Table of Contents
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RV
NOTE:
The Travel'r Fixed Flat Pitch
2012. This product is no longer available
for new product installation. References
in this manual to the Fixed Flat Pitch are
for service only.
T
C
ABLE OF
ONTENTS
Specifications ................................................................................................................................ 3
Canopy Replacement .................................................................................................................... 1
Installing the Tractioners .........................................................................................................................
Motor Replacement ....................................................................................................................... 5
Replacing the Motor - Series I ...............................................................................................................
Replacing the Motor - Series II ..............................................................................................................
Replacing the Gas Shock ............................................................................................................. 9
Diagnostics/Troubleshooting ..................................................................................................... 10
Wiring Diagram - Single Switch Prior to July 2010 ...............................................................................
Wiring Diagram - Single Switch - July 2010 and on ..............................................................................
Wiring Diagram - Travel'r LCDR Direct Response................................................................................
Wiring Diagram - Direct Response .......................................................................................................
LED Lighting ................................................................................................................................ 16
Switch Installation .................................................................................................................................
Replacing the LED Strip .......................................................................................................................
Canopy Harness Replacement .............................................................................................................
Attaching the Harness to Fabric Wrap ..................................................................................................
Standard Maintenance ................................................................................................................ 20
Fabric Care ...........................................................................................................................................
Arm Care ..............................................................................................................................................
Manual Override ...................................................................................................................................
Override With Emergency Terminals ................................................................................................
Override Without Emergency Terminals ...........................................................................................
Programming the Remote Receiver .....................................................................................................
Part Number Listing .................................................................................................................... 23
Part Number/Serial Number Location ...................................................................................................
Arms Part Number Configuration ..........................................................................................................
Roller Part Number Configuration .........................................................................................................
Illustrated Parts List ..............................................................................................................................
Travel'r, Fixed Pitch...........................................................................................................................
Travel'r, Adjustable Pitch...................................................................................................................
Optional Electronics ..........................................................................................................................
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VAILABLE IN
IXED
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ERVICE
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OTORIZED
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DJUSTABLE
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ANUAL
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ATIO
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ITCH
ODELS
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Table of Contents
Related Manuals for Carefree TRAVEL'RFIXED PITCH
Summary of Contents for Carefree TRAVEL'RFIXED PITCH
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Page 1: Table Of Contents
ERVICE ANUAL RAVEL OTORIZED ATIO WNING VAILABLE IN IXED ITCH AND DJUSTABLE ITCH ODELS NOTE: The Travel'r Fixed Flat Pitch Awning has been discontinued as of 08- 2012. This product is no longer available for new product installation. References in this manual to the Fixed Flat Pitch are for service only. -
Page 2: Awning Has Been Discontinued As Of
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. -
Page 3: Specifications
Direct Response Electronic Package available as an upgrade kit Available as a complete awning or as an upgrade to existing Carefree or A&E awnings with an 8’ extension. If upgrading an A&E with a steel roller tube it is also necessary to replace the roller tube with a Carefree aluminum roller tube. -
Page 4: Canopy Replacement
Carefree of Colorado Service Manual RAVEL ANOPY EPLACEMENT Split Grommet 1. Remove the canopy retaining screws in the awning rail. 2. Extend the awning out completely. 3. For awnings with LEDs in the roller tube: 3.1. On the motor side, remove the split grommet from the roller Canopy Harness tube. - Page 5 Service Manual Carefree of Colorado RAVEL 12. Clean and deburr the roller tube slots and awning rail/Alumaguard/Uniguard 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.
- Page 6 Carefree of Colorado Service Manual RAVEL 21. Check that the fabric is properly positioned. Adjust as required. 21.1. For vinyl canopies: Center the fabric on the roller tube. install the fabric retaining screws removed previously. 21.2. For acrylic canopies: The canopy is flared (tapered) only on the motor side. The canopy is centered in the roller tube.
