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SERVICE MANUAL TRAVEL R - E

1. LCDRO003 15 TRAVEL R Service Manual Carefree of Colorado STANDARD MAINTENANCE Maintaining the Carefree Manual Patio 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 an 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
2. 9 5 fa 6 approx approx approx METER NT r yo DI M en Du Y X Lr UA t Ui t Talia e TON E Awning Rail 3 1j ij 4 BN X 9 BN TH 909 i A ut ltt Typ F o PIET 6 Clearance from top of 14 5 gt g door g le Clearance B g eS AT N p from tap of M I t __ Flat Mounting Surface Area Flat Pitch amp Adjustable Vaia 41 Awning Length 31 2 x 67 i Steep Pitch E LH Fixed Flat Pitch amp Gy S 3 1 2 x 59 1 2 Detail A E Adjustable Pitch ei ine Fixed Steep Pitch of Arm of Arm TravelR003pc Figure 1 General Layout 052540 301r5 1 TRAVEL R Service Manual Carefree of Colorado CANOPY REPLACEMENT 10 x 5 8 Screw qty 4 j End Cap dL Roller Assembly LA i Align Slots Align Slots Detail A Detail B Upper Bracket After Market Installations Trim Polycord 1 From Fabric Trim Polycord 1 From Fabric Feeder Feeder 1 Piece Fabric 2 Piece Fabric Detail D Travelr014 Figure 2 Canopy Replacement Travel r Remove the canopy retaining screws in the awning rail Extend the awning out completely Remove the screws that attach the end caps to the roll bar and save While holding the roll bar up pull the roll bar out of the end cap of the motor head NCAUTION DO NOT ALLOW THE ROLL BAR TO DROP TOWARD THE GROUND THE TWISTING MOTION CAN CAUSE SERIOUS DAMAGE TO THE IDLER ARM 5
3. EXTEND L O of Colorado 9 f O C Carefree of Colorado Series 2 Ground Detail A Wall Mount Connector TravelR008 WIRING DIAGRAM SINGLE SWITCH JULY 2010 AND ON To Ground RED Motor Wire WHITE 1 BLACK Motor Wire DO p RED To 12VDC SK005a NOTES 1 If connector block is oriented with wires to the left reverse the motor wires WHITE connector block wire goes to RED motor wire BLUE connector wire goes to BLACK motor wire 2 For first time replacement installation refer to installation instructions furnished with replacement switch kit 14 052540 301r5 Carefree of Colorado WIRING DIAGRAM TRAVEL R DIRECT RESPONSE e a A y To 12VDC 4 Rear View of Switch Assy Extend Retract Z 187 18 20awg Female Spade Terminals qty 3 O Switch Cable Service Manual 187 14 16awg Female Spade Terminals qty 2 25 14 16awg Spade Terminals 1 Male 1 Female M Yellow Gray E m TO Chassis Ground TRAVEL R Override Terminal Contacts ref 052540 301r5 Control Module mounted in motor head
4. Series Switch 2a Place one lead of tester on 12V pin 3 Touch 2nd lead to the other pins one at a time on Ground pin 5 Touch 2nd lead to the 2b Place one lead of tester on Ground pin 1 Touch 2nd lead to the other pins one at a time 2c Place one lead of tester other pins one at a time i Retract 2 12V 3 052540 301r5 4 Extend 5 Ground Y Service Manual TRAVEL R Test Switch Function Single Switch Installation this test requires a continuity tester The Patio Switch used in the Single Switch Installation is a center on that is internally cross wired to short in the center position to provide dynamic braking for the motor to prevent drift when the awning is stopped Test 1 is for Series amp Il switches Use Test 2 for Series III switches Observe continuity for switch in center position extend position and retract position Series Il Switch 1a Place one lead of tester Pin Center Extend Retract YES Test OK all checks pass go to step on pin 2B Touch 2nd 3 N Y N 1b lead to the other pins 6 Y N Y one at a time 5B Y N N NO Test failed switch defective replace N no continuity Y continuity 1b Place one lead of tester Pin Center Extend Retract YES Test OK all checks pass Revaluate on pin 5B Touch 2nd 3 N N Y problem cause is not electric
5. Support the roll bar pull the roll bar out of the end cap of the idler head Allow the fabric and roll bar to hang down on the side of the RV Use care to not scratch the side of the RV 7 Mark the slots that the current fabric is in then remove any fabric retaining screws in the roll bar and tractioners used with Alumaguard Slide the roll bar off of the fabric 8 Determine the type of canopy replacement e If replacing a full fabric canopy or canopy with Alumaguard or canopy with Uniguard For arms using an upper mounting bracket it will be necessary to remove the upper bracket from one side After removing the bracket brace the arm using scaffolding or similar support NCAUTION THE LOWER MOUNTING SCREWS FOR ARMS USING THE UPPER BRACKET MAY NOT BE MOUNTED INTO STRUCTURAL MEMBERS OF THE COACH WALL FAILURE TO SUPPORT THE ARM CAN RESULT IN DAMAGE TO THE COACH WALL e For canopy only replacement for units with Alumaquard The fabric is crimped into the aluminum slat Use a large flat screw driver or similar tool to spread open the crimp on both sides of the fabric e For canopy only replacement for units with Uniquard Remove the retaining screws from both sides of the Uniguard 9 Slide the fabric out of the awning rail om D 2 052540 301r5 Carefree of Colorado Service Manual TRAVEL R 10 11 12 13 14 15 16 17 18 19 20 21 Clean and deburr the roll bar slots and awning rail Alumaguard Uniguar
