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AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL

D-11

14. Install outer bearing.

15 Install washer and spindle nut

16. While rotating the wheel, tighten the spindle nut with a 12" wrench until there is a slight tension. Then
back off one notch and install cotter pin. There should now be from .001" to .010" endplay in hub. If not,
back off one notch.

17. Check and retighten the lug bolts, if necessary, every 50 miles for the first 200 miles of travel. They
should be tightened to torque of 85 ft. lbs.

When greasing bearings by hand, place a glob of grease
in the palm of one hand and push the large end of the
bearing down into the grease (see illustration). Keep
turning the bearing around and forcing it down through
the grease until the grease is extruded up through the
opposite end. Wipe the extra grease in your hand around
the outside of the bearing. It's not necessary to fill the hub
and dust cap with grease.

AXLE AND RUNNING GEAR ASSEMBLY

1. Rubber torsion Axle
2. Unicast Hub and Drum
3. Valve Stem
4. Wheel
5. Brake Set
6. Lug Nuts
7. Shock Absorber
8. Shock Absorber Bushing
9. Dust Cover
10. Outer Bearing
11. Inner Bearing
12 Grease Seal
13. Spindle Cover
14. Retainer Bearing
15. Nylon Bushing

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Summary of Contents for INTERNATIONAL TRAILER

Page 1: ...AIRSTREAM AN AMERICAN LEGEND INTERNATIONAL TRAILER 2002 OWNERS MANUAL ...

Page 2: ......

Page 3: ...ntained in it useful however should you ever feel you may be getting in over your head please see your dealer to have the repairs made A brief explanation of the operation of the appliances such as refrigerator furnace water heater and others are explained in this manual However you will also find the manufacturer s information supplied in a packet included with this manual All information illustr...

Page 4: ...R Cleaning Chassis Windows Screens Power Jack Tires Axle and Running Gear Electric Brakes E INTERIOR FURNISHINGS AND ACCESSORIES Fabric Care Flooring Fixtures Central Control Panel Features Switches Storage Areas Smoke Alarm LP Gas Detector Fire Extinguisher F PLUMBING LP Liquid Petroleum Gas Water Water Pump Drainage Winterizing Drain and Waste Toilet G ELECTRICAL 12 volt Operation Battery Conver...

Page 5: ...kmanship of the trailer or component equipment as installed by the factory LIMITATION OF IMPLIED WARRANTIES All warranties of merchantability and fitness for a particular purpose whether written or oral expressed or implied shall extend only for a period of two years from the date of original purchase There are no other warranties which extend beyond those described on the face hereof and which ex...

Page 6: ...t accept any responsibility in connection with any of its trailers for additional equipment or accessories installed at any dealership or other place of business or by any other party Such installation of equipment or accessories by any other party will not be covered by the terms of this warranty IF REPAIRS ARE NEEDED If your trailer needs repairs under the terms of the basic Airstream Limited Wa...

Page 7: ...enses gasoline oil lodging meals telephone tolls and loss of work and loss of use of the trailer Some examples of consequential damages would be stained curtains due to rain leaks or delaminated floor caused by a plumbing leak Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you WARRANTY TRANSFER The b...

Page 8: ...armful to finishes if not washed off periodically Extremely hot or direct sunlight will deteriorate rubber and fade curtains and upholstery Conditions of this nature although they may be normal for the area are beyond Airstream s control and become the responsibility of the owner Although it is our obligation to correct a rain or plumbing leak within the terms of the limited warranty it is the own...

Page 9: ...te He can also provide you with additional copies if you need them ALL CENTERS OPERATE ON AN APPOINTMENT BASIS FOR THE UTMOST EFFICIENCY When you require service from the Airstream Factory Service Center or a Certified Dealer Service Center please contact the service manager for an appointment and kindly inform him if you are unable to keep the appointment date or wish to change it Service may be ...

Page 10: ...1 000 miles Torque 85 ft lbs EVERY 5 000 MILES OR 90 DAYS Exterior Door locks Lubricate with dry graphite Exterior Hinges Lubricate with light household oil LPG Hold Down Lubricate with light household oil LPG Regulator Check bottom vent for obstructions Main Door Striker Pocket Coat with paraffin Wheel Lug Bolts Torque to 85 ft lbs Break Away Switch Pull pin and lubricate with household oil 7 Way...

Page 11: ... parts with silicone lubricant Exterior Wax Do not use an abrasive cleaner or wax Escape Window Lubricate latches with WD 40 EVERY YEAR Battery Clean neutralize and coat terminals with petroleum jelly A Frame Step Wire brush and paint frame at front and rear LP Bottles Have purged by LP supplier Seams Check and reseal exterior seams windows lights and vents as needed Use Acryl R seam sealer or equ...

Page 12: ...FUSES Radio ATC 15 Amp Battery Cable Fuses Canadian approved trailers only SLC 50 Amp Power Center 20 30 amp Automotive fuses Battery Disconnect Relay ATC 5 amp 12 VOLT BREAKERS under bed 50 Amp Type 2 30 Amp Type 2 20 Amp Type 2 MISCELLANEOUS Water Hose Gaskets Wheel Bearing Grease Extra Hair Pin Clips for Hitch Grease Seals Dry Graphite WD 40 or Equivalent Aerosol Lubricant Oil Can with 30 Weigh...

Page 13: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL A 9 MAINTENANCE RECORD DATE DEALER SERVICE PERFORMED ...

Page 14: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL A 10 NOTES ...

Page 15: ...better to have one full and one empty locker than two half empty ones Special care must be taken not to overload the front and rear ends of the trailer NOTE Be realistic when ordering heavy duty springs Only springs heavy enough to support your loaded vehicle not including trailer are necessary Too harsh of spring rate will only shorten the life of the tow vehicle and trailer and will make your jo...