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Page 7: Installing The Tractioners
Service Manual Carefree of Colorado RAVEL 24. For awnings with LEDs in the roller tube: 24.1. Connect the canopy harness connector and LED connector. Then carefully push the connectors into the roller tube. 24.2. Place the split grommet over the canopy harness and press the grommet into the hole of the roller tube. -
Page 8: Motor Replacement
Carefree of Colorado Service Manual RAVEL OTOR EPLACEMENT STOP! Before continuing, it is necessary to determine which motor configuration is installed on the awning. I uses a bent sheet metal ERIES mounting frame. II uses a cast metal ERIES mounting frame. The mounting and attachment of the two configurations are different. - Page 9 Service Manual Carefree of Colorado RAVEL 2. (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.
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Page 10: Replacing The Motor - Series Ii
Carefree of Colorado Service Manual RAVEL – S EPLACING THE OTOR ERIES CAUTION The arms are under tension from the gas shocks. When the motor and/or roller tube is disengaged from the arm, the roller tube will be free to spin; both arms will extend from the gas shock tension. - Page 11 Service Manual Carefree of Colorado RAVEL 2. For Awnings Fully Retracted: 2.1 While holding both arms and the roller tube, remove the 5/16-18 screw. Allow the motor arm to extend out and away from the motor assembly and roller tube.
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Page 12: Replacing The Gas Shock
Carefree of Colorado Service Manual RAVEL EPLACING THE HOCK CAUTION The gas shock has approximately 85 lbs of pressure in the closed position. A pressurized shock can open rapidly when removed or released and cause personal injury and property damage. -
Page 13: Diagnostics/Troubleshooting
Service Manual Carefree of Colorado RAVEL IAGNOSTICS ROUBLESHOOTING 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. - Page 14 Carefree of Colorado Service Manual RAVEL D02 ( CONT 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"...
- Page 15 Service Manual Carefree of Colorado RAVEL XTEND OR XTEND OMPLETELY Visually confirm motor is working when control switch is pressed. Go to test B Go to test D02 – Awning Does Not Extend and/or Retract – page 10. Confirm that the arm channels, pivot points and contact points are Go to test C clean and clear of obstructions.
- Page 16 Carefree of Colorado Service Manual RAVEL IRECT ESPONSE WNING ETRACT URING INDY ONDITIONS The auto - retract system is only active when the power switch is in the ON position. Confirm awning operates normally using the standard Module is defective - replace extend/retract switch with power on.
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Page 17: Wiring Diagram - Single Switch Prior To July 2010
Service Manual Carefree of Colorado RAVEL 2010 IRING IAGRAM INGLE WITCH RIOR TO Series I and Series II switch hardware has been discontinued. For wiring replacement switches, use instructions provided with the Single Switch Kit. Motor Wires Motor Wires +12VDC... -
Page 18: Wiring Diagram - Direct Response
Carefree of Colorado Service Manual RAVEL IRING IAGRAM IRECT ESPONSE Ignition Switched +12VDC Ignition Version_______ Lockout 12VDC Sensor Ground (Optional) Splitter Extend/ Motion Retract On/Off Black Blue Control Carefree of Colorado Carefree of Colorado 12V DIRECT RESPONSE 12V DIRECT RESPONSE... -
Page 19: Led Lighting
Service Manual Carefree of Colorado RAVEL LED L IGHTING WITCH NSTALLATION 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. -
Page 20: Replacing The Led Strip
Carefree of Colorado Service Manual RAVEL LED S EPLACING THE TRIP 1. Extend the awning out completely. Clamp the Canopy 2. Disconnect power. Harness in this locaion 3. Use a non-permanent marker to mark the location of the ends of the LED strip. -
Page 21: Canopy Harness Replacement
