Freedom Freestyle Service Manual - E
Contents
1. LED Strip R001729 Harness R040616 206 Wire Channel 580101 Switch Kit includes item 5 019493 001 Fuse Kit includes in line fuse holder and 2A fuse Notes 1 LED strip item 1 is sent on a roll and cut to length during installation 052573 301 2 21 FREEDOM FREESTYLE NOTES 22 Service Manual Carefree of Colorado 052573 301 22. IN Endcap Plug Out Limit Switch The OUT limit switch stops the motor when the awning is fully extended 4mm Hex O WM011a 1 Extend the awning out completely 2 Confirm that the arms are fully extended The motor should stop and the fabric should be tight If the motor continues to run the fabric will sag or if the motor quits before the arms are fully extended it will be necessary to adjust the OUT limit switch 3 Using a 4mm Allen wrench turn the OUT limit switch CLOCKWISE increases time the motor runs during extension COUNTERCLOCKWISE reduces the time the motor runs NOTE It is best to make the adjustments in increments of a single turn 3 full turns of the screw equals approximately 2 of fabric extension 4 Extend and retract the awning several times to confirm that the adjustment is correct 5 Repeat steps 3 and 4 as required until the awning extends correctly IN Limit Switch NOTE The IN limit switch is not adjusted when the Direct Response system is installed The system electronics monitors the motor and shuts the motor off when the awning is fully retracted If the IN limit switch is accidently adjusted the motor may shut off before the awning is fully closed If this occurs turn the IN adjustment screw clockwise It is not necessary that the screw position matches the closed position The Direct Response electronics cont
3. Control Module low i sJ ELELEE m MI nine Casaq Gra ead rai SEB EB 2228 t mat Additional Ew Extend Retract z pue T x Switch 25 14 16awg Spade Terminals 1 Male 1 Female Chassis Ground FF001 REPLACING THE DiRECT RESPONSE MODULE The Direct Response Module is located on the LH side motor side of the lead rail NOTE The Freestyle awning will not operate electrically when the module is disconnected To Remove 1 Disconnect power to the awning Quick Disconnects 2 Remove the two screws holding the module Pull the module from the lead rail NOTE The mounting brackets are held in place by tension from the screws When the screws are removed the brackets will sit loosely in the lead rail Use care save the brackets Direct Response 3 Detach the quick release connectors Module 4 Setthe module aside To Install 1 Connect the wires Make sure to match wire color and size when making connections 2 Position the brackets 3 Tuck the wires and connectors behind the module and attach the module with the two screws removed previously 14 052573 301 2 Carefree of Colorado Service Manual FREEDOM FREESTYLE OPTIONAL LED LIGHTING An LED light strip is available as a factory installed option The strip is mounted in the lead rail with the harness routed through the awning with the Direct Response cable Route the twisted w
4. Against Roller Tube Polycord While Placing Screw Fabric Retaining Screws 12 16 in Ibs View of RH Idler Plug wwo244 Figure 3 Fabric Replacement Remove the two 2 screws holding the outer end cap Set the cap and screws aside m On the motor side remove the fabric retaining screw It may be necessary to rotate the roller tube to align the screw with the access hole in the inner cap Remove the fabric retaining screw from the left lead rail end plate Remove the RH lead rail end plate and the RH end cap Slide the roller tube and fabric out of the case and lead rail Remove the fabric retaining screw located through the RH end plug Unroll the old fabric and slide off the roller tube Unfold the replacement fabric NCAUTION WHILE THE AWNING FABRIC IS FAIRLY ROBUST CARE MUST BE TAKEN NOT TO SNAG IT WHILE SLIDING THE NEW FABRIC INTO THE ROLLER TUBE OR LEAD RAIL Tip Lightly spraying the slots with a dry silicone lubricant will help the fabric slide into the slot without staining the material 052573 301 2 3 FREEDOM FREESTYLE Service Manual Carefree of Colorado 9 10 11 12 13 14 15 16 17 18 19 20 Slide the black polycord of the fabric into the fabric slot Orient the fabric with the hem on the top the hem will then roll against the roller tube Center the fabric in the roller tube After the fabric is centered on the RH end plug pull and hold the excess
5. Lead Rail RH 3 12 R001630 Hardware Pack Arm Attach 1 Arm 13 RO12530 TB94L Spring Arm Assy LH 3 14 R012530 TB94R Spring Arm Assy RH 3 R012530 TB94M Spring Arm Assy Center Used on 4 5 and 5 meter only 3 4 6 15 R019468 006 Switch Kit 16 060686 002 Sensor Control Module 17 HR001679 Bracket Kit Sensor 18 R040616 006 Cable Channel Black R040616 005 Cable Channel White 19 019867 001 Bracket Kit 3m 4m 5 019867 002 Bracket Kit 4 5m 5m 5 20 019868 001 Screw Pack Awning Mount 3m 4m Not Shown 019868 002 Screw Pack Awning Mount 4 5m 5m Not Shown 21 901075 Manual Override Key NOTES 1 Color WHT White BLK Black GRY Satin 2 Motor Assy item 2 includes motor inner endcap bearing and one way drive Parts not available separately 3 Attaching hardware not included with spring arm assemblies Order item 12 4 Center arm for 4 5m and 5m awnings uses pivot assembly item 11 5 Bracket kit 3m 4m contains 3 brackets and screws Bracket Kit for 4 5m 5m contains 4 brackets Bracket kits do not include awning mounting screws order item 20 6 The middle spring arm is different than the outer arms Center arms can be identified by the blue dot located on or near the case connector of the arm Do not use center arms for replacing outer arms do not use outer arms to replace the center arm 20 052573 301 2 Carefree of Colorado Service Manual FREEDOM FREESTYLE OPTIONAL LED LiGHTING
