Monday, March 14, 2011

1995 Flagstaf by Cobra belt assembly and disassembly?

HOW TO REPAIR A CRANK LIFT SYSTEM
NOTE: ALWAYS RAISE AND LOWER ROOF SEVERAL TIMES AND MAKE SURE
THE DOOR FITS PROPERLY AFTER ANY LIFT SYSTEM REPAIRS.
REPLACING THE TELESCOPING LIFT ARMS
1. Raise the unit.
2. Remove the tent from the curtain tent track at the top of the roof
side.
3. Remove the lift arm cover.
4. Brace the roof up on all four corners between the end wall cap and
the roof ‘H’ rail.
5. Remove the screws from the sidewall cap and lift it up from the
body of the unit. NOTE: DO NOT UNTUCK THE TENT.
6. Remove the top arm bolt. CAUTION: ONLY CHANGE ONE ARM AT A TIME.
7. Crank the winch all the way down.
8. Remove the arm by lifting out of the sidewall pocket.
9. Replace the arm.
10. When replacing the arm, make sure the screw in the bottom of the
goes to the inside of the coach.
11. Reverse steps 2 through 7.
12. Adjust the height of the roof if needed (See adjusting roof
height).
REPLACING THE WINCH
1. Raise the unit.
2. Remove the winch cover found in cabinet or dinette seat.
3. Brace the roof up. Use caution.
4. Crank the winch down 4 or 5 times.
5. Remove the nuts on the eye bolts; these are located in the harness
square.
6. Remove the bolts that hold the winch to the floor.
7. Remove the screws that hold the winch to the sidewall.
8. Remove the winch.
9. Install the main cable on the new winch.
10. Place the new winch in the unit.
11. Reverse steps 2 through 7.
12. Adjust the roof height if necessary. (See adjusting roof height.) REPLACING THE EYE BOLTS
1. Raise the roof.
2. Remove the winch cover inside cabinet or under dinette seat.
3. Brace the roof up.
4. Crank the winch down 4 or 5 turns.
5. Remove the nuts from the eye bolt found on the harness square.
6. Remove the cable from the eye bolt. Bend they eye open just far
enough to slip the cable off.
7. Place the cable on the new eye bolt. Bend they eye open just far
enough to slip the cable on, and bend the eye shut.
8. Reverse steps 2 through 5.
9. Adjust the roof height if necessary. (See adjusting roof height.)
REPLACING THE 3/32” LIFT CABLE
1. Raise the roof.
2. Remove the winch cover inside the unit.
3. Brace the roof up.
4. Crank the winch 4 or 5 times.
5. Remove the nut from the eye bolt found on the harness square.
6. Remove all necessary dividers, step-ups and cable covers.
7. Remove the lift arm. (See removing telescoping arm.)
8. Remove the spring. (See steps for replacing spring.)
9. Pull the cable through all pulleys and out of the spring track.
Carefully note the route of the cable through the various pulleys
so that installation of the new cable will be correct.
10. Remove the slug from the cable, when you put the slug back into
the spring track, make sure the wide slot goes in the same corner
as the pulley.
11. Feed the cable back through the pulleys, starting from the winch.
12. Reverse steps 2 through 10.
13. Adjust roof according to the roof height adjustment steps.
REPLACING THE DOUBLE PULLEY WITH BRACKET
1. Raise the roof.
2. Brace the roof up.
3. Crank the winch 4 or 5 times.
4. Remove the bolts from the pulley track. (The pulley brackets are
located on the sidewall and the floor in opposite corner from the
winch.)
5. Break the pin weld on the bracket and pry apart. Drill through the
bracket to remove the weld area or split the two metal pieces with
a chisel. Drill from the backside of the bracket.
6. Remove the cables from the pulley. NOTE: If the cables are on top
or bottom side of the pulley.
