Jayco Camper Lift Cables: How Do They Work?

how do jayco camper lift cables work

Jayco camper lift cables are an essential component of the camper lift system. The lift system is used to raise and lower the roof of the camper, and typically consists of winches, cables, springs, and pulleys. The lift cables are connected to a winch, which generates the force required to elevate the roof through a system of pulleys. In this system, the winch also includes a clutch and brake system, which allows users to control the movement of the roof and prevents it from pushing back against the lift mechanism. While the specific design of the lift system may vary across different models and brands, the cable remains a prominent component in most designs. Due to the importance of the lift cables, it is crucial to regularly inspect them for any signs of damage and replace them if necessary.

Characteristics Values
Camper type Pop-up
Camper brand Jayco
Cable type Lift cable
Cable function To raise and lower the roof
Cable composition High-quality stranded material
Cable maintenance Regular checks for damage; lubrication and servicing at recommended intervals
Cable replacement Possible to do-it-yourself with minimal expense and a few household tools
Cable issues Broken cable or cable attachment; frayed, rusted or damaged
Cable repair tools Phillips screwdriver, flathead screwdriver, adjustable wrenches, pliers or vise-grips

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Winch and cable system

Jayco camper trailers use a winch and cable system to raise and lower the roof. The winch is located inside the camper, beneath a cover on the cabinet or dinette. The cable wraps around the winch, with one end bolted to it and the other bolted or crimped to the steel harness square. When the winch reels in the main cable, it activates the lifter cables, which are attached to the harness block with eye bolts. These cables then pull the drive slugs along a track bolted to the floorboard.

The drive slugs push the flexible rod springs through the track into the telescoping support posts, raising the roof. The winch also has a clutch and brake system, which allows the user to control the movement and prevents the roof from pushing back against the lift mechanism. This system is similar to the Goshen lift system, with the main difference being that the Goshen system uses springs, while the Jayco system uses pushrods.

When repairing or replacing the cables, it is important to first stabilize the camper with jacks and wheel chocks. The roof should be raised to the proper height, and if the winch is inoperable, this can be done manually by two people. Brace the roof and ensure that no corner is more than half an inch higher than any other. With the bracing in place, crank the winch down to remove tension from the cables.

To replace the main cable, unbolt it from the winch attachment and pull the free end through the harness square. Measure and replace it with a new cable of the same diameter, typically 3/16 inch. If the cable was crimped rather than bolted, replace the cable swage sleeves and crimp them tightly with pliers or vise-grips.

To replace a lifter cable, note how it is routed before removing it. Detach the cable from the drive slug and the eye bolt at the harness square. Measure the cable and replace it with a new one of the same diameter, usually 3/32 inch. Thread the new cable through a swage sleeve and loop it through the eye bolt, then route the other end through the floor track to the drive slug and crimp it in place. Pull the cable taut from the harness square side and crimp it, then adjust the cable tension by tightening the eye bolt and locking it in place.

After replacing cables, test the system by lifting and lowering the roof several times with the winch. With the roof raised, measure the height on all four sides to ensure that each corner is within half an inch of the others. Make any necessary adjustments by tightening or loosening the eye bolts through the harness square.

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Cable attachments

Jayco camper lift cables are connected in a similar manner to the Goshen lift system. The key difference is that in Jayco systems, springs are substituted with pushrods.

The Jayco's four lifter cables attach to the harness block with eye bolts and are routed to the drive slugs via pulleys. When the winch reels in the main cable, the lifter cables pull the drive slugs along a track bolted to the floorboard. The drive slugs then push the flexible rod springs through the track into the telescoping support posts to raise the roof.

The cable attachments to the eye bolts should be inspected. If the bolts are damaged, they should be replaced. Pulleys should be securely anchored and able to operate freely.