6. knuckles Have a second person lift up on the lead rail to relieve the pressure on the adjustment screws Using a 4mm allen wrench loosen the top screw Turn the bottom adjustment screw clockwise to raise the lead rail turn the adjustment screw counterclockwise to Figure 5 Pitch Adjustment lower the lead rail When the pitch is set at the desired angle tighten the top screw Repeat for each arm Ensure that the lead rail is parallel with the awning case U Arm Case Knuckie V Pitch Adjustment Screw FF003 Special Note The Freedom Freestyle lead rail self adjusts to accommodate the pitch No adjustment is required to the lead rail when the pitch is adjusted 052573 301 2 7 FREEDOM FREESTYLE Service Manual Carefree of Colorado MIDDLE ARM REPLACEMENT 4 5 AND 5 METER AWNINGS NCAUTION THE SPRING ARM IS UNDER TENSION TO OPEN USE EXTREME CARE AND FIRMLY HOLD THE SPRING ARMS DURING ASSEMBLY AND DISASSEMBLY TO AVOID ANY SUDDEN OR UNEXPECTED MOVEMENT BY THE ARM SERIOUS PERSONAL INJURY AND OR PROPERTY DAMAGE COULD OCCUR NCAUTION THE MIDDLE SPRING ARM IS DIFFERENT THAN THE OUTER ARMS CENTER ARMS CAN BE IDENTIFIED BY THE BLUE DOT LOCATED ON OR NEAR THE CASE CONNECTOR OF THE ARM DO NOT USE CENTER ARMS FOR REPLACING OUTER ARMS DO NOT USE OUTER ARMS TO REPLACE THE CENTER ARM Tools Required Flat blade screwdriver 1 4 needle nose pliers regular pliers and or e ring tool New e clips are included
7. occur to the awning 3 IN 1 is a registered trademark of the WD 40 company 18 052573 301 2 Carefree of Colorado Service Manual FREEDOM FREESTYLE PART NUMBER LISTING FREEDOM FREESTYLE PART NUMBER CONFIGURATION Example Part Number CA13858JVTM CA 138 58 JV TM Freedom WM 138 Black Gray Black TM Patio Awning 3 5 m SERIES CODE SIZE CANOPY COLOR CASE COLOR MOTORIZED CA 118 AVAILABLE FABRICS STANDARD TM Motorized Freedom 3m VINYL CoLoRKEv 1 25 WHITE Freestyle Patio c Awning 138 ACRYLIC Key 2 JV BLACK 3 5m CustomAcRYLIC _ 5 23 SATIN 157 s FOR COLORS REFER TO THE Sui COLOR CHART AVAILABLE ON LINE AT 177 www carefreeofcolorado com or 4 5 m www e carefree com 197 5 m Serial Number Part Number Location Serial Part Located on the NS Inside of the Left End of Case 052573 301r2 19 FREEDOM FREESTYLE Service Manual Carefree of Colorado FREEDOM FREESTYLE ILLUSTRATED PARTS LisT Item Part Number Description Notes 1 R001618XXX Endcap LH Outer 1 2 R001712XXX Motor Assy LH 1 2 3 R001620XXX Endcap RH 1 4 R040792 005 Plug White R040792 006 Plug Black 5 R001623 Roller Tube Endplug RH 6 R001624XXX End Plate Lead Rail LH 1 7 R001625XXX End Plate Lead Rail RH 1 8 R001621 Ramp Kit Leadrail 9 R001677 Pivot Assy Case 3 10 R001678 Pivot Assy Lead Rail LH 3 11 R001680 Pivot Assy
8. rail The lead rail is made to pivot on the lead rail connectors 32 Tighten the lower pitch adjustment screw until snug 33 Tighten the upper pitch adjustment screw 8 052573 301 2 Carefree of Colorado Service Manual FREEDOM FREESTYLE REPLACEMENT 1 Disconnect power to the awning Spring Arms 2 If the awning is extended Carefully push the lead rail toward the case so that the arms collapse While holding the lead rail in this position firmly tie the elbows of the spring arms together Use a minimum 1 2 rope do not use bungee cords When tying the rope use a non slip 6 um knot such as a square knot or equivalent Firmly Tie TE Elbows Together 3 lf the awning is closed Firmly brace the lead rail in the closed ae position A second person can hold the lead rail steady during the disassembly process NCAUTION FAILURE TO SECURE THE LEAD RAIL AS DESCRIBED WILL ALLOW THE SPRING ARMS TO EXTEND OUT SUDDENLY POSSIBLY CAUSING PERSONAL INJURY AND DAMAGE TO THE AWNING REMOVE OLD MOTOR ee RON 2 Retaining Screw Outer End Cap 9 Fabric Slot 1 Remove the two 2 screws holding the outer end cap Set the cap and screws aside Disconnect the motor wire quick disconnects located under the outer cap Remove the three 3 screws and spacer holding the inner end cap to the case Remove the two 2 motor screws NCAUTION IF THE AWNING IS CLOSED WHEN THE INNER END CAP IS DETACHED TH
