DIY RV Illustrated Repair Manual

CHAPTER 1

RECREATIONAL VEHICLES vs RESIDENTIAL CONSTRUCTION

New RV buyers often experience surprises and disappointment when they compare the build quality and maintenance requirements of RVs to traditional residential houses.  This contrast arises due to the unique nature and design of recreational vehicles and why RVs can sometimes fall short of residential expectations.

RVs are meant to travel over the nation’s roadways.  Therefore, RV manufacturers often prioritize lightweight materials to keep the vehicle’s weight manageable for towing and fuel efficiency.  This can result in the use of materials that may not be as durable or long-lasting as those used in residential construction.  Buyers may find that RV components like cabinets, countertops, and flooring are more susceptible to wear and tear.

RVs are designed to be compact and space-efficient, which can lead to limited interior space compared to a traditional home.  The need to fit all essential features into a smaller footprint can sometimes result in a sense of confinement and reduced comfort.

RV interiors may feature design choices that prioritize aesthetics over durability.  While residential homes often use materials that can withstand daily wear and tear, RVs may incorporate more delicate finishes and decorative elements.

RVs require regular maintenance due to their exposure to the elements and the constant vibration and movement experienced during travel.  Owners may be surprised by the frequency and range of maintenance tasks, which can include roof inspections, sealant reapplication, tire checks, and more.

RVs may not provide the same level of insulation and temperature control as residential houses.  Extreme temperature fluctuations can be a challenge, and some RVs may require additional insulation or heating/cooling solutions for comfort in different climates.

RV plumbing systems are more prone to freezing and potential issues due to the need for winterization and limited space for water tanks. Water leaks and plumbing maintenance can be more common in RVs.

RVs may have thinner walls and less sound insulation compared to traditional homes, which can lead to reduced privacy and increased noise levels when parked in close quarters with other RVs.

RVs often have limited storage space, which can be frustrating for those accustomed to the ample storage options available in residential homes.

RVs need to be designed to handle the stresses of travel, including vibrations, jolts, and flexing.  While residential houses are built for stability, RVs are constructed with mobility in mind.  The time it takes to build a fifth-wheel RV is obviously shorter compared to constructing a small one-bedroom house. RVs are built in controlled factory environments with standardized processes, which allows for faster production, usually about 4 days.   On the other hand, building a small house involves more variables, including site-specific factors and a great deal of attention to detail, and can take from two to six months each.  

Some new RV buyers are surprised by the total cost of RV ownership, which includes not just the purchase price but also maintenance, fuel, campsite fees, insurance, and ongoing operational costs. 

It is essential for prospective RV buyers to research and understand these differences between RVs and residential homes to set realistic expectations. Many RV enthusiasts embrace the RV lifestyle despite these challenges, appreciating the freedom and adventure that RV travel offers.  However, it is crucial to be prepared for the unique aspects of RV ownership to ensure a positive and enjoyable experience on the road.

Even Luxury RVs Have Issues

RVS REQUIRE REGULAR maintenance to stay in good working condition.  Here are some of the most common RV repairs that RV owners may encounter:

Electrical issues:  Problems with the RV’s electrical system are common.  This may include issues with the battery, wiring, or fuses.  Common symptoms of electrical issues may include lights that won’t turn on, appliances that won’t work, or other electrical components that malfunction.

Plumbing problems:  Issues with the RV’s plumbing system are also common.  This may include leaky pipes, clogged drains, or problems with the RV’s water pump.  Symptoms may include low water pressure, leaks, or unpleasant odors venting into the living space of your RV.

Roof damage:  RV roofs can become damaged from exposure to the elements and when passing by or under trees.  This may include cracks, leaks, or punctures.  Symptoms of roof damage may include water stains or dampness inside the RV and delamination of the roof membrane.

Tire issues:  RV tires can wear out quickly and may need to be replaced more frequently than car tires. Common tire issues may include flat tires, blowouts, or uneven wear.

HVAC problems:  The RV’s heating, ventilation, and air conditioning (HVAC) system may also experience problems.  Common issues may include malfunctioning thermostats, clogged filters, or issues with the RV’s air conditioning compressor.

Slide-out problems:  Many RVs have slide-outs, which can become misaligned, stuck or just malfunction.  Symptoms of slide-out problems may include difficulty extending or retracting the slide-out, or the slide-out becoming stuck in the wrong position.   

Tools All RV Owners Should Own and Know How to Use

Generally speaking, regular maintenance and inspections can help prevent many common RV repairs.  However, RV owners should be prepared and equipped to troubleshoot and address common issues to keep their RVs in good working condition.  There are several tools that RV owners should have on hand and be familiar with to help with maintenance and repairs while on the road.  Here are some examples:

Basic hand tools:  A set of basic hand tools, including screwdrivers, pliers, wrenches, hammer, cordless drill, and socket sets, can be very useful for general repairs and maintenance.  These make great gift ideas for birthdays, anniversaries, Mother’s or Father’s Day, Christmas, etc.

