diy repair and maintenance

7/27/2019 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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Trailers hitch

latch

mechanism:use light oil


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Trailers hitch

latch

mechanism:use light oil


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Trailers hitch

latch

mechanism:

use grease &

light oil


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Door hinge

& latch:use light oil


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Roof panels

where guide

rides:usesilicone spraySpray both

interior EDGE

& TOP of

aluminum

extrusion

silic

one

spray


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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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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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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 ! !

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