6. 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 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
7. awning moves in the wrong direction i e extends when retract is pushed reverse the two small wires plugged into the motor 14 Attach the front cover using the small screws removed previously 052540 301r5 Carefree of Colorado Service Manual TRAVEL R REPLACING THE MOTOR SERIES Il NCAUTION THE ARMS ARE UNDER TENSION FROM THE GAS SHOCKS WHEN THE MOTOR AND OR ROLL BAR IS DISENGAGED FROM THE ARM THE ROLL BAR WILL BE FREE TO SPIN BOTH ARMS WILL EXTEND FROM THE GAS SHOCK TENSION USE EXTREME CARE AND HOLD THE ARMS IN POSITION IT WILL BE NECESSARY TO HAVE AT LEAST ONE OTHER PERSON HOLDING THE IDLER ARM 10 x 5 8 Screw SS Rear Cover 5 16 18 Nylock Nut Motor Assembly Front Cover W Cast Metal Frame 5 16 18 x 1 3 4 3 Truss Head Screw DETAIL A DETAIL B Travelr017 Motor Red Wire Cable Red Wire Figure 7 Motor Replacement Series Il 1 For Awnings Fully or Partially Extended 1 1 Remove the front cover by removing the six 6 smaller screws from the back of the motor head Save cover and screws 1 2 Disconnect the motor and cable wires from inside the rear cover Note the location of each wire 1 3 Remove the rear cover by removing the two 2 large screws from the back of the motor head Save cover and screw 1 4 Remove the two square drive screws attaching the end cap to the roll bar and separate the roll bar and end cap It will be necessary to hold the roll bar and motor ar
8. codes Ltd 14 availability and codes 45 ALUMAGUARD UNIGUARD QK Vinyl or Polyweave With CUSTOM GRAPHICS 2 Refer to Sales and Order Information for Alumaguard 16 Refer to Sales and Order color availability and codes 17 Information for color OU Acrylic With Uniguard ja availability and codes OT Polyweave with Uniguard 49 POLYWEAVE Refer to Sales and Order 20 Information for color 21 availability and codes 052540 301r5 ACRYLIC Refer to Sales and Order Information for color availability and codes CUSTOM ACRYLIC 17 TRAVEL R Service Manual Carefree of Colorado ILLUSTRATED PARTS LIST Travel r Fixed Pitch Series Il Series Series Il Series I DETAIL B DETAIL A Idler Head Motor Head 20 21 22 23 Alumaguard Uniguard Detail C TravelR502 18 052540 301r5 Carefree of Colorado Service Manual TRAVEL R Item Part Number Description Notes 1 R001505XXX 1 2 Set Hardware Arm Assy Motorized RH Flat Pitch 1 2 R001507 XXX 1 2 Set Hardware Arm Assy Motorized RH Steep Pitch 1 2 2 R001506XXX 1 2 Set Hardware Arm Assy Idler LH Flat Pitch 1 2 R001508XXX 1 2 Set Hardware Arm Assy Idler LH Steep Pitch 1 2 3 R001094XXX Top Mounting Bracket Used w Aftermarket Only 1 4 R019319XXX Quick Mount Bracket Kit
9. 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 ROLL UP THE AWNING AND SECURE FOR TRAVEL ARM CARE The best method of keeping the arms and braces operating smoothly is to clean them Dirt and debris can cause the channels not to slide easily NOTE Avoid introducing water into the motorized housings Periodically wash out the channels with running water i e a hose to keep them clean If the arms still do not move easily lightly spray the contact and pivot points with a dry silicone lubricant after the arms have been
10. includes 4 brackets and hardware 1 5 R001532XXX Fascia 11 Flat Pitch qty 1 1 3 R001533XXX Fascia 3 Steep Pitch qty 1 1 3 6 R001252 Gas Shock Flat Pitch R001331 Gas Shock Steep Pitch 7 R001576 Shock Hardware Kit 8 R001104XXX Motor Assy Series 1 9 R001323 Kit Head Attach Hardware Series 1 10 R001324XXX Kit Motor Cover Series 1 4 11 R001326XXX Kit Motor Assy Series Il 1 5 12 R001328XXX Kit Motor Cover Series Il 1 4 13 R060414 006 Cable Motor 14 R001107XXX Idler Assy Series 1 15 R001325XXX Kit Idler Cover Series 1 4 16 R001327XXX Kit Idler Assy Series Il 1 5 17 R001329XXX Kit Idler Cover Series Il 1 4 18 19xx00 Roller Tube 3 slot 3 1 2 Dia 19 Canopy Refer to Canopy Order Form 20 20xx36XXX Alumaguard Assembly Only 1 21 R001246XXX xxx Uniguard includes 4 25 soft connect 1 R001246XXX xxxT Uniguard includes 5 25 soft connect 1 22 R001247XXX xxx Soft Connect 4 25 Wide 1 R001247XXX xxxT Soft Connect 5 25 Wide 23 901067 Tractioner set of two 24 R001605 Kit Single Switch 6 25 R014634 025 Extension Kit White The following parts are not shown 26 R014492 251 Hardware Pack w Top Bracket White 27 R014489 JV1 Hardware Pack w Top Bracket Black 28 R001697 Replacement Roller Kit Notes XXX Color xx Length in inches WHT White BLK Black 1 2 Arm assemblies are configuration specific and cannot be interchanged When ordering provide the following information part number serial number flat steep pi
11. Manual Carefree of Colorado NOTES 22 052540 301r5
