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Carefree TRAVEL'R ADJUSTABLE PITCH, Service Manual, Page: 1 / 48

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Carefree TRAVEL'R ADJUSTABLE PITCH Service Manual Download Page 1

S

ERVICE 

M

ANUAL

 

T

RAVEL

'

R

M

OTORIZED 

P

ATIO 

A

WNING

 

A

VAILABLE IN 

F

IXED 

P

ITCH AND 

A

DJUSTABLE 

P

ITCH 

M

ODELS

RV

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. 

T

ABLE OF 

C

ONTENTS

 

Specifications ................................................................................................................................ 3

 

Canopy Replacement .................................................................................................................... 1

 

Installing the Tractioners ......................................................................................................................... 4

 

Motor Replacement ....................................................................................................................... 5

 

Replacing the Motor – Series I ............................................................................................................... 5

 

Replacing the Motor – Series II .............................................................................................................. 7

 

Replacing the Gas Shock ............................................................................................................. 9

 

Diagnostics/Troubleshooting ..................................................................................................... 10

 

Wiring Diagram - Single Switch Prior to July 2010 ............................................................................... 14

 

Wiring Diagram - Single Switch - July 2010 and on .............................................................................. 14

 

Wiring Diagram - Travel'r LCDR Direct Response................................................................................ 14

 

Wiring Diagram - Direct Response ....................................................................................................... 15

 

LED Lighting ................................................................................................................................ 16

 

Switch Installation ................................................................................................................................. 16

 

Replacing the LED Strip ....................................................................................................................... 17

 

Canopy Harness Replacement ............................................................................................................. 18

 

Attaching the Harness to Fabric Wrap .................................................................................................. 19

 

Standard Maintenance ................................................................................................................ 20

 

Fabric Care ........................................................................................................................................... 20

 

Arm Care .............................................................................................................................................. 20

 

Manual Override ................................................................................................................................... 21

 

Override With Emergency Terminals ................................................................................................ 21

 

Override Without Emergency Terminals ........................................................................................... 21

 

Programming the Remote Receiver ..................................................................................................... 22

 

Part Number Listing .................................................................................................................... 23

 

Part Number/Serial Number Location ................................................................................................... 23

 

Arms Part Number Configuration .......................................................................................................... 23

 

Roller Part Number Configuration ......................................................................................................... 23

 

Illustrated Parts List .............................................................................................................................. 24

 

Travel'r, Fixed Pitch........................................................................................................................... 24

 

Travel'r, Adjustable Pitch................................................................................................................... 26

 

Optional Electronics .......................................................................................................................... 28

 

Summary of Contents for TRAVEL'R ADJUSTABLE PITCH

Page 1: ...g 10 Wiring Diagram Single Switch Prior to July 2010 14 Wiring Diagram Single Switch July 2010 and on 14 Wiring Diagram Travel r LCDR Direct Response 14 Wiring Diagram Direct Response 15 LED Lighting 16 Switch Installation 16 Replacing the LED Strip 17 Canopy Harness Replacement 18 Attaching the Harness to Fabric Wrap 19 Standard Maintenance 20 Fabric Care 20 Arm Care 20 Manual Override 21 Overrid...

Page 2: ... Pitch 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 For the fixed flat pitch and adjustable model set to the flat pitch the auto dump automatically releases to allow water to run off to prevent water pooling When the water is gone ...

Page 3: ...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 overr...

Page 4: ...ic retaining screws in the roller tube and tractioners used with Alumaguard Slide the roller tube off the fabric 9 Determine the type of canopy replacement 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 scaffoldi...

Page 5: ...lush on the top and bottom 13 2 3 Slide the canopy and rail adaptor into the awning rail Center the fabric and install any fabric retaining screws removed previously NOTE While the awning fabric is fairly robust care must be taken not to snag it on the awning rail 14 If removed install the upper mounting bracket 15 Position the fabric feeders on the roller tube Be sure to use the same slots as the...

Page 6: ...umaguard Uniguard Roller Tube Valance Canopy 2 5 2 5 Awning Rail Roller Tube Valance Canopy 1 5 Awning Rail LH Canopy Edge Parallel w Centerline of Arm Valance Canopy 2 3 Roller Tube Awning Rail Alumaguard 5 Uniguard 1 5 Alumaguard Uniguard LH Canopy Edge Parallel w Centerline of Arm 22 Roll the awning in and out several times to make sure that the fabric rolls squarely on the roller tube 23 Secur...

