TRAVEL`R - Lance Camper
Contents
1. S Soft Connect ENS 6 x 3 8 a Lx 6 x 3 8 Screw Alumaguard Screw Uniguard i Fabric EE E0014 Figure 3 Securing the Fabric 22 1 For vinyl awnings place screw through awning rail polyrod and canopy approximately 1 in from the end of the fabric 22 2 For Uniguard awnings place screw through awning rail polyrod and the soft connect material approximately 1 in from the end of the fabric 22 3 For Alumaguard awnings place screw on the outer edge of the Alumaguard not through the Alumaguard For Alumaguard installations go to Installing the Alumaguard Tractioners on page Error Bookmark not defined 052540 301r2 3 Table of Contents TRAVEL R Service Manual Carefree of Colorado INSTALLING THE TRACTIONERS The tractioners are used with the alumaguard metal fabric wrap and recommended for vinyl fabrics with Uniguard Place Screw Between Slots on Roller A Position Tractioner under View A A NT Alumaguard Uniguard Alumaguard Uniguard Place Screw Between Slots View A A on Roller Uniguard w Vinyl Fabric E0058 Figure 4 Installing the Tractioner 1 Partially extend the awning until the Alumaguard Uniguard is extended as shown 2 Unlock the keeper and wrap the tractioner around the roller tube 3 Position the tractioner under the Alumaguard Uniguard with a 1 4 gap between Alumaguard and tractioner Lock the keeper2. pitch models The awning rollbar and arms are made from light weight aluminum The awning fabric is heavy weight vinyl Travel r Patio Awning Specifications MAXIMUM EXTENSION 8 foot MAXIMUM LENGTH 21 feet PITCH FLAT Fixed DROP approximately 6 inches STEEP Fixed approximately 33 inches Measurement is from centerline of Awning Rail to centerline of rollbar MOTOR Power 10VDC 14VDC Circuit Rating 20 amp motor mounted in arm POWER SOURCE Motor and controls are routed and hardwired into the vehicle s 12V system EXTEND ACTUATION Gas Shock POSITION CONTROL Motorized roll out in CONTROLLER 3 position momentary ON center OFF Switch COLOR Frame White Black Canopy Available in a Variety of fabrics and colors refer to order sheet p Fabric Width 1 5 approx approx Eu peace He Wo _ I w d A d i E Awning Rail ERE D 1 b aTi Teal Typ rt t 4 o 1 6 min Drill Area for Drill Area for gt Clearance Upper Cable m Upper Cable c 9 from top of Routing ef 14 5 min Routing ED S door Est Clearance aot wil IOs Jt geg AN P mg oc a from top of door AN EE mr SES LEP EE p e2 ag 56 1 4 1 E Yo 64 1 4 Drill Area for x Lower Cable Routing 2 EN j Mounting Y __ Flat Mounting Surface Area wb Drill Area 2 el 3 1 2 x 67 Flat Pitch Hole Lower Cable Routing 2 3 1 2 x 59 1 2 S
3. n 15 Wlustrated Parts LISb suissesienic d stpideeliste s Ca brd1 BU aa n pA DM enabled RI BAM EA QUAM iR 16 052540 301r2 Printed in USA February 2007 PROPRIETARY STATEMENT The Travel r Patio Awning is a product of Carefree of Colorado located in Broomfield Colorado USA The information contained in or disclosed in this document is considered proprietary to Carefree of Colorado Every effort has been made to ensure that the information presented in the document is accurate and complete However Carefree of Colorado assumes no liability for errors or for any damages that result from the use of this document The information contained in this manual pertains to the current configuration of the models listed on the title page Earlier model configurations may differ from the information given Carefree of Colorado reserves the right to cancel change alter or add any parts and assemblies described in this manual without prior notice Carefree of Colorado agrees to allow the reproduction of this document for use with Carefree of Colorado products only Any other reproduction or translation of this document in whole or part is strictly prohibited without prior written approval from Carefree of Colorado SAFETY INFORMATION AWARNING A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY AND OR MAJOR PROPERTY DAMAGE NCAUTION A CAUTION INDIC
4. DETAIL B Figure 6 Motor Replacement Series I Motor Attach Bolts amp Nuts Motor ref 1 refer to Detail A For Awnings Fully or Partially Extended 1 1 On the right hand arm remove the front cover by removing the six 6 smaller screws from the back of the motor head Save cover and screws Motor Black Wire Cable Black Wire Motor Red Wire Cable Red Wire DETAIL C 10 x 5 8 Screw D ETAI L D Travelr015 1 2 Disconnect the motor and cable wires from inside the rear cover Note the location of each wire 1 3 Remove the rear cover by removing the one 1 large screw from the back of the motor head Save cover and screw 1 4 Goto step 3 052540 301r2 5 Table of Contents TRAVEL R Service Manual Carefree of Colorado 2 refer to Detail B For Awnings Fully Retracted NOTE This procedure will require replacing the front and rear motor covers in addition to the motor assembly 2 1 Place a large flat blade screwdriver or similar tool in the seam between the front and rear covers Using a twisting and prying motion break the covers off It may be necessary to use a hammer and lightly tap the screwdriver into the plastic to establish a starting point Tip Start at the bottom and work around the seam until the covers are off 2 2 Disconnect the motor and cable wires from inside the rear cover Note the location of each wire 2 3 refer to Figure 6 Detail B Firmly hold the motor and