When replacing the lifter cables, note how they are routed before removing them. Remove the screw at the inward side of the drive track, then remove the rod spring and drive slug through the end of the track. Detach the cable from the drive slug, and remove the other end from the eye bolt at the harness square. Loosen the eye bolt nut and lock nut to allow for adjustment later. Measure the cable and replace it with a new length of the same diameter. Most lifter cables are 3/32 inch.

Thread the new lifter cable through a new swage sleeve. Loop it through the eye bolt and back through the other side of the sleeve. Do not crimp yet. Route the other end of the cable through the floor track to the drive slug, and crimp it in place. Install the rod spring and inward side screw. Pull the cable taut from the harness square side, and crimp it. Adjust the cable tension by tightening the eye bolt, and lock it in place with the lock nut.

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Cable replacement

Step 1: Stabilize the Camper and Raise the Roof

Stabilize the camper with jacks and wheel chocks. If the winch is operable, crank it to raise the roof to the proper height. If not, the roof can be raised manually with the help of another person. Brace the roof and ensure that all four corners are level, with no corner more than half an inch higher than any other.

Step 2: Remove Tension from Cables and Prepare Work Space

With the bracing in place, crank the winch down to remove tension from the cables. Pull out bunks or benches to create an open workspace.

Step 3: Inspect and Replace Main Cable

The main cable wraps around the winch, which is located inside the camper, typically beneath a cover on the cabinet or dinette. Check the winch mounting bolts for any damage, ensuring the winch is secure. Unreel the cable and inspect its entire length. If the cable is broken, frayed, rusted, or damaged, it needs to be replaced. One end of the cable should be attached to the winch, while the other end is attached to the steel harness square, either by bolting or crimping.

To replace the main cable, follow these steps:

  • Unbolt the cable from the winch attachment.
  • Pull the free end of the cable through the harness square.
  • Measure the cable and replace it with a new length of the same diameter cable (typically 3/16 inch).
  • If the cable was crimped, replace the cable swage sleeves with new ones and crimp them tightly with pliers or vise-grips.

Step 4: Inspect and Replace Lifter Cables

The lifter cables attach to the harness block with eye bolts and are routed to the drive slugs via pulleys. Inspect these cables for any signs of fraying, breakage, rust, or other damage. If any damage is observed, they will need to be replaced.

To replace a lifter cable:

  • Note how the cable is routed before removing it.
  • Remove the screw at the inward side of the drive track.
  • Take out the rod spring and drive slug by pulling them through the end of the track.
  • Detach the cable from the drive slug and eye bolt at the harness square.
  • Loosen the eye bolt nut and lock nut for later adjustment.
  • Measure the cable and replace it with a new length of the same diameter (typically 3/32 inch).

Step 5: Install New Lifter Cable

  • Thread the new lifter cable through a new swage sleeve.
  • Loop the cable through the eye bolt and back through the other side of the sleeve, but do not crimp yet.
  • Route the other end of the cable through the floor track to the drive slug and crimp it in place.
  • Reinstall the rod spring and inward side screw.
  • Pull the cable taut from the harness square side and crimp it.
  • Adjust cable tension by tightening the eye bolt and locking it with the lock nut.

Step 6: Test and Adjust the Cable Installation

Slide the bunks or benches back into place. Test the new cable installation by lifting and lowering the roof several times with the winch. Measure the height of the camper's roof on all four sides with the door set, ensuring that each corner is within half an inch of the others. Make any necessary height adjustments by tightening or loosening the eye bolts through the harness square.

Important Notes:

  • When removing, installing, or adjusting cables, always remove tension from them by cranking the winch down with the roof braced in the raised position.
  • Broken and frayed cables can be sharp and may be dirty, rusty, or greasy. Handle them with care and wear eye protection.
  • Specialty hardware and components such as pulleys, drive tracks, and rod springs must be purchased from Jayco dealers.
  • Lubricate and service the lift system at recommended intervals.