Page 7: ...a quality silicone sealant NOTE Be sure to allow enough harness from the canopy to provide a 3 loop of harness and adequate length for the connectors to be pushed inside the wall before sealing the hole and harness with a quality silicone sealant 25 For canopies with LEDs at the awning rail Connect the LED strip to the harness for white LEDS or to the controller for RGB applications For Alumaguard...

Page 8: ... 8 16 x 6 Bolt Front Cover Rear Cover 3 8 16 Lock Nut Travelr015 Motor End Cap 10 x 5 8 Screw DETAIL D DETAIL A Motor Red Wire Cable Red Wire Motor Black Wire Cable Black Wire DETAIL C Motor ref Motor Attach Bolts Nuts Rear Cover ref Front Cover ref DETAIL B Motor Assembly W Bent Metal Frame Figure 2 Motor Replacement Series I 1 refer to Detail A For Awnings Fully or Partially Extended 1 1 On the ...

Page 9: ...otor 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 Whe...

Page 10: ...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 rolle...

Page 11: ...end cap to the roller tube and separate the roller tube and end cap 3 Position the new motor assembly in the arm channel and attach using one each 5 16 18 x 1 1 2 bolt and nylock nut 4 Attach the rear cover to the motor assembly using the large screws removed previously 5 Attach the motor and cable wires to the terminals inside the rear cover 6 Align the roller tube with the end cap on the motoriz...

Page 12: ...ew shock Damage to the surface of the shaft or damage to the barrel can cause the new shock to not work correctly 8 Unpack the new shock and carefully allow it to extend to its maximum length 9 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 10 Lift and hold the arm up in the area indi...

Page 13: ...TES 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 oriented YES Switch mounted OK go to test B 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...

Page 14: ...bove Series I Switch Retract Extend Center 6 5B 4 3 2B 1 Series II Switch Retract Extend Center 6 5B 3 2B Test 2 is for Series III switches Use Test 1 for Series I II switches Observe continuity for switch in center position extend position and retract position 2a Place one lead of tester on 12V pin 3 Touch 2nd lead to the other pins one at a time Pin Center Extend Retract YES Test OK all checks p...

Page 15: ...test D 1 Open the awning If the awning arm does not extend carefully pull the arm out as the fabric is unrolling 2 Does the fabric sag when the awning is extended 3 Inspect the shock Is there evidence of dirt build up and oil leaks on the rod 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 ...

Page 16: ... It may be necessary to try then reverse the leads on the battery and try again 5 Does the motor run YES Motor is good go to test D NO Motor is defective replace D Test Power Switch 1 Disconnect wires from Power Switch 2 Using a continuity tester place one lead on each terminal 3 With the switch in the OFF position circuit should be open 4 With the switch in the ON position circuit should be close...

Page 17: ...Ground To 12VDC BLACK Motor Wire RED Motor Wire RED BLACK WHITE BLUE 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 WIRING DIAGRAM TRAVEL R LCDR DIRECT...

Page 18: ...tion Switched 12VDC 12VDC Ground Splitter 2 1 Ignition Lockout Sensor Optional On Off Black Red Blue Gray Brown Yellow Black Black Red Black Additional Extend Retract Switch Brown Gray Yellow Ext Ret Com Motion Extend Retract TO EYE PORT on RP24 Program Mode Press to Learn Transmitter UP RR Version_______ Yellow White White Yellow Red Black M 1 Splitter is used only when the optional Lock Out Sens...

Page 19: ...ind the switch 4 Install the in line fuse 4 1 Near the switch cut the red 12VDC power line to the switch Do not strip the insulation 4 2 Insert a wire end into one of the wire channels until it butts up against the stop 4 3 Fold that half of the connector body over until the element contacts the wire Use pliers to crimp the connector closed 4 4 Repeat for the second wire end 4 5 Slide the fuse int...

Page 20: ...ole that is located behind the slot cover location Disconnect the connectors 7 Remove the existing LED strip 8 Clean the slot to remove any dirt and tape residue 9 Starting at the reference mark made previously remove the release paper from the back of the new strip and press the strip into the LED slot 10 At the end of the roller tube cut the LED strip to match the mark made previously To trim th...