Service Manual Carefree of Colorado RAVEL ANOPY ARNESS EPLACEMENT NOTE: Acrylic canopies uses a soft rivet in the hem next to the metal wrap to hold the harness in place. Dual tapered canopies do not use the rivet. If replacing a harness in a tapered canopy, skip steps 6 and 11.1. -
Page 22: Attaching The Harness To Fabric Wrap
3.2. For Uniguard: Tape the harness to the inside surface using a 2" x 8" piece of Velcro (loop). 3.3. For FLXguard: Position the harness approximately 3/8" from the edge of the material. Attach using a 1" x 6" piece of clear tape (the tape is a special bond tape available from Carefree). 052540-301r10... -
Page 23: Standard Maintenance
Service Manual Carefree of Colorado RAVEL TANDARD AINTENANCE Maintaining the Carefree Manual Patio Awning is easy. Just follow these basic steps: Always operate the awning according to the instructions. Periodically check that the fasteners are tight. Tighten if necessary. -
Page 24: Manual Override
Carefree of Colorado Service Manual RAVEL ANUAL VERRIDE If the original power source fails or is unavailable, the Travel'r has emergency override terminals (12V). The terminals can be used with a 10V-14V power source, such as a cordless drill battery or car battery. -
Page 25: Programming The Remote Receiver
Service Manual Carefree of Colorado RAVEL ROGRAMMING THE EMOTE ECEIVER Remotes are available with the factory installed Direct Response system. Remotes are not available for the Direct Response LCDR upgrade system. When adding or replacing a remote control, it is necessary to program the transmitter and receiver. -
Page 26: Part Number Listing
Carefree of Colorado Service Manual RAVEL UMBER ISTING UMBER ERIAL UMBER OCATION 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. -
Page 27: Illustrated Parts List
Service Manual Carefree of Colorado RAVEL LLUSTRATED ARTS Travel'r, Fixed Pitch Series I Series II Series I Series II DETAIL DETAIL (Idler Head) (Motor Head) Alumaguard Uniguard Detail RE TR AC T EX TE ND Ca re fre e of Co... - Page 28 Carefree of Colorado Service Manual RAVEL Item Part Number Description Notes 1/2 Set Hardware, Arm Assy, Motorized, RH Flat Pitch 1,2,7 R001507XXX 1/2 Set Hardware, Arm Assy, Motorized, RH Steep Pitch 1/2 Set Hardware, Arm Assy, Idler, LH Flat Pitch...
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Page 29: Travel'r, Adjustable Pitch
Service Manual Carefree of Colorado RAVEL Travel'r, Adjustable Pitch Alumaguard Uniguard DETAIL DETAIL (Motor Head) (Idler Head) Detail RE TR AC T EX TE ND Ca re fre e of Co lo ra do TravelR503a 052540-301r10... - Page 30 Carefree of Colorado Service Manual RAVEL Item Part Number Description Notes R001642XXX 1/2 Set Hardware, Arm Assy, Motorized, RH R001643XXX 1/2 Set Hardware, Arm Assy, Idler, LH R001094XXX Top Mounting Bracket Used w/ Aftermarket Only SG0014 Quick Mount Bracket Kit (includes 4 brackets and hardware)
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Page 31: Optional Electronics
Service Manual Carefree of Colorado RAVEL Optional Electronics Optional Upgrade LCDR Direct Response RE TR AC T OF F EX TE Aw ni ng Co nt ro Factory Installed Direct Response (OEM) Remote (see notes) Carefree of Colorado 12V DIRECT RESPONSE... - Page 32 Manufacturers (OEM's) may alter or change the placement, style and/or functional configuration of the switches. If your controls do not match the style or description included, contact the coach manufacturer for an accurate description. OEM furnished components are not covered by the Carefree warranty.
- Page 33 Carefree of Colorado NTRODUCTION From it's beginning in the early 70's, Carefree of Colorado has emerged as the premier manufacturer of quality awnings and accessories for Recreational Vehicles (RVs). Our full line of products can provide the accessories that match your life style;...
- Page 34 RAVEL ATIO WNING PERATION TANDARD WITCH PERATION Press to Retract To Operate the Awning: Press and hold the Patio Switch until the awning is in the desired position then release the switch. Press to Extend TravelR041 IRECT ESPONSE PERATION The optional Travel'r Direct Response system detects awning motion caused by windy conditions.
