Marquee Service Manual - E
Contents
1. Marquee009 052549 301r6 Carefree of Colorado ILLUSTRATED PARTS LIST UNITS BUILT PRIOR TO JULY 2010 Use this page for units that do not have an end plug in the RH end cap Use the next page if the unit has an end plug 2 Holes 9 12 lo n a pod Groove Older Style New DETAIL A ITEM PART NUMBER 1 2 R037318 005 3 R05401 7 001 4 R037319 00X 5 R001531 6 7 R040751 001 8 R001781XXX xxx 9 R001725 00X 10 R012530 TB32L 11 R012530 TB32R 12 R019804 001 13 R019804 002 R019853 001 14 R019799 001 15 R001630 16 R001605 17 R019819 001 18 Notes Service Manual DESCRIPTION Awning Rail See Hardware and Accessories End Cap White Only LH Wall Closeout End Cap RH Motor Kit Roller Tube See Hardware and Accessories Bearing Roller Tube RH Lead Rail End Plate Kit Spring Arm Assy LH Spring Arm Assy RH Connector Assy Case Window Connector Assy Case OtD Connector Assy Case Connector Assy Lead Rail Hardware Pack Arm Attach 1 Arm Switch Kit Owners Kit manual amp mounting screws Canopy Only Refer to Canopy Order Form 1 XXX Color xxx Length in inches 2 00X 005 for White 006 for Black 3 Two case connector configurations are used on the Marquee item 13 original item 14 new Refer to Detail A older style can be identified by the groove on the front face and the two holes through the top The new and old connectors are2. 2 Confirm that the arms are fully retracted The motor must stop when the awning is fully retracted If the motor continues to run or if the motor quits before the arms are fully retracted it will be necessary to adjust the IN limit switch 3 Using a 4mm Allen wrench turn the IN limit switch Clockwise increase time the motor runs during retraction counter clockwise 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 retracts correctly 8 052549 301r6 Carefree of Colorado Service Manual MARQUEE WIRING DIAGRAMS SWITCH INSTALLATION NO RELAY 2 1 4 57mm wall Rear View of Switch Panel Ground 12VDC FIN007 Covered Terminals Front View of Switch Panel on Bottom Through July 2010 Switch hardware shown above has been discontinued For wiring replacement switches use instructions provided with the Single Switch Kit To Ground BLUE Motor Wire WHITE BROWN Motor Wire mm sn RED To 12VDC SK005 July 2010 and On and Replacement Switches NOTES 1 If connector block is oriented with wires to the left reverse the motor wires WHITE connector block wire goes to BLUE motor wire BLUE connector
3. THE MOTOR CABLES WHEN PULLING THE MOTOR DO NOT LET THE ROLLBAR COME OUT MORE THAN 1 OTHERWISE THE ROLLBAR IDLER WILL DISENGAGE FROM THE OPPOSITE END PLATE IF THIS OCCURS REINSERT THE IDLER INTO THE ENDPLATE BEFORE CONTINUING Loosen the clamping screw on the connector and slide the old connector out of the case Insert the new connector assembly into the case and position at the marks made previously Tighten the clamping screw Reinstall the end plate Ensure that the idler pin of the roll bar is properly seated Ensure that the motor and crown are properly seated in the rollbar Reinstall the end caps Return to step 10 on the previous page B Two case connector configurations are used on the Marquee The older style prm ae es 4 052549 301r6 Carefree of Colorado Service Manual MOTOR REPLACEMENT This operation can be done while the awning is mounted on the RV PRELIMINARY STEPS 1 Disconnect power to the awning 2 If the awning is extended Refer to Detail A Carefully push the lead rail toward the case so that the arms collapse While holding the lead rail in this position firmly tie the eloows 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 knot or equivalent 3 lf the awning is closed Firmly brace the lead rail in the closed position A second person can hold the lead rail steady during the dis
