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9/6/07 Patio Awning Diagnostic Service Manual A & E

1. ee ee Below Awning Rail Head Screw Awning Rail With Drip Channel 14 x 3 Hex Head Screw Over Awning Rail Top Pivot Rafter Awning Rail With 14 x 3 Hex Drip Channel Head Screw Top Bracket Leg Mounted On Aw ning Rail 2 6 Bottom Mounting Bracket The bottom mounting brackets are screwed to the floor line of the unit and they support the weight of the awning They also provide a quick release to setup the awning in the patio position If a bottom mounting bracket settles sags or becomes loose it can reduce the clearance be tween the top casting of the torsion and the extension of the top mounting bracket making operation difficult Check the bottom mounting bracket for looseness or set tling and tighten or reposition accordingly for proper op eration A stand off is available and goes over molding and extends the Bottom Mounting Bracket away from the side of the coach approximately 3 4 inch if needed Molding Bottom Wall Bracket Standoff Kit 3104781 XXX 2 7 Stop Plug The stop plug is a mechanical stop that supports the main arm when opening and closing the awning It controls the clearance between the top casting of the torsion and the extension of the top mounting bracket This clearance should be 1 4 inch to 1 inch To adjust the clearance raise or lower the stop plug as needed On the 9000 Series awning the clearance should be kept to a minimum for best operation Main Arm e e 3 8
2. or unrolling during travel It also allows one person set up of the awning by preventing rollback When difficulties are experienced in rolling the awning up the tension on the torsion should be checked In most cases adding a few turns of torque to each end will correct the problem If all tension has been lost refer to the following chart and ap ply the specified number of turns as indicated This must be done with the awning extended two feet away from the coach Reference fabric change for torsion winding A WARNING Severe injuries can result from the rapid spin off of the top casting Use Vise Grips NEVER use bare hands to handle a top casting under spring tension 17 3 4 1 Cam Lock The cam assembly locks the roller tube from turning in one direction or the other according to which way the cam lock lever is flipped To check the cam lock on the A amp E awning unlock the main support arms Hook the pull rod into the pull strap and try to open the awning Be sure the cam lock lever is in the roll up position If the roller tube rotates 1 2 turn or more the cam lock must be replaced To check the roll down position of the cam lock open the awning to full extension Grasp the roller tube with your hands and try to turn the tube in the direction it will roll up If the tube can be rotated 1 2 turn or more the cam lock must be repaired or replaced Section 4 Other 4 1 Awning Rail y OPENING DOWNWARD OPENI
3. Sunchaser Knob Squeeze 8500 9000 Flip Pull down CAUTION Ensure the lock lever is not flipped to the roll up position prior to swinging the main arm away from coach Failure to do so can cause damage to the lock mechanism 3 Extend FRTA Slide one rafter arm up until it snaps into place Pull down and out on the sliding rafter to remove slack from the fab ric Tighten the black adjustment knob The tighter the rafters are the better the fabric look and be less prown to wind whipping Repeat for other side Slide the pull strap to the right end of the tube and wrap as shown 5 Height Adjustment Pull up on the lift handle and raise to desired height Swing handle down to lock button in hole Repeat for other side 6 Carport Position and pull the arm away to a vertical position Adjust height Drive stakes through holes in patio foot into the ground Repeat for other side CAUTION Whenever heavy or prolonged rain or wind is anticipated or you will leave the awning unattended it is best to close the awning Damage as a result of weather is not covered by warranty 7 Rain Position 1 2 TO CLOSE 1 From Patio Position Pull stakes from the ground lower arm to the shortest position swing arm toward the vehicle and snap the patio foot into the bracket Repeat for other side and proceed to next step CAUTION Ensure that the lock is in the roll down po sition pr