Page 16: ... corrosion within the breakaway switch pull the switch s pin straight forward and spray the inside of the switch through the hole with an electric contact cleaner such as Spra Kleen and re insert pin A drop of light household oil on the groove near the base of the pin will allow the pin to operate freely WHEN THE TRAILER IS CONNECTED TO THE TOW VEHICLE THE BREAKAWAY SWITCH LOOP SHOULD BE ATTACHED ...

Page 17: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL B 3 12 Volt Layout ...

Page 18: ...items such as generators heavy toolboxes or motorcycle racks to the back of the trailer Weight behind the axle will tend to magnify any sway that may occur when passing trucks or in gusty wind If a heavy generator is mounted on the rear bumper what may have been an almost unnoticeable sway turns into a severe sway you may not he able to control CAUTION Damage to your trailer caused by mounting hea...

Page 19: ...gue load to a lower value To determine tongue load unhitch tow vehicle and place the tongue hitch post on a scale The trailer must be properly loaded as determined above with your allowable personal cargo and variable weights Used a scale such as a bathroom scale that has a lower weight limit than your tongue load to check the tongue weight by using the following method see illustration Place a pi...

Page 20: ...y Control Device Although Airstream has not intruded into the hitch manufacturers field of expertise and preformed formal testing we find the vast majority of Airstream owners purchases sway control devices When passed by large trucks or when exposed to sudden crosswinds the trailer will be pushed and this action will be felt in the tow vehicle It s our understanding the sway control devices will ...

Page 21: ... trailer and reducing the weight on the for wheels of the tow vehicle With proper hitch installation and hitching up the bar should have a noticeable amount of the deflection or bending See figure 8 A little practice with your rig will teach you how far to pull the bar you may wish to mark the chain links that match your rig Always choose level ground for checking correct hookup Note If your tow v...

Page 22: ...aximum ground clearance Remove the jack pad See Figure 12 and stow in the car s truck along with the leveling jack and other gear used when stopped NEVER TOW YOUR TRAILER WITH THE JACK DOWN Check that the foldaway step is up and that the main door is completely closed and the deadbolt LOCKED for towing If it is not locked the constant vibration of travel may cause the main door to open with possib...

Page 23: ...at a lower speed It is both courteous and sensible to signal pull onto the shoulder and let them pass Your trailer is designed to be towed easily at any legal speed so if you are not careful you may be inclined to forget it is there The BRAKE CONTROLLER is activated when you apply the brakes of the tow vehicle Your tow vehicle brakes will automatically apply the trailer brakes first when properly ...

Page 24: ...ly power gently and use as little as possible Stay in the tracks of the vehicle ahead and keep the tow vehicle in the highest possible gear If you get stuck it is best to tow out the entire rig together without unhitching Despite the best hitch you will notice that whenever a large bus or truck overtakes your rig the displaced air first pushes the trailer rear slightly to the right and then affect...

Page 25: ... an arc Straighten the car and trailer by turning the steering wheel more sharply and then when they are in line straighten the steering wheel ALWAYS TRY TO BACK TO YOUR LEFT BECAUSE THE VISIBILITY IS MUCH BETTER See Illustration When you don t make it on the first try it is usually much easier to pull forward to your original position and start over If your spouse or traveling companion normally ...

Page 26: ...jack Remove and stow jack stand foot or wood block 7 Check clearance turn signals and stop lights 8 Check lug nuts 9 Check tires for correct pressure 10 Check that TV antenna is properly stowed 11 Adjust tow vehicle mirrors 12 Pull forward some 50 ft test brakes and check site for forgotten objects and cleanliness Home 1 Leave house key with your neighbors 2 Valuables and important papers should b...

Page 27: ...ilm 6 Make a checklist of clothing for everyone and toilet articles 7 Prescribed medications 8 Birth certificate 9 Medical insurance cards Motoring Essentials 1 Display the car and trailer registration properly 2 Carry valid drivers license 3 In Mexico you must have special auto insurance 4 Carry an extra set of the ignition and truck keys in a separate pocket or in your wallet 5 Keep an operating...

Page 28: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL B 14 NOTES ...

Page 29: ... escape route outside your escape window at every stop At each campsite make sure you have not parked in such a manner as to block the operation of the escape window by being too close to trees fences or other impediments Scenic views are one reason for traveling but don t park so the beautiful lake or steep cliff is just outside your escape window Never park your trailer so the escape windows can...

Page 30: ... installed sanitary dumping stations for just this purpose Booklets are available which lists these dumping stations When stopping for the night your Airstream is built to be safely parked in any spot that is relatively level and where the ground is firm Your facilities are with you You are self contained Unless the tow vehicle is needed for transportation it is not necessary to unhitch WARNING Do...

Page 31: ...one easily by backing the trailer up one or more 2 x 6 boards See Diagram We do not recommend placing tires in a hole for leveling LEVEL FROM FRONT TO REAR by disconnecting the hitch from the tow vehicle putting the jack pad under the hitch jack and adjusting the jack up or down until you are level Block or chock the wheels to keep the trailer from rolling Use STABILIZING JACKS at the two rear cor...

Page 32: ...for use with the city water feed The Power Cord hook up is on the roadside of the trailer The cord may be stored in the rear exterior compartment The power cord is plugged into the trailer receptacle and the City Power Service CAUTION When operating with city power make very certain that the service is 110 volt and not 220 volt Hook your SEWER WATER DRAIN HOSE in the SEWER DISPOSAL FACILITY and at...

Page 33: ...e refrigerator cabinet and behind the bedroom TV flip down shelf in the 22 FT AS model and above the desk and bedroom TV stand in the CCD model The interior telephone receptacle is by the main door beside the magazine rack in the 22 FT AS model and above the desk and bedroom TV stand in the CCD model WARNING Check your escape window s to make sure they will open completely Also make sure the terra...