4. le SERVICE MANUAL N vare fet MARQUEE WINDOW AND OVER THE Door OTD AWNINGS WINDOW TABLE OF CONTENTS m utspul4elo 2 iain a 1 Denon PT oia A Mx Urania ER ARA REMAIN 2 conn luudl s A 3 at gebe 25 lE vo cc 4 Replacmg ig i9 ifoyr n d TT rene 4 Molor We rin iecit RR EU P DIS 5 PEINE oor dI uu MEL LM a ee Sem ee 5 Motor Replacement w 2 Slot Roller Tube kit no R001531 seessseeeeeenee 6 Motor Replacement w 3 Slot Roller Tube kit no R001651 sssseeeeeeeeee 7 Seting Ine Morr Ul meee ber ee ee re er EER 8 boi LI HP ie ic Lc RR eene ema 9 Swiich ran oe Ng Relay oe uciet adi a XAR FAR th AA MR rk dead DR nipani 9 Switch Installation W Relay Module RTT 9 Optional LED Lighting RR ana nai aa a iaaea aaa aa 10 Swich NE TAN rite ND 10 Renlacing he LED SMID eme er 11 Hamness Bt SAN M TD na pL RNR eR E ARA 11 Removing FL NR 12 Loci E i us a T QE PT 12 Standard PRATER NRCS sociscienca a CEU OM UD AQUA D MUR AI MIDI 13 FLE j mec freee ee 13 C AQ DA P Em r 13 Motor AN ri ETT To o rmm 13 Pant N mbDer Ni NG RS 14 x uh d C ONTI ip eR NC 14 x g8LODIS 4 LOCA O mU 14 Illustrated Parte List Unis Buit Phor do duly EO TOLL eese pe cis q ibit ERU r
5. pull the roller tube out of the idler side Attach the end cap to the new motor Note that the orientation is with the wire pointing up Detail C Route the wire in the end cap as shown Secure using the retaining ring removed previously Route the new motor wire into the coach and attach or if the wires were cut splice the new wires to the existing wires Match the wires Blue to Blue and Brown to Brown Push the splices into the coach then use a quality silicone sealant to seal the wire hole into the coach NOTE If splicing the wires allow enough lead wire from the motor so that the completed splices can be pushed into the wall before sealing There is no room in the case for the splices Align the roller tube on the idler side and slide the roller tube and fabric into the awning Align the screw holes in the end cap and attach to the awning case 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 taunt the one way drive was installed backwards Retie the arms remove the motor and orient the one way drive as shown above To test restore power then extend and retract the awning After replacing the motor it will be necessary to adjust the motor limits page 8 052549 301r6 7 MARQUEE Service Manual Carefree of Colorado SETTING THE MOTOR LIMITS The limit switches are located inside t
6. N 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 e carefree com 052549 001 Marquee Installation Manual 052549 201 Marquee Owner s Manual 052549 301 Marquee Service Manual Carefree of Colorado 2145 W 6 Avenue Broomfield CO 80020 a Scott Fetzer company Carefree of Colorado Service Manual MARQUEE PRODUCT OVERVIEW The Marquee Window and OtD Over the Door 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 side wall The full tension canopy fabric allows the awning to be partially or fully extended for best shade coverage No vertical arms interfere with coach sidewalls custom graphics or equipment that may be mounted on the
7. Out of Case 4 67 c motor screws Motor Detail C Carefully pull the end cap away Motor Screws from the case and remove the retaining ring and motor wire from the end cap Set the end cap aside One Way Drive B Must Face Detail B Remove the retaining screw from Bearing Towards Motor the bearing and roller tube Pull the motor partially out from roller tube Retaining Motor Xe NCAUTION WHEN PULLING THE oe One Way Clip MOTOR OUT THE SERVICING TECHNICIAN Drive MUST USE CARE TO NOT BREAK OR DETAIL A DAMAGE THE MOTOR CABLES Disconnect the motor wires from inside the coach and pull out or clip the motor wires If cutting the motor wires be sure to leave enough wire that can be Retaining Screw stripped and spliced DETAIL B Pull the motor out of the roller tube and set aside Detail A On the new motor check that the one way drive is installed with the B facing 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 WILL NOT OPERATE AND THE ARMS WILL SPRING OUT WHEN RELEASED Detail B Slide the new motor into the roller tube and attach the 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 DO NOT OVER TIGHTEN maximum torque 16 in lbs Carefully pull the roller tube and fabric out of the case 4 6 This will
