Travel`r Adjustable Pitch Installation Manual
Contents
1. IT IS RECOMMENDED THAT AT LEAST THREE PEOPLE INSTALL THE AWNING DUE TO ITS SIZE AND WEIGHT Refer to the General Layout in Figure 1 on page 1 Check the location the awning is to be mounted Ensure that the awning will not interfere with other equipment on the vehicle such as a slide out room light fixtures exhaust vents etc 1 On the awning rail mark the location of the centerline of the motorized arm assembly Unroll the canopy one wrap NOTE While the awning fabric is fairly robust care must be taken not to snag it on the awning rail With one person holding each arm the third person should thread the polyrod the plastic rod on the edge of the fabric into the awning rail starting at one end Carefully move across the vehicle gently pulling the fabric into the rail until the awning is in the pre determined location Position the motorized arm on the coach Align the center of the motorized arm with the centerline marked in step 2 Butt the top of the rear channel against the awning rail as shown in Figure 7 IMPORTANT NOTE For Uniguard and Alumaguard installations the centerline of the roller tube must be 3 4 1 4 above the centerline of the awning rail If the arm cannot be positioned as shown and meet this requirement because of trim below the awning rail the installer must remove the trim where the arms mount or install a new awning rail below the trim Travelr012 Figu2. AO 2 cy T CANN CANNA Travelr002 Figure 2 Component Checklist M ITEM DESCRIPTION QTY NOTE D A OEM B Aftermarket A B O 1 Roller tube Assembly Ordered Separately O 2 Screw Hex Washer Head 6 x 3 8 O 3 Tractioner 2 4 Screw Truss Head SQ Drive 10 x 5 8 2 O 5 Arm Assembly LH 1 O 6 Arm Assembly RH 1 J Fascia Q 8 Rivet Moly 3 16 0 9 Screw Lag 1 4 x 1 1 2 10 Screw Lag KO 2 A i O 11 Screw HexWasherHead HO KBB 2 2 O 12 Top Mounting Bracket o oS y y odo a2 O 13 Screw Philips Pan Head KD o 2 D 14 NylockNut OY la O 145 Switch Kitt O 16 JumperCable tt J 3 Z O r D 1 Awning configuration is specified at time of order including awning length fabric color etc Check awning assembly against original purchase order Arms are configuration specific and are not interchangeable 2 Screws and Tractioners are furnished with rollbar assemblies equipped with optional Alumaguard 3 Place Jumper Cable item 16 and Owner s Manual item 17 with RV owner information 2 052540 021r7 Carefree of Colorado Installation Manual Adjustable TRAVEL R INSTALLATION REQUIRED PRE INSTALLATION PREPARATION 1 Park the vehicle on a flat surface and level the unit 2 IF THIS IS AN UPG
3. 6 inches STEEP approximately 33 inches Measurement is from centerline of Awning Rail to centerline of rollbar MOTOR Power 10VDC 14VDC Circuit Rating 15 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 White Black Available in a Variety of fabrics and colors refer to order sheet poo Width o approx approx l A 4 ne E E oe E aan o Q Io L4 E E h Awning Rail 90 TYP 1 004 l a 6 min Drill Area for Clearance a epics from top of Ong ef door EL LOE I Beg E 5o l gt Fc oO z gt E pii 64 1 4 ian l Fii c Lo i i ale t l li Drill Area for li i Lower Cable i1 H Routing Al i Egh ae d eg 1 Awning Length i Flat Mounting Surface Area Centerline Centerline 3 1 2 x 67 of Idler Arm of Motorized Arm TravelR003a Figure 1 General Layout 052540 021r7 1 ADJUSTABLE TRAVEL R Installation Manual Carefree of Colorado COMPONENT CHECKLIST Roller Tube ordered seperately
4. E a E n rl T Soft C t 6 x 3 8 eo_ 6 x 3 8 Lae x 318 Fabric Screw Screw __ Alumaguard Screw Uniguard Fabric E0014 Figure 11 Securing the Fabric 2 1 For vinyl awnings place screw through awning rail polyrod and canopy approximately 1 in from the end of the fabric 2 2 For Uniguard awnings place screw through awning rail polyrod and the soft connect material approximately 1 in from the end of the fabric 2 3 For Alumaguard awnings place screw on the outer edge of the Alumaguard not through the Alumaguard 052540 021r7 9 ADJUSTABLE TRAVEL R Installation Manual Carefree of Colorado REMOVING THE TEMPORARY ASSEMBLY PINS poe vee 2 pins are inserted into the back of the left idler head for lateral Stability during installation Using a pair of pliers remove and discard both pins NOTE The awning will temporarily operate with the pins in place however for long term use the pins must be removed TravelRO11 INSTALLING THE TRACTIONERS Figure 12 Removing the Assembly Pins The tractioners are used with the Alumaguard and Uniguard metal fabric wraps 1 4 Gap Position Tracti d l A EAE al Place Screw Between 7 View A A Alumaguard or Slots on Roller Alumaguard Uniguard Rg 1 4