9. screw should be positioned to thread 21 22 into the metal of the lead rail and the edge of the polycord Reattach the outer end cap on the LH side Torque screws to 15 in lbs After installing the canopy it may be necessary to adjust the motor limits for motorized awnings Refer to Adjusting the Motor Limits on page 11 052573 301 2 Carefree of Colorado Service Manual FREEDOM FREESTYLE REPLACING THE LEAD RAIL This procedure requires a minimum of two people This can be done while the awning is mounted on the vehicle If being done before the awning is mounted set the awning on a clean hard surface such as the floor of the shop 1 Open the awning completely There should be some slack in the fabric If necessary adjust the motor limits so that the motor can extend far enough to create slack in the fabric refer to page 11 ond mUUPPPPPPDPDPDPDPDPDTUT Measure Locations Measure Locations 77777 End Plate End Plate Ramp Arm Connector Center Ramp Arm Connector Ramp centered in lead rail Direct Response View of Back of Lead Rail Module FFO14 Figure 4 Replacing the Lead Rail 2 Remove the LH and RH end plates and set aside 3 Carefully measure and record the locations of the ramps arm connectors and Direct Response module 4 Loosen and slide out the outer ramps 5 Loosen the screws on the Direct Response module Twist the brackets slightly a
10. to match the mark made previously To trim the LED strip always cut between the 4 pad cluster as shown Route the new LED strip wires as shown and connect to the harness Restore power and test HARNESS REPLACEMENT T 2 16 Extend the awning out completely Separate the LED connectors at the lead rail Carefully pull the harness from the wire channel at the top of the arm At the awning case 3 1 The wire is routed with the motor wire To access the wire it will be necessary to remove the outer end cap from the motor side 3 2 Clip the harness then clamp the harness to prevent it from falling in the vehicle wall Connect the new harness to the LED strip Route the harness through the wire channel At the arm joints arch the cable slightly to avoid binding Tip Use a small tool such as a flat bladed screwariver to gently spread open the channel then insert the cable into the channel Do this for the entire length of the channel until the cable is fully inserted At the vehicle wall 6 1 Route the new harness through the wall to the switch or dimmer module Tip Tie the new harness to the old harness that was cut previously Use the old harness to pull the new harness through the wall to the desired location 6 2 Seal the wall entrance hole and harness with a quality silicone sealant 6 3 Connect the new harness to the switch Two 2 187 18 24 awg female disconnects are provided if connecting to a switch 6 4 A
11. wire Use pliers to crimp the connector closed 18awg Wir Single Pole 4 4 Repeat for the second wire end minimum Single Throw Switch GND 4 5 Slide the fuse into the fuse port vehicle Wall Ensure that is firmly seated E Wire Routed 5 Press ihe in line fuse wires and LED Strip in Lead Rail in Arm switch into the mounting hole Secure t the switch using two 2 6 x 1 2 L4 8 E BS II Screws RS SERA ON WN Connector at Lead Rail LEO 6 Snap the switch bezel over the switch frame 052573 301 2 15 FREEDOM FREESTYLE Service Manual Carefree of Colorado REPLACING THE LED STRIP Wire Channel NS NS Tie Strap Harness Connector 0 8 g 8 20 70214 Onea EE E 10 11 Cut Between Pads Adjust Length LED Strip LED Slot Extend the awning out completely Disconnect power to the awning and the LED strip Use a non permanent marker to mark the location of the ends of the LED strip Inside the lead rail disconnect the strip connectors Remove the existing LED strip from the lead rail Clean the slot to remove any dirt and tape residue Thread the new strip behind the lead rail connectors Starting at the reference mark on the harness end press the new strip into the LED slot At the end of the lead rail cut the LED strip
12. E SPRING ARMS WILL TRY TO OPEN CONTINUE TO HOLD THE LEAD RAIL CLOSED 4 Carefully pull the inner end cap away from the case and remove the wires from the end cap Set the end cap aside 5 Remove the fabric retaining screw then pull the motor out of the roller tube and set aside NCAUTION IF THE AWNING IS CLOSED WHEN THE MOTOR IS REMOVED THE SPRING ARMS WILL TRY TO OPEN SUPPORT THE ROLLER TUBE AND ALLOW THE AWNING TO OPEN SLOWLY THEN SECURE THE ARMS BY TYING THE ELBOWS TOGETHER AS DESCRIBED PREVIOUSLY 052573 301 2 9 FREEDOM FREESTYLE Service Manual Carefree of Colorado INSTALL THE NEW MOTOR Route Wire From Harness Thru Hole in End Cap 10 2 Retaining Screw 12 16 in Ibs Route Motor Wire Thru Hole in End Cap One Way Drive M4 x 25mm Screw x3 me 25 30 in lbs Ww Connect Motor Wires NEN with Harness Wires 9 sA Spacer x1 FF017 1 Check that the one way drive is installed on the new motor assembly with the B pointing toward the motor AWARNING THE ONE WAY DRIVE MUST BE ORIENTED WITH THE B FACING THE MOTOR IF THE DRIVE IS NOT ORIENTED CORRECTLY THE AWNING NOT TO OPERATE AND THE ARMS WILL SPRING OUT WHEN RELEASED Route the new motor wire through the hole in the end cap Align the one way drive with the roller tube and start sliding the new motor into the roller tube Route the wire from the harness through the hole in the end cap Align the bearing on the motor an