4. conditions allow roll it out and let it dry before rolling it up again This will help prevent mildew e Mildew does not form on the fabric itself but on the accumulated dust and dirt Periodically clean vinyl or woven acrylic e Always make sure the awning is extended high enough before opening the entry door e Apply silicone spray lubricant as needed to keep the awning s moving parts operating smoothly For ease of operation on hardware rub candle wax on all sliding surfaces 8500 and 8300 e Abrasion and weather are vinyl s worst enemies To avoid these problems you will need to keep your awning clean Use a mixture of 1 4 cup dish soap 1 4 cup liquid bleach and five gallons of warm fresh water Soap the top side of the fabric with this mixture then roll it up and let stand for five minutes Rolling up the awning will apply the mixture to the underside of the fabric Unroll the awning and hose off the top and bot tom with clean water Repeat if necessary and allow to completely dry A amp E 9000 e In addition to its beauty and soft translucence woven acrylic fabric offers the advantages of strength and breath ability It is water repellent but because it is a woven cloth it is not water proof To keep your acrylic awning clean simply hose it off occasionally and let it dry Do Not Scrub e Avoid touching the underside of the 9000 canopy when it is wet To do so will break the surface tension of the water and encourag
5. ter and encourage seepage through the fabric Because the acrylic is woven not a solid vinyl shifting may occur if the awning and pull strap are not centrally aligned with the fabric roller tube while the awning is being rolled up If necessary roll the awning out and adjust the alignment as you close the awning The 8300 and 8500 is a vinyl nylon reenforced fabric Abrasion and harsh weather are vinyl s worst enemies To avoid abrasion you will need to keep your awning fabric clean Use a mixture of 1 4 cup dish soap 1 4 cup bleach and five gallons of fresh water Soap the open awning with this mixture then roll it up and let stand for five minutes Rolling up of the awning will ap ply the mixture to the underside of the fabric Unroll the awning and hose off the top and bottom with clean water Repeat if necessary and allow to completely dry 3 1 Fabric 3 1 1 Position For the awning to operate properly the fabric must be positioned properly in the awning rail and on the roller tube Open the awning and check the position of the fabric between the top mounting brackets If the fabric is not centered remove the tek screws center it and replace the screws Once the fabric at the rail is properly positioned next check the position of the fabric on the roller tube The clearance from the end cap of the torsion assembly to the edge of the fabric must be the same on each end If it is not adjust the fabric on the tube as necessary On
6. the Elite 9000 and 9500 awning the fabric is held in place to the weatherguard with set screws Check the position of the fabric at each end of the weatherguard If the fabric has shifted remove set screws center the fabric and re set An awning that the fabric has shifted will open and close hard 3 1 2 TEK Screws The Tek screws are the two screws installed through the awning rail of the coach They keep the fabric from shift ing in the awning rail On vinyl and acrylic awnings they keep the poly rope in the fabric from shrinking with age If one Tek screw is missing the fabric will pull toward the remaining Tek screw causing the fabric to wrinkle With the awning open remove the tek screws and pull outward on the fabric stretch it and re secure the screw Do this on both sides to assist with the wrinkles at the weather guard and fabric If wrinkles are still present repeat the above stretching procedure This may have to be done 4 or 5 times before all wrinkles disappear 6 X 1 2 EK SCREW AWNING RA FABRIC EDGE ROLLER COVER 6 X 1 2 TEK SCREW gt 7 A f Z po Le AWNING RAIL FABRIC EDGE 3 1 3 Square If the fabric on the awning is out of square it could cause the fabric to telescope in one direction when rolling up or to not hang properly in the open position To check fabric for square measure from the top right hand corner of the fabric not the weatherguard to the bottom left hand cor ner at th