5. Wall Mount Connector TravelROO8b Figure 9 Switch and Wiring AWARNING FOR SERIES SWITCHES TERMINALS 1 AND 4 ARE CAPPED WITH FULLY INSULATED CONNECTORS THESE TERMINALS MUST REMAIN CAPPED AT ALL TIMES SWITCH REPLACEMENT The Series switch has been discontinued for replacement parts The replacement switch kit includes a Series Il switch switch plate terminals and screws The switches are functionally interchangeable but physically sized differently For an initial Series replacement it is necessary to replace the switch and the switch plate The new switch plate will fit in the same position as the old plate The difference is the switch cutout in the plate 1 Disconnect power to the switch 1 3 4 Minimum 2 1 4 Maximum Remove the existing switch and plate from the mounting surface 2 3 Disconnect wires from the switch 4 Push the new switch into the new faceplate until the locking tabs click into place behind the faceplate e Connect the wires to the switch as shown in the wiring diagram above 6 Carefully push the wires and switch into the mounting hole then attach the switch plate assembly using four 4 6 x 1 2 screws 6 x 1 2 Screw qty 4 TravelR021 Figure 10 Switch Installation 7 Restore vehicle power and test the awning operation NOTE If the awning operates opposite the switch markings extends when retract is pushed reverse the red and black motor wires on the back o
6. 4 Repeatfor the other end of the rollbar 5 Extend the awning to verify that the tractioners are lifting the metal wrap up and over the roller assembly 6 To secure the tractioner drill a 1 8 hole through the tractioner and rollbar roughly center the hole between two slots of the rollbar 7 Secure with one 1 10 square drive screw 052540 301r2 Table of Contents Carefree of Colorado Service Manual MOTOR REPLACEMENT Before continuing it is necessary to determine which motor configuration is installed on the awning SERIES uses a bent sheet metal mounting frame SERIES Il uses a cast metal mounting frame The mounting and attachment of the two configurations are different To distinguish between the two look at the motor head The bent sheet metal frame Series has two protruding bumps in the front cover There are also two exposed rivets on each side of the arm channel The cover for the cast metal Series II is smooth and there are no rivets Front Cover Configuration A Bent Sheetmetal Motor Mount Frame TRAVEL R Configuration B Cast Metal Motor Mount Frame Travelr016 Figure 5 Distinguishing the Motor Mount NOTE Motor assemblies and covers are not interchangeable between the two configurations REPLACING THE MOTOR SERIES I 3 8 16 P Lock Nut i RO Motor Assembly W Bent Metal A aye Frame LEX S Rear Cover Front Cover DETAIL A Rear Cover ref Front Cover ref
7. For Alumaguard installations Use a pair of side cutters or similar tool and crimp the aluminum Use care to not bend or distort the aluminum slats NOTE While the awning fabric is fairly robust care must be taken not to snag it on the awning rail 12 Position the fabric feeders on the roll bar Be sure to use the same slots as the old canopy 13 Slide the rollbar on to the new fabric Center the fabric and install any fabric retaining screws removed previously 14 Remove the feeders 15 If removed install the upper mounting bracket 16 Lift and align the roller assembly with the end cap on the motorized arm assembly Rotate the end cap until the slot in the cap aligns with the empty slot in the roller assembly and then press the roller assembly fully into the cap The end cap must seat squarely over the end of the roller assembly when complete NOTE The roller assembly must be oriented with the fabric going over the roller toward the coach wall 17 Secure the end cap to the roll bar using two 10 square drive screws 18 Repeat steps 17 and 18 to attach the idler arm assembly to the roll bar 19 Visually check that the fabric is squarely mounted Adjust as required 20 Roll the awning in and out several times to make sure that the fabric is square on the rollbar 21 Secure the canopy to the awning rail using one 6 x 3 8 hex head screw at both sides of the awning 4 Awning ei 7 y ers Awning Rain VAR Awning io
