Carefree TRAVEL'RFIXED PITCH Service Manual page 9

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RAVEL R
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.
Using a twisting 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 2, 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.
CAUTION
disengaged from the gears, the roller tube 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 roller tube, allow the awning to extend to the maximum position;
the fabric will unroll from the roller tube.
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 Go to step 3.
3. Remove the two square drive screws attaching the end cap to the roller tube and separate the roller
tube and end cap. It will be necessary to hold the roller tube and motor arm. Allow the arm to extend
out.
4. Use a scaffold or similar device to support the roller tube.
CAUTION
Do not allow the roller tube to drop toward the ground. The twisting motion can
cause serious damage to the idler arm.
5. 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.
6. Remove the motor assembly. The motor assembly consists of the motor, mounting frame, gears, shaft
and roller end cap.
7. Place the new motor assembly in position over the mounting bolt. Ensure that the spacer-washers are
all accounted for.
8. 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.
9. 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 roller tube 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 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.
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Service Manual
The arms are under tension from the gas shocks. When the motor is
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