Page 21: ...pull the new harness through the hem of the canopy 10 After the new harness has been routed in the canopy hem 10 1 Connect the canopy harness connector and LED connector Then carefully push the connectors into the roller tube 10 2 Place the split grommet over the canopy harness and press the grommet into the hole of the roller tube 11 At the vehicle wall 11 1 For acrylic canopies only Attach the n...

Page 22: ...to access the inside surface of the wrap 2 Clean the inside surface of the wrap 2 x 8 Velcro Loop 1 x 2 Velcro Loop ALUMAGUARD UNIGUARD LED008 FLXguard 1 x 6 Clear Tape Position Wire 3 8 From Edge 3 Attach the harness to the inside surface 3 1 For Alumaguard Use 1 by 2 pieces of Velcro loop taping the harness on each slat between the joints 3 2 For Uniguard Tape the harness to the inside surface u...

Page 23: ...re 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 ...

Page 24: ...d reattach the front cover 4 Detail C Attach the provided jumper leads to the terminals located on the rear of the motorized head 5 Connect the other ends of the jumper leads to a 12V source If the awning does not begin to move reverse the leads 6 Maintain contact throughout the retraction process CAUTION Be careful when retracting the awning as the awning may move abruptly Override Without Emerge...

Page 25: ...se retract function If a function button is pressed to train the receiver it will be programmed as the retract button Example Pressing the top button will program the top button for retract and the bottom button as extend Operational Notes Transmitter and receiver operate on frequency 433 MHz The receiver exits the program mode after ten seconds If the light does not come on the memory is full and...

Page 26: ...r Upgrade uses extended mounting channel and top mounting bracket OEM Original Equipment Manufacturer Installation ROLLER PART NUMBER CONFIGURATION Example Part Number Q J 1 8 7 9 0 0 STYLE CODE SIZE CANOPY COLOR FABRIC WRAP TYPE COLOR QJ 18 79 00 Vinyl Roller Assy 18 Length Ocean Blue Vinyl White Vinyl QJ Vinyl or Polyweave QL Acrylic With Alumaguard Ltd QK Vinyl or Polyweave With Alumaguard OU A...

Page 27: ...TRATED PARTS LIST Travel r Fixed Pitch TravelR502a 6 5 1 2 DETAIL A Motor Head Series I Series II DETAIL B Idler Head Series I Series II 6 B 10 11 18 8 9 12 15 14 9 17 16 24 13 25 Detail C Alumaguard 20 21 22 Uniguard 23 7 3 4 RETRACT EXTEND Carefree of Colorado 19 A 5 ...

Page 28: ...ies I 1 4 16 R001327XXX Kit Idler Assy Series II 1 5 17 R001329XXX Kit Idler Cover Series II 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 ...

Page 29: ... Colorado 26 052540 301r10 Travel r Adjustable Pitch TravelR503a 6 1 DETAIL A Motor Head DETAIL B Idler Head A B 13 9 12 11 14 2 8 6 3 10 Detail C Alumaguard 15 16 17 Uniguard 18 20 7 19 4 5a 5b RETRACT EXTEND Carefree of Colorado 5a 5b ...

Page 30: ...D 3 1 2 Dia 19xx00RB Roller Tube 4 Slot w White LED 3 1 2 Dia 14 Canopy Refer to Canopy Order Form 15 20xx36XXX Alumaguard Assembly Only 1 16 R001246XXX 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 R001008 O Ring Tractioner Retainer ...

Page 31: ...1 Splitter Used with Ignition Lockout 12 SR0095 Sensor Test Tool Direct Response 13 R060429 002 RF Remote Receiver 433 MHz Version 5 Direct Response 2 14 R060622 001 Key FOB Remote 433 MHZ Version 5 Direct Response 2 15 R001714 LED Strip White Short Lead Used with 18 or shorter 4 R001715 LED Strip White Long Lead Used with 19 and longer 4 16 R060733 001 LED Strip RGB Short Lead Used with 18 or sho...

Page 32: ...D STEEP PITCH AWNING AND TRAVEL R ADJUSTABLE PITCH AWNING Special Note This manual provides a basic description of the product and the standard operating controls provided by Carefree of Colorado Some Original Equipment 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 ...