5. Gap Place Screw Between 7 Slots on Roller View A A Uniguard wi Vinyl Fabric cose Figure 13 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 keeper 4 Repeat for 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 ATTACHING THE FASCIA The fascia fits inside the rear channel 1 Open the awning to provide access to the bottom of the rear channel Rear Channel 2 Press the bottom dimples on the fascia into the rear channel until they snap into the bottom holes in the sides of the rear channel H oles in Rear 3 Press the top of the fascia into the rear channel until the upper Fascia Channel dimples snap into the upper holes I Dim ples TravelR032c Figure 14 Attaching the Fascia 10 052540 021r7
6. 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 021 Adjustable Travel r Installation Manual 052540 221 Adjustable 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 Carefree of Colorado Installation Manual Adjustable TRAVEL R PRODUCT OVERVIEW The adjustable Travel r 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 rollbar and arms are made from light weight no rust aluminum The awning fabric is heavy weight vinyl Travel r Patio Awning Specifications MAXIMUM EXTENSION 21 feet PitcH FuaT ROP approximately
7. ner ouanseusenen denaeecueceiacnoe 10 PACIFIC ne F a CI ee E etc otectyg oo ER E E 10 052540 021r7 Printed in USA September 2012 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 CAUTION A CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT MAY CAUSE
8. INSTALLATION MANUAL ADJUSTABLE TRAVEL R ARMS AND CANOPY THIS MANUAL PROVIDES INSTRUCTIONS FOR ORIGINAL EQUIPMENT MANUFACTURER OEM AFTERMARKET INSTALLATIONS AND ARM UPGRADES FOR CURRENT CAREFREE AND A amp E AWNINGS Ne ok u 2 4 N J A T W PL X S lt Qly 7 a A a vetre TABLE OF CONTENTS ProdUCt OV Ci OW sarinsincina pienui u e NE NONON aa a ai 1 Travel r Patio Awning Specifications sccssccccaciexccccinwondcclencersrecnencancueladousisduceuda dadecduwenesausteniencedsesues 1 OID ONG IE O NOCKII S oarra a E A S A 2 INSANA O rE E E 3 Required Pre Installation Preparation cccccccecceecsseceeceeeceeeseeceeceeceeeseeeaeeteeseeesgecsesseeteeseeeseeteeeeeesaes 3 HSalng AR VY TIA IS A es cepts pect eccrine caene aE E 4 PASSE TTC NS ANINO ice aarti ce ete lod sets seins ete E EN 5 Mounting Ne AWNING cessas a a aa R a 6 Switch and Wiring Installation cece ceccceeccceeeeee cece eeeseeeeeeececeseeeesueeseeeeseeeseeessuceseeeesneeseeeseueeaeeesaess 8 Securing the Be AOC oy ciee tetscaccier tance em teeinnnisegaceiteres ete sca sdetonassetsiennd sida caniaeseienteise endl anne sesaloe an cae sioneivnaaneietaiiseeaioaatendaoonnnadoeseaes 8 Removing the Temporary Assembly PINS cccccccseceeeeeeeeeecaeeceecseeceecueceueeauecagesuecaeecaeecseeceeeaaes 10 Installing the ACTION CIES asec ere ctecrtctercceie ostc eee nase lt anemnnc vaisecancsibeies cabnmeuevmaseeun seGameadeimse
9. RADE FOR A MANUAL PATIO AWNING follow the awning manufacturer s instructions and remove the awning from the coach including the roller tube and canopy a Remove all brackets b Plug and seal all mounting holes The new Travel r arms may not match the locations of the old awning arms c Remove the roller tube from the arms and on a flat clean surface roll the fabric onto the roller tube d If the canopy is equipped with Alumaguard remove the tractioners and set aside These will be reinstalled after the new awning assembly is installed 3 IF THIS IS AN UPGRADE FOR A ONE TOUCH AWNING a If the existing installation uses an external wall plug the installer must furnish the mating plug for the new motor wires or remove the wall connector and wires Plug and seal the hole then follow the standard wiring instructions b Determine the existing wiring configuration e Configuration A Direct connection to switch Motor wires connect directly to switch through the wall mount connector If the connector is retained see step a it is not necessary to remove the existing switch e Configuration B Control box electronics A control box is installed between the connector and switches Disconnect and remove the existing control boxes wiring and switches The system is replaced with the single switch control e Configuration C Auto Retract All Disconnect and remove the existing control boxes wiring and switches The system