8. Hardware Maintenance e Replace any parts that become damaged e Periodically check all mounting hardware screws lags etc and re tighten when necessary 052540 301r2 13 Table of Contents TRAVEL R Service Manual PART NUMBER LISTING PART NUMBER SERIAL NUMBER LOCATION Carefree of Colorado Carefree of Colorado Dt 0000 Sn 0000000000 Pn XXXXXXXXX Carefree of Colorado Dt 0000 Sn 0000000000 Pn XXXXXXXXX Right Arm TravelRO13 The arm part numbers serial numbers are located on the inside of the arm channel The roll bar part numbers serial numbers are located on the roller tube and the valance care label ARMS PART NUMBER CONFIGURATION Example Part Number OV JV 50HW STYLE CODE COLOR ARM TYPE ARM CONFIGURATION CONTROLS OV JV 50 HW Travel r Black Flat Pitch AM OV Travel r 25 White 50 Flat Pitch OEM OEM Standard Arms JV Black 53 Steep Pitch HW AM Standard Arms All models use a Single Interior Switch AM Aftermarket or Upgrade uses extended mounting channel and top mounting bracket OEM Original Equipment Manufacturer Installation 14 052540 301r2 Table of Contents Carefree of Colorado ROLLER PART NUMBER CONFIGURATION Example Part Number Q J 18 79 79 Service Manual TRAVEL R STYLE CODE SIZE CANOPY COLOR FABRIC WRAP TYPE COLOR QJ 18 79 79 Vinyl Roller Assy 18 Length O
9. idler arms up while removing the three 3 motor attach bolts and nuts 2 4 Remove the motor from the motor mounting frame NCAUTION THE ARMS ARE UNDER TENSION FROM THE GAS SHOCKS WHEN THE MOTOR IS DISENGAGED FROM THE GEARS THE ROLL BAR WILL BE ABLE TO FREE SPIN AND BOTH ARMS WILL EXTEND FROM THE GAS SHOCK TENSION USE EXTREME CARE AND HOLD THE ARMS IN POSITION IT WILL BE NECESSARY TO HAVE AT LEAST ONE OTHER PERSON HOLDING THE IDLER ARM 2 5 While holding on to the arms and roll bar allow the awning to extend to the maximum position the fabric will unroll from the roll bar 2 6 On the right hand arm remove any pieces of the front and rear covers Remove the cover s attaching screws and save 2 7 Goto step 3 3 Remove the two square drive screws attaching the end cap to the roll bar and separate the roll bar and end cap It will be necessary to hold the roll bar and motor arm Allow the arm to extend out 4 Use a scaffold or similar device to support the roll bar NCAUTION DO NOT ALLOW THE ROLL BAR TO DROP TOWARD THE GROUND THE TWISTING MOTION CAN CAUSE SERIOUS DAMAGE TO THE IDLER ARM 5 Loosen and remove the 3 8 16 lock nut from the mounting bolt Make note of the number and order of the spacer washers between the arm mounting block and the motor head Tip When the nut is removed the bolt will slide out of the arm mounting block inside the arm channel Placing tape on the head of the mounting bolt and the spacers will pr
10. the arm assembly Rotate the end cap until the slot in the cap aligns with the empty slot in the roller assembly and then press the roller assembly fully into the cap The end cap must seat squarely over the end of the roller assembly when complete 13 Secure the end cap to the roller assembly using two 10 x 5 8 square drive screws 14 Partially retract the awning It may be necessary to lightly pull down on the lower arm at the mounting channel until the rollers are past the location of the stop bolts Always pull down from the bottom of the arm to avoid pinching 15 Reinstall the stop bolts removed in step 2 052540 301r2 9 Table of Contents TRAVEL R Service Manual Carefree of Colorado DIAGNOSTICS TROUBLESHOOTING The following procedures are intended to aid the service technician to logically resolve operational issues with the mechanical and standard electronics installations Common Operational Items The following are operational items that may come up as questions during normal operation These are also given in the operator s manual 1 The motor has a thermal protection circuit If the motor overheats the circuit will shut off the motor Wait approximately 15 minutes operation will return to normal As an example this may occur if the awning is fully closed and retract switch pushed repeatedly then the awning does not extend The awning seems to extend and retract slowly The operational range is 28 35 seconds t