Multimeter:  A multimeter is a tool that can measure electrical current, voltage, and resistance.  It can be helpful in diagnosing electrical problems and ensuring that the RV’s electrical systems are functioning properly.

Tire pressure gauge:  Maintaining proper tire pressure is important for safety and fuel efficiency. A tire pressure gauge allows RV owners to check the tire pressure and ensure that it is at the manufacturer’s recommended inflation level quickly and easily.

Leveling blocks:  Leveling blocks can be used to level the RV and prevent it from rocking or shaking while parked.  This can improve comfort and prevent damage to the RV’s leveling, plumbing, and propane refrigeration systems.

Torque wrench:  A torque wrench is a tool used to tighten bolts to a specific level of tightness. This is important for maintaining proper tension on critical components like wheel lugs and engine bolts.

Sewer hose and fittings:  RV owners should have a sewer hose and fittings for dumping waste from the RV’s holding tanks.

Emergency kit:  An emergency kit should include items like a first-aid kit, flashlight, LED flares/hazard lights, batteries, water, and non-perishable food.  This can be important in case of unexpected breakdowns or emergencies.

RV owners should also be familiar with how to use these tools and perform basic maintenance tasks, as well as knowing when to seek professional help for more complicated repairs.

The Primary Systems in an RV

An RV (recreational vehicle) typically has several primary systems that allow it to function as a self-contained living space. These systems may vary depending on the type and size of the RV, but some common primary systems include:

Electrical System: RVs have three electrical systems, 12 volt DC chassis, 12 volt DC house, and 120 volt AC house.  These systems provide power to the RV’s appliances, lights, and other electrical devices.  It typically includes a battery or set of batteries, an inverter, and a converter to switch between AC and DC power.

Plumbing System: This system provides water for the RV’s sink, shower, and toilet, as well as a way to remove wastewater. It typically includes a freshwater tank, a gray water tank, and a black water tank.

Propane System: This system provides fuel for the RV’s cooktop, oven, water heater, and furnace appliances that use propane. It typically includes one or more propane tanks and a regulator.

Heating and Cooling System: This system provides temperature control for the RV, keeping it comfortable in hot or cold weather. It may include a furnace, air conditioner, or both.

Chassis System: This includes the engine, transmission, suspension, and other components that allow the RV to move on the road.

Safety System: This includes features such as smoke detectors, carbon monoxide detectors, fire extinguishers, and emergency exits to ensure the safety of the RV occupants.

CHAPTER 2

RV ELECTRICAL

First, the basics:

Before we discuss the steps to troubleshoot common RV electrical issues, I want to address some common concerns some people have regarding working around electricity.  First, there is nothing wrong with have a healthy respect for electricity.  As a seasoned master electrician, I can assure you that overcoming a fear of electricity can be challenging, but it is possible with the right approach.  Here are some steps that may help:

Educate yourself:  Learn about electricity, how it works, and the safety measures you can take to protect yourself.  This can help you understand the risks and reduce anxiety.

Start small:  Begin with small electrical tasks, such as changing a light bulb or plugging in an appliance.   This can help you build confidence and feel more comfortable working with electricity.

Take a course or workshop:  Consider taking a course or workshop on electrical safety or basic electrical skills.  This can provide hands-on experience and expert guidance.

Practice safety measures: Always practice safety measures when working with electricity, such as wearing protective gear and turning off power sources before working on electrical components.

Seek support: If your fear of electricity is interfering with your daily life or causing significant anxiety, consider seeking support from a mental health professional or support group.

Remember that overcoming a fear of electricity takes time and patience.  Take it one step at a time and seek help if you need it.  With practice and education, you can develop the skills and confidence to safely work with electricity.

How Electricity Works

Electricity is the flow of electrons through a conductor, such as a wire.  Electrons are negatively charged particles that orbit around the positively charged nucleus of an atom.  Normally, electrons are tightly bound to their atoms and do not move around freely.  However, when an external force is applied to the atoms, such as a difference in electrical potential, some of the electrons can be knocked free from their atoms and become free to move.  This creates a flow of electrons through the conductor, known as an electric current.

The strength of electrical current is measured in amperes, or amps.  The rate at which electric charge flows through a conductor is measured in volts, or voltage.  The resistance to the flow of electric current in a conductor is measured in ohms.

Electricity can be generated in various ways, including through the movement of magnets inside a wire coil (known as electromagnetic induction), chemical reactions in batteries, or by harnessing the energy of falling water in hydroelectric power plants.

