Summit Service Manual
Contents
1. 15 To Replace the Lift AMS panna emu Nene 15 To Replace thelLift Bar 8 8 eese e Me Desccccseeseree Mes Mgr 16 Seting the Puoi aac nii A es T eM veh Th S 16 Standard M irNerlance m S eee 999 17 i 9 EUM D Ae Ce 17 HE SS at NRTOT dh Pe IOI A 4 mM CEAO E E T7 eS POSER e PR E T s P UN VA Ie 17 Serene PCA AL b uis ilr PITT OO ta CDL D tS EE 17 Pari Number ISMO e e T 18 Part NumbemSerial Number Location M ue Nee querens 18 e WE Icd ee REDEEM Nr REPE 19 SUM FI Miastrated Parts Eglises aoo lap Rent DUI DUE Diana Rae eat Rak RR RUN 20 Basic Summit Illustrated Paris List aac af i Ne De rin E tor RE ER PR ABER IPIE ERE LU M TUE stub bcd b rM b deba b RN 22 052520 301r1 1 SOKIII amp SuMMIT Service Manual Carefree of Colorado PRODUCT OVERVIEW Carefree s SOKIII amp Summit side out cover is available in 5 basic versions SOKIII Provides a side out cover with clean stylized appearance with a standard integrated deflector No locks or anti billow hardware is required This style is available for standard and XL widths Basic Summit Building on the SOKIII The Summit employs a unique lift bar system to provide a peaked contour to the fabric when Mounting Pad the room is open yet stores beneath the fabric when the room is closed This is excellent for shedding water and to prevent Wall Bracke2. Center the fabric on the rollbar then reinstall the fabric retaining screws The screws should go through the polycord and into the roll bar Do not put the screws through the fabric Refer to Detail A Roll the fabric onto the rollbar Make sure that the fabric rolls up straight Slide the white polyrod and fabric into the awning rail Center the fabric and rollbar over the room Roll up any slack material onto the roll bar Slide the right end of the roll bar into the right end cap then set the left end of the roll bar into the left end cap Attach with one 1 1 4 20 x 3 4 socket head screw removed earlier through the left end cap NOTE The roll bar cogs engage a protrusion in the right end cap 7 For XL Models Insert the center cover mount into the deflector splice and around the rolled fabric Secure with a new cotter pin included with replacement fabric 8 Firmly grasp the rollbar and fabric then remove the spring lock cotter pin inserted on the spring end of the rollbar Allow the spring to tension the fabric slowly while releasing the rollbar 9 Open and close the room to verify the fabric is rolling up straight Adjust as required 10 Reinstall the fabric retaining screws in the awning rail or adapter The screws should go through the rail fabric and polycord approximately 1 in from the edge of the fabric Refer to Detail A 11 Install the front cover N o o tQ 10 052520 301r1 Table of Contents Carefree
3. 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 IMPORTANT NOTE f the room must be closed during wet weather rain close the room in increments approximately 6 8 This is to allow water to run off while the room is closing and prevent sudden pooling HARDWARE MAINTENANCE e Replace any parts that become damaged e Periodically check all mounting hardware screws lags etc and re tighten when necessary 052520 301r1 17 Table of Contents SOKIII amp SuMMIT Service Manual PART NUMBER LISTING PART NUMBER SERIAL NUMBER LOCATION P PARTNUMBER COLOR nnn nnn SERIALNUMBER Carefree nnn nnn nnnnn SOK3047 Carefree of Colorado The part number serial number tag for the SOKIII amp Summit is located on the deflector toward the back This is under the canopy 18 052520 301r1 Table of Contents Carefree of Colorado Service Manual SOKIII amp SUMMIT SOK III ILLUSTRATED PARTS LIST DETAIL C Center Cover Support XL Only SOK3503 Item Part Number Description Notes 1 R001150XXX Brack
4. _t_ _1____ __ ______ z B o z Ww x W o o o RESTRICTIONS The Lift Bar Option is not suitable under any of the following conditions 1 Flat Drop Rooms and rooms where the room face drops more than the ranges given below ROOM EXTENSION 12 19 20 25 26 31 32 37 38 42 ALLOWABLE DROP o fo 1 1 25 1 5 The value is determined by measuring the height of the flange when the room is closed then opening the room completely and measuring the height of the flange again If the difference exceeds the ranges above the lift bar option is not suitable 2 Rooms with an awning mounted over the top of the slide out room 3 Rooms with an awning mounted on the face of the room where the top of the roll bar is less than 1 2 below the roof line of the room when the room is closed 4 Recessed rooms The lift bars store between the coach wall and the awning when the room is closed there is not enough clearance for the lift bar assembly 5 Measurement from the roof line of the room to the top of the flange cannot exceed 4 7 8 inches long bracket 052520 301r1 3 Table of Contents SOKIII amp SuMMIT Service Manual Carefree of Colorado THE FRONT COVER FoR RooMs UNDER 191 To Open the Cover For ease of cleaning the front cover can be rotated out of the way Two methods are used to attach the front cover Early Summits use spring loaded pins that project from the cover and into the end cap SOK Ill s a
5. 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 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 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 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