8. assembly process NCAUTION FAILURE TO SECURE THE LEAD RAIL AS DESCRIBED WILL ALLOW THE SPRING ARMS TO UNEXPECTANTLY EXTEND OUT POSSIBLY CAUSING PERSONAL INJURY AND DAMAGE TO THE AWNING 4 Determine the type of roller tube that is used on the unit Examine the idler end cap End caps without a removable plug uses a 2 slot roller tube follow the procedure on page 6 End caps with the removable plug uses a 3 slot roller tube follow the procedure on page 6 052549 301r6 MARQUEE Use care to not damage the walls etc pro Arms Firmly Tie Elbows Together Marquee012 Figure 4 Tying the Arms End Cap Without End Cap With Removable Plug Removable Plug 2 Slot 3 Slot Roller Tube Roller Tube Marquee028 Figure 5 Roller Tube Types MARQUEE Service Manual Carefree of Colorado MOTOR REPLACEMENT W 2 SLOT ROLLER TUBE KIT NO R001531 1 10 11 12 13 Remove the four 4 screws holding the end cap to the case Do not remove the two 2 motor screws NCAUTION IF THE AWNING IS CLOSED WHEN THE END CAP IS DETACHED THE SPRING ARMS WILL TRY TO OPEN CONTINUE TO HOLD THE LEAD RAIL CLOSED Pull the end cap and motor partially out NCAUTION WHEN PULLING THE MOTOR OUT OF THE ROLLER TUBE THE SERVICING TECHNICIAN MUST USE CARE TO NOT BREAK Motor Screws OR DAMAGE THE MOTOR CABLES Disconnect the motor wires from inside the Le vehicle and pull out or
9. at the large polycord goes into the lead rail the smaller polycord goes into the roll bar The hem should be on the down side Center the canopy into the slots of the rollbar and lead rail Remove any support material from the rollbar and attach the case end cap Restore power to the awning and roll the canopy onto the rollbar The fabric rolls under the roll bar Ensure the fabric rolls evenly onto the rollbar without wrinkling or folding Once the fabric is rolled taut remove the rope used to tie the arms together Extend the awning Attach the lead rail end plate using the top and bottom screws only Center the canopy into the slots of the rollbar and lead rail Hold the fabric in place and attach using the fabric retaining screw middle screw through one lead rail end plate On the opposite end of the lead rail stretch the fabric smooth and attach using the fabric retaining screw middle screw through the end plate After replacing the canopy it will be necessary to adjust the motor limits Follow the procedure on page 6 052549 301r6 Carefree of Colorado Service Manual MARQUEE SPRING ARM REPLACEMENT NCAUTION THE SPRING ARM IS UNDER TENSION TO OPEN USE EXTREME CARE TO 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 NOTE On replacement arms the connector assemblies are not included and must b
10. bi lt Pri Sub PSU T RR EFE ERAI P I QU 15 Illustrated Parts List Units Built After to July PDTO s enr tnr nri 16 otona LECL INUN eo ooo 17 052549 301r6 Printed in USA June 2014 PROPRIETARY STATEMENT The Marquee Awning is a product of Carefree of Colorado located in Broomfield Colorado USA The information contained in or disclosed in this document is considered proprietary to Carefree of Colorado Every effort has been made to ensure that the information presented in the document is accurate and complete However Carefree of Colorado assumes no liability for errors or for any damages that result from the use of this document The information contained in this manual pertains to the current configuration of the models listed on the title page Earlier model configurations may differ from the information given Carefree of Colorado reserves the right to cancel change alter or add any parts and assemblies described in this manual without prior notice Carefree of Colorado agrees to allow the reproduction of this document for use with Carefree of Colorado products only Any other reproduction or translation of this document in whole or part is strictly prohibited without prior written approval from Carefree of Colorado SAFETY INFORMATION AWARNING A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY AND OR MAJOR PROPERTY DAMAGE NCAUTION A CAUTIO