11. 1 1 2 Set Hardware Arm Assy Motorized RH Flat Pitch 2 i iE 1 2 Set Hardware Arm Assy Motorized RH Steep Pitch 2 2 information 1 2 Set Hardware Arm Assy Idler LH Flat Pitch 2 1 2 Set Hardware Arm Assy Idler LH Steep Pitch 2 3 R001094XXX Top Mounting Bracket Used w Aftermarket Only 4 R001532 Fascia White Flat Pitch 3 R001533 Fascia White Steep Pitch 3 5 R001099 Gas Shock Flat Pitch R001331 Gas Shock Steep Pitch 6 R001104 Motor Assy Series 7 R001323 Kit Head Attach Hardware Series 8 R001324XXX Kit Motor Cover Series 4 9 R001326 Kit Motor Assy Series II 5 10 R001328 Kit Motor Cover Series II 4 11 R060414 XXX Cable Motor 12 R001107XXX Idler Assy Series 13 RO01325 Kit Idler Cover Series 4 14 R001327 Kit Idler Assy Series II 5 15 RO001329 Kit Idler Cover Series II 4 16 19xx00 Roller Tube 3 slot 3 1 2 Dia 17 Canopy Refer to Canopy Order Form 18 R00298 Tractioner set of two 19 R001336 Kit Single Switch 6 20 R00786 Connector Plug amp Receptacle 21 R014634 0JV Extension Kit Black R014634 025 Extension Kit White The following parts are not shown R014489 001 Hardware Pack Flat Pitch R014492 251 Hardware Pack w Top Bracket R014489 101 Hardware Pack Steep Pitch Notes XXX Color xx Length in inches 1 2 Arm assemblies are configuration specific and cannot be interchanged When ordering provide the following information part number serial number flat steep pitch OVP oo Fascia k
12. ATES A POTENTIALLY HAZARDOUS SITUATION THAT MAY CAUSE MINOR TO MODERATE PERSONAL INJURY AND OR PROPERTY DAMAGE IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES NOTE A note indicates further information about a product part or step Tip A tip provides helpful suggestions Safety Notes e Always disconnect battery or power source before working on or around the electrical system e Always wear appropriate safety equipment i e goggles e Always use appropriate lifting devices and or helpers when lifting or holding heavy objects e When using fasteners use care to not over tighten Soft materials such as fiberglass and aluminum can be stripped out and lose the ability to grip and hold Reference Publications located www carefreeofcolorado com 052540 002 Travel r Installation Manual 052540 201 Travel r Owner s Manual 052540 301 Travel r Service Manual Carefree of Colorado 2145 W 6 Avenue Broomfield CO 80020 a Scott Fetzer company 303 469 3324 www carefreeofcolorado com Table of Contents Carefree of Colorado Service Manual TRAVEL R PRODUCT OVERVIEW The Travelr provides motorized awning comfort with Carefree s standards for looks strength and dependability It is the successful blend of style quality and economy The awning is available in two fixed
13. MOTOR AND OR ROLL BAR IS DISENGAGED FROM THE ARM THE ROLL BAR WILL BE FREE TO SPIN BOTH ARMS WILL EXTEND FROM THE GAS SHOCK TENSION USE EXTREME CARE AND HOLD THE ARMS IN POSITION IT WILL BE NECESSARY TO HAVE AT LEAST ONE OTHER PERSON HOLDING THE IDLER ARM 10 x 5 8 Screw S W Rear Cover 5 16 18 Nylock Nut Motor Assembly Front Cover W Cast Metal Frame 5 16 18 x 1 3 4 E Truss Head Screw DETAIL A DETAIL B Travelr017 Motor Red Wire Cable Red Wire Figure 7 Motor Replacement Series Il 1 For Awnings Fully or Partially Extended 1 1 Remove the front cover by removing the six 6 smaller screws from the back of the motor head Save cover and screws 1 2 Disconnect the motor and cable wires from inside the rear cover Note the location of each wire 1 3 Remove the rear cover by removing the two 2 large screws from the back of the motor head Save cover and screw 1 4 Remove the two square drive screws attaching the end cap to the roll bar and separate the roll bar and end cap It will be necessary to hold the roll bar and motor arm Allow the motor arm to extend to its maximum position 1 6 If the awning is only partially extended hold onto the idler arm and allow it to extend while supporting and guiding the roll bar and allowing the fabric to unroll 1 7 Using a scaffold or similar device support the roll bar NCAUTION DO NOT ALLOW THE ROLL BAR TO DROP TOWARD THE GROUND THE TWISTI
14. NCAUTION DO NOT ALLOW THE ROLL BAR TO DROP TOWARD THE GROUND THE TWISTING MOTION CAN CAUSE SERIOUS DAMAGE TO THE OTHER ARM 5 Support the arm in the area shown in Figure 8 6 Unscrew the shock barrel from the clevis in the mounting channel idi support and Lift in this area Travelr018 Tip Wearing a pair of rubber gloves will Figure 8 Replacing the Shock aid in gripping the surfaces of the shock 7 Unscrew the shaft from the clevis in the arm joint Set old shock aside NOTE It may be necessary to use vice grips or pliers on the old shock to unscrew the shock from the clevis DO NOT use vice grips or pliers on the new shock Damage to the surface of the shaft or damage to the barrel can cause the new shock to not work correctly Unpack the new shock and carefully allow it to extend to its maximum length Coat the threads of the shaft of the new shock with a non permanent thread lock i e loctite then screw the rod into the clevis of the arm elbow Hand tighten only 10 Lift and hold the arm up in the area indicated in Figure 8 The arm should be unfolded and extended as far as possible 11 Coat the threads of the barrel of the new shock with a non permanent thread lock i e loctite then screw the barrel into the clevis in the mounting channel Hand tighten only It will be necessary to grip and hold the shaft while turning the barrel 12 Align the roll bar with the end cap on