Electricity is used in many applications, such as powering appliances and lighting, operating electronic devices, and providing energy for transportation. However, it is important to handle electricity safely, as it can be dangerous if one gets distracted.

Why You Should Own a Multimeter

A multimeter is a useful tool for troubleshooting electrical issues.  

Here are some steps to use a multimeter to troubleshoot electrical issues:

Set the multimeter:  Set the multimeter to the appropriate function for the measurement you want to take.  For example, if you want to measure voltage, set the multimeter to the AC or DC voltage function.

Connect the probes:  Connect the probes to the appropriate terminals.  For example, if you want to measure voltage, connect the red probe to the positive (+) terminal and the black probe to the negative (-) terminal.

Test the circuit:  Touch the probes to the circuit you want to test.  For example, if you want to test a battery, touch the probes to the positive and negative terminals of the battery.

Read the display:  Read the measurement on the multimeter display.  For example, if you are measuring voltage, the display will show the voltage reading.

Interpret the results:  Interpret the results to diagnose the problem.  For example, if the voltage reading is low, the problem may be a low battery or a faulty power source.

Repeat as necessary:  Repeat the steps as necessary to test different circuits or components.

It is important to note that when using a multimeter, always follow the manufacturer’s instructions and safety guidelines.  Always wear appropriate protective equipment, such as gloves and safety glasses, when working with electrical components.

RV Electrical Systems Explained

An RV, or recreational vehicle, typically has three different electrical systems, each serving a unique purpose.  Understanding the different electrical systems in an RV is important for proper maintenance and troubleshooting.  It is essential to follow proper safety procedures when working with any electrical system.

Some manufacturers describe RV electrical systems as being a hybrid system that combines both 12V DC and 120V AC electrical systems.  Practically speaking, this statement is true.  Electrically however, the three systems are separate and must be so.  There are electrical components that allow the RV to operate on either DC or AC power, depending on the availability of an external power source.  The converter converts AC power to DC power to charge the battery and power low-voltage appliances and devices. The inverter changes DC power to 120V AC power to run residential refrigerators and other household types of items.

The 12V DC Chassis Electrical System.

The chassis electrical system in an RV is responsible for powering and controlling the various systems and components of the vehicle’s chassis, including the engine, transmission, and suspension.  The components of the chassis electrical system can vary depending on the make and model of the RV, but typically include:

Battery: The primary power source for the chassis electrical system.  It is typically a 12-volt battery that provides power to the starter motor, lights, and other electrical components.

Alternator: Responsible for charging the battery while the engine is running.  It converts mechanical energy from the engine into electrical energy to power the various electrical components of the chassis electrical system.

Starter motor: Responsible for turning over the engine and getting it started.  It draws power from the chassis battery and converts it into mechanical energy to turn the engine.

Ignition system: Responsible for providing the spark (in gasoline engines) that ignites the fuel in the engine’s cylinders.  It includes components such as the ignition coil, distributor, and spark plugs.

Sensors and control modules:  The chassis electrical system also includes various sensors and control modules that monitor and control the vehicle’s operation.  These can include sensors that monitor engine speed, temperature, and other parameters, as well as control modules that adjust engine timing, fuel injection, and other functions.

The power source for the chassis electrical system is the motorhome or tow vehicle’s starter battery, which is typically charged by the alternator while the engine is running.  The alternator converts mechanical energy from the engine into electrical energy to charge the battery and power the various components of the chassis electrical system.  The battery also provides power to the electrical components of the chassis electrical system when the engine is not running, such as when the RV is parked, or the engine is turned off.

The 12V DC House Electrical System:

The 12V DC electrical system is used to power low-voltage appliances and devices, such as lights, water pumps, and fans.  The system is powered by one or more house or coach batteries, which can be charged, through a converter, either by plugging the RV into an external power source or generator, or by using solar panels. The 12V DC system is separate from the 120V AC system and is typically through a separate set of fuses or circuit breakers and is usually powered by deep-cycle batteries (or a battery bank), which are separate from the engine-starting battery.

An RV’s 12-volt DC (Direct Current) house system is an essential part of its electrical setup, providing power to various components within the living area of the RV. Here are the key components that make up the RV’s 12-volt DC house system:

Deep-Cycle Batteries: Deep-cycle batteries are designed to provide a steady supply of power over an extended period.  They store electrical energy and serve as the primary source of 12-volt DC power for the house system.  RVs can have one or more deep-cycle batteries, typically located in a dedicated battery compartment.  Lead-acid batteries and lithium-ion batteries have different characteristics and safety considerations, which influence their storage locations in recreational vehicles (RVs):

Ventilation and Maintenance Requirements:  Lead-acid batteries release potentially harmful gases, primarily hydrogen gas, during charging, a process called off-gassing.  Adequate ventilation is required to disperse these