11. channels still do not slide easily lightly spray the joints with a dry silicone lubricant after the arms have been cleaned and dried thoroughly Hardware Maintenance e Replace any parts that become damaged e Periodically check all mounting hardware screws lags etc and re tighten when necessary MOTOR MAINTENANCE e Check all wiring and connections for wear Repair when needed e Check that the sealant is providing a good seal and no water is accumulating on the wiring 052549 301r6 13 MARQUEE Service Manual PART NUMBER LISTING PART NUMBER CONFIGURATION Carefree of Colorado 48 050 CW 25 WP Marquee 50 Toast acrylic White Window LH Box Awning Default STYLE SIZE CANOPY MOTOR CODE IN INCHES COLOR CASE COLOR EXTENSION LOCATION 48 050 50 ACRYLIC STANDARD amp WP No Code All Marquee 954 54 Refer to sales CUSTOM Window Awning LH Motor Awnings 060 60 i order Refer to salasonder Steep Pitch Default 066 66 B information for information for DP R specific codes specific codes and OtD RH Motor 072 72 and colors colors available Flat Pitch special order 084 84 available 096 96 gt 108 108 120 120 O 132 132 amp 144 144 156 156 PART NUMBER LOCATION The part number serial number is located on the inside of the lead rail 14 Carefree of Colorado Dt 0000 Sn 0000000000 Pn XXxxxxxxx
12. clip the motor wires If cutting the motor wires be sure to leave enough wire that can be stripped and End Cap Removing the Old Motor spliced Adaptor p Route Cable thru Slot in Closeout Pull the motor and end cap out of the roller 2 tube NCAUTION IF THE AWNING IS CLOSED WHEN THE END CAP IS REMOVED THE SPRING ARMS WILL TRY TO OPEN SUPPORT THE ROLLER TUBE AND ALLOW THE AWNING TO OPEN SLOWLY THEN SECURE THE ARMS AS DESCRIBED PREVIOUSLY Remove the end cap and closeout from the old motor End Cap Installing the New Motor Marquee030 Hold the closeout on the end cap and push the adaptor into the motor mount post in the end cap Align the motor screw holes in the end cap new adaptor and new motor Attach the motor to the end cap using two 2 M4 x 25 screws Note the orientation of the adaptor motor and wire shown in Detail B IMPORTANT NOTE On early units the motor was attached with M4 x 20mm screws current production uses M4 x 25mm screws When replacing a motor that is attached using the shorter screws discard the existing screws and attach the motor using the longer screws and washers included with the motor replacement kit Do not use the washers for units that already use the longer screws Detail A Route the motor cable through the slot in the closeout then between the closeout and cap Pull the cable out of the rear slot of the end cap Partially slide the new motor assembly into the roller tube Ensure that the
13. e ordered separately if the parts are to be replaced The following procedure requires two people 1 Open the awning to the maximum extension or as wide as possible This is to minimize the spring pn tension in the arms during this procedure B A Disconnect power to the awning Vans Pin g dpi Pin E Ring E Ring Use a scaffold ladder or other means to firmly support the lead rail 4 refer to Detail A At the lead rail remove the e ring and rotation pin from the arm and connector assembly JE lt Connector Assy Connector Assy NOTE For early configurations the e ring is Early Pin Configuration Current amp Replacement located between the arm clevis and the Beta A Pin Configuration connector Newer arms and replacements use a stepped pin with the e ring located at the end of the pin Lead Rail Connector Rotatation Pin 5 Firmly grasp the spring arm and allow the arm to extend to its maximum length outside the lead rail Have a second person hold or otherwise support the unattached end Bushing aty 2 6 refer to Detail B Inside the case remove the 6 32 X 25 set screw from the case connector and save Connector Assy 6 32 x 25 set screw Detail B Remove the rotation pin and arm from the awning Case Connector a arquee Remove the bushings from the flanges from the arm Figure 2 Arm Replacement If replacing the lead rail connector or case connector go t