15. NG MOTION CAN CAUSE SERIOUS DAMAGE TO THE IDLER ARM 1 8 Remove the 5 16 18 screw and nut then remove the motor assembly from the arm channel 1 9 Goto step 3 052540 301r2 7 Table of Contents TRAVEL R Service Manual Carefree of Colorado 2 For Awnings Fully Retracted 2 1 While holding both arms and the rollbar remove the 5 16 18 screw Allow the motor arm to extend out and away from the motor assembly and rollbar 2 2 Tie the idler arm in the closed or partially open position 2 3 Using a scaffold or similar device support the roll bar 2 4 Rotate the rollbar and motor head around to access the cover screws on the back 2 5 Remove the front cover by removing the six 6 smaller screws from the back of the motor head Save cover and screws 2 6 Disconnect the motor and cable wires from inside the rear cover Note the location of each wire 2 7 Remove the rear cover by removing the two 2 large screws from the back of the motor head Save cover and screws 2 8 Remove the two square drive screws attaching the end cap to the roll bar and separate the roll bar and end cap 3 Position the new motor assembly in the arm channel and attach using one each 5 16 18 x 1 1 2 bolt and nylock nut 4 Attach the rear cover to the motor assembly using the large screws removed previously Attach the motor and cable wires to the terminals inside the rear cover Align the roll bar with the end cap on the motorized arm assembly Rotate the end
16. S SERVICE MANUAL carelte TRAVEL R Colorado mmm MOTORIZED FIXED PITCH PATIO AWNING RV TABLE OF CONTENTS Product CN Pec OO O n 7 1 Traveir Falo Awning SpecmeathonS D T 1 Canopy Replat Dp PERPE RR A 2 Iste TD TFPI ssa ideribpr FopeRuQu EAA perle MD EROR NTA borne Cle Ha ra MUR EIE 4 Lost Hee pci PR Omm 5 Replacing the Motor Series dey ne er ero E nr 5 ac sapi Motor Seres El T H 7 Replacing ihe Gas SHOCK O A OEoo0 OE 9 Dia nostics Troubleshooting uosgdad i imad idit ui ks dan E RMMSREU RI M IMAMMMU DUUM D NADA M UM Dbda 10 Lipa pipe H RR 12 witch Replacement sssaaa Ebr EDEN EE DU AD AN ad E EA DE RN BREED TRENT M ax Ld bob M A LU ANE 12 cipdgpocqpE Digo 13 gg 24 eC eR LA Rhea 13 Lil MR T 13 POM Laus Mem t ME C eA ut M Lo E iE 13 PET LM usas penne dicht spada Mq Pre MD ap bro Re co a On D AR DDR olea D 13 Hare OIE ERIS spikka piani AB EE DEI HR ELIA GEL PUE TEDAE FI BE ER NRT IRR TEL M EUN FR RE 13 elu Ph ic li2 1g lll rie neenon 14 Part Numbenrserial Number Location ac RR QR T 14 Ams Pan Number I atosan Vibe ado heran a rip rien aida M e t taa DN 14 ap c4 id inops aeri io T
17. abric canopy or canopy with Alumaguard or canopy with Uniguard For arms using an upper mounting bracket it will be necessary to remove the upper bracket from one side After removing the bracket brace the arm using scaffolding or similar support NCAUTION THE LOWER MOUNTING SCREWS FOR ARMS USING THE UPPER BRACKET MAY NOT BE MOUNTED INTO STRUCTURAL MEMBERS OF THE COACH WALL FAILURE TO SUPPORT THE ARM CAN RESULT IN DAMAGE TO THE COACH WALL e For canopy only replacement for units with Alumaguard The fabric is crimped into the aluminum slat Use a large flat screw driver or similar tool to spread open the crimp on both sides of the fabric e For canopy only replacement for units with Uniquard Remove the retaining screws from both sides of the Uniguard 9 Slide the fabric out of the awning rail m I D 2 052540 301r2 Table of Contents Carefree of Colorado Service Manual TRAVEL R 10 Clean and deburr the roll bar slots and awning rail Alumaguard Uniguard as required If not previously done spread open the awning rail track to facilitate inserting the new fabric Tip Lightly spraying the slots with a dry silicone lubricant will help the fabric slide into the slot without staining the material 11 Unfold the replacement fabric then slide the new fabric into the awning rail Alumaguard Uniguard Center the fabric and install any fabric retaining screws removed previously Allow the fabric to hang down the side of the coach e
