REPAIR INSTRUCTIONS: CABLE

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Claude Silas Freeman
5 years ago
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1 The repair instructions describe replacing the Cable in the Easy Sun PARASOL Sunshade. These repair instructions are intended only for persons with experience of using the tools required. Please read the instructions carefully through before working. Damages caused by non-observance of the instructions are excluded from any liability and guarantee. We cannot guarantee that the repair described can be carried out without damaging the components involved. The repairs described below should be carried out by two people. Contents 1.0 Safety information Important symbols Safety information Included in delivery Tools Preparation Removing sunshade cover Remove the defective cable from the frame Removing the sunshade frame Remove ball joint Remove articulated joint part Remove winch handle Removing the winch housing cover Removing cable drum Fitting new cable Thread the cable in the articulated joint part Thread the cable through the guide tube and complete the ball joint Thread the cable through the guide 9 tube and complete the ball joint Assembling the sunshade frame Threading the cable into the bottom _ 10 middle piece and fixing Inserting the cable drum Inserting the winch handle Fitting the winch housing cover Refitting the sunshade cover Final check Safety information 1.1 Important symbols Special information is labelled with the following graphics in the manual: Caution! This symbol identifies information which refers to danger of injury and accident. This symbol identifies general tips for handling. This symbol identifies information which can avoid damage to the sunshade. Subject to alterations due to technical improvements. Page 1

2 1.2 Safety information Caution: Risk of trapping! There is increased risk of trapping at all sunshade frame joints. Bear these hazard locations in mind while working. Caution: Accident hazard! Only place the stepladder on firm ground and ensure that the ladder is held by a second person to safeguard against accidents. Caution: Risk of injury! It is very easy to cause injuries with the screwdriver. Ensure that none of your limbs are at risk from screwdriver use. Caution: Risk of injury! Only carry out these repairs if you are familiar with and are able to use the tools described safely. 2.0 Included in delivery Cable The blind rivets required for certain versions are NOT included in delivery. Three VA blind rivets (ø 5 mm) are required. 3.0 Tools Screwdriver; blade width: 3.5 mm Screwdriver; blade width: 7 mm Phillips screwdriver No. 2 Phillips screwdriver No. 3 Socket spanner; Diameter across flats (SW): 6,5 mm Allen key; Diameter across flats (SW): 4 mm Rubber hammer Drilling machine Metal drill bit; ø 8 mm Drift punch ø 4.5 mm Pipe wrench Stepladder Hammer Page 2 Subject to alterations due to technical improvements.

3 4.0 Preparation When carrying out the repairs described, use a stepladder and get help from a second person. Caution: Accident hazard! Only set up the stepladder on firm ground and ensure that the ladder is held firmly by a second person to prevent accidents. If it is impossible to set up the stepladder safely, lay the sunshade down on the floor to carry out repairs. To protect sunshade against damage you should place it on a suitable underlay (cardboard, carpet roll etc.). 4.0 Removing sunshade cover Open the sunshade about half-way. Release all material velcro bands on the sunshade frame from the inside. Sunshade frame Velcro band Close sunshade and remove all screws in the sunshade cover bottom fixing with a Phillips screwdriver. Open zip and closing tape in top cover fixing and remove cover downwards from sunshade frame. Top cover fixing Closing tape Zip Bottom cover fixing Sunshade cover Fixing screw Bracket for sunshade cover pull downwards from sunshade frame Subject to alterations due to technical improvements. Page 3

4 4.3 Remove the defective cable from the frame The seat for the cable is located on the lower frame seat. Remove the cable seat cover on the lower spoke stand centrepiece with a screwdriver. Cable Centre piece with cable seat Caution: Risk of injury! It is very easy to cause injuries with the screwdriver. Do not hold any limbs in the way of the screwdriver. Cable seat position Cover Unto the cable knots or pull the cable out of the cable seat. Withdraw the cable seat downwards out of the frame seat. Cable seat Cable 2. removing the cable seat 1. pull out defective cable 4.4 Removing the sunshade frame Loosen and remove side fixing screws between protective cap and upper frame seat with a Phillips screwdriver. Position of fixing screws Fixing screws Caution: Risk of injury! The fixing screws hold the complete sunshade frame to the ball joint. Get a second person to hold the frame securely while you loosen the fixing screws. Pull the complete frame with guide tube downwards from the ball joint. Remove the protective cap rom the guide tube. Top centre piece Guide tube 3.remove protective cap 1. loosen 2. pull frame downwards The sunshade must be removed from the frame foot to carry out further repairs. To protect the sunshade against damage you should place it on a suitable underlay (cardboard, carpet roll etc.). Page 4 Subject to alterations due to technical improvements.