12. N CAN CAUSE SERIOUS DAMAGE TO THE IDLER ARM Loosen and remove the 3 8 16 lock nut from the mounting bolt Make note of the number and order of the spacer washers between the arm mounting block and the motor head Tip When the nut is removed the bolt will slide out of the arm mounting block inside the arm channel Placing tape on the head of the mounting bolt and the spacers will prevent the bolt and the spacers from falling out when the nut and motor are removed Remove the motor assembly The motor assembly consists of the motor mounting frame gears shaft and roller end cap Place the new motor assembly in position over the mounting bolt Ensure that the spacer washers are all accounted for Secure using the washer and lock nut removed previously The nut should be tightened until snug but the motor head should be able to swivel by hand Attach the rear cover to the motor assembly using the large screw removed previously 10 Attach the motor and cable wires to the terminals inside the rear cover 11 Align the roll bar with the end cap on the motorized arm assembly Rotate the end cap until the slot in the cap aligns with the empty slot in the roller assembly and then press the roller assembly fully into the cap The end cap must seat squarely over the end of the roller assembly when complete 12 Secure the end cap to the roller assembly using two 10 x 5 8 square drive screws 13 Restore power and test operation If the
13. ND SERVICE MANUAL vare iet TRAVEL R MOTORIZED FIXED PITCH PATIO AWNING TABLE OF CONTENTS Progquet virili iaia iaia 1 rw De Ei coil eli Li iii iaia iii 1 Le Z5 au 2 fucile Rie MEI eig ir RTT 4 MR ie 5 Replacing he Molor perte 5 Replacing the Motor Seres M eT 7 Replacing the Gas SHOCK Km TT k iba Eei 9 Diagnostics Troubleshooting sinsin iraniani 10 Wiring Diagram Single Switch Prior to July 2010 sssssssssssssenememeeneennn 14 Wiring Diagram Single Switch July 2010 and on enne 14 Winng Diagram Travelr Direct Response 15 SISSE MONI I CK PURA U MA d 16 Farn Number i RU 17 Part Number Serial Number Location nennen nnn nennen nnn nnne nnt 17 Ame Fart Number aaa 17 Baller Far Number Coniguratio ara 17 Strate Pars LIS ananena E ERA SENES 18 Mee a a r aaa ai 18 Travel Adjustable PO diae aaa aria 20 12 Volt Direct Response Auto Retract System iiu iaia M MER RR p pid RD 21 052540 301r5 Printed in USA February 2012 PROPRIETARY STATEMENT The Travel r Patio Awning is a product of Carefree of Colorado located in Broomfield Colorado USA The information contained in or disclosed in this document is considered proprietary to Carefree of Colorado Every effort has been made to ensure that the information presented in the document is accurate
14. NOT EXTEND OR DOES NOT EXTEND COMPLETELY A Visually confirm motor is working when control switch is pressed YES Goto test B NO Go to test D02 Awning Does Not Extend and or Retract page 10 B Confirm that the arm channels pivot points and contact points are YES Gototest C clean and clear of obstructions NO Clean and Lubricate then retest If the arm still hangs up go to test C C Ifthe awning has Alumaguard check that the tractioners are installed YES Tractioners OK Go to test D and positioned correctly refer to page 4 NO Reposition and attach the tractioners according to the directions on page 4 and retest D 1 Open the awning If the awning arm does not extend YES Shock is defective replace See carefully pull the arm out as the fabric is unrolling procedure on page 9 2 Doesthe fabric sag when the awning is extended NO Shock extends with arm and is 3 Inspect the shock Is there evidence of dirt build up and oil solid Shock pressure is leaks on the rod approximately 85 Ibs Go to test E 4 Hand close and open the arm Is the tension from the shock mushy weak or missing NOTE To close the awning by hand push the head of the arm toward the coach Pulling down on the head or roll bar WILL NOT close the awning E This step only applies to new Uniguard and Alumaguard installations that do not extend correctly Check that the centerline of the roll bar is 3 4 1 4 above the cent
15. RAVEL R Configuration B Cast Metal Motor Mount Frame Travelr016 Figure 5 Distinguishing the Motor Mount NOTE Motor assemblies and covers are not interchangeable between the two configurations REPLACING THE MOTOR SERIES I 3 8 16 P Lock Nut X B US v4 Motor Assembly W Bent Metal A SIE Frame XN Rear Cover Front Cover DETAIL A Rear Cover ref Front Cover ref DETAIL B Figure 6 Motor Replacement Series I Motor Attach Bolts amp Nuts Motor ref 1 refer to Detail A For Awnings Fully or Partially Extended 1 1 On the right hand arm remove the front cover by removing the six 6 smaller screws from the back of the motor head Save cover and screws Motor Black Wire Cable Black Wire Motor Red Wire Cable Red Wire DETAIL C 10 x 5 8 Screw DETAIL D Travelr015 1 2 Disconnect the motor and cable wires from inside the rear cover Note the location of each wire 1 3 Remove the rear cover by removing the one 1 large screw from the back of the motor head Save cover and screw 1 4 Goto step 3 052540 301r5 TRAVEL R Service Manual Carefree of Colorado 2 4 refer to Detail B For Awnings Fully Retracted NOTE This procedure will require replacing the front and rear motor covers in addition to the motor assembly 2 1 Place a large flat blade screwdriver or similar tool in the seam between the front and rear covers Using a tw