Page 34: ...to be turned on while moving While traveling in these states you must use your common sense How cold is it How long will it be before you can turn the heat back on Is the temperature dropping or raising Remember when towing at 50 MPH the wind chill factor will cause the interior of the trailer to cool much faster than a trailer that is parked When parked in sub freezing temperatures make sure you ...

Page 35: ...l areas where the finish is exposed to salt air or in polluted industrial areas It will also protect the shell from minor scratches and make subsequent cleaning easier It is important to remove sap gum resin asphalt etc as soon as possible after they appear by washing and waxing Sunlight and time will bake harden these materials making them almost impossible to remove without heavy buffing If asph...

Page 36: ...nd escape window operation in the Camping section under Safety in this manual Clean your trailer windows the same way you clean the windows in your home Clean the seals with a damp cloth or mild detergent every three to six months taking care not to use strong solvents as they will damage the seals A coat of natural silicone lubricant applied after the seal has dried will keep it flexible Spread t...

Page 37: ...ler and of same or greater capacity 3 When ball is completely nested in socket push top of latch handle rearward until handle snaps into closed position Figure 2 4 Extend jack to ground and lift car trailer combination 2 4 to insure coupler is securely attached to tow ball Retract jack before towing 5 Insert padlock through hole in handle for theft prevention POWER JACK Hi Power Acme 3 000 Operati...

Page 38: ...Do not use the electric toggle switch raise and lower with the manual crank in place on the jack post The crank will spin if the switch operates motor and will cause serious injury Maintenance Once a year the power head should be removed and a liberal amount of grease preferably a grease with high melting point applied directly to the coupling on which the drive pin rests DO NOT POUR OIL into the ...

Page 39: ...Manufacturing Co 730 east Michigan Ave Battle Creek MI 49014 Customer Service Phone Parts Ordering 616 965 2371 Part Numbers are on Next Page P N Required Description 1 21047 1 CRANK 2 600 0011 1 HEX BOLT 20X 3 4 3 27268 1 CAP MACHINED BLACK 27341 WHITE 4 736 0005 1 ACTUATOR TOGGLE SWITCH AND NUT ...

Page 40: ...HER SPACER 27 27251 1 GREY WIRE ASSEMBLY 28 623 1216 1 GROOVE PIN 29 606 0009 2 10 X 3 8 SCREW LIMIT SWITCH 30 636 0000 1 HEX KEY 31 618 1002 1 LOCK WASHER 32 80504 1 SNAP BUSHING 33 80501 2 BUSHING 34 645 0024 1 FLANGE BUSHING 35 641 0009 1 BUSHING 36 635 0015 1 0 RING TOGGLE SWITCH SEAL 37 16434 2 HOLE PLUG 38 621 0004 2 1 8 DIA X 3 4 DOWEL 39 634 0023 1 RETAINER RING 40 27512 1 LIMIT SWITCH ASS...

Page 41: ...es To CHANGE A TIRE with a jack see the label affixed to the underbelly to the rear of the wheels This label says JACK with an arrow and points to a plate riveted to the mainframe rail where the jack head must be placed A flat tire may also be changed without the aid of a jack Drive the unit up on a ramp 8 wide 6 high and about 3 feet long at its base Position the good tire on the ramp This will r...

Page 42: ...ncluding your spare at least monthly when the tires are cool after the vehicle has stopped three hours and then driven less than one mile Do not reduce pressure when tires are hot Use a tire gauge to check pressure and maintain it at the recommended level 2 Never overload your tires The maximum load carrying capability of your tires is molded on the sidewall of the tire 3 Check your tires frequent...

Page 43: ...irstreams is stored under the front of the trailer The front handle of the tire carrier is a one inch tube protruding out from under the front A frame on the curbside It is secured by a bracket and bolt along the inside of the A frame rail Removing the bolts allows the front on the tire carrier to be lowered and the spare tire removed ...

Page 44: ...le checked on a random basis Alignment after delivery is the customer s responsibility CAUTION Never allow heat to he applied to the axle tube since the rubber providing the spring torsion action will he severely damaged Rubber torsion Axle Alignment Specifications Toe In each side 1 16 Tolerance 1 16 or Camber each side º positive Tolerance º or Wheel Bearing Maintenance 1 Jack trailer at marked ...

Page 45: ...en greasing bearings by hand place a glob of grease in the palm of one hand and push the large end of the bearing down into the grease see illustration Keep turning the bearing around and forcing it down through the grease until the grease is extruded up through the opposite end Wipe the extra grease in your hand around the outside of the bearing It s not necessary to fill the hub and dust cap wit...

Page 46: ...ar and trailer the BREAKAWAY SWITCH will set and lock the trailer brakes for a sufficient length of time to stop the trailer The switch is activated when the wire attached to it and to the car pulls out the small pin in the front of the unit THIS PIN SHOULD BE PULLED OUT LUBRICATED WITH LIGHT HOUSEHOLD OIL AND REPLACED EVERY 90 DAYS To prevent corrosion within the breakaway switch pull the switch ...

Page 47: ... in the brakes The high capacity electromagnets are energized and are attracted to the rotating armature surface of the drums which moves the actuating levers in the direction that the drums are turning The resulting force causes the actuating cam block at the shoe end of the lever to push the primary shoe out against the inside surface of the brake drum The force generated by the primary shoe act...

Page 48: ...pressure on the brake pedal It is important that your brake controller provide approximately 2 volts to the braking system when the brake pedal is first depressed and gradually increase the voltage to 12 volts as brake pedal pressure is increased If the controller jumps immediately to a high voltage output even during a gradual stop then the electric brakes will always be fully energized mid will ...

Page 49: ...ng braking When this adjustment is complete make a hard stop or two from 20 mph to check for wheel lockup and whether further fine tuning of the System Resistor is required GENERAL MAINTENANCE BRAKE ADJUSTMENT Brakes should be adjusted 1 after the first 200 miles of operation when the brake shoes and drums have seated 2 at 3000 mile intervals 3 or as use and performance requires The brakes should ...

