SOKIII Service Manual - E
Contents
1. 18 H001164 End Cap Assy Roll Bar LH 19 RO001165 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 25 R001364 Bumper Deflector Rubber pkg of 4 26 R001186 Center Latch Pin 27 Canopy Only Refer to Canopy Order Form 28 R001562 Bumper Guard pkg of 2 7 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 XL replacement extrusions and extrusion assemblies are sent out in two pieces and assembled during installation oND 052520 301r2 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 For older 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 7 9 New covers are mounted with screws Also refer to note 4 XL replacement cover includes both the LH and RH halves Set of two bumper guards item 28 is included with canopy replacements Summit awnings can be converted to the SOKIII by removing the lift bar assemblies 19 SOKIII amp SuMMIT2. 3 Deflector Width 1 25 Lift Arm I 6 2 NER SOKIII amp Summit E Standard w Short Deflector Bracket Width Room Width 8 approx Pen a Deflector Width Deflector Half Width u l j i ea L 3 E 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 301r2 Carefree of Colorado Service Manual SOKIII amp SUMMIT 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 and current Summits use screws that are threaded through the end cap and project into the cover Spring Loaded Attach Pin ps 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
3. Service Manual Carefree of Colorado BASIC SUMMIT ILLUSTRATED PARTS LIST B DETAIL E Center Latch Pin 12 or Longer Covers Only A V Obsolete S DETAIL A B Roll Bar Latch See Notes Spring Loaded Pin Attach Screw Attach DETAIL C DETAIL B Center Support Summit XL SOK3501sm 20005 2520 30112 Carefree of Colorado Service Manual SOKIII amp SuMMIT Item Part Number Description Notes 1 R001150XXX Bracket Deflector Mount Short 4 5 fa RO001534 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 5 6 6 R001520XXX End Cap LH Screw Cover Attach 5 6 7 Obsolete End Cap RH Spring Pin Cover Attach 5 6 8 R001521XXX End Cap RH Screw Cover Attach 5 6 9 Obsolete Roll Bar Latch 2 10 R001156 Roller Support 11 R001258 Center Support Plate XL Only 12 NLA Lift Bar Assy 8 13 NLA Lift Bar NLA Lift Bar XL Only 4 14 NLA End Cap Lift Bar 15 NLA Extension Arm Assy 12 16 9 Room Extension 8 17 610400 xxx Roller Tube 33xxx Roller Tube Assy XL Only 3 4 18 H001164 End Cap Assy Roll Bar LH 19 RO001165 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
4. cap This design has been discontinued in 2007 The second method uses screws that thread through the end cap and project into the cover x C Spring Loaded Cover Retaining Screw a Latch Lever Attach Pins 4 plcs 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 052520 301r2 3 SOKIII amp SuMMIT Service Manual Carefree of Colorado Method 1 Spring Loaded Pin Attach 1 2 Place the top pin of one end of the cover into the mounting hole of the end cap 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 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 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 fa
5. drill bit and ream the holes to allow the pop rivet to be pushed in 2 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 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 If 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 e Roll the fabric onto the rollbar The fabric must be oriented around the roll bar as shown 052520 301r2 13 SOKIII amp SuMMIT Service Manual Carefree of Colorado 10 11 12 13 14 15 16 14 e Detail B
6. 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 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
7. may cause the fabric to sag and not roll up correctly when the room is closed 6 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 052520 301r2 9 SOKIII amp SUMMIT Service Manual Carefree of Colorado 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 Canopy replacements include two 2 bumper guards that fits on the upper edge of the cover Install a bumper guard on each end of the cover The end of the bumper guards should be flush with the ends of the cover Secure the bumper guards on each end using a small amount of quality silicone sealant NOTE For XL models one guard should go on the LH end of the LH 4