16. al lead to the other pins 6 Y Y N one at a time NO Test failed switch defective replace N no continuity Y continuity I 6 la pa 3 Retract 6 pue 3 Retract Note SB deu P Center 58 Spcm 28 Center Fhe ilustrations are labeled for identification purposes 4 o SH ERU e in the procedures above sa I I Travelr019 Test 2 is for Series III switches Use Test 1 for Series amp Il switches Observe continuity for switch in center position extend position and retract position Pin YES Test OK all checks pass go to step 2b 2 4 N no continuity Y continuity NO Test failed switch defective replace All other pins should be NO in all switch positions Pin Center Extend Retract YES Test OK all checks pass go to step 2c N no continuity Y continuity NO Test failed switch defective replace All other pins should be NO in all switch positions Pin Center Extend Retract YES Test OK all checks pass Revaluate problem cause is not electrical N no continuity Y continuity NO Test failed switch defective replace All other pins should be NO in all switch positions Retract Note Center Extend Series Ill Switch The Series III switch terminals are not labeled The illustration is labeled for identification purposes in the procedures above Travelr019a 11 TRAVEL R Service Manual Carefree of Colorado D03 ARM DOES
17. 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 16 052540 301r5 Carefree of Colorado PART NUMBER LIST PART NUMBER SERIAL NUMBER LOCATION Left Arm ING Service Manual Right Arm ARMS PART NUMBER CONFIGURATION Example Part Number OV JV 50 HW TRAVEL R Arm part and serial numbers are located on the inside of the lower arm channel Roll bar part and serial numbers are located on the roller tube and valance care label TravelR013 STYLE CODE COLOR ARM TYPE ARM CONFIGURATION CONTROLS OV JV 50 HW Travel r Black Flat Pitch AM OV Travel 25 White 50 Flat Pitch OEM OEM Standard Arms JV Black 53 Steep Pitch HW AM Standard Arms AP Adjustable All models use a Single Interior Switch Pitch AM Aftermarket or Upgrade uses extended mounting channel and top mounting bracket OEM Original Equipment Manufacturer Installation ROLLER PART NUMBER CONFIGURATION Example Part Number Q J 18 79 79 STYLE CODE SIZE CANOPY COLOR FABRIC WRAP TYPE COLOR QJ 18 79 79 Vinyl Roller Assy 18 Length Ocean Blue Vinyl Ocean Blue Cream Weatherguard QJ Vinyl or Polyweave 12 VINYL VINYL 13 Refer to Sales and Order Refer to Sales and Order Information for color QL Acrylic With Alumaguard Information for color availability and
18. d as required If not previously done spread open the awning rail track to facilitate inserting the new fabric Tip Lightly spraying the slots with a dry silicone lubricant will help the fabric slide into the slot without staining the material Unfold the replacement fabric then slide the new fabric into the awning rail Alumaguard Uniguard Center the fabric and install any fabric retaining screws removed previously Allow the fabric to hang down the side of the coach e For Alumaguard installations Use a pair of side cutters or similar tool and crimp the aluminum Use care to not bend or distort the aluminum slats NOTE While the awning fabric is fairly robust care must be taken not to snag it on the awning rail Position the fabric feeders on the roll bar Be sure to use the same slots as the old canopy Slide the rollbar on to the new fabric Center the fabric and install any fabric retaining screws removed previously Remove the feeders If removed install the upper mounting bracket Lift and align the roller assembly with the end cap on the motorized arm assembly Rotate the end cap until the slot in the cap aligns with the empty slot in the roller assembly and then press the roller assembly fully into the cap The end cap must seat squarely over the end of the roller assembly when complete NOTE The roller assembly must be oriented with the fabric going over the roller toward the coach wall Secure the end cap to the rol