Page 50: ...NING DUST CAN BE REMOVED WITH A DAMP BRUSH Brake Lubrication Before reassembling apply a light film of Lubricate or similar grease on the brake anchor pin the actuating arm bushing and pin and the areas on the backing plate that are in contact with the brake shoes and magnet lever arm Apply a light film of oil on the actuating block mounted on the actuating arm CAUTION DO NOT GET GREASE OR OIL ON ...

Page 51: ...king the voltage so that low batteries will not affect the readings Voltage in the system should begin at 0 volts and as the controller bar is slowly actuated should gradually increase to about 12 volts This is referred to as modulation No modulation means that when the controller begins to apply voltage to the brakes it applies an immediate high voltage which causes the brakes to apply instantane...

Page 52: ...e system short is a matter of isolation If the high amperage reading drops to zero by unplugging the trailer then the short is in the trailer If the amperage reading remains high with all the brake magnets disconnected the short is in the trailer wiring All electrical troubleshooting procedures should start at the controller Most complaints regarding brake harshness or malfunction are traceable to...

Page 53: ... system resistor and synchronize Intermittent Brakes Faulty controller Broken wires Loose connections Test correct Repair or replace Find repair Brakes pull To one side Incorrect adjustment Grease or oil on linings or magnet Broken wires Bad connections Adjust Clean or replace Find repair Find repair Harsh Brakes Under adjustment Improper synchronization Improper controller Faulty controller Adjus...

Page 54: ...ssive wear or heavy scoring If worn more than 020 oversized or the drum has worn out of round by more than 015 then the drum surface should be turned If scoring or other wear is greater than 090 the drum must be replaced When turning the drum surface the maximum re bore diameter is as follows 10 Brake Drum 10 090 12 Brake Drum 12 090 10 electric brakes are standard on all trailer wheels on the Air...

Page 55: ...ode S Fabric Care Spot clean using a mild water free solvent or dry cleaning product Carefully follow instructions on such product Clean only in a well ventilated room Avoid any product containing carbon tetrachloride which is highly toxic Pretest small area before proceeding Use professional furniture cleaner when an overall soiled condition is reached Code W Fabric Care Spot clean using the foam...

Page 56: ...sed as there is the possibility it could scratch the surface A protective pad should always be placed under hot utensils Vinyl Covering Damp wiping with mild detergent does routine cleaning Using automotive or household cleaners designed for vinyl upholstery will perform more thorough cleaning Sinks Cleaning can be accomplished using mild liquid detergent with a soft cloth A complete Home Owners G...

Page 57: ...22 Ft CCD models Once the switch is turned on the pump will run until the water pressure reaches about 65 psi At this point an internal pressure switch will shut it off When a faucet is opened the water pressure will drop and the pump will start to run again The water pump should be turned off when the trailer is left unattended and when city water is being used as the fresh water supply Bathroom ...

Page 58: ...y no matter which position the Battery Disconnect Switch is in Fresh Air Vents A control handle operates the ceiling fresh air vents Turning clockwise will raise the vent Check your lid gaskets once a year Information on the front high volume roof vent may be found in the appliance section of this book Storage All cabinets and storage areas should have the heaviest items on the bottom and lighter ...

Page 59: ...arms FLASHING LIGHT Model E Pushing test button turns flashing safety light on Very thick smoke may obscure light 7 Smoke alarms have technical limitations and may not respond in all situations FIRE PREVENTION is your best safeguard 8 For a replacement Owner s Manual or Safety Checklist please indicate your unit model include a self addressed stamped envelope and send to WEEKLY TESTING OF YOUR SMO...

Page 60: ...brated The manufacturer must do repairs REPLACING THE BATTERY The smoke alarm will beep once a minute for at least 30 days when the battery is weak The battery must immediately be replaced with a fresh one The battery should also be changed if it does not sound an alarm when tested TO REPLACE THE BATTERY 1 Check if the tamper resist locking pin is installed in the smoke alarm see USING THE TAMPER ...

Page 61: ... this 1 Remove the breakaway locking pin from the unit by rocking pin back and forth 2 Put the smoke alarm back on the mounting bracket See section HOW TO INSTALL YOUR SMOKE ALARM 3 Using long nose pliers grab the head of the locking pin and insert into hole located on the side of the smoke alarm See Figure 8 4 The Tamper Resist feature is now installed and complete To Remove 5 Using long nose pli...

Page 62: ... recommended that the detector be disconnected from the battery during periods of storage There is a small heater on the sensor of the device which burns away impurities in the air during periods of normal use During periods when power is interrupted impurities can build up on the sensor When power is returned to the detector the detector alarm may activate until the impurities are burned off This...

Page 63: ...six months A loop is provided in the SCREEN RETAINING SPLINE so it can be rapidly removed Take hold of the loop and pull the rubber spline out of the screen frame The window screen can then be easily pushed out WARNING Check the emergency escape route outside your escape window at every stop At each campsite make sure you have not parked in such a manner as to block the operation of the escape win...

Page 64: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL E 10 NOTES ...

Page 65: ... When pressure is equalized the flow limiting device will supply normal flow to the system Equalization occurs in approximately 5 seconds and in most cases goes completely unnoticed If however an appliance is left on or there is a leak or open flow in the system the by pass pressure will not be able to equalize and allow the flow limiting device to re open Symptoms of this condition would be appli...

Page 66: ...g reconnect the pig tail and slowly open the cylinder valve The full cylinder now becomes the reserve LPG BOTTLES The following step by step procedure gives you the proper method of removing and installing these bottles 1 Rotate the black lever all the way over towards the reserve cylinder The indicator will turn green and the reserve cylinder becomes the service cylinder Now shut off the cylinder...

Page 67: ...avel WARNING Your LP tanks must be filled as directed by the tank manufacturer Instructions are located on a decal near the fill valve The decal must not be defaced WARNING Your LP tank must be and can only be placed in the proper position when remounting on the front of the trailer In any other position the base of the tank will not fit into the recess WARNING Use only the gas bottles furnished w...