6. RO001364 Bumper Deflector Rubber pkg of 4 26 Canopy Only Refer to Canopy Order Form Notes XXX Color xxx Length in Inches 1 2 Items 12 includes items 13 14 15 16 3 The XL replacement Roller Tube Assy includes the roll bar halves splice rivets end caps and pre wound spring 4 XL replacement extrusions and extrusion assemblies are sent out in two pieces and assembled during installation 5 End caps Items 6 8 are obsolete If replacing end caps it will be necessary to use items 7 amp 9 remove the spring pins from the ends of the cover and attach the cover to the new end caps with screws Use the product installation manual for detailed attachment instructions 6 Forolder assemblies with the spring pin attachment If replacing the cover assembly it will also be necessary to replace the end caps for the screw mount style items 6 8 New covers are mounted with screws Also refer to note 5 7 XL replacement cover includes both the LH and RH halves 052520 301r1 21 Table of Contents SOKIII amp SuMMIT Service Manual BASIC SUMMIT ILLUSTRATED PARTS LIST DETAIL A Roll Bar Latch See Notes DETAIL C Center Support Summit XL Only 22 Spring Loaded Pin Attach Screw Attach DETAIL B 23 Ye Jf Awning Rail V Rail Used With XL Only Carefree of Colorado DETAIL D SOK3501sm 052520 301r1 Table of Contents Items 12 includes items 13 14 15 16 Carefree of Colora
7. be necessary to repeat steps 1 3 until the affected arm set is removed from the coach 4 Slide the new arm set onto the lift bar and attach to the wall bracket and deflector in the same location as the old arm set NOTE Refer to the descriptive chart in the illustration for the correct screws used to attach the pads In 2007 the deflector profile was modified and requires different screws than the previous profile Examine the deflector to determine if it is style 1 or style 2 5 Slide the outer stop bolt into the lift bar channel Go to Setting the Stop Bolts on page 16 052520 301r1 15 Table of Contents SOKIII amp SuMMIT Service Manual Carefree of Colorado TO REPLACE THE LIFT BAR 1 Loosen and remove the outer stop bolts Set bolts aside 2 Loosen the inner stop bolts 3 Begin sliding the lift bar out of the carriers When the bar clears the first carrier remove the inner stop bolts from the channel and set aside Continue sliding the lift bar out of the remaining carrier 4 Begin sliding the new lift bar into the carriers When the bar is through the first carrier slide the inner stop bolts qty 2 into the channel Continue sliding the lift bar into the remaining carrier 5 Slide the outer stop bolts into the lift bar channel Go to Setting the Stop Bolts on page 16 SETTING THE STOP BOLTS 1 Extend the room out completely 2 Center the lift bar over the room Tighten the two OUTER stop bolts These should b
8. includes the roll bar halves rivets end caps and pre wound spring NOTE Because of the length of the XL roll bar the process requires 2 3 people Spring Locking Pin j Right Side Remove After Mounting With Sprocket Roll Bar Roll Bar Splice Black Left Side Polycord With Threaded Insert Roll Up Slack Before Mountings P Roll Bar in Deflector jl A Cover Mount Rail Adaptor 1 4 20 x 3 4 I ref Screw Detail B SOK3044 Figure 7 Replacing the XL Roll Bar 1 Assemble the new roll bar e Detail A Slide the roll bar halves together The splice is a tension fit It may be necessary to tap one end of the roll bar to press the two halves together Align the predrilled rivet holes in the roll bar and the splice NCAUTION USE CARE TO NOT BEND OR DISTORT THE ROLLBAR IF IT IS NECESSARY TO TAP THE END OF THE ROLL BAR USE CARE TO NOT DAMAGE THE ENDCAP e Attach the roll bar half to the splice using four 4 3 16 pop rivets NOTE If the rivets holes are slightly misaligned use a 10 drill bit and ream the holes to allow the pop rivet to be pushed in Close the room if open Remove the front covers Insert a cotter pin through the old roll bar and spring on the right end It may be necessary to twist the roll bar back and forth to align the holes Bend the ends over to ensure the pin does not accidentally come out Remove the center cover mount from the deflector Save the bracket and cotter
9. of Colorado Service Manual SOKIII amp SUMMIT STANDARD SPRING ROLL BAR REPLACEMENT The following procedure is used to replace the roll bar or spring or both AWARNING THESE PROCEDURES DEAL DIRECTLY WITH THE PRE WOUND SPRING TENSION IN THE ROLL BAR FAILURE TO EXCERCISE CARE AND OR FAILURE TO FOLLOW THE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY AND OR PROPERTY DAMAGE IF THE SPRING IS PREMATURELY RELEASED THE ROLL BAR CAN SPIN OUT OF CONTROL AND CAUSE PERSONAL INJURY AND OR PROPERTY DAMAGE RH Bearing and Spring Spring Assy Locking Pin Twist to Add Spring Winds Awning Rail ref or Rail Adaptor ref 1 4 20 x 3 4 Screw SOK3051 REMOVING THE RoLL BAR ASSEMBLY 1 Close the room if open 2 Remove the front cover if installed 3 Insert a 3 inch cotter pin through the roll bar and spring on the right end of the roll bar It may be necessary to twist the roll bar to align the holes Bend the ends over to ensure the pin does not accidentally come out 4 Remove the 1 4 20 socket head screw from the left end cap and set aside Do not discard 5 Lift the roll bar up and out of the deflector case To lift the roll bar lift the left end first then slide the roll bar out of the right end cap 6 Unroll the fabric from the roll bar 7 Remove the fabric retaining screws in the roll bar then slide the roll bar to the right and off of the fabric Fabric can only be removed from the left end of the roll bar 8 If rep