Page 33: ...s are made from light weight no rust aluminum The 100 billow proof worm gear drive motor eliminates the need for travel locks Can be installed using a single switch control or the Direct ResponseTM system Highest head clearance of any vertical arm awning WARNING Awnings are designed to provide shade and protection from the sun The effects of wind and rain on an awning are unpredictable and can cau...

Page 34: ... to Extend ON OFF Press Release to Retract LCDR005 To Operate the Awning Press the power switch to ON When power is on the Direct Response system is active and the manual controls are active When power is OFF all functions are disabled CAUTION It is strongly recommended that the power switch be set to OFF whenever the awning is not being operated and during transport This acts as a safety to preve...

Page 35: ... the pitch adjustment pin located on the long scissor arm Tip Applying LIGHT pressure on the arm will decrease the force required to press the pitch adjustment pins 3 Slide the scissor arm to the desired set hole towards the coach for a lower pitch and away from the coach for a higher pitch With the Awning Closed 1 Press in the pitch adjustment pin located on the long scissor arm 2 Slide the inner...

Page 36: ...or Cables with Quick Disconnects Cables with Quick Disconnects for Motor Cables with Quick Disconnects Only TravelR061b OVERRIDE WITH EMERGENCY TERMINALS CAUTION Do not use the emergency terminals without following the directions below The electronic circuit creates a dynamic brake for the motor by shorting and grounding the motor leads Steps 1 2 removes the brake to allow the emergency override t...

Page 37: ...on 1 The awning motor is equipped with a thermal protection circuit to protect the motor from overheating Operating the awning repeatedly over a short time period may cause the circuit to sense a overheat condition and shut off the motor If this occurs wait approximately 15 minutes to allow the motor to cool then operate the awning in normal fashion 2 The awning seems to extend and retract slowly ...

Page 38: ...abrics 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 require the material to be washed more frequently POOLING When water collects on the top of the fabric this is known as pooling This can occur during inclement weather or if a runn...

Page 39: ...rating 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: ...tube and arms are made from light weight no rust aluminum The 100 billow proof worm gear drive motor eliminates the need for travel locks The Carefree Direct ResponseTM electronic system Highest head clearance of any vertical arm awning WARNING Awnings are designed to provide shade and protection from the sun The effects of wind and rain on an awning are unpredictable and can cause severe damage t...

Page 41: ...ct the awning The pushbutton controls allow the user to choose between 3 factory preset sensitivity values threshold values Gust detection is incorporated into the Direct Response software When the motion value is suddenly and sharply increased above a safe maximum value then the 2 second persistence measure is overridden and the awning closes immediately WARNING The Carefree Direct Response Syste...

Page 42: ...wo position momentary contact switch This description also applies to any additional patio switches that may be installed EXTEND Press and release the switch The awning automatically opens To stop the awning before it is fully open press and release the extend switch a second time RETRACT Press and release the switch The awning automatically retracts until it is fully closed To stop the awning bef...

Page 43: ...convenient location The remote has a maximum operating range of 50 feet Actual distance may vary depending on the specific installation and location of the receiver in the vehicle To use turn system power ON at the control panel NOTE Power ON OFF and the Auto Retract sensitivity can only be operated at the control panel Extend Press and release The awning will extend out to the full extension and ...

Page 44: ...mmed as the retract button Example Pressing the top button will program the top button for retract and the bottom button as extend OPERATIONAL NOTES Transmitter and receiver operate on frequency 433 MHz The receiver exits the program mode after ten seconds If the light does not come on the memory is full and must be cleared To clear the memory PRESS AND HOLD the transmitter learn button While hold...

Page 45: ...or arm to the desired set hole towards the coach for a lower pitch and away from the coach for a higher pitch With the Awning Closed 1 Press in the pitch adjustment pin located on the long scissor arm 2 Slide the inner scissor arm up or down to the desired set hole NOTICE Before retracting the awning make sure that the individual arms are not more than three 3 pitch positions different between the...

Page 46: ...on the wires from the motor on the outside of the channel 3 Attach jumper wires to the motor wires 4 Connect the other ends of the jumper leads to a 12 14V source If the awning moves in the wrong direction reverse the leads 5 Maintain contact throughout the retraction process Hold the wires from the motor on the outside of the channel while closing the awning This provides access for opening awnin...

Page 47: ...he 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 tim...

Page 48: ...abrics 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 require the material to be washed more frequently POOLING When water collects on the top of the fabric this is known as pooling This can occur during inclement weather or if a runn...

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