8. on the rollbar For existing canopies it may be 6 x 3 8 Rail Adaptor necessary to remove the retaining screws from the rail adaptor Screw Straighten the fabric as required x L 1 Fabric If not previously done secure the fabric to the rail adaptor with LM two 2 6 x 3 8 hex head screws Reattach the center cover mount SOK3034 Figure 9 Securing the Fabric Reattach the covers 052520 301r2 Carefree of Colorado Service Manual SOKIII amp SuMMIT REMOVING THE LIFT BAR COMPONENTS NOTE Replacement lift arms and arm assemblies are no longer available The Summit and Summit Fl can be converted to the SOKIII by removing the lift arm assemblies and hardware These instructions apply to the Summit and Summit FI Outer Stop Bolt Outer Stop Bolt Lift Bar Inner Stop Bolt Carrier ref Lift Arm Assy Mounting Pad ref Mounting Pad ref S Deflector Summit Lift Bar Assembly Summit FI Lift Bar Assembly soeia Close the room if open Remove the front cover refer to page 3 For XL Models Remove the cotter pin and center cover mount Set parts aside e mo MD x 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 e Remove the 1 4 20 socket head screw from the left end cap and set aside Do not discard 6 Lift the roll bar
9. quc pel Lc ap c DO pre MERITI RR 16 i cq i M rHc 16 Jus e E A to E 16 xol cerns E E a a pE 16 Hardware Maitena Ericineae 16 Part NumberSerial Number Locatii S E 16 Parn Number Listing ce 17 ux te FT CIS bi Um moe 1T Summit FI Ilustrated Parts Ie ee ee nr er ney e PRES Pore ee ceria er Oo o ret 18 Ease Summit Illustrated Parts LIB care tarte to Er br ende a a eee bx e EE REEE 20 052520 301r2 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 Y Lift Arm the room is open yet stores beneath the fabric when the room y Jo is closed This is excellent for shedding water and to prevent Wall Bracket 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 basic Summit the mounting hardware is designed to Wall Bracket provide greater flexibility for installations The FI uses a lower profile wall mounting bracket that ca
10. 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 7 Loosen and remove the outer stop bolts 8 Loosen and remove the inner stop bolts 9 Slide the lift bar out of the carriers 10 Remove the screws from the inner and outer mounting pads and save 11 Remove the brackets from the vehicle wall Seal the holes with a quality silicone sealant 12 Roll up the slack material onto the roll bar NCAUTION Failure to roll up the slack before installing the roller tube will reduce the spring tension Reduced spring tension may cause the fabric to sag and not roll up correctly when the room is closed 13 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 14 Firmly grasp the roller tube and fabric then remove the spring lock cotter pin inserted on the spring end of the roller tube Allow the spring to tension the fabric slowly while releasing the rollbar 15 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 adaptor Straighten the fabric as required 16 For XL models Reattach the center cover mount 17 Reattach the covers 052520 301r2 15 S
11. 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 9 e Roll the fabric onto the roll bar The fabric goes over 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 NCAUTION Failure to roll up the slack before installing the roller tube will reduce the spring tension Reduced spring tension may cause the fabric to sag and not roll up correctly when the room is closed 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 fa
12. Deflector Rubber 23 R001186 Center Latch Pin 24 0157xxx Awning Rail 26 Canopy Only Refer to Canopy Order Form 27 R001562 Bumper Guard pkg of 2 Notes 1 XXX Color xxx Length in Inches 2 The roll bar latch has been discontinued For spares order RH end cap item 8 Also refer to note 5 3 The XL replacement Roller Tube Assy includes the roll bar halves splice rivets end caps and 4 052520 301r2 pre wound spring XL replacement extrusions and extrusion assemblies are sent out in two pieces and assembled during installation End caps 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 For older 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 XL replacement cover includes both the LH and RH halves The Summit may be converted to an SOKIII by removing the lift bar assembly and hardware 21 SOKIII amp SuMMIT Service Manual Carefree of Colorado NOTES 22 052520 301r2
13. ILLUSTRATED PARTS LIST DETAIL A Center Cover Support XL Only 17 DETAIL B Center Latch Pin 12 or Longer Covers Only SOK3503 Item Part Number Description Notes 1 R001150XXX Bracket Deflector Mount Short 4 5 6 2 R001534 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 R001258 Center Support Plate XL Only 9 610400 xxx Roller Tube 33xxx Roller Tube Assy XL Only 2 10 R001164 End Cap Assy Roll Bar LH 11 R001165 Spring Assy R001165XL Spring Assy XL Only 12 R001169XXX xxx Front Cover Assy 5 R001337XXX xxx Front Cover Assy XL Only 3 5 13 R001364 Bumper Deflector Rubber pkg of 4 14 R001562 Bumper Guard pkg of 2 4 15 R001186 Center Latch Pin used on 12 or Longer Covers Only 16 Canopy Only Refer to Canopy Order Form 4 17 0157xxx Awning Rail See Hardware and Accessories 18 R012711 005 Hardware Pack White not shown R012711 006 Hardware Pack Black not shown 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 XL replacement cover includes both the LH and RH halves 4 Set of two bumper guards item 14 is includ