10. al plug Motor Cable 3 1 refer to Figure 10 Drill a 5 16 hole through the vehicle wall for the motor cable 3 2 Route the cable through the hole to the switch location 3 3 Seal the cable and hole using a silicone sealant 4 At the switch location cut a rectangular hole 1 25 3 2cm x 1 88 4 8cm Figure 10 Cable Pass thru Drill Pattern 5 16 Hole H NN L p Bottom of Channel Routing TraveiRoie 5 16 Hole 6 x 3 4 Screw kk 1 25 38 2cm Min Clearance Left Side Orientaion From Mounting Face to SK002a Rear of Switch Connector skoozd 5 Determine the switch orientation 5 1 The wires of the connector extend from the side of the switch with 3 terminals on the back 5 2 For wire routing on the right side of the switch as shown in Details A and B orient the switch with the 3 terminals on the right 5 3 For wire routing on the left side of the switch as shown in Detail C orient the switch with the 3 terminals on the left 5 4 Push the switch into the faceplate until the tabs on the switch click into place behind the faceplate Ensure that the switch and faceplate are oriented so that the lettering is up and the wires are oriented as desired 5 5 Set switch aside 8 052540 021r7 Carefree of Colorado Installation Manual Adjustable TRAVEL R 6 Route the awning motor wires t
11. channel and out the hole in the top of the channel 3 3 Close the arm 3 4 Secure the top of the arm in the closed position using a plastic wrap or equivalent For Aftermarket and Upgrade Installations On each arm attach the top mounting bracket to the channel using the screw and nut as shown Top Mounting Bracket 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 10 Nylock Nut 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 10 x 2 Screw TravelRO22 Figure 5 Aftermarket Top Mounting Bracket NOTE The roller assembly must be oriented with the fabric going over the roller toward the mounting surface Secure the end cap to the roller assembly using two 10 square drive screws Repeat steps 5 and 6 to attach the non motorized arm assembly to the roller assembly Q S A A O A I I 10 x 5 8 Screw I End Cap End Cap 5 Alen Slots Align Slots 10 x 5 8 Screw TravelR004 Figure 6 Assembling the Awning CAUTION DURING ASSEMBLY AND INSTALLATION THE ARM ASSEMBLIES MUST REMAIN PERPENDICULAR TO THE ROLLER ASSEMBLY FAILURE TO HANDLE THE ARM ASSEMBLIES CAREFULLY CAN BEND THE DRIVE SHAFT 052540 021r7 5 ADJUSTABLE TRAVEL R Installation Manual MOUNTING THE AWNING CAUTION Carefree of Colorado
12. hrough the switch hole and attach to the switch connector To 12VDC To Ground RED Motor Wire RED Motor Wire BLACK Motor Wire BLACK Motor Wire To 12VDC CONNECTOR To Ground SK003a SK003d WIRE COLOR LH CONNECTOR ORIENTATION RH CONNECTOR ORIENTATION RED 12VDC WHITE RED motor wire BLACK motor wire BLUE BLACK motor wire RED motor wire BLACK Ground Ground 7 Runa minimum 16 awg wire from the power distribution panel auxiliary battery circuit or equivalent The circuit should be protected by a 15 amp fuse Run a minimum 16 awg wire to system ground Route the two wires through the mounting hole Butt splice the 12VDC wire to the RED connector wire Butt splice the ground wire to the BLACK connector wire 10 Attach the connector to the switch 11 Restore power and test the switch operation 12 If the awning operates opposite to the switch plate markings e Shut off power e Reverse motor wires connected to the blue and white connector wires e Restore power and test 13 Push the wires connector and switch into the mounting hole and secure the switch plate Use two 2 6 x 3 4 flat head screws SECURING THE FABRIC 1 Roll the awning in and out several times to make sure that the fabric is square on the rollbar 2 Secure the canopy using one 6 x 3 8 hex head screw at both sides of the awning 1 q1 Awning Rain Pobred Awning Rai Poros Awning N O cJ