19. erline of the awning rail Refer to 052540 002 Travel r Installation Manual and reposition arms as required 12 052540 301r5 Carefree of Colorado D04 Service Manual DIRECT RESPONSE AWNING DOES NOT AUTO RETRACT DURING WINDY CONDITIONS The auto retract system is only active when the power switch is in the ON position TRAVEL R D05 A Confirm awning operates normally using extend retract switch with power on the standard DIRECT RESPONSE STANDARD OPERATION YES Module is defective replace NO Go to Test D05 5 3 4 4 2 3 4 5 6 F Testwire continuity between motor and wire ends A Check Installation Integrity Use the wiring diagram and confirm that the components and wiring are properly installed and connected B Confirm Power Supply Is vehicle battery or power source providing 10V to 14V to the Power Switch C Test Motor Function 1 2 Remove the front cover of the motor head Disconnect the red and black wires from the module to the terminals inside the rear cover Attach jumper leads to the emergency terminals located on the back of the motor head Connect the other ends of the jumpers to a 12 18VDC power source i e drill battery It may be necessary to try then reverse the leads on the battery and try again Does the motor run D Test Power Switch 1 2 3 Disconnect wires from Power Switch Using a conti
20. ew motor assembly in the arm channel and attach using one each 5 16 18 x 1 1 2 bolt and nylock nut Attach the rear cover to the motor assembly using the large screws removed previously Attach the motor and cable wires to the terminals inside the rear cover 6 Align the roll bar with the end cap on the motorized arm assembly Rotate the end cap until the slot in the cap aligns with the empty slot in the roller assembly and then press the roller assembly fully into the cap The end cap must seat squarely over the end of the roller assembly when complete NOTE It may be necessary to close and hold the arm to align the end cap and roll bar Secure the end cap to the roller assembly using two 10 x 5 8 square drive screws Restore power and test operation If the awning moves in the wrong direction i e extends when retract is pushed reverse only the two motor wires in the rear cover Attach the front cover using the small screws removed previously 052540 301r5 Carefree of Colorado Service Manual TRAVEL R REPLACING THE GAS SHOCK NCAUTION THE GAS SHOCK HAS APPROXIMATELY 85 LBS OF PRESSURE IN THE CLOSED POSITION A PRESSURIZED SHOCK DO NOT ALLOW THE ROLL BAR TO DROP TOWARD THE GROUND THE TWISTING MOTION CAN CAUSE 10 11 12 13 14 15 CAN OPEN RAPIDLY WHEN REMOVED OR RELEASED AND CAUSE PERSONAL INJURY AND PROPERTY DAMAGE Open the awning NOTE The arm may not open completely when the shock has lost pre
21. isting and prying motion break the covers off It may be necessary to use a hammer and lightly tap the screwdriver into the plastic to establish a starting point Tip Start at the bottom and work around the seam until the covers are off 2 2 Disconnect the motor and cable wires from inside the rear cover Note the location of each wire 2 3 refer to Figure 6 Detail B Firmly hold the motor and idler arms up while removing the three 3 motor attach bolts and nuts 2 4 Remove the motor from the motor mounting frame NCAUTION THE ARMS ARE UNDER TENSION FROM THE GAS SHOCKS WHEN THE MOTOR IS DISENGAGED FROM THE GEARS THE ROLL BAR WILL BE ABLE TO FREE SPIN AND BOTH ARMS WILL EXTEND FROM THE GAS SHOCK TENSION USE EXTREME CARE AND HOLD THE ARMS IN POSITION IT WILL BE NECESSARY TO HAVE AT LEAST ONE OTHER PERSON HOLDING THE IDLER ARM 2 5 While holding on to the arms and roll bar allow the awning to extend to the maximum position the fabric will unroll from the roll bar 2 6 On the right hand arm remove any pieces of the front and rear covers Remove the cover s attaching screws and save 2 7 Goto step 3 Remove the two square drive screws attaching the end cap to the roll bar and separate the roll bar and end cap It will be necessary to hold the roll bar and motor arm Allow the arm to extend out Use a scaffold or similar device to support the roll bar NCAUTION DO NOT ALLOW THE ROLL BAR TO DROP TOWARD THE GROUND THE TWISTING MOTIO
22. l bar using two 10 square drive screws Repeat steps 17 and 18 to attach the idler arm assembly to the roll bar Visually check that the fabric is squarely mounted Adjust as required Roll the awning in and out several times to make sure that the fabric is square on the rollbar Secure the canopy to the awning rail using one 6 x 3 8 hex head screw at both sides of the awning 14 Awning Rain VERUS Awning MI Vasa Awning po B uS N Soft Connect TZ 6 x 3 8 ili 6 x 3 8 Screw Alumaguard Screw Uniguard Fabric i E0014 Figure 3 Securing the Fabric 21 1 For vinyl awnings place screw through awning rail polyrod and canopy approximately 1 in from the end of the fabric 21 2 For Uniguard awnings place screw through awning rail polyrod and the soft connect material approximately 1 in from the end of the fabric 21 3 For Alumaguard awnings place screw on the outer edge of the Alumaguard not through the Alumaguard For Alumaguard installations go to Installing the Tractioners on page 4 052540 301r5 3 TRAVEL R Service Manual Carefree of Colorado INSTALLING THE TRACTIONERS The tractioners are used with the alumaguard metal fabric wrap and recommended for vinyl fabrics with Uniguard Pa 1 4 Gap Place Screw Between Slots on Roller A Position Tractioner under View A A I Alumaguard Uniguard Alumaguard Uniguard 1 4 Ga