13. O D Pda 15 Replacing E Ot 16 Een PRAETURA OLOR QM HELLE d D RD AF MN 16 ip qp spon RR errante 17 le S TN OH ETUR GEOP EAS EEE E E E E E KO ree 17 PRU E E ebd KORR T dec EN M EUM sels CEDE AD DA ena Fb CAPE POR OU N 17 xc p Er profe RN 17 PACT 2 T o NN TE I OE 17 dil a canta Se eta N e PEP P E 18 Mandal COE Soo d ne ua M dE MU LE M EE NR E 18 Parn Number mi a RE Uu 19 Freedom Freestyle Part Number Configuration unice nen entrenar nh n 19 ucibus dm lugubre ade iow CREE D oo rer Peer aE 19 Freedom Freestyle ll strated Faris LIBE cien i qti T o Tw La rcr ade o dpa 20 LEON LER KONIN eie oiii ort on us o rupi adea ipod cientes oppeto ees quati 21 PROPRIETARY STATEMENT The Freedom Freestyle Awning is a product of Carefree of Colorado located in Broomfield Colorado USA The information contained in or disclosed in this document is proprietary to Carefree of Colorado Every effort is made to ensure that the information presented in this 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 tile page Earlie
14. TROL 12V Motorized w tubular motor 12V Direct Response Standard MOTOR SPECIFICATIONS Motor Type Tubular Power 12VDC Minimum 10VDC Output 30 Watts Nominal Current 2 5Amps Max Current 14Amps stall min voltage Torque Continuous 6Nm 4 5 ft lbs Tightening 18Nm 13 2 ft lbs Speed 24 rpm COLORS AVAILABLE Case Satin White or Black Fabric Vinyl Special Note Dimensions are provided in centimeters Conversion formulas are provided below Inches Centimeters _ Millimeters 7 2 54 25 4 Centimeters Inches x 2 54 Millimeters Inches x 25 4 2 052573 301 2 Carefree of Colorado Service Manual FREEDOM FREESTYLE CANOPY REPLACEMENT This procedure requires two people 1 Open the awning 18 24 Spring Arms 2 Disconnect power to the awning comer NEA RU Carefully push the lead rail toward the case so that the arms collapse the fabric is slack While holding the lead rail in this position firmly tie the ET elbows of the spring arms together Use a minimum 1 2 rope do not use bungee cords When tying the rope use a non slip knot such as a square Firmly Tie knot or equivalent Elbows s NCAUTION FAILURE TO SECURE THE LEAD RAIL AS DESCRIBED WILL Figure 2 Tying the Arms ALLOW THE SPRING ARMS TO EXTEND OUT POSSIBLY CAUSING PERSONAL INJURY AND DAMAGE TO THE AWNING RH End Plate Hem Rolls _
15. d slide into the roller tube pr or se S gu Through the access hole in the inner end cap attach the fabric retaining screw through the bearing and in the fabric slot The screw must be positioned to thread into the metal of the roller tube slot and the edge of the polycord It may be necessary to rotate the roller tube to align the access hole and fabric slot 7 Align the screw holes in the inner end cap and attach to the awning case using three 3 M4 x 25 screws and 1 spacer in the front attach hole 8 If not previously done terminate the wires from the motor with 187 male disconnects to match the harness wire Attach the motor and harness wires matching the wire colors Blue to Blue and Brown to Brown Fold and tuck the wires and connectors to fit inside the outer end cap 9 While holding the lead rail carefully remove any roller tube supports and arm ties Allow the lead rail to extend until the fabric is taut If the lead rail continues to extend after the fabric is taut the one way drive was installed backwards Retie the arms remove the motor and orient the one way drive as shown 10 To test restore power then extend and retract the awning 11 After replacing the motor it will be necessary to adjust the motor limits page 11 12 After testing and adjusting the motor limits attach the outer end cap 10 052573 301 2 Carefree of Colorado Service Manual FREEDOM FREESTYLE ADJUSTING THE MOTOR LIMITS OUT
16. ed See page 11 REPLACING THE LEAD RAIL CONNECTOR 1 2 3 10 11 12 Remove the arm according to the instructions on page 6 Remove the lead rail end plate Carefully measure and mark the location of the existing Remove connector and ramp and sensor when installed EL Ramp End Plate Loosen the securing screw and slide the existing ramp from eee the lead rail Module FF015 Loosen the screws on the sensor Twist the brackets slightly and lift the sensor and brackets away from the lead rail Disconnect the module from the wire harness Quick connects are found behind the module Loosen the securing screw and slide the existing connector from the lead rail Insert the new connector assembly into the lead rail and position at the marks made previously NCAUTION Failure to position the connector correctly will cause the arm and lead rail not to close correctly Tighten the outer securing screw For the sensor cable Route the cable behind the new connector Reconnect the module to the wire harness Position the module and brackets and tighten the screws Install the ramp Attach the lead rail end plate Return to Replacing the Arm on page 6 PiTCH ADJUSTMENT The pitch for Freedom Freestyle can be adjusted to optimize the installation 1 4 5 Loosen Top Screw when Adjusting Tighten When Finished Open the awning to access the adjustment screws J 3 located on the arm case