7. to the first generation used in 1992 Prior to the special nut the hardware used a nutsert to hold the knob tight 930022 Apply spray lubricant to the threaded portion of the nut and knob once a year or as needed for smooth operation SPECIAL NUT 2 2 Black Adjustment Knob The black adjustment knob tightens the secondary rafter to the main rafter to keep the fabric taut in the full open position When closing the awning the knob should not be tightened down until after the awning is rolled up and the travel lock is engaged Attempting to open the aw ning without first loosening the black adjustment knobs can damage the slider of the secondary rafter making it difficult to open the awning Apply spray lubricant to the threaded portion of the knob once a year or as needed for smooth operation If Knob is frozen to nut it will need to be replaced with part number 3105421 014 2 3 Lift Handle Lock Button The push button of the lift lock assembly locks the main support arm to the adjustable arm assembly and controls the height of the awning in the open position To check it open the awning to full extension Look inside the main support arm and activate the button to see if the locking pin is moving in and out of the hole in the adjustable arm assembly If the locking pin does not move or has been broken off the lift handle assembly must be replaced At times the lock pin of the lift handle assembly can break off and jam between the l
8. Awning KU 17 BZ SIAC Wal eser E EE Or 17 This program will address the most common system problems associated with the A amp E Patio Awnings supplied by Dometic Corporation Our intent is to provide you with a guideline of checks to make should you encounter one of the following symptoms en Bi 1 Black adjustment knob will not tighten Special Nut Knob 2 2 2 2 3 Awning will not roll up straight Fabric Position 3 1 1 Fabric Square 3 1 3 4 Weatherguard wrinkled Seams 3 1 4 Sidewall 4 5 Fabric does not hang well 1 2 2 Main support arm will not extend Lift Handle Lock Button a Adjustable Arm 4 8 2 Tek Screws Tube Deflection Sidewall Out of square kb Stitches 3 1 5 Seams 3 1 4 Stop Plug 2 7 Bottom Mounting Brackets 2 6 9 2 5 Top Mounting Brackets 9 Fabric Position Operation 6 Must lift arm s to open awning 7 Awning arm s stay up against side of coach when trying to open awning Rafters Black Adjustment Knob Torsions 3 A 9 Awning will not stay in rolled down position 17 10 Fabric leaks at roller tube Stitches 11 2 8 11 Awning stops at guard when rolling up Rafters 10 Stop Plug 2 7 Torsions 17 Awning Rail 17 Top Mounting Bracket 9 Operation l T 8 Awning will not roll up CO a Na ec JI ec a anaana nana na zb na ze Sch co co N O O gt gt gt N zl oln A AO SS Operation 1 1 To Open 1 Loosen Knob and Unlock Hardware Loosen
9. Dia Hole Closest To Main Arm 5 16 18 x 1 Shoulder Bolt 5 16 18 Lock Nut Inner Arm 2 8 RAFTERS The rafters telescope from the top mounting brackets to the main support arms to provide tension on the fabric in the full open position If the rafters are bent or twisted this will hinder the operation of the awning Open the aw ning and remove the secondary rafter from the main sup port arm Sight down the main and secondary rafters and check for any bends twists or deflection If one or the other rafter is not true it should be replaced Note A bent rafter arm is not a warranty item If the arm was straight at delivery and unit is bent now something has bent the arm as improper operation or an act of na ture 10 Section 3 Fabric Roller Tube Assembly FRTA The fabric roller tube assembly consist of Fabric Alumi num Guard 858 amp 9000 only Roller Tube and Torsions Each component can be diagnosed then repaired or re placed The 9000 fabric is woven acrylic not canvas In addition to its beauty and soft translucence woven acrylic fabric offers the advantages of strength and breath abil ity It is water repellent but because it is a woven cloth it is not water proof To keep your acrylic awning clean simply hose it off occasionally and let it dry Do Not Scrub Avoid touching the underside of the 9000 canopy when it is wet To do so will break the surface tension of the wa
10. Dometic DIAGNOSTIC SERVICE MANUAL A amp E SUNCHASER 8500 9000 Patio Awnings USA SERVICE OFFICE Dometic Corporation 2320 Industrial Parkway Elkhart IN 46516 574 294 2511 CANADA Dometic Distribution 46 Zatonski Unit 3 Brantford Ontario CANADA NST 5L8 519 720 9578 REVISION Form No 3106934 015 9 07 Replaces 3106934 007 2007 Dometic Corporation LaGrange IN 46761 This service manual is the result of the dedication of The Dometic Corporation Technical Warranty and its engineering Staff in giving service people the nec essary instruction for making accurate analyses of certain conditions Provided is a diagnostic chart leading a qualified mechanic into the service manual pages to locate and solve symptoms which may occur Dometic has continued its commit ment in providing service people with this the most up to date information about servicing Dometic RV accessories SAFETY INSTRUCTIONS This manual has safety information and instruc tions to help users eliminate or reduce the risk of accidents and injuries RECOGNIZE SAFETY INFORMATION This is the safety alert symbol When you see this symbol in this manual be alert to the potential for personal injury Follow recommended precautions and safe op erating instructions UNDERSTAND SIGNAL WORDS Asignal word WARNING OR CAUTION is used with the safety alert symbol They give the level of risk for potential injury A WARNING Indic
