Tag Archives: wiring

Troubles on the Road

There’s no perpetual motion machine, no unbreakable machine, no way to escape certain things like maintenance and repairs. We may try to avoid working on things that are still “sort of working”, but we’ll eventually get our hands dirty. Many of us are, consciously or unconsciously, aware of deferred maintenance, known more familiarly as procrastination.

Debbie and I try to keep up with all the required and advisable maintenance on our truck and Airstream trailer. In ten years, we’ve had very few problems, maybe not ten in all until our travels this summer. This story is one of my longer ones — Sometimes, like everyone else, we learn we missed something important. In this case, more than several things:

(1) Two months ago we learned our trailer brakes were broken. Fortunately we discovered the damage in Airstream’s excellent service facility in Jackson Center OH. The great folks in the service shop were going to do a quick brake adjustment. But it turned out to be more — much more.

Short story, Airstream replaced the electric brake magnets on all four wheels, turned all four drums, and put our brakes back together again for us. Ouch! We didn’t even know they were coming apart. Airstream Service DOES IT RIGHT! We’re good now, thanks to them.

(2) Both the charge converter and the solar charger quit charging the batteries on our way to the Region 2 Rally in early June. We need these to keep the trailer’s batteries up to keep our lighting, music, fans, and water pump working.

We were using the lights and fans, so we seemed to have battery power. But the battery monitor, a really cool Trimetric 2025, showed the batteries were discharging and not getting any juice from the chargers. Strange.

Finally I turned off the charge converter on the 120vac breaker panel in the trailer. The trailer’s lights and fan died immediately. I pulled the 12 volt system main (30a) fuses. They looked okay and I put them back in place. Everything turned back on and the batteries were getting a charge from the charge converter. The contacts for the two small 30 amp fuses for the 12 volt system weren’t letting juice get through the contacts until I removed and reinserted them. Okay — fixed.

(3) Next, our solar charge controller had stopped noticing sunlight. Instead of the soft amber light signaling everything is copacetic, we now had a bright red indicator light. No more charging from our solar panels, no matter how great the sunlight. We’d replaced our solar charge controller before, but only after it had a stunning smelly electrical circuit board failure.

Figuring I had nothing to lose, I pulled the fuses on all the power connections to solar power system, took the solar charge controller out, and took it apart. Apparently all the smoke was still inside. This time there were no smelly surprises, no charred diodes. I carefully cleaned the contacts, board and components, reassembled the solar charge controller, and put power back to it. It works perfectly. Yep! I probably only needed to do a power reset on it in the first place. We’ll call the extra work preventive maintenance.

(4) A few days later at a rally with the Airstream club’s Region 2 folks near Penn State, we had another surprise. Thanks to John Hussar for doing a propane safety check on our trailer (and even our gas grill!) One of the hoses showed a slight leak on a crimped fitting, according to John’s very sensitive meter. During our stay in Albuquerque NM we had Randy at R and L Propane Service make us a new set of hoses to connect the propane tanks to the gas regulator.

(5) Next, our shower head stopped working. Nothing but a dribble out of it. While we were at the Airstream Service facility I felt courageous enough to tear into the shower plumbing. I’d tried cleaning the shower head but didn’t find anything in it. I wondered about the long flexible hose. Killing two birds with one stone, I replaced the kitchen faucet with the shower hose. Great flow! Years ago a friend told me he’d removed his shower’s vacuum breaker. It’s at the bottom of the hose, where the water comes through the shower wall in a nice chrome elbow. These come in all shapes, ours looked like this:


Okay, not the cut-off valve, not the hose, not the shower head. I took off the vacuum breaker, reconnected the shower hose and the most amazing thing happened. We have incredibly great flow and pressure, like never before. Why didn’t I do this ten years ago? Good grief!