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Cable maintenance

Inspect the Cables Regularly:

Before embarking on any journey or after prolonged use, it is essential to inspect the cables for any signs of damage or wear and tear. Check for fraying, breakage, rust, or any other abnormalities. Pay close attention to the attachment points, such as the eye bolts, winch, and distribution block. Ensure that the cables are properly tensioned and securely anchored.

Lubricate and Service the Lift System:

Follow the manufacturer's recommendations for lubricating and servicing the lift system, including the cables, at specified intervals. This will help reduce friction and wear, extending the lifespan of the cables.

Replace Damaged Cables:

If any damage is identified during inspection, it is crucial to replace the affected cables promptly. Here are the general steps to replace a cable:

  • Stabilize the Camper: Use jacks and wheel chocks to stabilize the camper. Ensure the roof is raised to the proper height and brace it securely to prevent accidental lowering.
  • Remove Tension: Crank the winch down to release tension from the cables. This step is crucial for safety and ease of maintenance.
  • Access the Cables: Depending on the cable's location, you may need to remove cushions, panels, or access panels to gain clear access to the cables, winch, and pulley system.
  • Inspect and Measure: Once you have access to the cables, carefully inspect the entire length of the cable. Identify the attachment points and measure the cable's length.
  • Acquire Replacement Cable: Purchase a new cable of the same diameter and length. You can source cables from hardware stores, Jayco dealers, or RV dealers.
  • Detach the Old Cable: Using appropriate tools, carefully detach the old cable from its attachment points. Be cautious of sharp edges and wear protective gear, including eye protection.
  • Install the New Cable: Feed the new cable through the same route as the old one, following the pulleys and tracks. Ensure the cable is securely attached at both ends, using crimps or bolts as required.
  • Test and Adjust: Once the new cable is installed, test the lift system by raising and lowering the roof several times. Make any necessary adjustments to ensure even lifting at all corners.

By following these maintenance procedures, you can help ensure the reliable operation of your Jayco camper's lift system, reducing the risk of unexpected failures during your travels.

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Cable vendors

Jayco camper lift cables are available from a variety of vendors, including hardware stores, Jayco camper dealers, and other RV dealers. The cables can also be purchased online from websites such as eBay and PopUpParts.com. Some vendors, like PopUpParts.com, offer a range of lift system parts for different camper models, while others, like eBay, provide access to multiple sellers offering Jayco lift cables.

When purchasing Jayco lift cables, it is important to ensure compatibility with your specific camper model. Vendors like PopUpParts.com specify compatibility with "most models" of Jayco campers, while eBay sellers may provide more specific information based on their product listings. It is always a good idea to confirm the cable specifications, such as length and diameter, before making a purchase.

In addition to the cables themselves, vendors may also offer related components, such as swage sleeves, eye bolts, pulleys, drive tracks, and rod springs. These specialty hardware items are typically available from Jayco dealers, ensuring compatibility and a proper fit for your camper.

When repairing or replacing Jayco camper lift cables, it is recommended to follow the instructions provided by Jayco or seek guidance from experienced individuals. Online forums and communities, such as PopUpPortal.com, can be a valuable resource for learning about the repair process and identifying reliable vendors for the required parts.

Frequently asked questions

You will need a Phillips head screwdriver, a flathead screwdriver, a 10mm spanner (or socket), and a pair of pliers.

First, stabilize the camper and raise the roof to the proper height. Remove the cable from the winch attachment and pull the free end through the harness square. Measure the cable and replace it with a new length of the same diameter cable. Thread the new cable through a swage sleeve, loop it through the eye bolt, and back through the other side of the sleeve. Route the other end of the cable through the floor track and crimp it in place. Reattach the cable to the winch attachment and test the cable installation by lifting and lowering the roof several times.

Common issues include broken or frayed cables, rust, and damage to cable attachments such as eye bolts and pulleys.

Always remove tension from the cables before removing, installing, or adjusting them. Frayed and broken cables can be sharp and may be dirty, rusty, or greasy, so handle them with care and wear eye protection.

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