17. eedom Freestyle Installation Manual 052573 201 Freedom Freestyle Owner s Manual 052573 301 Service Manual Carefree of Colorado 2145 W 6 Avenue Broomfield CO 80020 a Scott Fetzer company 052573 301r2 Printed in USA September 2013 FREEDOM FREESTYLE Service Manual Carefree of Colorado PRODUCT OVERVIEW Freedom Awnings are state of the art lateral arm awnings When retracted the housing provides protection against the elements while the streamlined styling blends in with the coach sidewall tensioned canopy fabric allows the awning to be extended partially or fully for best shade coverage Each unit is equipped with lateral support arms No vertical arms interfere with coach sidewalls custom graphics or equipment that may be mounted on the sidewalls Freedom Freestyle Specifications e Fully retractable and self storing e Motorized e The sealed awning motor operates on standard 12VDC range 10VDC to 14VDO e Case and frame are constructed of high strength aluminum extrusions protected with a polyester paint finish e Stainless steel fasteners and hardware e SPECIFICATIONS 9 7cm Awning Width Pel 40 8cm ii Fabric Width 4 257 T wm001a Figure 1 General Dimensions LENGTHS meters 3 0 3 5 4 4 5 5 0 inches 118 168 157 177 197 EXTENSION 250cm 98 LEAD RAIL SUPPORT 4m or less 2 Lateral Spring Arms 4 5 amp 5m 3 Lateral Spring Arms POSITION CON
18. gilt SERVICE MANUAL f e Cale 11 FREEDOM FREESTYLE 12V MOTORIZED LATERAL ARM Box AWNING W DIRECT RESPONSE 052573 301r2 Printed in USA September 2013 TABLE OF CONTENTS A O 2 Canopy PR 3 nicer 5 Ne U K Ce O 5 installing the New Lead Rall t 5 7 MT m 6 Rsplacing the Lead Rall COROBOIOI Fi Pien ric c Lm 7 Middle Arm Replacement 4 5 and 5 Meter 5 8 nie j A O 1 7 7 1 9 Remove OWS Mot 9 eral TE NON RO a ua ULL EC IL mU Ma qc EL 10 POMS TS OE DUTIES ac EMEND OPI DAN GERA 11 CORSI CONTRE TTD Tn 11 INSIDE Neate ots 11 Troubleshooting and DISgnos ausu uu eden pea 6n bid uuu UK EReREISMREEERUSRRRE REDE DAPRE E MAR CRUM KE 12 Gommon Cperabondd HETS at RP CA Ha iw tar ADR A MR L 12 SERIE on pH ERREUR EUER ada ase A a a ea A T 14 Replacing the Direct Response Module Luise icai aatauie Ri eire 14 Sere uu uUCcCcc 15 rd Ln n e O
19. ing a good seal and no water is accumulating on the wiring 052573 301 2 17 FREEDOM FREESTYLE Service Manual Carefree of Colorado ARM NOISE After a period of use the arm knuckle joints may slide together slightly making a squeaking or squealing noise this is normal and not a reason for concern To reduce the sound apply a few drops of multi purpose oil 3 1 1 or equivalent on the knuckle joint seams Operate the awning and repeat 3 4 times to allow the oil to penetrate into the joint Apply Light Oil in Joint Seams 477 Lead Rall WM017 Case Center Knuckle MANUAL OVERRIDE If power to the vehicle is not available the awning can be safely hA Plug retracted using the manual override located on the idler right end 3 8 Square Key of the case NOTE This procedure cannot be used to extend the awning 1 Remove the plug from the right end cap and save or 3 8 Socket Drive Extension 2 Insert the optional override key or a 3 8 socket drive extension and handle into the square drive hole inside the end cap 3 Turn the handle counterclockwise until the awning is retracted 4 Replace the plug WM012 A CAUTION After closing the awning with the manual override the lead rail may move out from the case 1 4 1 2 This is normal and the awning is secure for travel until power is restored or repairs completed Do not attempt to force the lead rail in with the override serious damage can
20. ire cable for the LED lighting into the vehicle with the motor cable Seal the hole and wires with a quality silicone sealant NOTE There is approximately 13 feet of wire from the wall entry point Controls should be located within this distance CAUTIONS A Do not route the wire over sharp edges or heat sources that can cut or fray the wires or wire insulation A Damage that is a result of improper routing may void warranty SWITCH INSTALLATION NOTE Installers may choose to furnish the control switch The installation requires that the power line 12VDC be attached to a dedicated 2A circuit breaker or a 2A in line fuse must be installed between the switch and power source For easy access locate the fuse close to the switch 1 Determine the location of the switch 2A In line Fuse 12VDC Line 2 At the switch location cut a 1 1 8 x 1 1 2 hole 3 Wire the switch as shown below Wire terminals at the switch are 187 18 24 awg female disconnects NOTE Allow adequate slack in the 12VDC power line so that the in line fuse installed in step 4 can be accessed from behind the switch 4 Install the in line fuse 4 1 Near the switch cut the red 12VDC power line to the switch Do not strip the insulation 4 2 Insert a wire end into one of the wire channels until it butts up against the stop 4 3 Fold that half of the connector 12VDC 18 24aw body over until the element Bhd tuns Female Disconnect x2 contacts the
