sun garden Easy Sun Setup guide

REPAIR INSTRUCTIONS:
CABLE
Page 1
Issue: 06.2004 Subject to alterations due to technical improvements.
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
1.1 Important symbols
Special information is labelled with the following graphics in the manual:
Note
This symbol identifies information which can avoid damage to the sunshade.
Caution!
This symbol identifies information which refers to danger of injury and accident.
Note
This symbol identifies general tips for handling.
1.0 Safety information _____________ 1
1.1 Important symbols ________________ 1
1.2 Safety information ________________ 2
2.0 Included in delivery ____________ 2
3.0 Tools ________________________ 3
4.0 Preparation ___________________ 3
4.0 Removing sunshade cover __________ 3
4.3 Remove the defective cable
from the frame ___________________ 4
4.4 Removing the sunshade frame _______ 4
4.5 Remove ball joint _________________ 5
4.6 Remove articulated joint part ________ 5
4.7 Remove winch handle _____________ 6
4.8 Removing the winch housing cover ___ 6
4.9 Removing cable drum _____________ 6
5.0 Fitting new cable ______________ 7
8.0 Thread the cable in the articulated
joint part _______________________ 7
5.2 Thread the cable through the guide
tube and complete the ball joint ______ 8
5.3 Thread the cable through the guide ___ 9
tube and complete the ball joint ______ 9
5.4 Assembling the sunshade frame ____ 10
5.5 Threading the cable into the bottom _ 10
middle piece and fixing ___________ 10
5.6 Inserting the cable drum __________ 11
5.7 Inserting the winch handle _________ 11
5.8 Fitting the winch housing cover _____ 12
5.9 Refitting the sunshade cover _______ 12
6.0 Final check __________________ 12

REPAIR INSTRUCTIONS:
CABLE
Page 2 Issue: 06.2004
Subject to alterations due to technical improvements.
2.0 Included in delivery
3.0 Tools
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.
• Cable
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.
Note
The blind rivets required for certain versions
are NOT included in delivery.
Three VA blind rivets (ø 5 mm) are required.
❏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
❏Hammer
❏Drilling machine
❏Metal drill bit; ø 8 mm
❏Drift punch ø 4.5 mm
❏Pipe wrench
❏Stepladder

REPAIR INSTRUCTIONS:
CABLE
Page 3
Issue: 06.2004 Subject to alterations due to technical improvements.
➭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.
Sunshade frame
Velcro band
Closing tape
Zip
Top cover fixing
Bottom cover fixing
Fixing screw
Sunshade
cover
Bracket for
sunshade cover
pull downwards from
sunshade frame
4.0 Removing sunshade cover
➭Open the sunshade about half-way.
➭Release all material velcro bands on the
sunshade frame from the inside.
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.
Note
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.).

REPAIR INSTRUCTIONS:
CABLE
Page 4 Issue: 06.2004
Subject to alterations due to technical improvements.
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.
4.4 Removing the sunshade frame
➭Loosen and remove side fixing screws
between protective cap and upper frame
seat with a Phillips screwdriver.
Top centre piece
Guide tube 2. pull
frame
downwards
3.remove
protective
cap
Fixing screws
1. loosen
Position of
fixing screws
Cable seat
position
➭Unto the cable knots or pull the cable out of
the cable seat.
➭Withdraw the cable seat downwards out of
the frame seat.
1. pull out defective cable
4.3 Remove the defective cable from the frame
➭Remove the cable seat cover on the lower
spoke stand centrepiece with a screwdriver.
Cable seat
Cable
2. removing the
cable seat
Cable Centre piece
with cable seat
Cover
➭Pull the complete frame with guide tube
downwards from the ball joint.
➭Remove the protective cap rom the guide tube.
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.
Note
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.).
The seat for the cable is located on the lower
frame seat.

REPAIR INSTRUCTIONS:
CABLE
Page 5
Issue: 06.2004 Subject to alterations due to technical improvements.
4.5 Remove ball joint
➭Loosen fixing screw in ball joint upper part
with screwdriver and remove upper part. fixing screw
1. loosen
2. remove
➭Remove brake lever and brake block from
ball joint lower part.
➭Withdraw ball joint lower part from
articulated joint part.
➭Remove deflector pulley from articulated
joint part.
4.6 Remove articulated joint part
➭Remove all fixing rivets (fixing screws) from
the articulated joint part.
Notes 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.
Note
Ensure that you protect the
articulated joint part against
damage with suitable padding
when using a pipe wrench.
removing brake parts
Ball joint
lower part
Brake lever
Brake block
pull out
Ball joint
lower part
remove
Deflector pulley
1. drill out
rivet heads
2. remove
rivet
shafts
3. rotating ...
Ball joint upper part
Articulated joint part
Note
The articulating joint part is fixed either using rivets
or screws, depending on the sunshade version
...and pulling out
articulated
joint
part

REPAIR INSTRUCTIONS:
CABLE
Page 6 Issue: 06.2004
Subject to alterations due to technical improvements.
Note
If the cover is tight it can be released
by lightly tapping the crankshaft with a
rubber hammer or wooden block.
4.9 Removing cable drum
➭Remove the defective cable
from thesliding tube.
loosen
withdraw cable
Cable clamp
4.8 Removing the winch housing cover
➭Loosen housing cover fixing screws
with Phillips screwdriver.
➭Withdraw cover from winch housing.
loosen
remove
cover
Housing cover Crankshaft
➭Open cable clamp by loosening fixing
screws and pull cable out of clamp.
4.7 Remove winch handle
➭Loosen grub screw with Allen key (SW 4 mm).
➭Withdraw winch handle from location hole.
loosen
remove
Winch
handle
Allen key (SW 4 mm)
Withdraw
drum axle
Cable drum
Drum axle
➭Pull drum axle out of housing.
➭Pull cable drum out of winch housing. Withdraw
cable drum
➭Loosen cable knot and remove
the cable from the cable drum.
or:
Cable drum
Cable drum
loosen
Depending on version:

REPAIR INSTRUCTIONS:
CABLE
Page 7
Issue: 06.2004 Subject to alterations due to technical improvements.
Ball joint lower part
Brake lever
Pivot pin
Ball joint upper part
Fixing screw
Cable
Brake lever
tighten
Ball joint lower part
➭Put ball joint upper part on.
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.
➭Screw upper part fixing screw in and
tighten.
➭Place brake lever with the pivot pin in the
corresponding bore ( ) in the lower part.
➭Guide the cable through the articulated joint
part.
➭Place deflector pulley in articulated joint part
and thread cable in the deflector pulley guide
groove.
➭Set the ball-jointed lower part provided with an
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.
Ball joint lower part
Deflector pulley
articulated
joint part
insert
locate and
thread cable
insert and
thread cable
Ball joint lower part
Brake block
➭Place brake block in the assembled lower
part and place cable in the brake block
recess.
5.0 Fitting new cable
8.0 Thread the cable in the articulated
joint part

REPAIR INSTRUCTIONS:
CABLE
Page 8 Issue: 06.2004
Subject to alterations due to technical improvements.
Guide tube
Ball joint
Fixing bores
Brake wedge
Brake lever
➭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.
5.2 Thread the cable through the guide
tube and complete the ball joint
➭Insert brake tube into guide tube.
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).
➭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.
Brake tube
Guide tube
removing the guide tube
threading in
the cable
Guide tube
Supporting roller
Brake wedge
Centring bush
Detail 1:
Brake
wedge
Detail 2:
Centring bush
Brake wedge
Brake tube Centring bush
Brake tube

REPAIR INSTRUCTIONS:
CABLE
Page 9
Issue: 06.2004 Subject to alterations due to technical improvements.
➭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.
Note
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.
➭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.
press in
swivel
Guide tube
Centring bush
Cable seat
Winch
housing
Cable
2. push in
cable seat
Fixing bores
Sliding
tube
1. push in
cable
➭Rivet articulated joint part with three blind rivets. Blind rivet ø 5 mm
Articulated
joint part
Blind rivet
ø 5 mm

REPAIR INSTRUCTIONS:
CABLE
Page 10 Issue: 06.2004
Subject to alterations due to technical improvements.
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.
Cover
1. thread in the cable
2. push in
cable seat
3. knot cable end
Cable seat
Bottom
centre piece
5.4 Assembling the sunshade frame
➭Undo the securing knot and remove cable
seat.
➭Remove the guide bush locking screw
located on the side of the guide tube.
➭Screw in the guide bush locking screw
located on the side of the guide tube.
Note
When screwing in the fixing screws,
ensure that the drill holes do not slip.
➭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.
removing the locking screw
Note
Before unscrewing the locking screw,
secure the guide bush with adhesive
tape against falling out.
Guide bush
Top centre
piece
2. push on frame
1. push on
protective cap
3. screw in fixing
screws
4. screw in locking screws
Fixing drill
holes
Guide tube
Locking screw
Protective cap
Note
Overtightening of the fixing screws
leads to destruction of the guide tube.

REPAIR INSTRUCTIONS:
CABLE
Page 11
Issue: 06.2004 Subject to alterations due to technical improvements.
a
➭Withdraw the cable out of the winch housing
is far as possible.
5.6 Inserting the cable drum
➭Insert the cable drum in the winch housing.
➭Wind the cable on as far as possible by
turning the cable drum to the left.
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.
Winch handle
Allen key (SW 4 mm)
2. Ttghten
Recess
Crankshaft
location hole
1. insert
push in drum axle
Drum axle
turn
cable drum Winchhousing
push cable in
Cable clamp
tighten
Note
When pulling out, the sunshade
frame should not stick.
➭Thread the cable into the cable clamp from the
right, and close the cable clamp by tightening
the fixing screws.
➭Cut the cable off approx.1 cm in front of the
cable clamp / cable knot (a).
Cable drum
Cable drum
Cable drum
Cable drum
Cable drum with cable eye:
Cable drum with cable clamp:
➭Thread the cable from the right through the
eye on the new cable drum and knot the
cable.
Note
• Tie the knot as near as possible
to the cable drum eye.
knot
thread through
➭Push the drum axle in.
Ensure that the drum axle recess locates
over the cable drum catch.
Note
Overtightening of the grub screw
causes damage to the Allen screw.

REPAIR INSTRUCTIONS:
CABLE
Page 12 Issue: 06.2004
Subject to alterations due to technical improvements.
Note
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.
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.
➭Insert the cover in the winch housing.
➭Insert fixing screws and tighten.
Brake spring
insert spring ends
into gap
Turn cable
Catch
tighten
Fixing screws
Check all sunshade adjustment functions for
correct functioning after you have completed
the repairs (observe operating manual).
Note
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).
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.
➭Open the sunshade about half-way and fix
all velcro bands to the sunshade frame.
pull onto sunshade frame from below
Closing tape
Zip
Top cover fixing
Bottom cover fixing
Fixing screw
Sunshade
cover
Bracket for
sunshade cover
Sunshade frame
Velcro band
6.0 Final check