10. pin Repeat the process of the other end and set the cover aside 3 For threaded screws Unscrew the allens head screws in both end caps until the end of the screws clears the cover it is not necessary to remove the screws from the end caps Repeat for other side then lift the cover up and set aside Attaching the Front Cover Two methods are used to attach the cover The first method uses spring loaded pins that project from the cover and into the end cap This design has been discontinued in 2007 The second method uses screws that thread through the end cap and project into the cover A Cover Retaining Screw a Latch Lever dodi 4 ples Center Latch Pin Method 1 Spring Loaded Pin Attach Method 2 Screw Attach 12 or Longer Covers Only SOK3046 Figure 4 Attaching the Front Cover 4 052520 301r1 Table of Contents Carefree of Colorado Service Manual SOKIII amp SUMMIT Method 1 Spring Loaded Pin Attach 1 Place the top pin of one end of the cover into the mounting hole of the end cap 2 On the other end of the cover press the top pin into the cover and set the cover into position Adjust the position until the pin springs out and into the mounting hole of the second end cap Repeat the procedure for the bottom pins 4 For covers 12 feet and longer Locate the latch lever at the center of the cover Using a screw driver or similar tool push the lever to the left and hold press the cover into position then relea
11. CO 80020 a Scott Fetzer company 303 469 3324 www carefreeofcolorado com Table of Contents Carefree of Colorado Service Manual SOKIII amp SUMMIT TABLE OF CONTENTS dis ede 1 fI 2 anm Sm ODDO OD C MOA noire o ied t Rd ERO e E Ia ce ERE IEEE REIS IO EROR EU ERE Mise iN eti Or UR E 3 The Fron e ee aai For ROOMET 4 Bg c raga 40 ne c 4 EE tie smi COVO PT Qu LU UL E 4 PoC the Front COYS Wr 4 0 ed DS Ue m rr E AS UR cop E rt 6 Pd Me LOB iassdiaraiieliieatvien ynan aA aT aE A E Drei a I TEMOR vi DT DEA 6 Attaching me dut COYS rn a n 7 Heels ete T Rue Mf c n ret tee ee eee 8 Seke jedete le nen 9 Notes on Using an Ex LOB osos genoma mtien epe Sai M rSn iA 9 Canopy Replac emeni PME fh de d m 10 Removing the Old Fabric ONE Ju Wb UT UO Aum 10 Meran the New PEDI Gossip A Ne rait o arie Rea gettin gr i era 10 Standard Spring Roll Bar Replacemt amp nt 4 cese essere ecce ener 11 Removing the Roll Bar Assembly f Aaeeeiai aaa aaaea aa a aaa A 11 Rebuilding the Roll Bar p Vd Werte OCT TRIRED me 12 l stalling the Rol Barn am W m A 12 Replacing the XL Roll HAP geese Mhpesnnnnnnnnnnnnnnnnnnnnnnnn nananana nga aae Sannan anaa a sina 13 Replacing the Lift Bar COmponentse M 4 M Annn 2
12. Canopy Only Refer to Canopy Order Form Notes XXX Color xxx Length in Inches 1 2 3 The roll bar latch has been discontinued For spares order RH end cap item 8 Also refer to note 6 4 The XL replacement Roller Tube Assy includes the roll bar halves splice rivets end caps and pre wound spring 5 XL replacement extrusions and extrusion assemblies are sent out in two pieces and assembled during installation 6 Endcaps Items 5 7 are obsolete If replacing end caps it will be necessary to use items 6 amp 8 remove the spring pins from the ends of the cover and attach the cover to the new end caps with screws Use the product installation manual for detailed attachment instructions 7 Forolder assemblies with the spring pin attachment If replacing the cover assembly it will also be necessary to replace the end caps for the screw mount style items 6 8 New covers are mounted with screws Also refer to note 6 8 XLreplacement cover includes both the LH and RH halves 052520 301r1 23 Table of Contents SOKIII amp SuMMIT Service Manual Carefree of Colorado NOTES 24 052520 301r1 Table of Contents This Manual is Compliments of Northwest RV Supply 86325 College View Road Eugene OR 97405 Local 541 746 9092 Toll Free 866 678 7467 Fax 541 736 5573 http www nwrvsupply com mail nwrvsupply com Northwest RV Supply carries a large spectrum of surplus used and new RV parts and components Ple
13. Deflector Mount Tall 2 R001150XXX Bracket Deflector Mount Short 2a Spacer 1 4 Deflector Bracket 3 R001151XXX Cover Deflector Mount Bracket 4 R001250 Bracket Lift Bar Assy Mount 5 R001153XXX xxx Deflector Assy R001338XXX xxx Deflector Assy LH XL Only 3 R001339XXX xxx Deflector Assy RH XL Only 3 6 Obsolete End Cap LH Spring Pin Cover Attach 7 R001520XXX End Cap LH Screw Cover Attach 8 Obsolete End Cap RH Spring Pin Cover Attach 9 R001521XXX End Cap RH Screw Cover Attach 10 R001156 Roller Support 11 R036428 001 Center Support Plate XL Only 12 GEXXX17 Lift Bar Assy 12 16 9 Room Extension 2 GEXXX26 Lift Bar Assy 17 26 Room Extension 2 GEXXX42 Lift Bar Assy 26 1 42 Room Extension 2 13 R001160 xxx Lift Bar R001346XXX xxx Lift Bar XL Only 3 14 R001161 End Cap Lift Bar 15 RO01162 17FI Extension Arm Assy 12 16 9 Room Extension R001162 26FI Extension Arm Assy 17 26 Room Extension R001162 42FI Extension Arm Assy 26 1 A2 Room Extension R001361 xx Set Arm Assy Fl XL Only 16 R001176 Stop Bolt 17 610400 xxx Roller Tube 33xxx Roller Tube Assy XL Only 3 18 R001164 End Cap Assy Roll Bar LH 19 R001165 Spring Assy R001165XL Spring Assy XL Only 20 R001169XXX xxx Front Cover Assy Spring Pin Attach 6 21 R001337XXX xxx Front Cover Assy Spring Pin Attach XL Only 6 7 22 0157xxx Awning Rail 23 R001193 xxx Awning Rail Adaptor Optional used w FI 24 R038130 xxx V Rail XL Only 25