Page 68: ...is used for long periods of time WARNING Portable fuel burning equipment including wood and charcoal grills and stoves shall not be used inside the recreational vehicle The use of this equipment inside the recreational vehicle may cause fires or asphyxiation WARNING A warning label has been located near the LP gas container This label reads DO NOT FILL CONTAINER S TO MORE THAN 80 PERCENT OF CAPACI...

Page 69: ...81613 Cover LP wing handle 3 601281 5 8 x 5 8 x 5 8 Brass Union Tee 4 600004 Copper tubing 5 8 ID 5 600008 Copper tubing 3 8 ID 6 601159 02 Tubing cover 50 Poly CSA approved 7 600003 Tee 5 8 x 3 8 x 3 8 8 600436 Forged flare nuts 5 8 9 600435 Forged flare nuts 3 8 10 380887 Floor grommet 11 380886 Floor grommet 12 600661 Grounding clamp to1 13 500839 Copper wire bare 8 ga 14 500038 Lug ground 15 3...

Page 70: ...or panel For some time the open faucet will only sputter This is because the water heater is being filled and air is being pushed out through the lines Once the water heater is full a steady stream of water will come from the faucet Now open a cold faucet It will sputter for a short time but will soon expel a steady stream All other faucets can now be opened until all air is expelled Once the syst...

Page 71: ...ces all previous switch designs 2 Valve plate assembly 3 Diaphragm drive assembly 4 Motor 5 Complete Pump Head assembly includes 1 2 3 replaces all previous switch designs Switch and Check Valve Repair The check valve hydraulic switch mechanism and micro switch are accessible by removing the switch cover CAUTION Care should be taken in removing the switch cover screws Within the mechanism is a spr...

Page 72: ... the B terminal the switch is bypassed and the pump cannot shut off Pressure will build up until the motor stalls If the proper fuse has been used it will blow If a larger fuse than recommended has been used the motor will stall and may burn out Check Valve Problems Due to contamination from debris or lime build up the check valve may fail to properly seat To correct clean out the area and replace...

Page 73: ...nd clamp it You can make a perfect plug from a barb fitting size with a cap tightly screwed on the threads Turn the pump switch on The pump should come on run a few seconds and then shut off If it remains off the problem is NOT the pump The problem is in the system If however the pump goes on and off there may be a problem in the pump There may be an internal leak in the pump that allows water to ...

Page 74: ...ld be applied to both sides of each bearing FAILURE TO PRIME Failure to prime can be caused by the presence of some foreign matter lodged in the valve preventing it from seating To correct remove any such foreign bodies CAUTION Do not remove the stainless steel screens These filter screens should be cleaned without removing them from the plastic housing PUMP CHAMBER REPAIR Replacement of broken pi...

Page 75: ...ter 3 Pour the solution water bleach into the tank and fill the tank with potable water 4 Open all faucets Hot Cold allowing the water to run until the distinct odor of chlorine is detected 5 The standard solution must have four 4 hours of contact time to disinfect completely If you double the solution this concentration allows for contact time of one 1 hour 6 When the contact time is completed dr...

Page 76: ...pare hose should one fail or become damaged unexpectedly After hooking up the hose and turning on the city water valve provided in the park slowly open a faucet There will be a lot of spurts and sputtering until all the air is expelled from the trailer system If the is empty it will take some time before all the air is expelled and you get a steady flow of water at the faucet Once a steady flow is...

Page 77: ... read and follow usage instructions enclosed any scour pad or scrub sponge before use Caution Do not use pads or sponges that specifically do not recommend use for cleaning polished services Caution Many pads or sponges with green fibrous surface such as Scotch Brite heavy duty scrub sponges contain microscopic mineral particles that can scratch nearly all polished services including this faucet f...

Page 78: ...stem with pliers pull cartridge 18 straight up Reinstall has follows Install cartridge 18 into valve body with notched flat on stem facing forward Be sure to position the ears of the cartridge in the front and back Reinstall the retainer clip 14 that straddles the ears on the cartridge 4 Reinstall the retainer nut 11 and pivot stop 9 with the stop in front as shown in Step 4 above Reinstall DD was...

Page 79: ...e D Washer 11 Retainer Nut 12 Wave Spring Washer 13 Bearing Washer 14 Retainer Clip 15 Pull out Spout 16 Screen Washer 17 Hose 18 Cartridge 19 Spout Receptor 20 Threaded Discharge Tube 21 Supply Tubes 2 22 Deck Ring 23 Deck Ring Gasket 24 Deck Plate 25 Gasket 26 Deck Plate Studs 2 27 Threaded Fitting 2 28 Clamp Bar 2 29 Spacer 2 30 Small Mounting Nut 2 31 Mounting Bracket 32 Mounting Nut 33 Counte...

Page 80: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL F 16 Notes ...

Page 81: ...uple of faucets until the water will no longer comes out An additional 1 drain plug is located on the bottom of the tank inside the galvanized box The plug is accessible by removing an inspection plate close to the petcock that can be seen on the bottom of the tank support pan There may be a little Styrofoam insulation covering the plug that should be carefully removed Note For winterizing purpose...

Page 82: ...press hand spray thumb button on the telephone showerhead while holding down inside the tub and drain all water from the flexible hose Unscrew the heads on both spray units and store 5 Turn the pump switch OFF after all water has been removed from the storage tank 6 Remove outlet hose from water pump 7 Disconnect the water pump inlet connection and turn the pump on until all the water is expelled ...

Page 83: ...roadside hinged front dinette seat on International on the water heater to by pass flow position open valve B close valves A and C See illustration below In some models the valves may be in a horizontal pattern or on top of the heater rather than the vertical shown in the illustration Valve operating sequence will be the same To by pass the water heater for winterizing close valves A and C and ope...