18. cap until the slot in the cap aligns with the empty slot in the roller assembly and then press the roller assembly fully into the cap The end cap must seat squarely over the end of the roller assembly when complete NOTE It may be necessary to close and hold the arm to align the end cap and roll bar Secure the end cap to the roller assembly using two 10 x 5 8 square drive screws Restore power and test operation If the awning moves in the wrong direction i e extends when retract is pushed reverse only the two motor wires in the rear cover 9 Attach the front cover using the small screws removed previously 8 052540 301r2 Table of Contents Carefree of Colorado Service Manual TRAVEL R REPLACING THE GAS SHOCK NCAUTION THE GAS SHOCK HAS APPROXIMATELY 85 LBS OF PRESSURE IN THE CLOSED POSITION A PRESSURIZED SHOCK CAN OPEN RAPIDLY WHEN REMOVED OR RELEASED AND CAUSE PERSONAL INJURY AND PROPERTY DAMAGE 1 Open the awning NOTE The arm may not open completely when the shock has lost pressure or is removed It may be necessary to carefully pull the arm out and away from the vehicle to open the awning 2 Remove the stop bolts and save 10 x 5 8 Screw qty 2 KS Remove the two square drive screws attaching the end cap to the roll bar and separate the roll bar and end cap It will be necessary to hold the roll bar and motor arm Allow the arm to extend out 4 Use a scaffold or similar device to support the roll bar
19. cean Blue Vinyl Ocean Blue Cream Weatherguard QJ Vinyl or Polyweave 12 VINYL VINYL 43 Refer to Sales and Order Refer to Sales and Order Information for color QL Acrylic With Alumaguard Information for color availability and codes Ltd 14 availability and codes 45 ALUMAGUARD UNIGUARD QK Vinyl or Polyweave With CUSTOM GRAPHICS 2 Refer to Sales and Order Information for Alumaguard 16 Refer to Sales and Order color availability and codes Information for color OU Acrylic With Uniguard 17 availability and codes CUSTOM M 18 POLYWEAVE ALUMAGUARD UNIGUARD OT Polyweave with Uniguard 49 BEDS UE Refer to Sales and Order Information for color Refer to Sales and Order availability and codes 20 Information for color 24 availability and codes ACRYLIC Refer to Sales and Order Information for color availability and codes AVAILABLE IN HORIZONTAL OR VERTICAL STRIPE OR SOLID CUSTOM ACRYLIC 140 custom colors are available 052540 301r2 15 Table of Contents TRAVEL R Service Manual Carefree of Colorado ILLUSTRATED PARTS LIST Series Series Il DETAIL A Motor Head Derceded pere Series I Series Il DETAIL B Idler Head TravelR502 16 052540 301r2 Table of Contents Carefree of Colorado Service Manual TRAVEL R Item Part Number Description Notes
20. event the bolt and the spacers from falling out when the nut and motor are removed 6 Remove the motor assembly The motor assembly consists of the motor mounting frame gears shaft and roller end cap 7 Place the new motor assembly in position over the mounting bolt Ensure that the spacer washers are all accounted for 8 Secure using the washer and lock nut removed previously The nut should be tightened until snug but the motor head should be able to swivel by hand 9 Attach the rear cover to the motor assembly using the large screw removed previously 10 Attach the motor and cable wires to the terminals inside the rear cover 11 Align the roll bar with the end cap on the motorized arm assembly Rotate the end cap until the slot in the cap aligns with the empty slot in the roller assembly and then press the roller assembly fully into the cap The end cap must seat squarely over the end of the roller assembly when complete 12 Secure the end cap to the roller assembly using two 10 x 5 8 square drive screws 13 Restore power and test operation If the awning moves in the wrong direction i e extends when retract is pushed reverse the two small wires plugged into the motor 14 Attach the front cover using the small screws removed previously 6 052540 301r2 Table of Contents Carefree of Colorado Service Manual TRAVEL R REPLACING THE MOTOR SERIES ll NCAUTION THE ARMS ARE UNDER TENSION FROM THE GAS SHOCKS WHEN THE
21. f the switch 12 052540 301r2 Table of Contents Carefree of Colorado Service Manual TRAVEL R STANDARD MAINTENANCE Maintaining the Carefree Manual Patio Awning is easy Just follow these basic steps e Always operate the awning according to the instructions e Periodically check that the fasteners are tight Tighten if necessary e Keep the awning fabric and arms clean FABRIC CARE NCAUTION DO NOT USE OIL BASED CLEANERS OR ANY CAUSTIC GRANULATED OR ABRASIVE TYPE CLEANERS ON YOUR CAREFREE PRODUCT 1 One of the best ways to keep the fabric looking good and to delay the need for deep or vigorous cleanings is to hose fabrics off on a monthly basis with clear water This practice will help prevent dirt from becoming deeply imbedded in the fabric In most environments a thorough cleaning will be needed every two to three years 2 When it s time for a thorough cleaning the fabric can be cleaned while still on an awning frame e For Vinyl Fabric Use a soft brush and warm water with soap e For Acrylic Fabric Use a stiff brush and warm water with soap 3 When cleaning the fabric it is important to observe the following e Always use a natural soap never detergent e Water should be cold to lukewarm never more than 100 F e Air dry only Never apply heat to the fabric e Always allow the fabric to dry thoroughly before rolling up the awning Mildew Mildew is a fungus growth that looks like dirt Vinyl coated polyester