14. E Cotter Pin Detail A Detail B Detail C SOK3025t 1 Remove the LH half of the front cover 1 1 Locate the latch lever at the center of the cover Using a screw driver or similar tool push the lever to the left and hold carefully pull the center of the cover out until the latch pin cannot engage the locking channel 1 2 For spring loaded pins Using a small pin through the access holes in the LH end cover press in the lower attach pin then carefully pull the cover until the pin clears the hole Repeat for top hole Lift the cover up and away from the center cover mount Set cover aside 1 3 For threaded screws Unscrew the allens head screws in the LH end cap until the end of the screws clears the cover it is not necessary to remove the screws from the end caps Pull the cover up and away from the center cover mount Set cover aside 2 Remove the RH half of the front cover 2 1 Locate the latch lever at the center of the cover Using a screw driver or similar tool push the lever to the left and hold carefully pull the center of the cover out until the latch pin cannot engage the locking channel 2 2 For spring loaded pins Press in the attach pins in the center cover mount and lift the cover up until the pins clear the holes Pull the cover from the RH end cap Set cover aside 2 3 For threaded screws Unscrew the allens head screws in the RH end cap until the end of the screws clears the cover it is not necessary to remove the screws from
15. SERVICE MANUAL C fiee SOKIII amp SUMMIT Colorado SipE OuT COVER RV THIS MANUAL CONTAINS INFORMATION FOR SOKIII SOKIII XL SUMMIT SUMMIT XL SumMIT FI AND SUMMIT FIXL SOKIII Summit Summit XL I Summit w Peaked Contour These instructions apply to all models listed Details and procedures unique to a specific model are labeled appropriately 052520 301r1 Printed in USA January 2008 Table of Contents PROPRIETARY STATEMENT The SOKIII and Summit series of Side Out Room Covers 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 pr
16. ap 7 Locate the latch lever at the center of the covers Using a screw driver or similar tool push the lever to the left and hold press the cover into position then release the latch lever The latching pin is spring loaded and will slide into the locking channel For Threaded Screw Mounts 2 Examine the two cover halves One half has spring loaded attachment pins on one end the second has none Lift the first cover half with the pins and insert the pins through the mounting holes of the center cover support 3 Align the cover with the RH end cap and screw the cover retaining 1 4 20 x 1 1 2 socket head screws through the end cap and into the cover Hand tighten only NOTE If replacing the end caps the bottom screw holes in the end caps are threaded at the factory It will be necessary to force thread the top holes in the end cap using the supplied screws 4 Lift the second cover half up and slide the inside end onto the protruding attach pins of the first cover 5 Align the second cover with the end cap and screw the cover retaining screws through the end cap and into the cover Hand tighten only 6 Locate the latch lever at the center of the covers Using a screw driver or similar tool push the lever to the left and hold press the cover into position then release the latch lever The latching pin is spring loaded and will slide into the locking channel 052520 301r1 7 Table of Contents SOKIII amp SuMMIT Service Manual Carefre
17. ase feel free to visit our website for additional information
18. c Summit and Summit FI Outer Stop Bolt Carrier ref Lift Arm Assy Lift Arm Attaching Screws Deflector Wall Bracket Style 1 Style 2 Mounting Pad ref Summit 1410 x 3 4 10 x 3 4 10 x1 Deflector Thread Type A Thread Type A Self Drilling Summit Lift Bar Assembly Summit Fl 12x 11 4 10x2 10 x 2 1 2 Lift Bar Self Drilling Thread Type A Self Drilling outer Stop Bolt Carrier ref Lift Arm Assy p SOK3052 Mounting Pad ref Deflector Summit Fl Lift Bar Assembly 1 Close the room if open 2 Remove the front cover refer to page 4 3 For XL Models Remove the cotter pin and center cover mount Set parts aside 4 Insert a 3 inch cotter pin through the roll bar and spring on the right end of the roll bar It may be necessary to twist the roll bar to align the holes Bend the ends over to ensure the pin does not accidentally come out 5 Remove the 1 4 20 socket head screw from the left end cap and set aside Do not discard 6 Liftthe roll bar up and out of the deflector case To lift the roll bar lift the left end first then slide the roll bar out of the right end cap Set the roll bar and fabric on the roof out of the way TO REPLACE THE LIFT ARMS 1 Loosen the outer stop bolt and slide out of the channel and save 2 Remove the screws from the inner and outer mounting pads and save 3 Slide the arm set off of the lift bar NOTE If replacing an inner arm set on an XL model it will
19. do Service Manual SOKIII amp SUMMIT Item Part Number Description Notes 1 R001150XXX Bracket Deflector Mount Short 1a Spacer 1 4 Defector Bracket 2 R001151XXX Cover Deflector Mount Bracket 3 R001152 Bracket Lift Bar Assy Mount 4 R001153XXX xxx Deflector Assy R001338XXX xxx Deflector Assy LH XL Only 4 R001339XXX xxx Deflector Assy RH XL Only 4 5 Obsolete End Cap LH Spring Pin Cover Attach 6 6 R001520XXX End Cap LH Screw Cover Attach 6 7 Obsolete End Cap RH Spring Pin Cover Attach 6 8 R001521XXX End Cap RH Screw Cover Attach 6 9 Obsolete Roll Bar Latch 3 10 R001156 Roller Support 11 R036428 001 Center Support Plate XL Only 12 ZEXXX17 Lift Bar Assy 12 16 9 Room Extension 2 ZEXXX26 Lift Bar Assy 17 26 Room Extension 2 ZEXXX42 Lift Bar Assy 26 1 42 Room Extension 2 13 R001160 xxx Lift Bar R001346XXX xxx Lift Bar XL Only 4 14 R001161 End Cap Lift Bar 15 R001162 17 Extension Arm Assy 12 16 9 Room Extension R001162 26 Extension Arm Assy 17 26 Room Extension R001162 42 Extension Arm Assy 26 1 42 Room Extension R001347 xx Set Arm Assy XL Only 16 R001176 Stop Bolt 17 610400 xxx Roller Tube 33xxx Roller Tube Assy XL Only 4 18 R001164 End Cap Assy Roll Bar LH 19 R001165 Spring Assy R001165XL XL Spring Assy XL Only 20 R001169XXX xxx Front Cover Assy 7 21 R001337XXX xxx Front Cover Assy XL Only 7 8 22 R001364 Bumper Deflector Rubber 23 0157xxx Awning Rail 24 R038130 xxx V Rail XL Only 25
