14 to12-10
Yellow= 12-10
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Installation of Quick Splice1. Align wires 2. Compress tab into connector
3. Snap cover into place 4. Pray it works
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Testing for 12VDC problems
Buy or build a 12VDC test light
Check switch; is it on ?
Check fuse; if fuse blows you have a shortCircuits must have a load or device to operate. Ashort means part of circuit is going around thedevice and blowing the fuse.
Shorts: bare wire touching ground; bad device
Loose connection
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Testing for 12VDC problemsWith power on check for power
Buy decent volt-ohm test meterwith buzzer to hear continuity
Continuity = connection across entire circuit
Connect continuity meter to each end of wire (NOpower one!) and listen for tone = continuity
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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
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120VAC: Household current
AC, outlets, converter input, appliances, etc.Connecting to shore-power (nautical term)
NO POWERin trailer
1. Plug fully inserted in
campground outlet?
2. Breaker switches on atcampsite power box?
3. Trailers breaker switches
on? (inside converter)
1 2
3
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120VAC: Household currentAC, outlets, converter input, appliances,
Check GFIC outlet.Push TEST button,
then RESET button.
Outlets can also bedaisy-chained withone GFIC outlet
protecting othersdownline.
12
3
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120VAC: Household currentAC, outlets, converter input, appliances,
Microwave ovens and wall A/Cunits may have their own GFImodule on the end of the
power cord. Locate the GFImodule (plugged into a 120VACoutlet).
Push TEST button, thenRESET button.
If no module on end of cord,check GFI outlet somewhere
else in trailer & reset there.
test & reset
buttons
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A simple, e!ective fix
Even very lightcorrosion can cause
electrical problems.Spray with electronictuner cleanerandlube
Around $15-$20 per11oz. aerosol can
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Inspection
ReplacingCleaning &
repacking
Adjusting
4. Axles & Wheel Bearings
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Whenever trailer needs to bejacked-up off the ground
Support with jack stands,not just jack
Use steel stands, NOT
concrete blocks orlumber piles!
Shake the trailer firmly
before you go under it!Stabilizers are NOTjacks!
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Inspection:
Roller bearings
Worn, grooved,cracked, burnt
raceBent, worn, crackedcage
Loose bearingswhen under load
race or cup
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Replacing wheel bearings
View of YouTube.com
Only di"cult part is driving outthe race or cup
Wear eye protection
Use a flat-nose punch, drift pin,bar of brass (steel)
Drive out carefully; dont jamrace cockeyed
Drive new race in straight untilseated; do NOT chip it !
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Cleaning & Repacking
Wash good bearing in solvent (mineral spirits, etc.)
Wipe dry or blow dry with compressed airBUT DO
spin the bearing (itll explode!)Pack with high-speed wheelbearing grease.
Check axle seal: greasebeyond axle flange? Replaceespecially with brakes!
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Repacking w/ grease gun
Straight steel nozzle works easily; rubber hose OK
Pump grease in until it comes around side ofbearing then stop; do not overfill
Carefully wipe out excessgrease with pinky finger.Caution SHARP EDGES!
Excess grease expands & can blowo!dust cap; lose grease causing bearing failure!
greasebearings
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Replacing bearing seal
Seals are inexpensive
Be sure to install themSTRAIGHT into hub
Seals only on backside
Double-check againstaxle for exact fit prior to
installation
Use 2x2 scrap & malletor hammer to install
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Adjusting bearing tension
Run nut down firmly;back-o!& spin drum/hub; tighten until drag.
Pull hub/drum out at 12
& 6 oclock & feel forplay (thump). Tightenjust until no thump.
Cotter pin curvesinternally; not straight
Cold chisel: mark slots
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Adjusting bearing tension (continued)
Cut o!excess cotter pinone side, bend overother end of spindle.
This is all the extra
grease you need; dontoverfill.
Drive dust cap onstraight; make sure itsseated properly or itmay fall o!(grease loss= bearing failure)
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5. Thems the breaksbrakes!But you can easily fix them
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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
http://www.al-ko.us/download/ALKO_Owner_Man._2-7K__05_2014.pdfhttp://www.al-ko.us/download/ALKO_Owner_Man._2-7K__05_2014.pdfhttp://www.al-ko.us/download/ALKO_Owner_Man._2-7K__05_2014.pdfhttp://www.al-ko.us/download/ALKO_Owner_Man._2-7K__05_2014.pdfhttp://www.al-ko.us/download/ALKO_Owner_Man._2-7K__05_2014.pdfhttp://www.al-ko.us/download/ALKO_Owner_Man._2-7K__05_2014.pdfhttp://www.al-ko.us/download/ALKO_Owner_Man._2-7K__05_2014.pdfhttp://www.al-ko.us/download/ALKO_Owner_Man._2-7K__05_2014.pdfhttp://www.al-ko.us/http://www.al-ko.us/ -
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Brake system components
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Brake drum Brake assembly
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driving stopping
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Inspection
Remove dust capRemove cotter pin
Remove nut
Remove outer bearing
Pull o!hub/brake drum
Check inner (axle) seal
Check bearings, races,etc.
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Inspection (contd)
Inspect brake lining
Check magnet wear
Check wiring
Replace seal if needed
Clean brake drum w/spray brake cleaner fluid
Pull magnet arm toconfirm brake actuation
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Repair (contd)
Consider replacing entirebrake assembly ($60 perside); just 4 bolts; all newparts
Replace component parts:$brake shoes, $springs,$magnet clip or spring, etc.
Check all brake wires &connections for continuity
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Repair & adjust
Carefully reinstall hub/drum; do not drag & tearnew seal
Re-torque spindle nut;install new cotter pin
Spin each drum with
same approximate force.Do they spin evenly?
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Inspection (contd)
Determine direction totighten / loosen brakes
Alternate methods:
Spin, tighten, spin, etc.until even spinning bothbrakes; brake spin 1 rev.
Tighten until drum stops;
back o!5 clicks.
Listen for light friction /rubbing
Inspection ( td)
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Inspection (contd)
Most laws require abreakaway switchon
trailers w/ brakes. If thetrailer separates from thepull vehicle, a cable willactivate the switch andSLAMS*on the trailersbrakes.
Pull the cable to listen forthe brakes to activate BUTimmediately reinsert the
key to shut o!the brakes.*Applies full voltage =excessive drain ontrailers battery.
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Test drive
Increasing brake shoedrag reduces fueleconomy, but increases
stopping power becausethe magnet can onlyswing so far. More drag= less distance formagnet to swing tomake more brake shoecontact. Find the happymedium.
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HAPPY CAMPING ! !