DIY Repair and Maintenance

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DIY: Novice Maintenance & Repair
You really CAN do it!
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 first time.
If you break down, you know better how to
fix it or have it fixed.
You can do repairs when YOU
want 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” !
Tasks we’ll 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
Trailer’s hitch
latch
mechanism:
use light oil
1. Simple items needing lubrication
Trailer’s hitch
latch
mechanism:
use light oil
1. Simple items needing lubrication
Trailer’s 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
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i
c
o
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e
s
p
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a
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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 trailer’s 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
you’ll 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 fixture is smooth
or cushioned so as to not cut, wear or abrade the
bungee due to rubbing or chafing.
Test your first bungee installation before doing
the second bungee: erect roof several times.
Check for cord being too loose or too tight.
3. Simple Electrical Issues
You’ll be shocked at how much you can do!
12VDC lighting & wiring
You won’t get a shock, it’s only 12 volts.
But a direct “short” to the battery can cause:
sparks; fire; 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 trailer’s 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 fixture
Interior lighting: wiggle fixture;
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. Trailer’s 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 fix…
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 firmly
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 flat-nose punch, drift pin,
bar of brass (steel)
Drive out carefully; don’t 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 (it’ll explode!)
Pack with high-speed wheel
bearing grease.
Check axle seal: grease
beyond axle flange? 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 overfill
Carefully wipe out excess
grease with pinky finger.
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 fit prior to
installation
Use 2x2 scrap & mallet
or hammer to install
Adjusting bearing tension
Run nut down firmly;
back-o! & spin drum/
hub; tighten until drag.
Pull hub/drum out at 12
& 6 o’clock & 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; don’t
overfill.
Drive dust cap on
straight; make sure it’s
seated properly or it
may fall o! (grease loss
= bearing failure)
5. Them’s the breaks brakes!
But you can easily fix them
Download AL-KO
Owner’s 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 (cont’d)
Inspect brake lining
Check magnet wear
Check wiring
Replace seal if needed
Clean brake drum w/
spray brake cleaner fluid
Pull magnet arm to
confirm brake actuation
Repair (cont’d)
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 (cont’d)
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 (cont’d)
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 trailer’s
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
trailer’s 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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