7. Break the pin weld on the new bracket and place the cable back in
the same place. Drill from the backside of the bracket.
8. You don’t have to weld the new bracket; a bolt will hold it when
you put it back in place.
9. Reverse steps 2 through 6.
10. Make sure the cables do not rub on the wheel well.
11. Adjust roof according to the roof height adjustment steps. REPLACING THE 2 x 2 STEEL BLOCK (HARNESS SQUARE)
1. Raise the roof.
2. Brace the roof up.
3. Crank the winch 4 or 5 times.
4. Remove the winch cover.
5. Remove the nuts from the eye bolts.
6. Remove the main cable from the winch. (See main cable
replacement.)
7. Remove the 2 x 2 steel block from the cable.
8. Reverse steps 2 through 7.
9. Adjust roof according to the roof height adjustment steps.
REPLACE THE CURVED BRACKET WITH AND WITHOUT PULLYES
1. Raise the roof.
2. Brace the roof up.
3. Remove the lift arm. (See lift arm replacement.)
4. Remove the spring. (See spring replacement.)
5. Unbolt the curved bracket from the floor.
6. Unscrew the curved bracket from the sidewall. Note: If you are
replacing the curved bracket in the winch corner, you must remove
the winch (See winch replacement.)
7. Install the new bracket.
8. Reverse steps 2 through 7.
9. Adjust roof according to the roof height adjustment steps.
REPLACE THE SPRING
1. Raise the roof.
2. Brace the roof up.
3. Crank the winch 4 or 5 times.
4. Remove the arm. (See arm replacement.)
5. Remove the spring.
6. Remove the spring rivet from the end of the spring and use on new
spring.
7. Replace the spring. NOTE: When placing the spring back into the
spring track, you might have to pry up on the spring to guide it
in the spring track.
8. Reverse steps 2 through 7.
9. Adjust roof according to the roof height adjustment steps.
REPLACING THE SPRING TRACK WITH OR WITHOUT PULLEYS
1. Raise the roof.
2. Brace the roof up.
3. Remove the lift arm. (See lift arm replacement.)
4. Remove the spring (See spring replacement.)
5. Pull the cable out of the spring track and pulley, if the track
has a pulley on it.
6. Remove the necessary cabinets.
7. Unbolt the spring track from the floor.
8. Replace the track.
9. Repeat steps 2 through 7.
10. Adjust roof according to the roof height adjustment steps. REPLACING THE SPRING RIVET
1. Raise the roof.
2. Brace the roof up.
3. Crank the winch down 4 or 5 turns.
4. Remove the lift arm. (See lift arm replacement.)
5. Remove the spring rivet on the end of the spring.
6. Reverse steps 2 through 5.
7. Adjust roof according to the roof height adjustment steps.
REPLACING THE DRIVE SLUG
1. Raise the roof.
2. Brace the roof up.
3. Crank the winch down 4 or 5 times.
4. Remove the arm. (See arm replacement.)
5. Remove the spring (See spring replacement.)
6. Pull the cable out of spring track.
7. Remove the drive slug from the cable.
8. Place new drive slug on the cable.
9. Place the new drive slug back into he spring in the corner with
the track pulley. If the track does not have a pulley, you turn
the wide slot towards the lower front corner of the spring track.
10. Reverse steps 2 through 7.
11. Adjust roof according to the roof height adjustment steps.
REPLACING THE MAIN CABLE 3/16”
1. Raise the unit.
2. Brace the roof up.
3. Remove the winch cover inside the dinette seat or cabinet.
4. Crank winch down 4 or 5 turns.
5. Remove the cable keeper nut and bolt on the side of the winch
spool. Unwrap the cable from the spool.
6. Pull the cable back through the 2 x 2 steel block (harness square)
then remove.
7. Thread the new cable through the center hole of the 2 x 2 steel