20. e of Colorado COVER BUMPERS The cover is shipped with bumpers to prevent rattling Quantities are two 2 for units under 10 three 3 for units 10 to 14 and five 5 for units 14 and longer To replace missing or damaged bumpers 1 In the positions shown fully press the first round section into the inner slot This is the same slot that the latch springs or cover attach screws mount in Please note the orientation of the bumper Tip Press one end of the bumper into the slot While holding the bumper in place gently stretch the bumper This will temporarily make the diameter smaller and easier to press into the slot 2 Stretch the bumper around and press the second round section into the outer slot typ 4 typ C if od 4 1 4 Deflector Length_ 0 S A y Covers 12 and Longer and XL Cover Halves pa Outer Slot Center Bumper Used On 4 e 10 14 Lengths Only E a A 2 7 p n o d i a b gt E n P Je m i fia 1 Covers Under 12 lo X Expo Cover Shown in Raised Position LS5E j N Ssok3039 8 052520 301r1 Table of Contents Carefree of Colorado Service Manual SOKIII amp SUMMIT END CAP REPLACEMENT NOTES a All replacement end caps use the threaded screw mounts for the cover All replacement covers are attached using the threaded screw mounts Refer to the illustrati
21. e placed next to the outer face of the carriers but with adequate clearance for a socket or closed end wrench to fit over the bolt head 3 Close the room 4 Center the lift bar over the room Tighten the two INNER stop bolts These should be placed next to the inner face of the carriers but with adequate clearance for a socket or closed end wrench to fit over the bolt head 5 Install the roll bar e Roll up any slack material onto the roll bar e Slide the right end of the roll bar into the right end cap then set the left end of the roll bar into the left end cap Attach with one 1 1 4 20 x 3 4 socket head screw removed earlier through the left end cap NOTE The roll bar cogs engage a protrusion in the right end cap e For XL Models Insert the center cover mount into the deflector splice and around the rolled fabric Secure with a new cotter pin included with replacement fabric e Firmly grasp the rollbar and fabric then remove the spring lock cotter pin inserted on the spring end of the rollbar Allow the spring to tension the fabric slowly while releasing the rollbar 6 Install the front cover 16 052520 301r1 Table of Contents Carefree of Colorado Service Manual SOKIII amp SUMMIT STANDARD MAINTENANCE Maintaining a Carefree SOKIII or Summit side out cover is easy Just follow these basic steps e Periodically check that the fasteners are tight Tighten if necessary e Keep the awning fabric and lift arms clean
22. ed through the left end of the roll bar Set the roll bar aside The fabric can hang down the side of the coach e Lift the new roll bar up and slide onto the edge of the fabric edge with black polycord The fabric can only be inserted into the left side of the rollbar e Detail B Center the fabric and roll bar and secure using two 2 6 x 3 8 phillips head screws through the polycord and rollbar Do not put the screws through the fabric Refer to Figure 8 Roll up the slack material onto the roll bar Slide the right end of the roll bar into the right end cap then set the left end of the roll bar into the left end cap Attach with one 1 1 4 20 x 3 4 socket head screw through the left end cap Remove the spring locking pin from the roll bar Open and close the room to ensure that the fabric is rolling up Awning Rail straight on the rollbar For existing canopies it may be 6 x 3 8 necessary to remove the retaining screws from the rail adaptor Straighten the fabric as required If not previously done secure the fabric to the rail adaptor with two 2 6 x 3 8 hex head screws Reattach the center cover mount Reattach the covers Screw 1 e Z Rail Adaptor Le Fabric we SOK3034 Figure 8 Securing the Fabric 052520 301r1 Table of Contents Carefree of Colorado Service Manual SOKIII amp SUMMIT REPLACING THE LiFT BAR COMPONENTS These instructions apply to the basi
23. et Deflector Mount Short 2 Spacer 1 4 Deflector Bracket 3 R001151XXX Cover Deflector Mount Bracket 4 R001153XXX xxx Deflector Assy R001338XXX xxx Deflector Assy LH XL Only R001339XXX xxx Deflector Assy RH XL Only 5 R001520XXX End Cap LH Screw Cover Attach 6 R001521XXX End Cap RH Screw Cover Attach 7 R001156 Roller Support 8 R036428 001 Center Support Plate XL Only 9 610400 xxx Roller Tube 33xxx Roller Tube Assy XL Only 2 10 4 mR001164 End Cap Assy Roll Bar LH 11 R001165 Spring Assy R001165XL Spring Assy XL Only 12 R001169XXX xxx Front Cover Assy R001337XXX xxx Front Cover Assy XL Only 3 13 R001364 Bumper Deflector Rubber pkg of 4 14 Canopy Only Refer to Canopy Order Form 15 0157xxx Awning Rail Notes 1 XXX Color xxx Length in Inches 2 The XL replacement Roller Tube Assy includes the roll bar halves splice rivets end caps and pre wound spring 3 XLreplacement cover includes both the LH and RH halves 052520 301r1 19 Table of Contents SOKIII amp SuMMIT Service Manual Carefree of Colorado SUMMIT FI ILLUSTRATED PARTS LIST DETAIL C Center Support Summit XL Only 20 Spring Loaded Pin Attach Screw Attach DETAIL B N amp y NE Awning Rail Rail Adaptor V Rail Used With XL Only DETAIL D SOK3502sm 052520 301r1 Table of Contents Carefree of Colorado Service Manual SOKIII amp SUMMIT Item Part Number Description Notes 1 R001150XXX T Bracket