13. ing position mark the position with a chalk line Awning rail must be level Seal the back of the rail with silicone sealant or putty tape ree sia e end o e 4 Align the awning rail onto the wall and secure with 10 x 3 4 screws J awning rail Use all the attach holes in the rail 4 b a NCAUTION P MAKE SURE THE SCREWS ARE SECURELY MOUNTED TO THE STRUCTURAL FRAME Cg lt gt OF THE VEHICLE 5 Use a screwdriver to spread open one end of the awning rail on the T0012a installation side Sas ae Figure 4 Adjusting the 6 File any sharp edges or burrs from the end of the rail This will help Awning Rail protect the awning fabric from damage during installation 7 Spray inside the awning rail track with a dry silicone lubricant 4 052540 021r7 Carefree of Colorado Installation Manual Adjustable TRAVEL R ASSEMBLING THE AWNING 1 2 Decide on the location of the switch to determine the cable routing If the motor cable is to be routed through the RV wall at the bottom of the arm slip the cable through the slot at the bottom of the track refer to Figure 10 Go to step 4 If the motor cable is to be routed through the RV wall at the top of the arm 3 1 Remove the plastic wrap at the top of the motorized arm Partially open the arm being careful to not let the arm extend more than NOTE The arm is under tension from the gas shock located in the arm 3 2 Pull the motor cable from the back of
14. is replaced with the single switch control Travel r Direct Response Auto Retract is available as a separate upgrade kit SROO093 for the Travel r Patio Awning c Remove the awning from the coach including the roller tube and canopy d Remove all brackets Plug and seal all mounting holes The new arms may not match the locations of the old awning arms f Remove the roller tube from the arms and on a flat clean surface roll the fabric onto the roller tube g If the canopy is equipped with Alumaguard remove the tractioners and set aside These will be reinstalled after the new awning assembly is installed For upgrades follow the instructions for aftermarket installations Check where the awning arms will be installed The arms fit snug to the side of the vehicle and must not cover or interfere with exhaust vents lights etc 6 If there is an awning rail installed check that the awning rail runs the full length of the awning Please refer to the note under Installing an Awning Rail before proceeding Refer to the important note on page 6 about the required positioning of the centerline of the roller tube For the bottom 3 mounting holes if mounting into structure use the 1 4 x 1 1 2 screws if not attaching into structure use the furnished moly rivets NOTE The upper mounting holes all configurations MUST attach into structure using the screws provided OEM Installations f structural backing is not available for the
15. re 7 Vertical Arm Positioning Hold the arm assembly perpendicular to the awning rail and drill a 5 32 hole through the 2 mounting hole and attach the motorized arm using a 1 4 x 1 1 2 lag screw NOTE For the bottom 3 mounting holes when attaching into structure use 1 4 x 1 1 2 screws if not attaching into structure use the furnished moly rivets Moly rivets require a 1 4 hole in place of the 5 32 pilot hole The upper mounting holes all configurations must be attached into structure using the screws provided OEM Installations f structural backing is not available for the upper mounting holes it will be necessary to use the aftermarket top brackets to attach into the structural members at the roof line 052540 021r7 Carefree of Colorado Installation Manual Adjustable TRAVEL R 7 Confirm that the arm is perpendicular to the Aftermarket Mounting Holes awning rail attach the arm through the 1 1 4 x 2 1 2 Screws Only mounting hole shown in Figure 8 using a 5 32 S er ie pilot hole and a 1 4 x 1 1 2 lag screw 8 Position the roller assembly so that it is perpendicular to the motorized arm assembly l Position the non motorized arm perpendicular to 4 ea on the roller assembly oN 9 Drill a 5 32 hole through the 2 mounting hole and attach the non motorized arm using a 1 4 x 1 1 2 lag screw g OEM _Configuration_ Configura