14. handle into the square drive hole inside the endcap 3 Turn the handle counterclockwise until the awning is retracted Marquee032 NCAUTION 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 are completed Do not attempt to force the lead rail in with the override serious damage can occur to the awning 12 052549 301r6 Carefree of Colorado Service Manual MARQUEE 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 s time for a thorough cleaning the fabric can be cleaned while still on the awning frame Use a stiff brush and warm water with soap 3 When cleaning the fabric it is important to observe the followi
15. he case near the end cap It is necessary to extend the awning to access the switches The OUT limit switch stops the motor when the awning is fully extended The IN limit switch stops the motor when the awning is fully retracted 4mm He 79 Figure 6 Motor Limit Switches Adjusting the OUT Limit Switch 1 Extend the awning out completely Marquee008 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 Adjusting the IN Limit Switch NCAUTION THE IN LIMIT SWITCH MUST BE SET TO SHUT OFF THE MOTOR WHEN THE AWNING IS CLOSED THE MOTOR MUST NOT CONTINUE TO RUN AFTER THE AWNING IS CLOSED OTHERWISE DAMAGE TO THE MOTOR WILL OCCUR IF THE MOTOR CONTINUES TO RUN AFTER THE AWNING IS CLOSED 1 Retract the awning in completely
16. ire 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 1 13 2A In line Fuse mm 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 12VDC 4 3 Fold that half of the connector body over until the element 18 24awg 2A In line Fuse Female Disconnect x2 contacts the wire Use pliers tO t8awg wir Single Pole crimp the connector closed minimum Single Throw Switch GND 4 4 Repeat for the second wire end Vehicle Wall 4 5 Slide the fuse into the fuse por
17. ll entrance hole and wires with a quality silicone sealant NOTE 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 052549 301r6 11 MARQUEE Service Manual Carefree of Colorado REMOVING THE AWNING Screw Location M Screw Location Arm Mount Arm Mount Mounting Rail Nn gt Rail Marquee014 Open the awning Remove the three screws that are through the bottom of the case Close the awning Disconnect power to the awning Disconnect the motor wires from the switch Rotate the awning upward in the awning rail Pull the wire out of the RV wall ONO a F WON gt Using one person at each end of the awning continue rotating the awning upward until the awning mounting rail slides out of the awning rail on the RV MANUAL OVERRIDE For models built after July 2010 a manual override is available If power to the vehicle is not available the awning can be safely oo Plug retracted using the manual override located on the idler right end of the case 3 8 Square Key or 3 8 Socket NOTE This procedure cannot be used to extend the awning Drive Extension 1 Remove the plug from the right endcap and save oe 7 2 Insert the override key or a 3 8 socket drive extension and
18. motor drive is properly seated inside the roller tube Route the new motor wire into the vehicle and attach or if the wires were cut splice the new wires to the existing wires Match the wires Blue to Blue and Brown to Brown Push the splices into the vehicle then use a quality silicone sealant to seal the wire hole into the vehicle NOTE f splicing the wires allow enough lead wire from the motor so that the completed splices can be pushed into the wall before sealing There is not clearance room in the case for the wires and splices Finish pressing the motor into the roller tube make sure that the bearing is aligned with the roller tube Attach the end cap to the case While holding the lead rail carefully remove any roller tube supports and arm ties Allow the lead rail to extend until the fabric is taunt To test restore power then extend and retract the awning After replacing the motor it will be necessary to adjust the motor limits page 8 052549 301r6 Carefree of Colorado Service Manual MARQUEE MOTOR REPLACEMENT W 3 SLOT ROLLER TUBE KIT NO R001651 10 11 12 13 14 15 16 NCAUTION IF THE AWNING IS CLOSED WHEN THE END CAP 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 ABOVE Remove the three 3 screws holding the Pull Roller Tube and Fabric end cap to the case Remove the two 2