11. LL TOWARD AWNING RAIL CANOPY 3 8 CHANNEL HINGE SLAT B STRIP A EO 5 16 ROD IN 1 4 CHANNEL AWNING RAII Drill out 1 8 pop rivet or spread crimp before sliding out fabric ee l VINYL STRIP A pea Trim poly rope Ba even and crimp Po end Current guards have a set screw in the channel Reinstall the set screw to keep fabric from shifting 15 Torque chart for 8500 and 9000 series awnings Torque chart for Sunchaser 8300 awnings TORSION WINDING FOR LARGE STABILIZER 8300 o BT Je 2 o aT Je 2 PFT o 8T Jo 8 8500 amp 9000 TORSION ASSEMBLY Awning Model 8500 amp 9000 Model 8500 amp 9000 Length Standard Heavy Duty N TORSION WINDING FOR SMALL STABILIZER 8300 AWNING LENGTH TURNS UP TURNS OPEN BEI 8H Oo 9T 8 10FT jg f4 DEI jg 4 12FT 8 13 FT J9 f5 Once the torsion have been wound lock the tension on 14 FT 9 J15 the 8500 9000 with a long cotter pin on the 8300 sun 15 FT chaser awning use a nail Now the awning can be rein stalled back on the coach Follow the instalation instruc 16 FT tions for the model awning you are working on O o OO CO o o CO CO o o Ov S 3 2 Pull Strap When closing the awning the pull strap should be rolled up at an angle from the center of the roller tube This will keep the awning from telescoping forward or rearwar
12. NG OUTWARD OPENING UPWARD There are three types of awning rail openings used in the RV industry Of these type A and B are acceptable for use on the 9000 Series awning Type C should never be used on the 9000 Series awning as it could cause a binding problem on the aluminum guard assembly but it is acceptable on the vinyl awnings On coaches with combinations drip awning rail a stand off may be needed for proper operation and keep the roller tube from hitting the rail Part number 3109623 003 4 2 Sidewall Before condemning the fabric for sags or wrinkles the awning rail and sidewall should be checked Open the awning and sight down the rail to see if the rail or sidewall varies up down inward or outward This must be taken into consideration when checking a fabric
13. as sembly and holds the awning in the open extended po sition This allows the rafter to pivot toward the roller tube The most common mounting location for each top mounting bracket would be directly over the awning rail so the screws go through the C portion of the rail On the Series 9000 awning the top mounting bracket can be mounted lower when possible for better coverage in the closed position If the top mounting bracket is mounted above center of the awning rail the aluminum guard will not cover the fabric properly If this is the case relocate the top mounting bracket accordingly Over the years A amp E has used a variety of Top Mounting Brackets on different hardware Today s Top Mounting Bracket should mount on the A amp E hardware going back to late 1980 All brack ets have slotted holes for the mounting screws allowing them to be adjusted side to side for proper alignment To adjust the brackets close the awning and sight down the main support arm and the main rafter The clearance on each side of the rafter should be approximately 1 4 inch If clearance is not correct adjust the top mounting bracket s as necessary On coaches with combination drip awning rail a stand off may be needed for proper op eration and to keep the roller tube from hitting the rail Part number 3109623 003 Mount Top Bracket a Over Awning Rail 14 x 3 Hex Head Screw Rafter Awning Rail With Drip Channel Mount Top Bracket
14. ates a potentially hazard ous situation which if not avoided could result in death or serious injury 7 Or Ulol NE Indicates a potentially hazard ous situation which if not avoided may result in minor or moderate injury SI el E When used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in prop erty damage Read and follow all safety information and in structions CONTENTS PAGE NO Diagnostic Flow Chart 4 Section 1 Operation Section 2 Hardware Components 21 E Te OCH TI EE 8 2 2 Black Adjustment KiObD ccccesceeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeseeeenensessanensanens 8 2 3 Lift Handle Lock Bases eege EgeeE 8 2 4 Adjustable Arm Assembly sssasssessnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnne 8 2 5 Top Mounting Bracket cccccessseeseseeeeseeseeeeeeseseeeeeeeeeeseesenseaeseanessenens 9 2 6 Bottom Mounting Bracket ccccccsssseeseeeeeeeeeeeeeeeeeeseeeeeeenessaneesenenseees 9 Beh SOP PNG EE 10 20 E 10 Section 3 Fabric Roller Tube Assembly FRTA 2A NON E 10 Oe fa OS IO NEE 10 Ki CT 10 a ig E oe UN E 11 SIA SEIMS ee ee re ee emcee en eee ere eee eee 11 Bo ig Rs eo a DES aae ee eee 11 3 1 6 Fabric Roller Torsion Change cccsssseecssssesseseseesneseeeeeesees 11 22 od bs if EE 17 39 R ller VT 17 3A NOUS IONS sereen an A E E E E E 17 34 1 Eege 17 Section 4 Other 4 14