24. lacing only the roll bar and or spring only e Fold the fabric on top of the coach and out of the way 9 Jf replacing the fabric and roll bar and or spring e Remove the fabric screws in the awing rail or rail adaptor and set aside e Slide fabric out of the awning rail or rail adaptor and remove from the coach 10 Remove the old spring tension e Reinstall the roll bar in the deflector assy e While firmly holding the roll bar have a second person pull the spring locking pin Allow the roll bar to slowly unwind completely NCAUTION USE A PAIR OF GOOD QUALITY WORK GLOVES TO PROTECT THE HANDS WHILE HOLDING ONTO THE ROLL BAR INSULATED RUBBER GLOVES PROVIDE A SOLID GRIP DO NOT ALLOW THE ROLL BAR TO SPIN FREELY 11 Remove the roll bar from the deflector after the spring is completely unwound 052520 301r1 11 Table of Contents SOKIII amp SuMMIT Service Manual Carefree of Colorado REBUILDING THE ROLL BAR ASSEMBLY 1 Drill out the rivets holding the LH bearing and RH bearing and spring assy Remove and set aside the parts to be replaced Fully insert the LH bearing assembly into the roll bar and rivet in place using 3 16 pop rivets Fully insert the RH bearing and spring assembly into the roll bar and rivet in place Lift the assembled roll bar no fabric up and install into the deflector assembly Slide the right end of the roll bar into the right end cap then set the left end of the roll bar into the left end cap Attach
25. nd current Summits use screws that are threaded through the end cap and project into the cover Spring Loaded Attach Pin pus Latch Lever Center Latch Pin 12 or Longer Covers Only Back Out Lower Cover Screws until End of Screw Clears Cover 2 plcs Spring Loaded Pin Attach Threaded Screw Attach SOK3005b Figure 3 Opening the Front Cover 1 For covers 12 feet and longer Locate the latch lever at the center of the cover Using a screw driver or similar tool push the lever to the left and hold carefully pull the center of the cover out until the pin clears the latch 2 For spring loaded pins Using a small pin through the lower access hole in one end cover press in the lower attach pin then pivot the cover until the pin clears the hole Repeat for the other end then rotate the cover out of the way 3 For threaded screws Unscrew the lower allen head screw until the end of the screw clears the cover Repeat for other side then rotate the cover out of the way To Remove the Cover 1 For covers 12 feet and longer Locate the latch lever at the center of the cover Using a screw driver or similar tool push the lever to the left and hold carefully pull the center of the cover out until the pin clears the latch 2 For spring loaded pins Using a small pin through the lower access hole in one end cover press in the lower attach pin then carefully pull the cover until the pin clears the hole Then do the same for the upper
26. o the roll bar and install the roll bar into the new end caps Attach the front cover refer to page 4 or page 7 for XL models NOTE For first time installation with the replacement end caps The bottom screw holes are threaded at the factory It will be necessary to force thread the top holes in the end cap using the supplied screws The screws do not thread into the cover p oND Notes on Using an Existing Cover Existing covers with the spring loaded pins can be used with the thread style end caps by pulling the spring pins out of the cover most pins can be removed with a pair of pliers Some later models in 2007 uses a 1 piece spring assy This assembly is staked into the cover and will not pull out e To remove these pins set the cover onto a padded surface to avoid scratches e Using a 1 4 drill carefully drill out the stake The pin assembly 1 Piece Spring Assy Drill Out ua can then be removed Stake Dimple 4 4 Drill e Be sure to deburr and clean the drilled area and remove all debris and sharp projections that could damage the canopy when the room is closed 052520 301r1 9 Table of Contents SOKIII amp SuMMIT Service Manual Carefree of Colorado CANOPY REPLACEMENT Screw Used w Rail Adapter V Awning Rail Fabric Retaining Awning Rail Screws Zz Fabric No Awning Rail ref MV lt or Rail Adaptor ref Roll Bar 1 4 20 x 3 4 De
27. ohibited without prior written approval from Carefree of Colorado SAFETY INFORMATION A WARNING 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 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 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 O www carefreeofcolorado com 052557 001 SOK III Installation Manual 052557 011 SOK III XL Installation Manual 052520 001 Summit Installation Manual 052543 001 Summit XL Installation Manual 052541 001 Summit FI Installation Manual 052543 101 Summit XL w FI Hardware Installation Manual 052530 001 Summit Upgrade for SOK II Discontinued 052520 301 SOKIII amp Summit Service Manual Carefree of Colorado 2145 W 6 Avenue Broomfield
28. on on page 4 b For first time replacement of end caps used with the spring loaded pin cover attach it will be necessary to replace both end caps c The original cover with spring loaded pins is no longer available as a replacement part If it is necessary to replace the cover it will also be necessary to replace the end caps both Mounting screws are included with the end caps d If replacing a cover with the spring loaded pins it will be necessary to replace the end caps for the threaded screw mount style Spring Locking Pin Latch Retainer 1 4 20 x 3 4 Screw ref 10 32 x 1 Screw m L3 8 per End Cap x7 x N DETAIL A SOK3054 1 Remove the front cover if installed refer to page 4 or page 6 for XL models 2 Insert a 3 inch cotter pin through the roll bar and spring on the right end of the roll bar It may be necessary to twist the roll bar to align the holes Bend the ends over to ensure the pin does not accidentally come out 3 For older units with the ratchet latch Detail A Remove the latch retainer and latch These will not be reused Remove the 1 4 20 x 3 4 socket head cap screw from the left end cap Lift the left end of the roll bar and pull the roll bar out of the right end cap Set the roll bar and fabric out of the way i e on the roof It is not necessary to remove from the coach Remove the attaching screws and end caps and set aside Install the new end caps Roll up any slack material ont