(6) Shortly after, Debbie’s vanity lights went dim. These are pretty high tech LED super-bright (205 lumens) lights (similar to these.) They seem 1.5X brighter than 12 diode pucks, even though they’re only 3 LEDs. Expensive too, at $19 each through Camping World (you can find them cheaper but might not receive warranty replacement at on-line stores.) Fortunately there’s a Camping World next door to Randy’s Propane Service place and they stock these. Okay, another problem fixed on this trip.

(7) Then, our kitchen cabinet door just barely worked. I’d tightened the Grass hinge screws but the screws wouldn’t stay tight. The door became really sloppy. I’d tighten the two hinges and the door worked perfectly. For a few days, then loose again. I finally took the hinges off, inserted big round toothpicks in the woodwork’s screw holes, and reattached the hinges. A month later and still okay.


(8) On our I-40 voyage into New Mexico I was blowing my horns to say HI in morse code (dit dit dit dit dah dah) to W5AOX Jim while talking on the ham radio with him as we crossed paths East and West. When I keyed the microphone, the horns died, the ham radio quit, and the GPS went blank. No power to any of these accessory loads. I’d overloaded the circuit because the new air horn compressor is a power hog and so is the ham radio when I’m talking full power. Short fix, replaced the 25 amp blade fuse for the accessory circuit and good to go. Project for later – add a dedicated fused line from the battery to the air compressor.

(9) During our stay in New Mexico, the truck’s air horn system completely died. The dash switch had power and I detected power to the relay. Oddly, the primary line only had 11.5 volts compared to the truck’s 12.5+ volts. Instead, I waited until I could get into the project mentioned at the bottom of number (8) above.

If I’d remembered how the line was connected I might sooner have figured out the problem and easily made a temporary repair (just as well I didn’t.) Here’s what I used when I had spliced the air compressor’s line power:

Solderless Wire Quick Splice Connector

Solderless Wire Quick Splice Connector

As soon as I removed the tape from the joint and saw this connector I knew why voltage was low and no current could get to the load — the inexpensive splice connector didn’t hold up. I removed the splice and installed a new (fused) wire straight to the battery. Everything is good. Many of you are probably saying, “He should have run a line direct from the battery in the first place.” You’re right. That’s what I did for the ham radio because we always do that for ham radios.

(10) On our way back from NM, I reached up to turn one of the reading lamps above our bed. It fell loose into my hand, tethered only by the 12vdc wires. Granted, the shelf it’s screwed into is a thin material but heck, I was just re-aiming it! For a long time I’ve wondered if I could, some day, get the squeak out of the ball joint that allows aiming these neat little lights.


I squirted a tiny spray of Boeshield T-9 onto the ball joint and the swivel. Wowzers, I should’ve done this years ago! The light head swivels and aims silently and smoothly. Just one more case where deferring maintenance probably hastened the attachment failure. Oh yeah, and I reattached the lamp to the shelf in new holes.

(11) On the way home from New Mexico two weeks ago we drove eastward through two days of hard rain on I-40. On the second day we realized neither the fridge nor the water heater would light on propane. The water heater’s never given us a minute of trouble and the control board is potted in some kind of epoxy so looks really waterproof. The fridge, on the other hand, has been troublesome off and on for all ten years of travels.

Good news, the fridge still worked on electric (110vac) and our inverter and batteries can handle the load. The drain on the batteries wouldn’t be a big issue for short drives but we were driving Farmington NM to Charlotte NC in four days, averaging 450 miles daily.

Dinosaur P-711 board

Dinosaur P-711 board

Also good news, we have Dinosaur Electronic’s P-711 control board for Dometic fridges and Dinosaur has GREAT customer and tech phone support. I talked with Chris at Dinosaur who determined the board was functioning but perhaps it’s the thermocouple?

fridge thermocouple

fridge thermocouple

On the way to Camping World the next day, the water heater and fridge both fired up perfectly. We’ve been asked a few times what spare parts we carry for our RV. Just added a (spare) thermocouple for the fridge — Chris at Dinosaur may have been right and we’ll be ready.

We had more maintenance issues in June and July this year than in the ten previous years. We should be good now, everything’s been fixed. Now, everything works perfectly and we don’t have to do any maintenance until the next thing happens — or maybe we should? I think yes we should.