21. lternate method At the wall splice the new harness to the existing harness using 24 awg butt connectors Push the connectors into the vehicle wall Seal the wall entrance hole and wires with a quality silicone sealant NOTE Be sure to allow enough harness from the arm to provide a slack in the harness and adequate length for the connectors to be pushed inside the wall before sealing the hole and harness with a quality silicone sealant 052573 301 2 Carefree of Colorado Service Manual FREEDOM FREESTYLE STANDARD MAINTENANCE Maintaining a Carefree 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 is time for a thorough cleaning the fabric can be cleaned while still on the awning frame e For Vinyl Fabric Use a soft brush and warm water with soap e For Acrylic Fabric Use a stiff brush and war
22. ly to its maximum extension NCAUTION When the arm is closed it can open with significant force Use care when opening the arm Tip Use a floor or ground cover and place one knuckle and arm half on the ground Have one person firmly hold the arm half on the ground while the second person carefully opens the other arm half 13 If the sensor cable is routed on the replacement arm a Attach a piece of wire channel to the top of each section of the arm using double sided tape If using new channel cut each piece slightly shorter than the arm extrusion 14 Lift the arm assembly into position and slide the pivot into the lower hole of the case connector 6 052573 301 2 Carefree of Colorado Service Manual FREEDOM FREESTYLE 15 16 17 18 19 20 Secure the pivot assembly to the case connector with the retaining clip Slide the arm onto the lead rail connector and secure using the pin and clip removed previously For the LH arm route the cable through the wire channel At the arm joints arch the cable slightly to avoid binding Do not twist the cable Tip Use a small tool such as a flat bladed screwdriver to gently spread open the channel then insert the cable Do this for the entire length of the channel until the cable is fully inserted Remove the supports from the lead rail After replacing the arm it will be necessary to adjust the pitch to align the lead rail and case See page 7 Adjust the motor limits as requir
23. m 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 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 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 require the material to be washed more frequently 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 retract the awning in steps 8 12 to dump the water This will help prevent the fabric from stretching or distorting Leaking On vinyl canopies side hems and poly cords are stitched in with a sewing machine On occasion this stitching may allow water to seep or leak through the stitches This is normal and not a defect covered by warranty Treat the seams with a quality seam sealer MOTOR MAINTENANCE e Check all wiring and connections for wear Repair when needed e Check that the sealant is provid
24. n the fabric This is to minimize the spring tension in the arms during this procedure Disconnect power to the awning Pin Lead Rail Connector Use a scaffold ladder or other means to support the lead rail If replacing the LH motor side arm carefully remove the sensor cable from the wire channel on top of the arm Use care to not bend break or compromise the cable 5 At the lead rail firmly hold the spring arm and remove the clip and pin that secures the arm to the lead rail connector Set parts aside to be reused WM036 Allow the arm to extend below the lead rail Support the end of the arm Loosen the pitch adjustment screws Remove the retaining clip from the case connector Remove the arm from the awning Clip Pitch Adjustment Screws a CLAP 7 gt Bottom Hole of Case Connector If replacing the lead rail connector go to page 7 then return here FF013 9 Remove the pivot assembly from the arm by removing the set screw and pin 10 If the arm has wire channel mounted for the sensor cable carefully remove the channel from the arm to reuse on the new arm 11 Install the pivot assembly on the new arm using the pin and set screw removed previously Torque set screw to 15 20 in lbs 12 Using two people firmly hold the new arm assembly and remove the shipping ties Allow the arm to open slow
25. nd lift the sensor and brackets away from the lead rail Disconnect the module from the wire harness Quick connects are found behind the module NOTE It will be necessary to hold and support the lead rail during the removal and assembly 6 Loosen the arm connector screw for one arm and slide the arm and connector out of the lead rail Allow the arm to extend fully and support the arm with a ladder or scaffolding 7 Repeat for the second arm NOTE If the unit has a center arm loosen the screw The arm connector is moved as the lead rail is slipped from the canopy 8 Loosen and slide out the center ramp 9 Slide the lead rail off the canopy fabric If the unit has a center arm slide the arm out of the lead rail while sliding the lead rail off the fabric INSTALLING THE NEW LEAD RAIL 1 Mark the new lead rail with the dimensions and locations measured previously NCAUTION WHILE THE AWNING FABRIC IS FAIRLY ROBUST CARE MUST BE TAKEN NOT TO SNAG IT WHILE SLIDING THE NEW FABRIC INTO THE LEAD RAIL Tip Lightly spraying the slots with a dry silicone lubricant will help the fabric slide into the slot without staining the material 2 Lift the lead rail up and slide onto the fabric Center the fabric in the lead rail If the unit has a center arm begin sliding the arm into the lead rail at the same time Slide the center ramp into the lead rail Do not tighten at this time Slide one arm connector into the lead rail Slide the othe