23. lifting or holding heavy objects e When using fasteners use care to not over tighten Soft materials such as fiberglass and aluminum can be stripped out and lose the ability to grip and hold Reference Publications located www carefreeofcolorado com 052540 002 Travel r Installation Manual 052540 201 Travel r Owner s Manual 052540 301 Travel r Service Manual Carefree of Colorado 2145 W 6 Avenue Broomfield CO 80020 a Scott Fetzer company 303 469 3324 www carefreeofcolorado com Carefree of Colorado Service Manual TRAVEL R PRODUCT OVERVIEW The Travelr provides motorized awning comfort with Carefree s standards for looks strength and dependability It is the successful blend of style quality and economy gt The unique scissor style arms provide maximum strength stability and ease of operation Worm gear style motor is billow proof eliminates the need for travel locks gt Available in 3 styles Fixed Flat Pitch Fixed Steep Pitch Adjustable Pitch For the fixed flat pitch and the adjustable set to the flat pitch the auto dump feature automatically releases to allow water to run off to prevent water pooling When the water is gone the arms return to the fully extended position The Adjustable Pitch Travel r has easy to use 6 position pitch adjustment The pitch can be left in any position and the awning will roll up completely When the awning is rolled back out it rolls out to the pitch setting previo
24. m Allow the motor arm to extend to its maximum position 1 6 If the awning is only partially extended hold onto the idler arm and allow it to extend while supporting and guiding the roll bar and allowing the fabric to unroll 1 7 Using a scaffold or similar device support the roll bar NCAUTION DO NOT ALLOW THE ROLL BAR TO DROP TOWARD THE GROUND THE TWISTING MOTION CAN CAUSE SERIOUS DAMAGE TO THE IDLER ARM 1 8 Remove the 5 16 18 screw and nut then remove the motor assembly from the arm channel 1 9 Goto step 3 052540 301r5 7 TRAVEL R Service Manual Carefree of Colorado 2 For Awnings Fully Retracted 2 1 While holding both arms and the rollbar remove the 5 16 18 screw Allow the motor arm to extend out and away from the motor assembly and rollbar 2 2 Tie the idler arm in the closed or partially open position 2 3 Using a scaffold or similar device support the roll bar 2 4 Rotate the rollbar and motor head around to access the cover screws on the back 2 5 Remove the front cover by removing the six 6 smaller screws from the back of the motor head Save cover and screws 2 6 Disconnect the motor and cable wires from inside the rear cover Note the location of each wire 2 7 Remove the rear cover by removing the two 2 large screws from the back of the motor head Save cover and screws 2 8 Remove the two square drive screws attaching the end cap to the roll bar and separate the roll bar and end cap Position the n
25. m should be unfolded and extended as far as possible Coat the threads of the barrel of the new shock with a non permanent thread lock i e loctite then screw the barrel into the clevis in the mounting channel Hand tighten only It will be necessary to grip and hold the shaft while turning the barrel Align the roll bar with the end cap on the arm assembly Rotate the end cap until the slot in the cap aligns with the empty slot in the roller assembly and then press the roller assembly fully into the cap The end cap must seat squarely over the end of the roller assembly when complete Secure the end cap to the roller assembly using two 10 x 5 8 square drive screws Partially retract the awning It may be necessary to lightly pull down on the lower arm at the mounting channel until the rollers are past the location of the stop bolts Always pull down from the bottom of the arm to avoid pinching Reinstall the stop bolts removed in step 2 052540 301r5 9 TRAVEL R Service Manual Carefree of Colorado DIAGNOSTICS TROUBLESHOOTING The following procedures are intended to aid the service technician to logically resolve operational issues with the mechanical and standard electronics installations Common Operational Items The following are operational items that may come up as questions during normal operation These are also given in the operator s manual 1 The motor has a thermal protection circuit If the motor overheats the circui
26. nuity tester place one lead on each terminal With the switch in the OFF position circuit should be open With the switch in the ON position circuit should be closed E Test the Extend Retract Switch 1 Using a continuity tester place one lead on center pin Place the second lead on bottom pin Put the switch in the center position and measure the continuity Circuit should be open Press the switch down Extend Circuit should be open Press the switch up Retract Circuit should be closed Move the second lead to the top pin Put the switch in the center position and measure Circuit should be open Press the switch down Extend Circuit should be closed Press the switch up Retract Circuit should be open 052540 301r5 YES Go to test B NO Correct as required YES Go to test C NO Correct as required YES Motor is good go to test D NO Motor is defective replace YES Switch is good go to test E NO Switch defective replace switch assy YES Switch is good go to test F NO Switch defective replace switch assy YES Wire continuity good module is defective replace NO Repair as required then reconnect the wires 13 TRAVEL R Service Manual Carefree of Colorado WIRING DIAGRAM SINGLE SwiTCH PRIOR TO JULY 2010 Series and Series Il switch hardware has been discontinued For wiring replacement switches use instructions provided with the Single Switch Kit Z