19. ng 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 Pooling When water collects on the top of the fabric this is known as pooling This can occur during inclement weather or if a running air conditioner discharges over the awning The water is dumped when the awning is retracted It is recommended that if water accumulates on the top retract the awning in steps 8 12 to dump the water This will help prevent the fabric from stretching or distorting The effects of wind and rain on an awning are unpredictable Severe damage to the awning and the vehicle may result IF WIND OR EXTENDED PERIODS OF RAIN ARE EXPECTED RETRACT THE AWNING ARM CARE The best method of keeping the arms operating smoothly is to clean them Periodically wash out the channels with running water i e a hose to keep them clean If the
20. not interchangeable Identify the correct connector before ordering 4 Motor kit item 5 includes bearing drive and end spacer 5 Attaching hardware is not furnished with spring arm assemblies Order item 16 Item 16 includes pins Set screw retaining ring and bushings 6 End plate kit item 9 includes two end plates and hardware End plates are universal and may be used on the left or right side 7 Lead rail item 8 includes end plate kit item 9 052549 301r6 MARQUEE Marquee502a NOTES 2 N w 0 01 OT N o 15 MARQUEE ILLUSTRATED PARTS LIST Uurrs BUILT AFTER TO JULY 2010 Use this page for units that do have an end plug in the RH end cap Use the previous page if the unit does not have an end plug 16 PART NUMBER R001660XXX R001661XXX R040792 00X R001651 R001623 R019853 001 R019799 001 R001630 R012530 TB32L R012530 TB32R R001725 00X R001362XXX xxx R001605 901075 Service Manual DESCRIPTION End Cap LH End Cap RH End Plug Manual Override Motor Kit Roller Tube Roller Tube End Plug RH Connector Assembly Case Connector Assembly Lead Rail Hardware Pack Arm Attach 1 Arm Spring Arm Assembly LH Spring Arm Assembly RH See Tools and Hardware End Plate Kit Lead Rail Awning Rail See Tools and Hardware Canopy Only Refer to Canopy Order Form Switch Kit Manual Override Key 1 XXX Color xxx Length WHT White BLK Black 2 00X 005 for White 006 fo
21. o page 4 then return to step 10 10 Firmly hold the ends of the new arm assembly and remove the shipping ties Allow the arm to slowly open to its maximum extension NCAUTION WHEN THE ARM IS CLOSED IT CAN OPEN WITH SIGNIFICANT FORCE USE CARE WHEN OPENING THE ARM 11 Insert the two bushings into the rear flanges of the new arm assy 12 Lift the new arm up and position the rear arm flanges over the case connector 13 Slide the rotation pin through the arm flanges and case connector Align the groove in the pin with the set screw hole in the connector bracket 14 Secure the pin in place with the 6 32 x 25 set screw removed previously 15 Carefully bend the arm and place the front flanges of the arm over the lead rail connector 16 Attach the arm using the rotation pin and e ring removed previously The e ring goes into the groove of the pin and between the top of the connector and upper flange 17 Restore power and test operation 052549 301r6 3 MARQUEE Service Manual Carefree of Colorado Replacing the Lead Rail Connector Refer to Figure 3 1 Carefully mark the location of the existing connector in the lead rail Make note of the bracket orientation 2 Remove the lead rail end plate 3 Loosen the large hex screw in the center of the bracket and slide the out bracket out of the lead rail 4 Insert the new connector assembly into the lead rail and position at the mark