29. pin Remove the 1 4 20 socket head screw from the left end cap and set aside Do not discard Lift the roll bar up and out of the deflector case To lift the roll bar lift the left end first then slide the roll bar out of the right end cap 8 lf replacing the fabric and roll bar e Remove the fabric screws in the awing rail adaptor and set aside e Slide the roll bar and fabric out of the rail adaptor and remove from the coach e Unfold the new fabric and slide the edge of the fabric edge with black polycord into the replacement rollbar The fabric can only be inserted from the left side of the rollbar e Center the fabric on the roll bar and secure using two 2 6 x 3 8 phillips head screws through the polycord and rollbar Do not put the screws through the fabric Refer to Detail A on page 052520 301r1 13 Table of Contents SOKIII amp SuMMIT Service Manual e Roll the fabric onto the rollbar The fabric must be oriented around the roll bar as shown 9 10 11 12 13 14 15 16 14 e Detail B Slide the white polyrod and fabric into the awning rail adaptor Carefree of Colorado Ensure that the two halves of the adaptor are pushed together no gaps Center the fabric over the room If replacing only the roll bar e Unroll the fabric from the roll bar e Remove the fabric screws in the roll bar and set aside e Slide the roll bar to the right while holding the fabric The fabric can only be remov
30. se the latch lever The latching pin is spring loaded and will slide into the locking channel Method 2 Screw Attach 1 If removed thread the 1 4 20 x 1 1 2 socket head screws into the end caps On one side thread the screws until flush with the inside of the end cap On the other side thread the screws until they project out of the end cap approximately 1 2 NOTE If replacing the end caps the bottom screw holes are threaded at the factory It will be necessary to force thread the top holes in the end cap using the supplied screws 2 Lift the cover up and place one end over the screws that project out of the end cap The screws fit into the slots of the cover 3 Align the cover with the other end cap and thread in all the attach screws thru the end caps and into the cover Hand tighten only 4 For covers 12 feet and longer Locate the latch lever at the center of the cover Using a screw driver or similar tool push the lever to the left and hold press the cover into position then release the latch lever The latching pin is spring loaded and will slide into the locking channel 052520 301r1 5 Table of Contents SOKIII amp SuMMIT Service Manual Carefree of Colorado FOR XL MODELS Removing the Cover Mounting Holes u a Spring Loaded Attach Pins Spring Loaded Pin Attach e Spring Loaded ud Attach Pins Center Cover Mount Cover Retaining Screws gt Latch Lever Threaded Screw Attach Center Latch Pin
31. service Awning Rail Extension Gutter For Fl installations an optional rail extension is available This allows the installer to use an existing rail while providing clearance for the lift bar and arms A unique V rail is standard equipment for the XL versions w lift bars Width Room Width 8 approx gt ia Deflector Width 1 25 Lift Arm Lift Arm I 6 2 mE SOKIII amp Summit Standard w Short Deflector Bracket Width Room Width 8 approx gt foe m Deflector Width 1 25 7 Deflector Half Width yp i d Y a LLL t I coe L2 jd Summit amp Summit FI XL w Tall Deflector Bracket Dimensions are approximate actual dimensions may vary based on the side out configuration and options installed SOK3048 Figure 2 General Dimensions 2 052520 301r1 Table of Contents Carefree of Colorado Service Manual SOKIII amp SUMMIT SUMMIT ARM APPLICATION CRITERIA AVAILABLE ROOM WIDTHS BASIC amp FI 42 191 AVAILABLE EXTENSIONS 12 42 XL amp FIXL 192 390 AVAILABLE LIFT ARM APPLICATIONS ROOM WIDTH VS ROOM EXTENSION ROOM WIDTH Uses Short Lift Bar Arm Set Uses Mid Length Lift Bar Arm Set SSeS eos Long Lift Bar A C C a Up Long Lift Bar Arm Set
32. t pooling on the canopy This version is commonly used for OEM installations Summit FI Flexible Install Using the same lift bar system of the basic Summit the mounting hardware is designed to Wall Bracket provide greater flexibility for installations The Fl uses a lower profile wall mounting bracket that can adapt to a variety of mounting surface conditions The wall mounting brackets and lift arms are not interchangeable with the basic Summit Because of the versatility this is the popular Mounting Pad version used for aftermarket applications Summit FI SOK3049 Figure 1 Identifying Lift Hardware Summit XL Designed for rooms 192 to 390 wide the unit uses the same hardware as the basic Summit The major extrusions deflector roll bar and cover are made in two pieces and spliced together during installation Used for custom OEM applications Summit FIXL Same as the XL above except with the FI lift bar hardware Options Deflector Mounting Brackets For Summit applications two standard bracket styles are available to mount the defector roll bar to the room face A short bracket and a tall bracket The brackets can be mounted into the room structure for stability while accommodating a variety of flange heights Front Cover Case The cover is available for all versions of the SOKIII amp Summit When installed it provides a closed case for the roll bar and fabric The cover can be easily opened and or removed for cleaning and