Page 84: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL F 20 22 Ft International AS Fresh Water Layout 22 Ft International CCD Fresh Water Layout ...

Page 85: ... in your tank Monitor Panel Check your monitor panel frequently When the MAIN HOLDING TANK BLACK is completely full sewage cannot be emptied from the toilet bowl If the AUXILIARY HOLDING TANK GREY is overfilled drain water will backup into the tub and cause an unpleasant cleaning job Never drain the tanks at any place other than an approved dumping station For complete instructions on this panel s...

Page 86: ...ter will usually dissolve the solids into suspension so the tank can be drained Keep the auxiliary tank valve open when connected to a sewer outlet Draining the tanks as described will protect them from freezing during storage When traveling in sub freezing temperatures use a winterizing solution designed for RV use Follow the directions on the container Drain Systems Cleaning The only cleaning ag...

Page 87: ...ee 1 4 600156 Tee Sanitary 5 600308 Adapter ABS female Sloan 6 600538 Vent V 200 automatic 7 600144 P trap ABS 1 8 600822 Adapter P trap 9 600160 04 Pipe ABS DVW 3 10 600820 3 single socket 90 degree 11 601482 Dump valve rotating assembly 12 601266 Flange closet 3 x 4 slip fit 13 195329 229 Reducer adapter 3 to 1 14 601267 04 Nipple 3 diameter threaded one end 15 340084 20 Clamp hose 81 1 75 16 60...

Page 88: ...ter will continue to run into the bowl for a short time after the pedals are released When you wish to conserve water hold the hand spray head over the bowl and hold down the thumb operated lever Now when you depress the pedal all the water is routed through the hand spray CAUTION When you dump the bowl of the toilet make sure all paper and solids have cleared the slide mechanism before you allow ...

Page 89: ...onverter and then to the rest of the trailer Open the brown decorative door on the front of the converter under the dinette to access the panel and its fuses A 12 volt layout diagram is shown later in this section BATTERY DISCONNECT SWITCH The disconnect switch is used to separate the battery from the 12 volt distribution panel and converter charging system When the switch is turned use on and the...

Page 90: ... with a damp cloth and dry thoroughly The terminals should be tight and free of corrosion To clean terminals neutralize with a solution of baking soda rinse in clear water and dry Note Care must be used to make sure soda is not allowed to enter battery cells To insure maximum battery capacity on the charge and the discharge the battery terminals and the inside portion of the cable connector should...

Page 91: ...from the car s generator or alternator through the seven way connector Your automobile s voltage regulator controls the charge rate It is important to keep the seven way connector clean One method is to use Spra Kleen Whenever possible use the automatic built in charge of the converter system for charging The charging circuit automatically controls the current reducing it as the battery increases ...

Page 92: ...is not working first confirm the RV supply or shoreline cord is plugged into a live circuit Then check all the 120 volt breakers in your RV distribution panel to make sure they are on If the breaker is tripped follow the instructions to reset the breakers If the breaker trips again consult an electrician or certified RV technician CONVERTER OPERATION The MagneTec 7300 series electronic power conve...

Page 93: ...g A Confirm 120 volt power is going into converter B Disconnect the 12 wire from the master switch C Using a voltmeter check voltage output between heavy positive and negative wires coming out of converter D The voltage must be within 13 8 and 14 0 volts The meter of the tester should be calibrated periodically E If converter is not within these voltages have it serviced by a qualified technician ...

Page 94: ...omponent etc The following paragraphs describe methods of isolating shorts and opens There are several other approaches that may be used however these may be used as a guide Shorts 1 Locate circuit that has short by noting fuse blown or cycling breaker 2 Remove fuses or wire from breaker and open all switches Check for continuity between 12 volt wire or shorted circuit and ground If it cannot be d...

Page 95: ...d Make necessary connections 2 Master Kill switch not turned on 3 Discharged trailer battery Charge battery 4 Trailer battery on wrong polarity Make proper connections to battery terminals PROBLEM Tripping Breaker CAUSE REMEDY 1 Overloaded circuit Turn off switches to reduce load 2 Electrical short Find tripping breaker distribution panel and identify circuit Check the circuit for defective wiring...

Page 96: ...n of the sidewall and ceiling on the curbside with branches running straight out to the lights and fans All models are pre wired for solar panel The following diagrams list the circuits and show the location of the harness and give the wire color and gauge for each function DIAGRAMS 12 volt exterior and 7 way plug all 22 Ft International AS CCD 12 volt Layout 22 Ft International AS CCD 12 volt Dis...

Page 97: ...UAL G 9 12 VOLT EXTERIOR Note The 7 way wire is spliced to the main harness in the front of the trailer One of these wires is not spliced onto a wire of the same color It is the back up wire that is yellow in the cable and black in the harness ...

Page 98: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL G 10 22 Ft International 12 Volt Layout ...

Page 99: ...AL G 11 12 VOLT INTERIOR Distribution Panel USA The low voltage distribution panel is located in the MagneTec Series 7300 Power Center Open the brown door to access the panel International CCD Models See 12 volt circuit assignments on next page ...

Page 100: ...PINK CS GALLEY LOCKER LIGHT 02 88 FURNACE 03 40 REFER LIGHT 01 00 RANGE HOOD LIGHT 00 70 RANGE HOOD FAN 01 10 1 2 AND 3 CEILING LIGHTS 08 64 TOTAL AMPS 17 72 CIRCUIT 4 20 AMP 12 GA BROWN FRONT FANTASTIC FAN 03 00 FRONT TV JACK BOOSTER 05 00 WARDROBE LIGHT 01 44 TOTAL AMPS 09 44 CIRCUIT 5 20 AMP 12 GA BLUE WATER HEATER IGNITION 01 00 MONITOR PANEL 00 00 WATER PUMP 07 00 2 BULB DINETTE LIGHT 02 88 2...