- Page 35 Carefree of Colorado DJUSTING THE ITCH DJUSTABLE ITCH WNING The Travel'r arms have 6 pitch adjustment settings from minimum pitch to maximum pitch. The awning can be extended and retracted in any of these positions without having to reset the pitch between uses. See the Warnings about unequal pitch settings.
- Page 36 RAVEL ATIO WNING MERGENCY PERATION If the original power source fails or is unavailable, the Travel'r has emergency override connections (12V). The override can be used with a 10V-14V power source, such as a cordless drill battery or car battery. Travel'r models built through 2012 have override terminals on the back of the motor head.
- Page 37 Carefree of Colorado VERRIDE ITHOUT MERGENCY ERMINALS This procedure does not apply if Direct Response is installed. Locate and separate the quick disconnects Hold Wires Outside of Channel located in the motor arm channel. Position When Arm is Closing the wires from the motor on the outside of the channel.
- Page 38 RAVEL ATIO WNING WNING Maintaining a Carefree Awning is easy. Just follow these basic steps: Always operate the awning according to the instructions. Periodically check that the fasteners are tight. Tighten if necessary. Keep the awning fabric and arms clean.
- Page 39 WNER ANUAL RAVEL 12V M OTORIZED WNING WITH IRECT ESPONSE Before operating the awning, carefully review the Owner's Manual. The manual contains important safety information, detailed operating instructions, common maintenance procedures and other useful information. The Adjustable Pitch Travel'r with Direct Response is only offered through select OEMs.
- Page 40 Vehicles (RVs). Our full line of products can provide the accessories that match your life style; no matter what type of RV you own. Check with your dealer to discover the products that can make your life more Carefree. The Travel'r awning provides motorized awning comfort with Carefree's standards for looks, strength and dependability.
- Page 41 WARNING The Carefree Direct Response System is a premier electronic auto-retract system that provides protection against adverse elements; but no auto-retract system is a guarantee against severe or destructive weather; the effects of wind and rain on an awning are unpredictable and may cause severe damage to the awning and/or vehicle.
- Page 42 Carefree of Colorado PERATION The Direct Response system uses 3 switches at the control panel. Power Switch; Patio Switch and Motion Sensitivity Switch. Press to Retract Motion Sensitivity Power Power Press to Extend DR039 OWER WITCH ON ..... The up position activates the Patio switch and the Auto-Retract OWER system and provides power to the awning.
- Page 43 Gently move the roller tube up and down in a vertical motion. If the awning retracts, the system is working properly. If the awning does not retract, contact an authorized Carefree dealer for repairs. Operate the awning with the Patio switch until the system is repaired.
- Page 44 Carefree of Colorado ROGRAMMING THE EMOTE ECEIVER When adding or replacing a remote control, it is necessary to program the transmitter and receiver. Stop Indicator Program Light Button DR020 Power to the control box must be on. Press and release the “Press to Learn Transmitter” button on the bottom of the receiver box.
- Page 45 RAVEL ATIO WNING DJUSTING THE ITCH The Travel'r arms have 6 pitch adjustment settings from minimum pitch to maximum pitch. The awning can be extended and retracted in any of these positions without having to reset the pitch between uses. See the Warnings about unequal pitch settings. Awning Open Awning Closed Outer...
- Page 46 Carefree of Colorado MERGENCY PERATION If the original power source fails or is unavailable, the Travel'r has emergency override connections (12V). The override can be used with a 10V-14V power source, such as a cordless drill battery or car battery.
- Page 47 Open and close the awning in short bursts 2 or 3 times, the awning will then open normally. Ignition Lockout Sensors: If the optional Carefree EL ignition lockout is installed the system will disable the extend function while the vehicle ignition key is in the ON position.
- Page 48 Carefree of Colorado WNING Maintaining a Carefree Awning is easy. Just follow these basic steps: Always operate the awning according to the instructions. Periodically check that the fasteners are tight. Tighten if necessary. Keep the awning fabric and arms clean.