block (harness square). Make sure that the needle bearing and
flat washers are in place between the crimp and steel block.
8. Thread cable through the winch spool and reattach with cable
keeper.
9. Crank the winch to the up position, holding tension on the cable.
Make sure you have two wraps of cable on the winch spool when unit
is down.
10. Reverse steps 2 through 4.
11. Adjust roof according to the roof height adjustment steps.
NOTE: WHEN REPLACING ANY LIFT SYSTEM PART, YOU SHOULD ALWAYS RAISE
AND LOWER THE UNIT 4 OR 5 TIMES TO MAKE SURE IT IS OPERATING PROPERLY.
CHECK ROOF HEIGHT AND ADJUST IF NECESSARY. SET THE DOOR TO MAKE SURE
IT IS STILL FITTING CORRECTLY. ADJUSTING THE ROOF HEIGHT
1. Raise the roof. NOTE: USE ROOF SUPPORT ON CORNER BEING ADJUSTED
‘G’. Measure from the bottom of the ‘H’ on the ‘H’–rail to the
edge of the sidewall cap. The measurement should be 47 ¼”, no
more than 47 ¾” for earlier 4 stage units. If you don’t have
enough room for the upper door to fit properly, raise the rear
arms to 47 ¾”. NOTE: For later 4 stage units the measurement is 46
¼” with a maximum of 46 ¾”. Also, the 3 stage units with the
higher side wall measurement was 42 ¼” to 42 ¾”.
2. If the measurements are not right, adjust the length of the bolts
by moving the nuts one way or the other. Lengthen they eye bolt
to lower, shorten eye bolts to raise.
3. To find out which eye bolt goes to which arm, pull an individual
3/32 cable and watch which corner of the roof goes up.
4. After the roof height is adjusted properly, set the red vinyl
cable so it is tight. Adjust the cable at the roof sideboard and
move up. This cable will tell you when the roof is up to the
correct height.
5. MAKE SURE THE NUTS ON THE EYE BOLTS ARE TIGHT. L&W CRANK UP LIFT SYSTEM – PART NUMBER INDEX
ALL PART NUMBERS FOUND IN CLASS CODE 16650
CALL US TOLL FREE! @ 1-800-239-6157
1 WINCH WITH CABLE KEEPER… REAR CRANK 2515531
WINCH WITH CABLE KEEPER… FRONT CRANK 2515055
2 WINCH TUBE WITH NUT 2515062
3 TELESCOPING LIFT ARM STAGE 4 2515530
TELESCOPING LIFT ARM STAGE 3 2515029
4 CABLES – MUST CALL FOR QUOTE
5 ARM INSERTS 4 STAGE 2515075
ARM INSERTS 3 STAGE 2515076
6 CURVED BRACKET WITHOUT PULLEY.. 3 OR 4 STAGE 2515035
7 CURVED BRACKET WITH PULLEY.. REAR CRANK 2515058
CURVED BRACKET WITH PULLEY.. FRONT CRANK 2515037
8 FLOOR TRACK WITH 1 PULLEY.. 4 STAGE 2515039
FLOOR TRACK WITH 1 PULLEY.. 3 STAGE 2515069
9 FLOOR TRACK WITHOUT PULLEY.. 4 STAGE 2515540
FLOOR TRACK WITHOUT PULLEY.. 3 STAGE 2515068
10 FLOOR TRACK WITH 2 PULLEYS.. 4 STAGE 2515038
FLOOR TRACK WITH 2 PULLEYS.. 3 STAGE 2515059
11 FLOOR TRACK WITH 1 PULLEY REAR.. 4 STAGE 2515044
FLOOR TRACK WITH 1 PULLEY REAR.. 3 STAGE 2515052
12 FLAT BRACKET WITH PULLEY 2515033
13 HARNESS SQUARE 2515034
14 MAIN CABLE.. MUST CALL OFFICE FOR QUOTE
15 REFER TO NUMBER 4
16 VINYL INSERT IN CURVED BRACKET – 12” LONG 2515537
17 PUSH ROD – 4 STAGE 2515541
PUSH ROD – 3 STAGE 2515060
18 CRANK HANDLE WITH TUBE – FRONT OR REAR 2515032
19 KEEPER NUTS WITH STAR WASHERS 2515048
20 EYEBOLT 2515513
21 WASHER (FLAT) 2555001
22 NEEDLE OR THRUST BEARINGS 2515022
23 CRIMPS 3/16” LARGE SIZE 2515545
24 CRIMPS 3/32” SMALL SIZE 2515544
25 DRIVE SLUG USED INSIDE 2515543
26 TERMINAL FOR LIMIT CABLE – NOT STOCKED
27 LIFT ARM COVER 2036230
28 KEEPER FOR WINCH 2515077
29 RIVET FOR PUSH ROD 2515042
30 PULLEY DOUBLE 2515063
PULLEY SINGLE 2515064
TO ORDER LIFT SYSTEM PARTS YOU MUST HAVE COMPLETE SERIAL NUMBER.
GOSHEN STAMPING SAFETY POSTS MAY BE USED WITH L&W PART # 2515604.