15. d and will prevent a bulge from forming in the area where the strap is rolled up If the pull strap is rolled up at one end of the awning it can cause the fabric to telescope in that direction during roll up and create a bulge or wrin kles at that end This could cause the awning arm to stay against the side of the coach when trying to open 3 3 Roller Tube The roller tube is a 3 1 2 inch diameter tube It has 3 sym metrical grooves to retain the poly ropes of the awning fabric If the fabric appears to have more than normal sag the roller tube deflection must be taken into consideration Depending on the length of the awning the roller tube can deflect from one to five inches with the awning in the open position Installing a tension rafter will usually remove 80 per cent of sag and roller tube deflection All awnings 22 feet and longer must be installed with heavy duty hard ware which includes a center tension rafter a center sup porter and heavy duty adjustable arm assemblies If the roller tube is bent it will bounce up and down when opening and closing the awning Note A Roller Tube that is snapped in the center is not a warranty item This is normally caused by an act of na ture 3 4 Torsions The torsion assembly has a wound coil spring which pro vides tension on the roller tube to roll the awning up into the travel position The right hand torsion end cap contains a cam assembly which prevents the awning from billowing
16. e poly rope Now measure from the top left hand corner to the bottom right hand corner as shown below AWNING RAIL FABRIC 1ST POLY ROPE ROLLER TUBE Hle DISTANCE FROM FABRIC TO END CAP SAME ON EACH END In this check the difference of the two dimensions should be no more than one inch If it is more the fabric is out of square and replacement would be necessary 3 1 4 Seams The seams of the vinyl awning are electronically weld ed together with a heat seal The welded seams are the strongest part of the fabric If the fabric has wrinkles or sags it may be due to improper seam welding A close inspection may reveal the seams to be the source of the problem If so fabric replacement would be needed Whenever wrinkles are detected in the fabric stretching of the weatherguard should be performed before the fab ric is condemned for bad seams See 2 1 2 for stretching instructions 3 1 5 Stitches The side hems and poly ropes of the awning are stitched in with a sewing machine At times the stitches can allow water to leak through to the inside of the roller tube On vinyl awnings the stitches should be sealed with seam sealer available at sporting goods stores This will stop the water from running down the inside of the roller tube For the woven acrylic fabric of the 9000 9500 Series aw ning scotch guard is an approved sealant When sew ing in the poly ropes of the fabric if a straight line is not followed
17. e seepage through the fabric e Because acrylic is a woven fabric shifting may occur if the awning and pull strap are not centrally aligned with the fabric roller tube while the awning is being rolled up If necessary roll the awning out and adjust the alignment SECTION 2 Hardware Components Main Rafter Knob With Nut Knob With Nut Secondary Rafter a U Main Support Arm Slider Catch wl Ze Travel Lock Lift Lock Handle Adjustable Arm Bottom Mounting Bracket 2 1 Special Nut The special nut is simply a threaded fastening device used to tighten down the black adjustment knob If the knob will not tighten first remove the secondary rafter assem bly from the hardware Turn the knob to determine if the nut is stripped or spinning If so replace the special nut If you cannot turn the knob it will be necessary to replace both the special nut and the black adjustment knob To replace the nut open awning and remove the two screws at the bottom of the main arm that keeps the rafter from sliding out The rafters won t come apart until the knob is removed from the nut If the knob is frozen it will need to be cut off for removal Using a hack saw cut the knob stud as close to the rafter as possible without hurting the finish on the rafter Replace with new nut Part number 3307663 017 Dometic has used several versions of the nut for the knob The current nut will fit hardware back