5 4.5 Remove ball joint Loosen fixing screw in ball joint upper part with screwdriver and remove upper part. 1. loosen fixing screw 2. remove Ball joint upper part Remove brake lever and brake block from ball joint lower part. Articulated joint part removing brake parts Ball joint lower part Brake block Brake lever Withdraw ball joint lower part from articulated joint part. Remove deflector pulley from articulated joint part. Ball joint lower part pull out remove Deflector pulley 4.6 Remove articulated joint part The articulating joint part is fixed either using rivets or screws, depending on the sunshade version Remove all fixing rivets (fixing screws) from the articulated joint part. s about rivet removal 1. Carefully drill out the rivet heads using 8 mm drill. 2. Knock out the rivet shafts inwards using the drift punch. Knock the articulated joint part out of the sliding tube with the rubber hammer at the same time as rotating it. Ensure that you protect the articulated joint part against damage with suitable padding when using a pipe wrench. 1. drill out rivet heads 2. remove rivet shafts 3. rotating......and pulling out articulated joint part Subject to alterations due to technical improvements. Page 5

6 4.7 Remove winch handle Loosen grub screw with Allen key (SW 4 mm). Withdraw winch handle from location hole. remove Winch handle loosen Allen key (SW 4 mm) 4.8 Removing the winch housing cover Loosen housing cover fixing screws with Phillips screwdriver. Withdraw cover from winch housing. If the cover is tight it can be released by lightly tapping the crankshaft with a rubber hammer or wooden block. Housing cover loosen remove cover Crankshaft 4.9 Removing cable drum Pull drum axle out of housing. Pull cable drum out of winch housing. Drum axle Withdraw drum axle Withdraw cable drum Depending on version: Open cable clamp by loosening fixing screws and pull cable out of clamp. Cable clamp loosen withdraw cable or: Loosen cable knot and remove the cable from the cable drum. loosen Remove the defective cable from thesliding tube. Page 6 Subject to alterations due to technical improvements.

7 5.0 Fitting new cable 8.0 Thread the cable in the articulated joint part Guide the cable through the articulated joint part. articulated joint part locate and thread cable Deflector pulley Place deflector pulley in articulated joint part and thread cable in the deflector pulley guide groove. insert Set the ball-jointed lower part provided with an Ball joint lower part axle into the articulated joint part and insert the axle into the deflector pulley. Please give special attention to the following: ensure that the deflector pully does not become jammed in the articulated joint part ensure the cable is placed exactly in the deflector pulley guide. Place brake block in the assembled lower part and place cable in the brake block recess. Brake block Ball joint lower part insert and thread cable Place brake lever with the pivot pin in the corresponding bore ( ) in the lower part. Pivot pin Brake lever Ball joint lower part Put ball joint upper part on. Fixing screw tighten Please give special attention to the following: that the brake lever pivot pin and the upper part guiding pain locate into the correct drill holes. ensure that the cable can move freely in the ball joint. Ball joint upper part Screw upper part fixing screw in and tighten. Ball joint lower part Brake lever Cable Subject to alterations due to technical improvements. Page 7

8 5.2 Thread the cable through the guide tube and complete the ball joint Remove the guide tube from the frame. Pull the brake tube out of the guide tube. Push the cable into the brake tube and guide it through the guide tube. removing the guide tube threading in the cable Guide tube Brake tube Guide tube Brake tube Centring bush Insert brake tube into guide tube. Brake wedge Please give special attention to the following: ensure that the supporting roller is located in the brake wedge (see Detail 1) ensure that the guides on the lower end of the brake tube locate into the grooves in the guide tube centring bush (see Detail 2). Detail 1: Brake wedge Detail 2: Centring bush Brake tube Centring bush Supporting roller Brake wedge Push guide tube onto ball joint shaft as far as stop, and align to fixing bores provided there. Please give special attention to the following: the exact position of the brake wedge relative to the brake lever. free movement of cable within the guide tube. Fixing bores Brake lever Guide tube Brake wedge Ball joint Page 8 Subject to alterations due to technical improvements.