27. o test C confirm the wires to from the switch to the connector are NO Rewire the switch according to the correctly placed wiring diagram D02 THE AWNING DOES NOT EXTEND AND OR RETRACT A Check Installation Integrity YES Goto test B Use the wiring diagram and confirm that the components and NO Correct as required wiring are properly installed and connected B Confirm Power Supply YES Goto test B Is vehicle battery or power source providing 10V to 14V to the NO Correct as required Switch C Test Motor Function YES Motor is good go to test D 1 Forinstallations with an external plug Disconnect plug NO Motor is defective replace 2 Forinstallations with a single switch Remove switch plate and disconnect the motor wires from the switch 3 Attach jumper leads to the emergency terminals located on the back of the motor head 4 Connect the other ends of the jumpers to a 12 18VDC power source i e drill battery It may be necessary to try then reverse the leads on the battery and try again 5 Does the motor run D Test wire continuity between motor and wire ends YES Wire continuity good reconnect the wires disconnected in the previous test then go to test D NO Repair as required then reconnect the wires disconnected in the previous test D02 is continued on next page 10 052540 301r5 Carefree of Colorado D02 CONT E
28. p Place Screw Between Slots View A A on Roller Uniguard w Vinyl Fabric E0058 Figure 4 Installing the Tractioner 1 Partially extend the awning until the Alumaguard Uniguard is extended as shown 2 Unlock the keeper and wrap the tractioner around the roller tube 3 Position the tractioner under the Alumaguard Uniguard with a 1 4 gap between Alumaguard and tractioner Lock the keeper 4 Repeat for the other end of the rollbar 5 Extend the awning to verify that the tractioners are lifting the metal wrap up and over the roller assembly 6 To secure the tractioner drill a 1 8 hole through the tractioner and rollbar roughly center the hole between two slots of the rollbar 7 Secure with one 1 10 square drive screw 052540 301r5 Carefree of Colorado Service Manual MOTOR REPLACEMENT Before continuing it is necessary to determine which motor configuration is installed on the awning SERIES uses a bent sheet metal mounting frame SERIES Il uses a cast metal mounting frame The mounting and attachment of the two configurations are different To distinguish between the two look at the motor head The bent sheet metal frame Series has two protruding bumps in the front cover There are also two exposed rivets on each side of the arm channel The cover for the cast metal Series II is smooth and there are no rivets Protruding Bumps in Front Cover Configuration A Bent Sheetmetal Motor Mount Frame T
29. ssure or is removed It may be necessary to carefully pull the arm out and away from the vehicle to open the awning Remove the stop bolts and save 10 x 5 8 Screw qty 2 Remove the two square drive screws attaching the end cap to the roll bar and separate the roll bar and end cap It will be necessary to hold the roll bar and motor arm Allow the arm to extend out Use a scaffold or similar device to support the roll bar NCAUTION SERIOUS DAMAGE TO THE OTHER ARM Support the arm in the area shown in Figure 8 Unscrew the shock barrel from the clevis in the mounting channel Tip Wearing a pair of rubber gloves will aid in gripping the surfaces of the shock eS N Support and Lift in this area Travelr018 Figure 8 Replacing the Shock Unscrew the shaft from the clevis in the arm joint Set old shock aside NOTE It may be necessary to use vice grips or pliers on the old shock to unscrew the shock from the clevis DO NOT use vice grips or pliers on the new shock Damage to the surface of the shaft or damage to the barrel can cause the new shock to not work correctly Unpack the new shock and carefully allow it to extend to its maximum length Coat the threads of the shaft of the new shock with a non permanent thread lock i e loctite then screw the rod into the clevis of the arm elbow Hand tighten only Lift and hold the arm up in the area indicated in Figure 8 The ar