18. ed as shown ROLLER TUBE SLIDE OUT TORSION ASSEMBLY b N ROLLER TUBE FABRIC GROooveE PLACE END CAP GUIDE ON ROLLER GROOVE SC NN SLIDE FABRIC VALANCE AND ROPE VALANCE ROPES NOTCH THROUGH GUIDE Dometic requires the use of the end cap guide to prevent damages to the fabric when replacing the fabric roller tube Place the end cap guide supplied with the replace ment fabric roller tube on the end of the roller tube Slide the fabric and valance ropes through the end cap guide and onto the roller tube Note When changing the fabric it is vital that the same grooves be used This eliminates the need to redrill any holes i e center support Guide the roller tube over the poly ropes of the fabric Be careful not to damage the roller tube or the fabric Install the pull strap Center the fabric on the roller tube and hand roll the entire assembly in the same direction as the original fabric Note The number of sections in the Aluminum guard can vary from each model number The standard was 6 sections for the 9000 series awning in the early nineties Today s 9000 and 8500 series awnings come with 5 sec tions of guard When installing a new fabric on an older 9000 series awning one section will have to be removed To reduce the possibility of the poly rope interfering with the cam lock mechanism the right hand torsion requires the valance rope to be cut off even with the roller tube The poly rope on the fab
19. ift handle assembly and the adjust able arm assembly making it difficult to extend the main support arm Replacement part number 830582 001 X To replace the lift handle assembly open the awning and remove the adjustable arm assembly Drill out the two 3 16 pop rivets and install the new lift handle assembly 2 4 Adjustable Arm Assembly The adjustable arm assembly allows for telescoping height adjustment of the main support arm and it connects to the bottom mounting bracket to support the weight of the aw ning If the main support arm cannot be extended freely the adjustable arm assembly should be checked Remove the adjustable arm assembly and check for nicks burrs bends or twists If any deflection is noted the ad justable arm assembly must be replaced For ease of op eration rub candle wax on all sliding surfaces To remove an adjustable arm that has been bent and forced back into the main support arm remove the complete main support arm Using another adjustable arm as a slide hammer come in from the top and remove the bent adjustable arm Chances of the main arm being bent would be slim Once the bent adjustable arm is removed a new arm should go back in and work OK Note A bent adjustable arm is not a warranty item If the arm was Straight at delivery and unit is bent now some thing has bent the arm as improper operation or an act of nature 2 5 Top Mounting Bracket The top mounting bracket supports the main rafter
20. ior to swinging arms toward vehicle Failure to do so can cause damage to the lock mechanism 2 Lower Arms To Stop Bolts Raise the lift handle to release the lock button Lower main arm to the stop plug Swing the handle down to engage the lock button in a hole Repeat for other side 3 Loosen knob and release slider During light rain lower end opposite from door to shed water and prevent pooling Slide the rafter arm down to the bottom of the main arm Leave black adjustment knob loose Repeat for other side 4 Roll Up FRTA Grasp the pull strap pull toward you and flip the locking lever up to the ROLL UP position CAUTION Do not release the awning pull strap now It is under tension and could snap back against the vehicle side Slide the pull strap to the center and using it to control speed allow the awning to return to the vehicle side Note Allow the strap to wind diagonally to prevent a bulge in the fabric On the 9000 series when rolling up the awning the roller tube assembly should not be slowed down before reach ing the aluminum guard This could cause the roller tube to stall at the guard Tighten black adjustment knob Sunchaser Awnings Squeeze rafter into arms to engage latch 8500 amp 9000 Flip travel lock latch down Repeat for other side Your awning is now ready for travel HELPFUL HINTS FOR AWNING CARE Whenever the awning is wet while rolled up as soon as