26. polycord to one side of the fabric slot Place one 1 10 x 2 PHSD screw through the fabric slot hole and polycord The screw must be positioned to thread into the metal of the roller tube slot and the edge of the polycord The screw action will pull the polycord further into the slot hole DO NOT OVERTIGHTEN maximum torque 16 in lbs After the screw is installed trim the excess polycord Roll the fabric onto the roller tube Note the direction of the wrap as shown The view is of the RH plug Allow adequate fabric to extend past the roller tube to cover the distance to the lead rail Slide the fabric into the lead rail and the roller tube into the case Align the roller tube with the motor drive and bearing Press the roller tube into the case Align the RH end cap with the roller tube and case and attach using the screws and spacer removed previously Torque screws 15 in lbs On the motor side align the fabric slot of the roller tube and the access slot through the inner end cap Attach the fabric retaining screw through the motor bearing and into the roller tube Open and close the awning to confirm that the fabric rolls and unrolls squarely Adjust the fabric position in the lead rail as required Center the fabric in the lead rail Trim any excess polycord flush with the inside of the lead rail end plates Attach the RH end plate and the fabric retaining screws both ends NOTE The top screw secures the fabric in the lead rail The
27. position and measure the continuity Circuit should be open 2 2 Press the switch down Extend Circuit should be open 2 3 Press the switch up Retract Circuit should be closed 2 4 Move the second lead to the top pin Put the switch in the center position and measure Circuit should be open 2 5 Press the switch down Extend Circuit should be closed 2 6 Press the switch up Retract Circuit should be open 052573 301 2 Carefree of Colorado D02 Service Manual LEAD RAIL DOES NOT CLOSE CORRECTLY FREEDOM FREESTYLE A Does lead rail close parallel to the case YES Go to test B NO Correct the pitch setting so arms are even Refer to page 7 Does lead rail stop before reaching case 1 15 the fabric rolling onto the roller tube correctly The fabric must roll onto the roller tube from the bottom YES Go to test B2 NO Using the close position of the Switch overextend the awning until the fabric rolls under the roller tube Check the motor out limit switch page 11 so that the motor stops when the fabric is extended and still wrapped beneath the roller tube 2 Is the motor stopping before the awning is closed YES If the in motor limit switch is not correct the lead rail can stop before reaching the case Refer to page 11 NO Go to test C Is the arm lead rail connector in the wrong position 1 Do the arm elbows strike the case befo
28. r arm connector into the lead rail Align the arm connectors with the measurement marks made previously and tighten the screws Route the sensor cable behind the new connector Reconnect the module to the wire harness Position the module and brackets and tighten the screws NOR OY 8 Slide the outer ramps onto the lead rail and align with the measurement marks Align the center ramp in the center of the lead rail Tighten all screws to 25 30 in lbs 9 Attach the end plates The top screws are the fabric retaining screws NOTE The top screw secures the fabric in the lead rail The screw should be positioned to thread into the metal of the lead rail and the edge of the polycord 10 After installing the lead rail it may be necessary to adjust the motor limits for motorized awnings Refer to Adjusting the Motor Limits on page 11 052573 301 2 5 FREEDOM FREESTYLE Service Manual Carefree of Colorado ARM REPLACEMENT This procedure is for replacing the outside arms For the middle arm on 4 5 and 5 meter awnings refer to page 8 NCAUTION THE SPRING ARM IS UNDER TENSION TO OPEN USE EXTREME CARE AND FIRMLY HOLD THE SPRING ARMS DURING ASSEMBLY AND DISASSEMBLY TO AVOID ANY SUDDEN OR UNEXPECTED MOVEMENT BY THE ARM SERIOUS PERSONAL INJURY AND OR PROPERTY DAMAGE COULD OCCUR 1 Open the awning to the maximum extension or as wide as possible Adjust the motor limits see page 11 to allow the lead rail to over extend and create slack i
29. r 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 THAT IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY AND OR MAJOR PROPERTY DAMAGE NCAUTION A CAUTION INDICATES 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 not to over tighten Soft materials such as fiberglass and aluminum can be stripped out and lose the ability to grip and hold Reference Publications located O www e carefree com 052573 001 Fr