22. pen the awning several inches to expose the Spring Arms arm elbows Refer to Detail A Using a minimum 1 2 rope firmly tie the elbows of the spring arms together L Firmly Ti do not use bungee cords When typing the Elbows Together rope use a non slip knot such as a square knot DETAIL A or equivalent NCAUTION Fabric Slot Pointed Toward Opening AND DAMAGE TO THE AWNING Use the extend button to unroll the canopy until Fabric Retaining Screw the fabric slot in the tube is aligned with the Typical Both Sides End Plate awning case opening DETAIL B Marquee013 Disconnect power to the awning Figure 1 Canopy Replacement Remove the idler side end cap and lead rail end plate and set aside On the opposite end of the lead rail remove the fabric retaining screw middle screw from the end plate NOTE It will be necessary to firmly support the roll bar and keep it from coming out of the case 10 11 12 13 14 15 16 17 18 19 and off of the motor during the next steps From the idler end of the rollbar simultaneously slide the old canopy out of the roller tube and lead rail Inspect the slots in the roll bar and lead rail Clean and deburr as required Lightly spraying the inside of the slots with a dry silicone lubricant will aid in sliding the new fabric in Slide the new canopy into the lead rail and roller Both edges must be done at the same time Orient the fabric so th
23. r Black 3 Motor Kit includes bearing and one way drive 4 Attaching hardware not included with spring arm assemblies Order item 9 Item 9 includes pins set screw and retaining ring e be used on the left or right side 6 Lead rail item 14 includes end plate kit item 12 Carefree of Colorado Marquee504 NOTES 2 5 End plate kit item 12 includes two end plates and hardware End plates are universal and may 052549 301r6 Carefree of Colorado OPTIONAL LED LIGHTING ITEM PART NUMBER 1 R060732 001 R060732 003 SR0101 R019493 001 R060740 001 R040616 206 R001716 ouhwhd Notes 1 LED strip item 1 is sent on a roll and cut to length during installation 052549 301r6 Service Manual DESCRIPTION LED Strip White Used on awning 67 and longer LED Strip White Used on awning 66 and shorter Switch Kit includes item 3 Fuse Kit includes in line fuse holder and 2A fuse Harness Wire Channel Slot Cover pkg of 2 1 length ea MARQUEE LED503 NOTES 1 1 17 MARQUEE Service Manual Carefree of Colorado NOTES 18 052549 301r6
24. s made previously 5 Tighten the securing screw 6 Attach the lead rail end plate Case ref Groove on Bottom Groove on Bottom Lead Rail ref e e Wl Connector it Early Case Connector Current Case Connector Lead Rail Connector eee Upper Groove Set Window Steep Pitch Case ref Groove on Top Lead Rail ref al 2 Connector Mounted _ o in Upper Groove Set Connector in Early Case Connector Current Case Connector Lead Rail Connector Lower Groove Set OtD Flat Pitch 2 Holes O Grooves at i t Q can be identified by the groove on the front face and the two holes through the top The early and current connectors are not interchangeable Early Style Current Style Marquee011 Figure 3 Spring Arm Connector Placement Replacing the Case Connector Refer to Figure 3 1 Carefully mark the location of the existing connector in the case Make note of the bracket orientation 2 Remove the end cap Refer to details on page 2 e For the idler side remove the screws and slide the end cap off of the roll bar idler and set aside It will be necessary to support the rollbar e For the motor side remove the end cap screws and slide the end cap and motor out from the case and rollbar about 3 4 It will be necessary to support and hold the roll bar when separating the motor NCAUTIONS WHEN PULLING THE MOTOR OUT OF THE CASE THE SERVICING TECHNICIAN MUST USE CARE TO NOT BREAK OR DAMAGE