9 Check the swivel brake function before further assembly. Test sequence: lead the cable through the cable seat press the cable seat pins into the guide tube centring bushes and try swivelling the ball joint. The brake is in correct working order if the ball joint only swivels with difficulty or not at all. Guide tube Centring bush Cable seat swivel press in In order to prevent the cable slipping out of the guide to during further assembly work, make a knot in the free end of the cable. 5.3 Thread the cable through the guide tube and complete the ball joint Push the cable through the sliding tube as far as the winch housing. Fixing bores 2. push in cable seat Push the articulated joint part into the sliding tube and align with fixing drill holes. Please give special attention to the following: the exact position of the drill holes in the sliding tube and articulate joint part to the free movement of the cable within the sliding tube. Sliding tube 1. push in cable Cable Winch housing Rivet articulated joint part with three blind rivets. Blind rivet ø 5 mm Articulated joint part Blind rivet ø 5 mm Subject to alterations due to technical improvements. Page 9

10 5.4 Assembling the sunshade frame Undo the securing knot and remove cable seat. removing the locking screw Remove the guide bush locking screw located on the side of the guide tube. Before unscrewing the locking screw, secure the guide bush with adhesive tape against falling out. Guide bush Push protective cap and upper sunshade frame centre part onto guide tube as far as the stop. Align the side fixing drill holes in the centre part with the drill holes in the guide tube. Screw in the fixing screws in the centre part with a Phillips screwdriver and tighten. Fixing drill holes Protective cap Guide tube 1. push on protective cap 2. push on frame When screwing in the fixing screws, ensure that the drill holes do not slip. Overtightening of the fixing screws leads to destruction of the guide tube. Top centre piece Locking screw 3. screw in fixing screws 4. screw in locking screws Screw in the guide bush locking screw located on the side of the guide tube. 5.5 Threading the cable into the bottom middle piece and fixing Thread the cable into the bottom centre piece and the cable seat. Push the cable seat into the centre piece from beneath. Make a knot in the cable end and push into the cable seat. Close off the cable seat by pushing the cover in. Bottom centre piece Cable seat 1. thread in the cable 2. push in cable seat 3. knot cable end Page 10 Subject to alterations due to technical improvements. Cover

11 5.6 Inserting the cable drum Withdraw the cable out of the winch housing is far as possible. When pulling out, the sunshade frame should not stick. with cable clamp: Thread the cable into the cable clamp from the right, and close the cable clamp by tightening the fixing screws. Cable clamp tighten push cable in with cable eye: Thread the cable from the right through the eye on the new cable drum and knot the cable. Tie the knot as near as possible to the cable drum eye. Cut the cable off approx.1 cm in front of the cable clamp / cable knot (a). knot a thread through Insert the cable drum in the winch housing. Wind the cable on as far as possible by turning the cable drum to the left. turn cable drum Winchhousing Push the drum axle in. Ensure that the drum axle recess locates over the cable drum catch. Drum axle push in drum axle 5.7 Inserting the winch handle Insert the winch handle in the crankshaft location hole. The recess in the handle must face the grub screw. Insert grub screw and tighten. When tightening, ensure that the grub screw engages exactly in the recess. Overtightening of the grub screw causes damage to the Allen screw. Crankshaft location hole 1. insert Winch handle Recess 2. Ttghten Allen key (SW 4 mm) Subject to alterations due to technical improvements. Page 11

12 5.8 Fitting the winch housing cover Align the catch with the cable drum so that a gap can be seen. Align the ends of the brake spring in the housing cover with the gap between cable drum and catch. Brake spring Turn cable Catch Insert the cover in the winch housing. If the cover does not align with the winch housing after insertion, this can be remedied by lightly rotating the winch handle from side to side. Insert fixing screws and tighten. 5.9 Refitting the sunshade cover Push the sunshade cover onto the sunshade frame from below. Close the closing tape and zip in the upper cover fixing. Screw in all screws on the lower cover fixing. tighten insert spring ends into gap Fixing screws Top cover fixing Closing tape Zip Bottom cover fixing Sunshade cover Fixing screw Bracket for sunshade cover pull onto sunshade frame from below Open the sunshade about half-way and fix all velcro bands to the sunshade frame. 6.0 Final check Check all sunshade adjustment functions for correct functioning after you have completed the repairs (observe operating manual). If the sunshade does not open completely, you will have to re-tension the cable in the winch housing (see chapters 4.8 and 5.6). Sunshade frame Velcro band Page 12 Subject to alterations due to technical improvements.

Hardware and Components:

Hardware and Components: (A) 4X 5/16 x 1 Carriage Bolt (B) 2X 5/16 x 2-1/4 Carriage Bolt (C) 2X 5/16 x 3-1/4 Hex Bolt (D) 2X 5/16 x 3/4 Hex Bolt (E) 2X 5/16 x 1-1/4 Hex Bolt (F) 5/16 x 2-1/4 Hex Bolt (G)