22. fabrics are mildew resistant because of a chemical biocide in the vinyl coating Under ordinary conditions mildew will not appear However in areas where high temperature and humidity are common mildew can be a problem and required the material to be washed more frequently Thoroughly rinse the fabric with clean water and allow to air dry completely before rolling up the awning Pooling When water collects on the top of the fabric this is known as pooling This can occur during inclement weather or if a running air conditioner discharges over the awning The water is dumped when the awning is retracted It is recommended that if water accumulates on the top retract the awning in steps 8 12 to dump the water This will help prevent the fabric from stretching or distorting The effects of wind and rain on an awning are unpredictable Severe damage to the awning and the vehicle may result IF WIND OR EXTENDED PERIODS OF RAIN ARE EXPECTED ROLL UP THE AWNING AND SECURE FOR TRAVEL ARM CARE The best method of keeping the arms and braces operating smoothly is to clean them Dirt and debris can cause the channels not to slide easily NOTE Avoid introducing water into the motorized housings Periodically wash out the channels with running water i e a hose to keep them clean If the arms still do not move easily lightly spray the contact and pivot points with a dry silicone lubricant after the arms have been cleaned and dried thoroughly
23. he components and NO Correct as required wiring are properly installed and connected B Confirm Power Supply YES Goto test B Is vehicle battery or power source providing 10V to 14V to the NO Correct as required Switch C Test Motor Function YES Motor is good go to test D 1 Forinstallations with an external plug Disconnect plug NO Motor is defective replace 2 Forinstallations with a single switch Remove switch plate and disconnect the motor wires from the switch 3 Attach jumper leads to the emergency terminals located on the back of the motor head 4 Connectthe other ends of the jumpers to a 12 18VDC power source i e drill battery It may be necessary to try then reverse the leads on the battery and try again 5 Does the motor run D Test wire continuity between motor and wire ends YES Wire continuity good reconnect the wires disconnected in the previous test then go to test D NO Repair as required then reconnect the wires disconnected in the previous test D02 is continued on next page 10 052540 301r2 Table of Contents Carefree of Colorado Service Manual TRAVEL R D02 CONT E Test Switch Function Single Switch Installation this test requires a continuity tester The Patio Switch used in the Single Switch Installation is a center on that is internally cross wired to short in the center position to provide dynamic braking for the motor to prevent drift when the awning is stopped 1 P
24. it includes one fascia and screws Head cover kits include one front cover one rear cover and screws Series Il replacement motor and idler assemblies includes screw and nut Series switch has been discontinued for spares Switch kit includes Series Il switch face plate 4 screws and 4 insulated terminals 052540 301r2 17 Table of Contents TRAVEL R Service Manual Carefree of Colorado NOTES 18 052540 301r2 Table of Contents
25. lace one lead of tester YES Test OK all checks pass go to step on pin 2B Touch 2nd E2 lead to the other pins one at a time NO Test failed switch defective replace N no continuity Y continuity Observe continuity for switch in center position extend position and retract position 2 Place one lead of tester Pin on pin 5B Touch 2nd 3 lead to the other pins 6 one at a time YES Test OK all checks pass Revaluate problem cause is not electrical NO Test failed switch defective replace N no continuity Y continuity Observe continuity for switch in center position extend position and retract position SS pM LLLILI Retract kep ca 3 6 fcrc 3 8P Note 5BK gt a9 2B 5B gt 2B The Series II switch terminals are not pa ma 4 labeled The illustration is labeled for Extend Extend identification purposes in the procedures above Series Switch Series Il Switch Travelr019 D03 ARM DOES NOT EXTEND OR DOES NOT EXTEND COMPLETELY A Visually confirm motor is working when control switch is pressed YES Goto test B NO Go to test D02 Awning Does Not Extend and or Retract page 10 B Confirm that the arm channels pivot points and contact points are YES Gototest C clean and clear of obstructions NO Clean and Lubricate then retest If the arm still hangs up go to test C C Ifthe awning has Alumag