Page 101: ...TS 01 80 FURNACE 03 40 REFER LIGHT 01 00 RANGE HOOD LIGHT 00 70 RANGE HOOD FAN 01 10 3 HALOGEN GALLEY LOCKER INDIRECT LTS 02 70 3 HALOGEN DINETTE LOCKER READING LTS 02 70 3 HALOGEN DINETTE LOCKER INDIRECT LTS 02 70 TOTAL AMPS 16 10 CIRCUIT 4 20 AMP 12 GA BROWN FRONT FANTASTIC FAN 03 00 TV JACK BOOSTER 05 00 WARDROBE LIGHT 01 44 TOTAL AMPS 09 44 CIRCUIT 5 20 AMP 12 GA BLUE WATER HEATER IGNITION 01 ...

Page 102: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL G 14 22 Ft International 510907 05 Tail light harness ...

Page 103: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL G 15 22 Ft International 510907 01 Harness Front Clearance Lights ...

Page 104: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL G 16 22 Ft International 511562 Interior Body Harness ...

Page 105: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL G 17 22 Ft International 511653 Ceiling Harness ...

Page 106: ...ling to prevent damage Turn elevating crank in the Down direction until resistance is noted Antenna is now locked in travel position Checking Operation 1 Tune TV receiver to nearest station and rotate antenna for best picture and sound 2 Turn off switch on power supply Picture on TV receiver should be considerably degraded with the power off DO S 1 Do check parking location for obstructions before...

Page 107: ...ent Procedure NOTE It is not necessary to remove the rotating gear housing 11 from the base plate 14 or remove the antenna from the roof to replace the shaft and gear assembly STEP 1 Lower antenna to travel position Loosen set screw on elevating crank 23 remove crank spring 20 and directional handle 19 STEP 2 Remove top retaining ring 5 from top pin 4 holding top elevating tube in rotating gear ho...

Page 108: ...er Plastic 7 Grommet Plastic 8 EG 87 Elevating Gear 9 Tube Square Elevator 10 Elevating Shaft Assy 11 Housing Rotating Gear 12 Ring Quad Seal 13 Bearing Nylon 14 Housing Base Plate 15 Bearing Nylon 17 Plate Ceiling 18 Screw 19 Handle Directional 20 Spring Handle 21 Decal Crank Cover 22 Bearing Nylon 23 Elevating Crank Set Screw 27 Boot Gear Housing 30 Bumper Rubber 31 Screw ...

Page 109: ...as a small coax cable jumper running between the hook ups to complete the cable TV circuit when in use To install a satellite system use the following procedure 1 Remove the jumper wire from the coax faceplate 2 Hook a portable dish into the Cable TV receptacle in the roadside rear underbelly compartment This feeds the dish signal to the input side of the faceplate 3 Install the satellite receiver...

Page 110: ...n installation CAUTION The red wire must be fused with a 10 amp in line fuse at the 12 volt positive 2 The positive red and negative black leads from the battery that connect to the solar meter charge controller are located in the galley roof locker behind the radio 3 The positive yellow and negative green leads that connect to the solar meter charge controllers are located in the galley roof lock...

Page 111: ...ssy 7 Handle Assy 8 Trim Ring Assy Removal and Replacement 1 Working from the outside top of trailer remove the screws holding the fan protective cap and remove the cap 2 Remove the 6 screws securing the fan flange to the outer skin 3 Pull the fan out to the extent of the wiring harness and unplug the harness 4 Remove the fan assembly 5 To install reverse the removal procedures ...

Page 112: ...t auto calibrates itself so that it can read from 0 to 100 regardless of the height of the tank The sender scans the water level through the tank wall using patented digital techniques programmed into the sender microprocessor When the sender transmits the water level information to the display it sends a digital code that has built in error detection making it impossible for the display to read a...

Page 113: ...he display will show Sht indicating a short circuit If the display receives corrupted data then it will show Err indicating that an error has occurred With these diagnostic features programmed into the display microprocessor and the digital nature of the tank level sensing technology it is almost impossible for the system to indicate an incorrect water level and in the very unlikely event it does ...

Page 114: ...tinuously monitor one tank level 1 Note that only the holding tanks can be continuously monitored with this procedure not the voltage or the LP Gas level 2 Press the button and release it the display will power up and show the following a The battery voltage is shown for 2 5 seconds Wait until the display cycles through to the tank that you want to monitor for example if you are filling the fresh ...

Page 115: ...the button While it is held down you will see dlA indicating that the display will proceed to the diagnostic functions If you hold the button down longer than about 8 seconds the display will shut itself off 5 When the button is released the display will start cycling through the sender diagnostics After the fresh water tank sender diagnostics are done the LP GAS LED will light and the LPG level w...

Page 116: ...or water or mud buildup right on the sender c The third diagnostic is the minimum signal level The single horizontal line on the left digit indicates this parameter The tank must be no more than 80 full for this number to be valid Normal minimum signal levels should be in the 0 to 2 range If the signal level is high incorrect readings may occur Check for water or mud buildup right on the sender d ...

Page 117: ...itch to advanced diagnostic operation where it transits the raw received signal level for each receive segment each receive segment is called a point in the following description 4 Follow the directions in the previous section up to step 4a for the sender to be reviewed For example to review the grey water sender press the button during LPG scan and wait until the grey LED is lit and the display s...

Page 118: ...eiving the most recent set of advanced diagnostic data from the same sender This data can be stepped through just like the first set 11 If you do not press the button for 30 seconds the display will shut itself off If the button is repeatedly pressed to cycle through the data over and over this process can be repeated indefinitely Monitor Wire Color Function Red 12V power input to gauge can be als...

Page 119: ...nd and attach the ground lug to it thus providing the unit with proper grounding To operate self contained simply disconnect the power supply cable When your trailer is hooked up to 110 volt AC the converter system automatically charges the trailer batteries with the battery disconnect switch in the use on position and if the 7 way cord is hooked up your automobile battery as well The speed and de...