30. t will shut off the motor Wait approximately 15 minutes operation will return to normal As an example this may occur if the awning is fully closed and retract switch pushed repeatedly then the awning does not extend 2 The awning seems to extend and retract slowly The operational range is 28 35 seconds to extend or retract If the power supply is on the low side of the range 10V the awning will move slower 3 The awning may appear to move jerkily When the fabric is rolled out the Alumaguard or Uniguard may bounce creating a wave like motion in the canopy fabric This will create the appearance of moving jerkily 4 With Uniguard the awning sticks or hangs up When Uniguard is installed with a vinyl canopy the vinyl will have a tendency to cling to the Uniguard when not used over an extended period Open and close the awning in short bursts 2 or 3 times the awning will then open normally In the charts below YES is a positive response to the test NO is a negative response DO1 THE AWNING OPERATES IN REVERSE OF THE SWITCH PLATE This condition generally occurs during new installations or when major components have been replaced A Confirm Switch is mounted in correct position and correctly YES Switch mounted OK go to test B oriented NO Carefully remove the switch rotate 180 and reinstall in panel Reconnect harnesses and retest B Confirm switch is wired correctly Use the wiring diagram and YES Switch wired OK go t
31. tch Oo switch kits 052540 301r5 Fascia kit includes one fascia and screws Head cover kits include one front cover one rear cover and screws Series Il replacement motor and idler assemblies includes screw and nut Switch kit includes switch faceplates screws and connector Kit replaces all previous single 19 TRAVEL R Travel r Adjustable Pitch d DETAIL B Idler Head 20 Service Manual gt E 5 X XA N N 4 DETAIL A Motor Head Alumaguard Detail C Carefree of Colorado Uniguard TravelR503 052540 301r5 Carefree of Colorado Item Part Number Description Notes 1 R001642XXX 1 2 Set Hardware Arm Assy Motorized RH 1 2 R001643XXX 1 2 Set Hardware Arm Assy Idler LH 1 3 R001094XXX Top Mounting Bracket Used w Aftermarket Only 1 4 R019319XXX Quick Mount Bracket Kit includes 4 brackets and hardware 1 5a R019284 005 Fascia w external stop pin White qty 2 4 R019284 006 Fascia w external stop pin Black qty 2 4 5b RO19678 005 Fascia w o stop White qty 2 4 R019678 006 Fascia w o stop Black qty 2 4 6 R001252 Gas Shock 7 R001576 Shock Hardware Kit 8 R001326XXX Kit Motor Assy 1 9 R001328XXX Kit Motor Cover 1 10 R060414 006 Cable Motor 11 R001327XXX Kit Idler Assy 1 2 12 R0O01329XXX Kit Idler Co
32. usly set Canbeinstalled using a single switch control or with the Direct Response electronic system Specifications LENGTH 12 21 366 640cm EXTENSION 8 244cm Drop Flat Pitch 12 30 5cm Drop Steep Pitch 36 91cm Values are approximate actual dimensions may vary with specific installations EXTENSION TIME 28 Seconds approx RETRACT TIME 32 Seconds approx POWER REQUIREMENTS 12VDC operating range 10VDC to 14VDC Circuit Rating 15 amp POWER SOURCE Motor and controls are routed and hardwired into the vehicle s 12V system EMERGENCY RETRACT Electrical override system external power source COLOR Hardware White or Black Fabric Vinyl Polyweave or Acrylic Fabric with Alumaguard or Uniguard Fabric Wrap Weatherguard vinyl or Metal Wraps Alumaguard or Uniguard OPTIONS Direct Response Electronic Package available as an upgrade kit Available as a complete awning or as an upgrade to existing Carefree or A amp E awnings with an 8 extension If upgrading an A amp E with a steel roller tube it is also necessary to replace the roller tube with a Carefree aluminum roller tube An optional Rail Extension Kit available for Mesa amp Yoder sidewalls 5 H Fabric Width
33. ver 1 2 13 19xx00 Roller Tube 3 slot 3 1 2 Dia 14 Canopy Refer to Canopy Order Form 15 20xx36XXX Alumaguard Assembly Only 1 16 RO01246XXX xxx Uniguard includes 4 25 soft connect 1 R001246XXX xxxT Uniguard includes 5 25 soft connect 1 17 R001247XXX xxx Soft Connect 4 25 Wide 1 R001247XXX xxxT Soft Connect 5 25 Wide 1 18 901067 Tractioner set of two 19 R001605 Switch Kit 3 20 R014634 025 Extension Kit White The following parts are not shown 21 R014492 251 Hardware Pack w Top Bracket White 22 R014492 JV1 Hardware Pack w Top Bracket Black 23 R001167 Replacement Roller Kit Notes 1 XXX Color xxx Length in inches Service Manual 2 Head cover kits include one front cover one rear cover and screws 3 Switch kit includes switch faceplates screws and connector Kit replaces all previous single switch kits 4 Fascia kits include two fascia plates and screws 12 Volt Direct Response Auto Retract System R060686 001 R019468 006 R060688 006 c J ma J ge Sensor Control Module Switch Kit Cable Description TRAVEL R Notes 1 A Travel r upgrade kit SR0093 is available and contains items 1 thru 3 and attaching hardware 2 The following options are NOT available with this system Remote Control Ignition Lockout 052540 301r5 21 TRAVEL R Service

SERVICE MANUAL TRAVEL R - E

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