14. OKIII amp SuMMIT Service Manual Carefree of Colorado 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 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 or
15. SERVICE MANUAL N vare iet SOKIII amp SUMMIT SIDE OUT COVER THIS MANUAL CONTAINS INFORMATION FOR SOKIII SOKIII XL SUMMIT SUMMIT XL SUMMIT Fl AND SUMMIT FIXL IMPORTANT NOTE The Summit series of side out covers has been discontinued and has limited replacement parts The Summit series side out covers can be converted to an SOKIII side out cover by removing the lift bar mechanism refer to page 15 SOKIII Summit Summit XL These instructions apply to all models listed Details and procedures unique to a specific model are labeled appropriately 052520 301r2 Printed in USA February 2012 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 tile 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 agree
16. Slide the white polyrod and fabric into the awning rail adaptor 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 removed 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 9 Roll up the slack material onto the roll bar NCAUTION Failure to roll up the slack before installing the roller tube will reduce the spring tension Reduced spring tension may cause the fabric to sag and not roll up correctly when the room is closed 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 Awning Rail Open and close the room to ensure that the fabric is rolling up a straight
17. ainer 1 4 20 x 3 4 Screw ref 10 32x1Screw e 3 per End Cap x7 E il TN i DETAIL A SOK3054 1 Remove the front cover if installed refer to page 3 or page 5 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 onto the roll bar and install the roll bar into the new end caps Attach the front cover refer to page 3 or page 6 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 s 9 o0 90 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 mos
18. bric as required Secure the fabric to the rail with two 2 46 x 3 8 hex head screws 052520 301r2 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 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 Right Side Remove After Mounting With Sprocket Roll Bar Roll Bar Splice S Black Left Side Polycord With Threaded Insert Roll Up Slack Before Mountings Roll Bar in Deflector v 5 Center Cover Mount Rail Adaptor ref 1 4 20 x 3 4 Screw l Detail B SOK3044 Figure 8 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
19. cover half and one goes on the RH end of the RH cover half 12 Install the front covers Cover Bumper qty 2 Install On Each End Of Cover Flush With End of Extrusion SOK3065 Figure 7 Bumper 10 052520 301r2 Carefree 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 Spring Locking Pin Ne Twist to Add Spring Winds RH Bearing and Spring Assy 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
20. ctory It will be necessary to force thread the top holes in the end cap using the supplied screws 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 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 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 301r2 Carefree of Colorado Service Manual SOKIII amp SuMMIT FoR XL MODELS Removing the Cover Mounting Holes p Spring Loaded 7 Attach Pins E Spring Loaded Pin Attach Spring Loaded Attach Pins Center Cover Mount Cover Retaining Screws gt Latch Lever Threaded Screw Attach Center Latch Pin a 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 ca
21. d 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 with 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
22. dinary 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 IMPORTANT NOTE f the room must be closed during wet weather rain close the room in increments approximately 8 12 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 PART NUMBER SERIAL NUMBER LOCATION Deflector ref SSERIALNUMBER Serial Number Part Number P PARTNUMBER Carefree is located on the deflector and beneath the fabric mmn on the roller tube COLOR LL LJ SOK3047 Revision 6 01 12 052520 301r2 Carefree of Colorado Service Manual SOKIII amp SuMMIT PART NUMBER LISTING SOK III
23. ed with canopy replacements 5 Replacement covers mount with screws If replacing an older cover that uses spring pins it will be necessary to also order end caps items 5 6 6 Units 155 or less order length uses 2 brackets Units 156 191 uses 3 brackets XL Units 283 or longer uses a quantity of 5 brackets 052520 301r2 17 18 SOKIII amp SUMMIT Service Manual SUMMIT FI ILLUSTRATED PARTS LIST DETAIL E Center Latch Pin 12 or Longer Covers Only I SSS Obsolete j R Spring Loaded Pin Attach Screw Attach DETAIL C DETAIL B Center Support Summit XL SOK3502sm 052520 301r2 Carefree of Colorado Carefree of Colorado Service Manual SOKIII amp SuMMIT Item Part Number Description Notes 1 R001 150XXX T Bracket Deflector Mount Tall 6 2 R001150XXX Bracket Deflector Mount Short 4 5 2a RO001534 Spacer 1 4 Deflector Bracket pkg of 2 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 4 7 R001520XXX End Cap LH Screw Cover Attach 8 Obsolete End Cap RH Spring Pin Cover Attach 4 9 R001521XXX End Cap RH Screw Cover Attach 10 R001156 Roller Support 11 R001258 Center Support Plate XL Only 16 R001176 Stop Bolt 17 610400 xxx Roller Tube 33xxx Roller Tube Assy XL Only 3