There are pictures and diagrams for more help.Please click on the link below:----
---------------
The diagrams are on the last 3 pages.

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Tent Camper Cable Drive Lifter Repair Procedure:---


SPRING CHANGE PROCEDURE

It is important when changing springs to do only one end of the camper at a time. The roof should be down before repairing to take pressure off of the system. Refer to attached drawing for parts (A through Q) locations.

  1. Remove the tie bar plates (K) by removing two (2) self-tapping screws.
  2. Remove the two (2) screws that attach the spring tubes (N for rear, S for front) to the master tube (L).
  3. Remove two (2) screws each from floor plates that attach the spring tubes to the frame of the camper.
  4. Pull the spring (P) out from the bottom of the telescoping posts (A, B, & C).
  5. Pull the spring tube off of the spring.
  6. Pull the spring assembly (2 springs attached) out of the master tube (L).
  7. Put the new spring assembly in the master tube and push all the way to the stop. Note: The cable (J) lays between the springs and must s
    lide freely.
  8. Put the spring tubes on the springs. (You may put some oil in tube to ease pushing spring through).
  9. Attach the spring tubes to the corner of the frame of the camper.
  10. Attach the spring tubes to the master tube.
  11. Attach the tie bar.
  12. Repeat the above procedure on the opposite end of the camper if necessary.


CABLE REPLACEMENT PROCEDURE


  1. Start with rear tubes first. Follow instructions 1, 2, 3, 4 & 6 above with roof down.
  2. Hold pair of springs in one hand, lay crimped end of cable and pusher plate over end of springs, then insert springs and cable into master tube, pushing them all the way to the opposite end.
  3. Run cable around pulley (M) and insert end of cable into master tube between the two (2) springs and feed it through to the front. If you are unable to feed due to grease in the master tube, you will need to disconnect spring tubes on the other end or pull springs out the opposite end to assist getting cable through.
  4. Pusher plate (see Cable Path diagram) in middle of cable must be in front of springs.
  5. Wrap cable around drum on winch one turn, then push end of cable out slot on side of winch housing and secure end under cable keeper (I). Tighten bolt securely.
  6. Re-assemble lift tubes to corner of frame to the end of master tube and re-assemble tie plate.

System should be ready to use. You may put more grease in the master tube.

If front and back of the roof do not start up at the same time you need to adjust the pulley (M). To Raise front of roof earlier adjust pulley forward to raise rear move pulley toward back of unit.

Spring Length Chart For Cable System

1994-2001 Single Post Value Line Freedom / Mac and 1995-2001 Single Post Low Wall Mid Line Premier / Classic

  • 8' - 122''
  • 10' - 134''
  • 12' - 139''

1999 - 2001 Single Post High Wall Mid Line Premier / Classic and 1998 - 2000 Signature

  • 12' - 146''

2001 Double Post Value Line & Mid Line

  • 8' - 128''
  • 10' - 139''
  • 12' - 146''

NOTE: All springs shipped will be 146'' in length (part # L-323) and should be cut to the above lengths.

2004 HW Units

  • 12' - 154'' (Part # L-336


Cable Length Chart for Cable System

PART # L-39 / YELLOW - 202'' O.A., 69'' P.P.

  • (Cut to Length for BEIGE - 172'' O.A., 69'' P.P.)
  • FS Models: 176SD, 176ED, 176ST, 176LTD, 617

PART # L-34 / PURPLE - 265'' O.A., 93'' P.P.

  • (Cut to Length for GRAY - 241'' O.A., 93'' P.P.)
  • (Cut to Length for BROWN - 211'' O.A., 93'' P.P.)
  • FS Models: 205, 206, 206ST, 206LTD, 208, BR19ST, BR19T/H, 620, 620ST, 720, 820

PART # L-41 / BLACK - 276'' O.A., 115'' P.P.

  • (Cut to Length for GREEN - 246'' O.A., 115'' P.P.)
  • FS Models: 226, 226D, 227, 228, 228D, 229
  • 1995-1998 to Unit # 44289: 623, 623DD, 624D, 625D, 822, 823, 823XR, 824ST, 825D

PART # L-57 / RED - 292'' O.A., 133'' P.P.

  • (Same as ORANGE - 292'' O.A. 133'' P.P.)
  • (Cut to Length for BLUE - 270'' O.A.. 133'' P.P.)
  • FS 1999-Current: 425D, 523, 524SS, 524ST, 623, 625D, 725D, 822, 823, 823D, 824ST, 825D, 923, HW25ST, HW25CK, HW25S/C, HW625D, HW825D

O.A = Overall Length

P.P.= Push Pull Length


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