Page 120: ...ion PLUS protection from Ground Faults that might result from contact with a HOT load wire and ground IMPORTANT NOTE The GFCI circuit breaker will NOT reduce shock hazard if contact is made between a HOT load wire and a neutral wire or 2 HOT load wires Each GFCI circuit breaker is calibrated to trip with a ground current of 5 milliamperes or more Since most persons can feel as little as 2 milliamp...

Page 121: ...t each month and record the date on the chart 1 With handle B in ON position press PUSH TO TEST button A 2 Handle B should move to TRIP position indicating that GFCI breaker has opened the circuit 3 To restore power move handle B to OFF and the to ON Important If handle B does not move to TRIP position when test button is pressed the GFCI breaker protection is not complete If this happens replace ...

Page 122: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL G 34 22 FT International AS 110 Volt Layout ...

Page 123: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL G 35 22 FT International CCD 110 Volt Layout ...

Page 124: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL G 36 22 ft International AS CCD 110 Volt Breaker Assignment ...

Page 125: ... Packet is a set of literature covering all operating and maintenance instructions If the literature is misplaced please contact the air conditioner manufacturer or your Airstream dealer for replacement The voltage to the air conditioner is critical We commonly refer to 110 or 120 volts but a check with a voltmeter may find voltage much lower Your air conditioner will probably not function if the ...

Page 126: ...erter when plugged into city power Operating instructions are located in your Owners Packet If they should become misplaced new literature can be ordered direct from the manufacturer or your Airstream dealer The manufacturer also offers a detailed service guide for your furnace WARNING Carefully read all the manufacturer s instructions prior to operating NEVER store flammable material next to the ...

Page 127: ...ng gas ranges in their home will find little difference in the operation of the range in a recreation vehicle Other customers used to electric ranges may be a little apprehensive at first but will quickly gain confidence The basic operation of the gas ranges have been the same for many years but please be sure to read all the directions furnished by the manufacturer and located in the Owner s Pack...

Page 128: ...is not moving liquid ammonia will accumulate in portions of the evaporator tubing This will slow the circulation of hydrogen and ammonia gas or in severe cases completely block it resulting in a loss of cooling Any time the vehicle is parked for several hours with the refrigerator operating the vehicle should be leveled to prevent this loss of cooling The vehicle needs to be leveled only so it is ...

Page 129: ...l probably be an unusual sound such as air escaping through the pipe as the water begins to flow There should be no smoking or open flame near the faucet at the time it is open SAFETY If your water system is full and cold and the water heater is ignited the system can see pressures as high as 120 psi before the relief valve starts to open Since the water system normally operates in the 40 psi rang...

Page 130: ...ing fan CAUTION Never place Lindeen or a like cover over ceiling fan Greatly restricted airflow increased sound levels will occur WHEN EQUIPPED WITH REVERSE SWITCH 1 Turn fan motor off by a Setting 3 speed switch to O OFF b Closing Dome c Selecting center position on IN OUT rocker switch 2 Wait for fan blade to stop 3 Select IN position brings air from the roof area into your coach pressurizes ins...

Page 131: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL H 7 HIGH VOLUME ROOF VENT ...

Page 132: ...COLORED 5A 1031 05 3 SPEED SWITCH 3K754 5B 1033 09 DIAL LABEL BLK POLY 5C 1032 05 NUT 7 16 x 28 UNEF ZINC 5D 1034 09 KNOB SOFT TOUCH PT 6 P 5E 9001 09 DPDT HOT STAMPED w CROSS KNOB 5F 1140 09 1741Z BLACK 5G 2143 05 EXTENSION 1 1 8 ZINC 5H 1142 05 8 32 x l 3 4 P H PH m s ZINC 2 51 1038 88 x 3 8 F H PH t s COLOR 2 5J 1039 8 x 2 3 4 F H PH w s COLOR 5K 6050 05 DOME LIFT MOTOR 200 0262A 5L 6035 MOTOR ...

Page 133: ...t on your trailer is relatively easy 1 With trailer on fairly level ground measure from ground to bottom of frame front and rear 2 Adjust front jack until measurements are equal 3 Now measure from ground to the inside top of ball coupler This figure is the hitch height The hitch ball is then usually set to 1 higher according to the spring weight of your tow vehicle to allow for it to settle when t...

Page 134: ...ns E 1 Control Panel E 3 G 24 Dimensions I 1 Dinette E 2 Doors Main D 2 Screen D 2 Drain Valves F 17 Drainage F 17 Drapes E 1 Dump Valves F 21 Electrical G 1 12 Volt G 1 110 Volt C 4 G 31 Circuit Breakers G 4 G 11 G 31 G 36 Diagrams 12 Volt G 4 110 Volt G 31 7 Way Cable B 2 G 9 Power Cord C 4 G 31 Trouble Shooting G 6 Escape Window C 1 C 5 D 2 E 9 Exhaust Fans E 3 F 4 G 23 H 6 Extended Stay C 3 Ex...

Page 135: ...ervice A 5 7 Way Conn B 2 G 9 Sewer Hose C 4 F 21 Shower E 2 Sink E 2 Smoke Alarm E 5 Solar Panel G 22 Specifications I 1 Stabilizing C 3 Step B 8 D 2 Storage E 4 F 18 Stove H 3 Suspension D 10 Table E 2 Tires D 7 I 1 Tongue Latch D 3 Tongue Weight B 5 Toilet F 24 Towing B 1 B 9 Tow Car B 1 B 6 TV C 5 TV Antenna G 18 Upholstery E 1 Valves Drain F 17 Vents E 4 H 6 Warning Introduction Warranty A 1 ...

Page 136: ...AIRSTREAM INTERNATIONAL TRAILER OWNERS MANUAL Notes AIRSTREAM INC 2001 ...

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