25. sidewalls Awning Specifications e Fully retractable and self storing e The sealed awning motor operates on standard 12VDC range 10VDC to 14VDO e Fabric is woven acrylic e Case and frame are constructed of high strength aluminum extrusions protected with a polyester paint finish e Stainless steel fasteners and hardware EXTENSION 36 AVAILABLE WIDTHS OtD 50 54 60 66 72 Window 50 54 60 66 72 7 8 9 10 11 12 amp 13 LEADING EDGE POSITION ACTUATION AND CONTROL Power Lateral Arm Spring Minimum Tension Open Position Control Motorized Roll Out In Controlled by Electrical Motor MOTOR SPECIFICATIONS Motor Type Tubular Power 12VDC Minimum 8VDC Output 30 Watts Nominal Current 2 5Amps Max Current 14Amps stall min voltage Power Source Motor and controls are routed and hardwired into the vehicle s 12V system Torque Continuous 6Nm 4 5 ft lbs Tightening 18Nm 13 2 ft lbs Speed 15 rpm COLORS AVAILABLE Case Standard White Black Custom Champagne and Pewter Fabric Woven Acrylic Fabric refer to sales literature for colors available Awning Width Fabric Width 3 approx j l D Marquee001a 052549 301r6 1 MARQUEE Service Manual Carefree of Colorado CANOPY REPLACEMENT 1 FAILURE TO SECURE THE LEAD RAIL AS DESCRIBED WILL ALLOW THE SPRING ARMS TO UNEXPECTANTLY EXTEND OUT POSSIBLY CAUSING PERSONAL INJURY O
26. t lal cuire Routed Ensure that it is firmly seated Gi in ree ouie Pe LED Strip in Lead Rail 5 Press the in line fuse wires and switch into the mounting hole Secure i54 pas Sy INO GM jus KHE mE HEHET Connector at the switch using two 2 6 x 1 2 PSS DN TS TS jum serewis i Lead Rail LEDOO2c 6 Snapthe switch bezel over the switch frame 10 052549 301r6 Carefree of Colorado Service Manual MARQUEE REPLACING THE LED STRIP Cut Between Pads to Adjust Length 7 0 088 0 6 8 33 a 4 Wire Channel Harness ao mo Mo OND 4 LED Slot LED Strip Slot Cover Slot Cover Marquee034 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 Remove the slot covers from the ends of the LED strip and set aside Inside the lead rail disconnect the connectors Carefully pull the wire and connector for the LED strip out of the lead rail through the hole that is located behind the slot cover location Remove the existing LED strip from the lead rail Clean the slot to remove any dirt and tape residue Starting at the reference mark made previously press the new strip into the LED slot At the end of the lead rail cut the LED strip to match the mark made previously To trim the LED strip always cut between
27. the 4 pad cluster as shown 10 Route the new LED strip wires into the lead rail and connect to the harness 11 Press the slot covers into the LED slot 12 Restore power and test HARNESS REPLACEMENT 1 2 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 clip the harness Clamp the harness going into the vehicle 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 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 Alternate 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 wa
28. wire goes to BROWN motor wire 2 For first time replacement installation refer to installation instructions furnished with replacement switch kit SWITCH INSTALLATION W RELAY MODULE Relay Installer Furnished Module Switch SPDT Center OFF Installer Furnished Switch Rear View of Connectors Shown SPDT Center OFF Butt Splice 5 plcs Gray Brown Brown Yellow Yellow Detail A Alternate Wire Connection PV3007 Figure 7 Relay Module Installation The relay module allows installations to use up to two 2 single pole switches not available from Carefree Switch characteristics Single Pole Double Throw DPDT Momentary ON center OFF Momentary ON OFF Momentary ON 052549 301r6 9 MARQUEE Service Manual Carefree of Colorado OPTIONAL LED LIGHTING 1 Follow the standard mounting instructions for the awning these are found in the awning installation instructions 2 Route the twisted wire cable for the LED lighting into the vehicle with the motor cable wire 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 The wire should be secured to the wall of the vehicle where it is exposed on the outside of the vehicle Use a quality silicone sealant adhesive N Do not route the w
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