26. o extend or retract If the power supply is on the low side of the range 10V the awning will move slower The awning may appear to move jerkily When the fabric is rolled out the Alumaguard or Uniguard may bounce creating a wave like motion in the canopy fabric This will create the appearance of moving jerkily With Uniguard the awning sticks or hangs up When Uniguard is installed with a vinyl canopy the vinyl will have a tendency to cling to the Uniguard when not used over an extended period Open and close the awning in short bursts 2 or 3 times the awning will then open normally In the charts below YES is a positive response to the test NO is a negative response D01 This condition generally occurs during new installations or when major components have been replaced A D02 THE AWNING DOES NOT EXTEND AND OR RETRACT THE AWNING OPERATES N REVERSE OF THE SWITCH PLATE Confirm Switch is mounted in correct position and correctly YES Switch mounted OK go to test B oriented NO Carefully remove the switch rotate 180 and reinstall in panel Reconnect harnesses and retest Confirm switch is wired correctly Use the wiring diagram and YES Switch wired OK go to test C confirm the wires to from the switch to the connector are NO Rewire the switch according to the correctly placed wiring diagram A Check Installation Integrity YES Goto test B Use the wiring diagram and confirm that t
27. teep Pitch Centerline Mounting of Motorized Arm Awning Length Hole Centerline Centerline of Idler Arm of Motorized Arm Flat Pitch Arm Steep Pitch Arm 052540 301r2 TravelR003 Figure 1 General Layout 1 Table of Contents TRAVEL R Service Manual Carefree of Colorado CANOPY REPLACEMENT 10 x 5 8 Screw qty 4 ij End Cap dll Roller Assembly LA i Align Slots Align Slots Detail A Detail B Upper Bracket After Market Installations Trim Polycord 1 From Fabric Feeder Feeder 1 Piece Fabric 2 Piece Fabric Detail D Travelr014 Figure 2 Canopy Replacement Travel r Remove the canopy retaining screws in the awning rail Extend the awning out completely Remove the screws that attach the end caps to the roll bar and save While holding the roll bar up pull the roll bar out of the end cap of the motor head NCAUTION DO NOT ALLOW THE ROLL BAR TO DROP TOWARD THE GROUND THE TWISTING MOTION CAN CAUSE SERIOUS DAMAGE TO THE IDLER ARM 5 Support the roll bar pull the roll bar out of the end cap of the idler head Allow the fabric and roll bar to hang down on the side of the RV Use care to not scratch the side of the RV 7 Mark the slots that the current fabric is in then remove any fabric retaining screws in the roll bar and tractioners used with Alumaguard Slide the roll bar off of the fabric 8 Determine the type of canopy replacement e If replacing a full f
28. uard check that the tractioners are installed YES Tractioners OK Go to test D and positioned correctly refer to page Error Bookmark not NO Reposition and attach the defined tractioners according to the directions on page Error Bookmark not defined and retest D 1 Open the awning If the awning arm does not extend YES Shock is defective replace See carefully pull the arm out as the fabric is unrolling procedure on page 9 2 Does the fabric sag when the awning is extended NO Shock extends with arm and is 3 Inspect the shock Is there evidence of dirt build up and oil solid Shock pressure is leaks on the rod approximately 85 lbs Go to test E 4 Hand close and open the arm Is the tension from the shock mushy weak or missing NOTE To close the awning by hand push the head of the arm toward the coach Pulling down on the head or roll bar WILL NOT close the awning E This step only applies to new Uniguard and Alumaguard installations that do not extend correctly Check that the centerline of the roll bar is 3 4 1 4 above the centerline of the awning rail Refer to 052540 002 Travel r Installation Manual and reposition arms as required 052540 301r2 11 Table of Contents TRAVEL R Service Manual Carefree of Colorado WIRING DIAGRAM EXTEND Oc of Colorado Nu E EXTEND FON O f O Carefree of Colorado Rear Detail A
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