Next post may be about spare parts — what else do we carry?

See you down the road!

Jim and Debbie

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It’s finally warming a little

We are enjoying slowly warming temperatures and will hopefully start seeing less cold. We’ve been wishing for weeks it would warm up, maybe we can go to the beach sometime. Or even hang out poolside — with the cool and breezes we haven’t often felt tempted to get down to just swimsuits.

Sunset over Lake Okeechobee

One evening we walked a little of the Lake Okeechobee rim to watch the sunset. It was a good one, not only because the wind was down and weather a little warmer, but we had a pretty nice sunset too. From our door to the rim’s footpath is only 1/2 mile, so we’ll do this some more.

This past few week’s persistent and strong winds have disinclined us to try and hit any tennis together but we’ll probably try to get out next week a few times. Jim gets out once or twice a week with the town’s local tennis group for a few sets of doubles. We both would play a lot more if tennis courts were on our park’s campus.

Debbie is enjoying aerobics 3 days a week plus line dancing another day, and we both are in a dancing class on Wednesdays. This year we have continued working on waltz and the sixteen step (Polka, you know), and are adding a swing step that is sort of similar to Shag. The start step, and turns, and twinkles are interchangeable between both dances. Now we just need practice to keep from forgetting what we’re learning.

Today has been really sunny with the sky a beautiful deep blue color. First low-wind morning in over a week, and we hit 70 degrees for the first day in many. We had a productive shopping trip this morning to the flea market vendors for some electrical fittings and some used tools for upcoming projects. And Jim picked up a small relay from Radio Shack for another wiring project.

Speaking of projects, Jim’s had a lot of fun with a few of them these cool several days. He mounted a very small switch on the doors of our wardrobes. Our LED lights inside the wardrobe now turn on automatically when we open the door. Convenient this is, but we are still getting used to it. We sometimes turn the light off accidentally, instead of letting the little switch do it.

He added a GPS-18pc puck to our Kenwood ham radio. We now have dynamic GPS tracking whenever our truck goes anywhere. This is a novelty for us, to watch where our truck has been. You can see what the tracking looks like for yourself here, if you’re interested. This link shows the past 24 hours, and you can select from the right side of your screen for longer or shorter periods.

Today Jim rewired some of the 12 volt accessory power distribution for our truck. We have the gps puck, a navigation gps, and a tire pressure monitoring system all getting their power from accessory plugs, like cigarette lighter plugs. These are bulky and sometimes get in the way.

So Jim removed two of these accessory plugs and replaced them with Andersen power poles. These nifty connectors are a standard among many amateur radio operators, and are very effective for mobile wiring, especially since he is soldering all his wire connections.

He also plans to change the main circuit for the accessories so it is fed through a 12vdc spst relay instead of feeding through a switch. We installed a switch to allow a convenient disconnect for all the accessories we added in the truck cab. Our re-wiring of the trailer’s ham radio power circuit went so well Jim wants to replicate it in the truck.

The relay allows us to turn power off and on for a large wire circuit using a small switch and control wire. The relay is like a heavy duty switch we can mount out of sight under the dash somewhere. The benefit is to allow smaller (less bulky) wire and terminals to the switch, so the switch doesn’t need as much space. And, the relay is a better connector between the battery and the accessories. Plus, it gives Jim something fun to do.

Tonight is only going to be 40 degrees F, warmer than any of the past several nights. And tomorrow is going into the mid-70s so we’re expecting a really nice day. We’re ready for the nicer weather — if we thought somewhere else would reliably have nicer weather we’d seriously have considered relocating.

Wherever you are, we hope you too are seeing a little warmer weather on its way. Our weather has been as variable and cooler-than-normal as everywhere else. Just not as cool as most places, so we’ll stay here and wait for warm days. And we’ll start seeing the warming weather over the next two weeks. Bring it on — we can do with a little warming!

Jim and Debbie
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