16. the upper mounting bracket using 2 ea 1 4 x 2 1 2 lag screws Attach the 3 lower mounting hole with a 1 4 x 1 1 2 lag screw or moly rivet 14 For OEM configurations Drill 5 32 pilot holes for the upper mounting holes then attach using 2 ea 1 4 x 1 1 2 lag screws Attach the 3 lower mounting hole with a 1 4 x 1 1 2 lag screw or moly rivet 052540 021r7 7 ADJUSTABLE TRAVEL R Installation Manual Carefree of Colorado SWITCH AND WIRING INSTALLATION CAUTION ALWAYS DISCONNECT THE VEHICLE BATTERY AND ELECTRICAL SOURCES BEFORE WORKING WITH THE ELECTRICAL WIRING AND COMPONENTS Notes 1 Failure to follow the wiring instructions in this publication may void the motor warranty 2 DO NOT wire two or more motors to one switch No parallel wiring 3 All wiring must conform to NEC National Electrical Code and local codes 1 Determine the final location of the switch NOTE If the distance from point of entry to the switch location is greater than 32 81cm the installer must furnish a splice between the motor cable and switch location 2 FOR ONE TOUCH UPGRADES 2 1 Ifthe external wall plug has been removed and sealed go to step 3 2 2 If using the wall plug measure the motor cable from the arm to the plug Trim the wire and terminate with an installer furnished mating connector Attach the new connector to the wall plug and proceed to step 12 3 For installations using the cable with a direct connection to the switch no extern
17. tion _ Upper Mounting Holes Arm Extended Out 10 Check the alignment the arm assembly must be perpendicular to the roller assembly When the alignment is correct drill and attach the arm through the 1 mounting hole shown in Figure 8 using a 5 32 drill bit and a 1 4 x 1 1 2 lag screw 3 Mounting Hole 11 Hold the awning closed and carefully remove the plastic wraps at the top of the arms The awning will open a few inches For 1 2 and 3 use 1 4 x 1 1 2 Screws Or 3 16 Moly Rivets 12 Open the awning about 18 or until the top mounting holes on the arms are visible To open 2 Mounting Hole 12 1 Cap the exposed end of the wires from the motor cable to avoid grounding or shorting These must remain capped and detached from the switch when Figure 8 Arm Mounting Hole Locations using the emergency terminals 1 Mounting Hole Lower Mounting Holes meveicon 12 2 Attach the supplied jumper cables to the emergency terminals located on the back of the motorized head N RH Motor Head 12 3 Connect the other ends of the jumper leads to a 12V source Aa E i e drill battery If the awning does not begin to move Emergency reverse the leads Terminals TravelR010c Figure 9 Emergency Terminals 13 For Aftermarket configurations Drill 5 32 pilot holes for the upper mounting holes through the bracket and the 3 lower mounting hole for each arm Then attach
18. upper mounting holes it will be necessary to use the aftermarket upper arm mounting bracket so that the upper brackets can mount into the structural members at the roof line 052540 021r7 3 ADJUSTABLE TRAVEL R Installation Manual Carefree of Colorado INSTALLING AN AWNING RAIL NOTE For canopies WITHOUT Alumaguard or Uniguard If the vehicle already has a full length awning rail installed skip to step 5 The awning rail and arms must be positioned so that any existing trim does not interfere with the awning arm when in the closed position For Alumaguard and Uniguard installations If the existing awning rail is incorporated into the coach trim or a drip rail it will be necessary to mount a standard awning rail flat on the coach wall The awning rail and arms must be positioned so that any existing trim does not interfere with the Alumaguard or Uniguard s Flex Connect or the awning arm when in the closed position ALUMAGUARD UNIGUARD Flex Connect Must Be Flat When the Awning is Closed Standard Awning Rail Mounted to Coach Wall Standard Awning Rail Mounted to Coach Wall f f Coach Wall Coach Wall E0050 Figure 3 Fabric Wrap Positioning 1 Determine the optimum positioning of the awning so that the arms will not interfere with the door frame or light fixtures The centerline of the awning rail should be above the door opening a minimum of 6 for vinyl and 7 for Alumaguard Uniguard After determining mount
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