30. re the awning is closed YES The lead rail connectors are set to far from the end of the lead rail Loosen the screw and slide the connector toward the end of the lead rail Make sure both sides are even Make adjustments in small increments and retest 2 Dothe arm elbows strike the lead rail before the awning is closed YES The lead rail connectors are set to close to the end of the lead rail Loosen the screw and slide the connector away from the end of the lead rail Make sure both sides are even Make adjustments in small increments and retest gt C Connectors Too Far From Lead Rail End Connectors Too Close To Lead Rail End Arm Connector Connectors Correct Arms Close Evenly FF019 052573 301 2 13 FREEDOM FREESTYLE Service Manual Carefree of Colorado WIRING To 12VDC 187 14 16awg Female Spade Terminals qty 2 EN Rear View of Switch Assy Extend Retract 187 18 20awg Female Spade Terminals qty 3 Brown
31. rols the closed position 052573 301 2 11 FREEDOM FREESTYLE Service Manual TROUBLESHOOTING AND DIAGNOSTICS The following procedures are intended to aid the service technician to resolve operational issues with the electronics installation Common Operational Items The following are operational items that may come up as questions during normal operation 1 The awning seems to extend and retract slowly The operational range is 20 25 seconds to extend or 25 35 seconds to retract If the power supply is on the low side of the range 10V the awning will move slower 2 After a period of use the arm knuckle joints may slide together slightly making a squeaking or Carefree of Colorado squealing noise this is normal and not a reason for concern Refer to page 18 In the charts below YES is a positive response to the test NO is a negative response are properly installed and connected 001 THE AWNING DOES NOT EXTEND AND OR RETRACT A Check Installation Integrity YES Go to test B Use the wiring diagram and confirm that the components and wiring NO Correct as required B Confirm Power Supply YES Go to test C Is vehicle battery or power source providing 10V to 14V to the Switch NO Correct as required NOTE The battery may have a surface charge when not in use This will give a false value if testing Test the battery under load to receive a valid value C Test Motor Function YES Motor i
32. s good go to test D 1 Remove the outer end cap on the motor side NO Motor is defective replace 2 Disconnect the motor wires from the harness 3 Connect the motor wires to a 12 14VDC power source i e drill battery If the awning does not move reverse the leads on the battery and try again NCAUTION Be sure to attach the MOTOR leads to the battery Connecting the harness wires to the power source will seriously damage the Direct Response module 4 Does the motor run D Test wire continuity in the harness YES Wire continuity good reconnect the 1 There are two wires from the module to the motor connection wires disconnected in the previous test 2 There are four wires from the module to the switches then go to test E 3 There is one wire to chassis ground NO Repair as required then reconnect the 4 Confirm the wires are isolated and not shorted against the wires vehicle or each other E Test Switch Function YES Switches are good Module is 1 Test Power Switch defective replace 1 1 Disconnect wires from Power Switch NO Switches are defective replace 12 1 2 Using a continuity tester place one lead on each terminal 1 3 With the switch in the OFF position circuit should be open 1 4 With the switch in the ON position circuit should be closed 2 Testthe Extend Retract Switch 2 1 Using a continuity tester place one lead on center pin Place the second lead on bottom pin Put the switch in the center
33. with the replacement arm Special Note Carry the necessary tools ties or sleeves and new e clips These must readily available during the procedure 21 Open the awning 2 to 3 feet Pin Lead Rail Connector 22 Disconnect power to the awning 23 At the lead rail firmly hold the spring arm and remove the clip and pin that secures the arm to the lead rail connector Set pin aside to be reused Arm 24 Fold the arm and secure using a large zip tie or cord Do not use bungee cords 25 Loosen the pitch adjustment set screws Sp 26 Remove the retaining clip from the case connector Pitch Adjustment Screws Retaining Clip Bottom Hole of Case Connector FF013a 27 Remove the arm from the awning and set aside NCAUTION When the arm is closed it can open with significant force Use care when opening the arm 28 Lift the arm assembly into position and slide the pivot assembly into the case connector NOTE the pivot goes into the lower hole of the connector 29 Secure the pivot assembly to the case connector with a new retaining clip large 30 Firmly hold the new arm assembly and remove the shipping ties Allow the arm to open slowly 31 Slide the arm onto the lead rail connector and secure using the pin removed previously and a new clip small NOTE When aligning the pin through the arm and lead rail connector it may be necessary to pivot the lead
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