33. tail A Screw SOK3050 Figure 6 Canopy Replacement Removing the Old Fabric 1 Remove the fabric retaining screws from the awning rail or rail adapter Do not discard 2 Remove the front cover if installed 3 For XL Models Remove the cotter pin and center cover mount Set parts aside 4 Insert a 3 inch cotter pin through the roll bar and spring on the right end of the roll bar It may be necessary to twist the roll bar to align the holes Bend the ends over to ensure the pin does not accidentally come out 5 Remove the 1 4 20 x 3 4 socket head cap screw from the left end cap Lift the left end of the roll bar and pull the roll bar out of the right end cap 6 Hold the rollbar and slide the fabric out of the awning rail or rail adaptor NCAUTION WHEN UNROLLING AND ROLLING FABRIC ON THE ROLL BAR DO NOT LET THE SPRING LOCK COTTER PIN COME OUT 7 Ona suitable work surface unroll the fabric from the roll bar 8 Remove the fabric retaining screws in the roll bar then slide the fabric out of the groove Make note of which end is left and right and the orientation of the fabric when it was rolled Installing the New Fabric 1 Unfold the new fabric and slide the edge of the fabric edge with black polycord into the rollbar The fabric can only be inserted from the left side of the rollbar NOTE The black polycord should only extend past the fabric approximate 1 2 to 1 Trim any excess polyrod off before sliding the fabric into the rollbar
34. the end caps Pull the cover up and away from the center cover mount Set cover aside 3 Forfabric replacement or roll bar service remove the cotter pin and center cover mount Set parts aside 6 052520 301r1 Table of Contents Carefree of Colorado Service Manual SOKIII amp SUMMIT Attaching the Front Cover Mounting Holes x p Spring Loaded 7 Attach Pins Spring Loaded Pin Attach e E we Spring Loaded a Attach Pins Center Cover Mount Cover Retaining Screws a7 Latch Lever Threaded Screw Attach Center Latch Pin RN Detail A Detail B Detail C SOK3025f Figure 5 Attaching the Front Cover 1 If removed insert the center cover mount into the deflector splice and around the rolled fabric Secure with the cotter pin removed earlier For Spring Loaded Pin Mounts 2 Examine the two cover halves The RH half has spring loaded attachment pins on both ends the second half has pins on one end only Lift the RH cover up and set the pins into the mounting holes of the RH end cap In the center press the pins into the cover and set into position Adjust the position until the pins pop out through the mounting holes of the center support 5 Lift the second cover half up and slide the inside end onto the protruding attach pins of the first cover 6 Atthe LH end cap press the pins into the cover and set cover into position Adjust the position until the pins pop out into the mounting holes of the end c
35. ver the top of the roll bar toward the coach If the fabric was removed from the coach e Slide the fabric black polycord on to roll bar The fabric can only be inserted from the LEFT end of the roll bar e Center the fabric and roll bar and secure using two 2 6 x 3 8 phillips head screws through the polycord and rollbar Do not put the screws through the fabric e Roll the fabric onto the roll bar The fabric goes over the top of the roll bar toward the coach e Slide the white polyrod and fabric into the awning rail Center the fabric over the room e Roll up the slack material onto the roll bar Slide the right end of the roll bar into the right end cap then set the left end of the roll bar into the left end cap Attach with one 1 1 4 20 x 3 4 socket head screw through the left end cap Remove the spring locking pin from the roll bar Open and close the room to ensure that the fabric is rolling up straight on the rollbar For existing canopies it may be necessary to remove the retaining screws from the rail Straighten the fabric as required Secure the fabric to the rail with two 2 6 x 3 8 hex head screws 052520 301r1 Table of Contents Carefree of Colorado Service Manual SOKIII amp SUMMIT REPLACING THE XL ROLL BAR If the roll bar exhibits recognizable bowing then it is recommended that it be replaced with an updated roll bar assembly Part number for the complete roll bar assembly is 33xxx The replacement assembly
36. with 5 6 7 one 1 1 4 20 x 3 4 socket head screw through the left end cap NCAUTION THE NEXT STEPS ARE ADDING TENSION TO THE SPRING IT IS STRONGLY RECOMMENDED THAT TWO PEOPLE PERFORM THE OPERATION USE EXTREME CARE IF THE SPRING IS PREMATURELY RELEASED THE ROLL BAR CAN SPIN OUT OF CONTROL AND CAUSE PERSONAL INJURY AND OR PROPERTY DAMAGE SEE THE CAUTION ABOVE ABOUT THE USE OF GLOVES Firmly grasp the roll bar and twist toward the coach Each full rotation of the roll bar is equal to one wind of the spring Continue to rotate the roll bar until the appropriate number of spring winds is achieved for lengths 96 and under 13 winds for lengths 97 191 20 winds not including XL models for lengths 192 and longer 15 winds XL models only On the right end of the roll bar insert a cotter pin through the roll bar and spring It may be necessary to rotate the roll bar to align the holes Bend the ends over to ensure the pin does not accidentally come out Remove the roll bar from the deflector INSTALLING THE ROLL BAR 1 12 If the fabric was left on the coach e Slide the roll bar on to the fabric The fabric can only be inserted from the LEFT end of the roll bar e Center the fabric and roll bar and secure using two 2 6 x 3 8 phillips head screws through the polycord and rollbar Do not put the screws through the fabric refer to Detail A on page 10 e Roll the fabric onto the roll bar The fabric goes o
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