24. ft 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 2 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 3 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 5 Roll up any slack material onto the roll bar gt A NCAUTION Failure to roll up the slack before installing the roller tube will reduce the spring tension Reduced spring tension
25. lace 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 i4 1 4 Deflector Length typ 4 m l typ m od Covers 12 and Longer and XL Cover Halves SA Outer Slot Center Bumper Used On e e 10 14 Lengths Only N Cou o i E j E mam a 2 A amp B l I Ms 1 Covers Under 12 Qo X p Cover Shown in Raised Position a j N ly Ssok3039 052520 301r2 7 SOKIII amp SuMMIT Service Manual Carefree of Colorado 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 illustration on page 3 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 Ret
26. n 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 service Awning Rail Extension Gutter For FI 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
27. 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 replacing only the roll bar and or spring only e Fold the fabric on top of the coach and out of the way 9 If 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 301r2 11 SOKIII amp SuMMIT Service Manual Carefree of Colorado REBUILDING THE RoLL BAR ASSEMBLY 1 7 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 an
28. r 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 6 052520 301r2 Carefree of Colorado Service Manual SOKIII amp SuMMIT 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 p
29. re Installation Manual Discontinued 052530 001 Summit Upgrade for SOK II Discontinued 052520 301 SOKIII amp Summit Service Manual Carefree of Colorado 2145 W 6 Avenue Broomfield CO 80020 a Scott Fetzer company www carefreeofcolorado com Carefree of Colorado Service Manual SOKIII amp SuMMIT TABLE OF CONTENTS dis odes 17 c e 2 SE FREE PORE enone EEG EEO ae 3 Fa Rooms Jndor o eee ee ER E eT 3 ie bu qus eerte PU pt T 3 Ii 05 0 1f AMT ETT ccc 3 d cR Posnddco Sem pU 3 aud ioo rm T Ne 5 ipis he COVO CE E o o E omm 5 Attaching the Front Cover QE 6 LOVE BUMP EE aaan aR EE TE OR ARR RU AOL tu DR 7 masks le soe clipo qp aeriana Eden 8 Notes on Using an Existing COVEf RR E o S USE mm 8 Goanopy HapDIAGOIPRIE ase chiara Urt ak RE RM pena en RUM EFE NEU PK EUMD A MEE RME DIM dAA AF M R7 RI din dd d RR A 9 ec une elds me Od PIDIE gee Remeber eee t Mee wer rr MM AE PM MM Ea Lade UE 9 Ines ino PM FADE as ccc eb E RU UM M MD ALL CHE EE 9 Standard Spring Roll Bar Replacement e eeeeeeee eese eeeeeeeeeeene eene nnnnn nnn 11 Removmg the Roll Bar ASSemDly mmm 11 Rebuilding ihe Roll Bar ASsSembly ARR oo TORUM 12 STRUD NEUE E E A E A ORA E UR E N 12 Replacing the XL Ron B r RT 13 Removing Ihe Lift Bar DCompof HB EN eon iexed enia hd M RUM FERM UU B MM KE xEN URRN AER ERU M EAUIN AMAA KU RM EM MEME MERE 15 ic
30. refully 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 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 052520 301r2 5 SOKIII amp SuMMIT Service Manual Carefree of Colorado Attaching the Front Cover Mounting Holes p E E Attach Pins Spring Loaded Pin Attach Z p Center Cover Mount Cover Retaining Screws a La
31. s 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 A AAWARNING 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 052520 001 Summit Installation Manual Discontinued 052543 001 Summit XL Installation Manual Discontinued 052541 001 Summit FI Installation Manual Discontinued 052543 101 Summit XL w FI Hardwa
32. t 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 can then be removed 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 1 Piece Spring Assy 1 4 Drill 8 052520 301r2 Carefree of Colorado Service Manual SOKIII amp SuMMIT CANOPY REPLACEMENT Spring Locking Pin TN Screw Used w Rail Adapter V Awning Rail Rail Adapter aam Fabric Retaining PET Screws Fabric Se oc P Awning Rail ref or Rail Adaptor ref Roll Bar 1 4 20 x 3 4 Detail 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 le
33. tch Lever Threaded Screw Attach Center Latch Pin T Cotter Pin 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 At the 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 cap 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 cente
Download Pdf Manuals
Related Search