21. it could cause the fabric to hang improperly A close inspection of the stitching could reveal the cause of a sag or pucker 3 1 6 Fabric Roller Torsion Change In all instances of fabric or roller tube replacement it will be necessary to have a large work area to allow complete unrolling of the awning This work area must be clean and smooth so the fabric will not be damaged Remove the awning from the coach and carefully lay on the ground To keep the awnings from unwinding during this step be sure the cam lock lever is in the roll down position The spring tension should be pinned on both torsions for ease and safety for removal of awning Sunchaser 8300 Torsion Pinning To keep the awning from unwinding be sure the lock lever is in the roll down position and a nail inserted in each tor sion assembly for positive locking of the roller tube The left end should be done first Insert a nail into hole on the left end cap Grasp roller assembly and release Safe T Lock lever Allow awning to roll up slowly until it stops against the pin Insert the pin into the right end cap to hold it in place Complete instructions Form 3105903 XXX A WARNING Severe injuries can result from the rapid spin off of the top casting Use Vise Grips NEVER use bare hands to handle a top casting under spring tension 3 16 A INSERT NAIL Ba A ROLLER TUBE END CAP 8500 amp 9000 Torsion Pinning To keep the awnings from unwinding during
22. ler tube Insert pin through torsion rod and hex stud Slide 3 4 deep well socket over hex stud and 1 4 pin Slide 3 4 hex head stud into torsion rod Move to roll up position A WARNING Improper release of this spring tension can result in damage to the awning severe per sonal injury or both Once the tension has been removed mark the location of the cam lock lever on the roller tube and drill out the rivets with a 3 16 drill bit and remove the torsion from the roller tube Roll the awning completely out on a clean smooth surface With the awning laying flat slide the roller tube out from fabric The metal roller cover on 8500 and 9000 models may be crimped to the poly ropes Use needle Nose pli ers and flat blade screw driver to spread open the channel before removing fabric On newer units the guard is held to the fabric with a set screw at the ends of the channel remove the set screws and slide the guard off the fabric Note Some 9000 model awning secured the fabric to the roller cover with 1 8 pop rivets It is necessary to remove the 1 8 pop rivets from both ends of the roller cover Once the rivets are removed you can slide the fabric out of the cover Unfold the new fabric and lay it on top of the existing fab ric in the exact same position Be sure the new fabric is the correct size and color If roller tube is being replaced make sure it is the correct length and position it with the notch locat
23. ric side is cut 6 longer than the roller tube Stretch the poly rope and pull it toward the center of the roller tube Make sure it is locked in the notch of the groove in the roller tube Reinstall the torsion assembly in the roller tube Align the rivet slots on the end cap with the holes in the roller tube in the exact same position as the original If a new roller tube is being used make sure the fabric has been installed as the original unit The poly ropes on the left hand end of the roller tube should be trimmed in the same as the right hand then install the left hand torsion ROLLER TUBE FABRIC STRETCH FABRIC ROPE TIGHT AND PULL DOWN AND INTO THE CENTER OF ROLLER TUBE MAKE SURE IT IS LOCKED IN THE NOTCH ON THE BOTTOM OF THE GROOVE CUT VALANCE ROPE EVEN WITH THE END OF THE ROLLER TUBE NOTE Placing the end caps as suggested usually posi tions the lock lever in the proper position when awning is closed The awning should be opened and closed several times and checked The cam lock lever should be at the 11 00 position when awning is in the closed position The end cap may have to be removed and repositioned if it is not in the proper location 8500 and 9000 Torsion Identification Models 8500 and 9000 19 25 have been manufac tured with both standard and heavy duty torsion springs Before reinstalling the torsion properly identify Standard or Heavy Duty the springs This is necessary for proper
24. this step be sure the cam lock lever is in the roll down position A 1 8 cotter pin can be inserted in each torsion assembly for positive locking of the roller tube Complete instructions Form 3107299 XXX MOVE LEVER POSITION TO ROLL DOWN POSITION RIGHT HAND SIDE VIEWED FROM FRONT TOP CASTING A WARNING release of this spring tension the aw injury or both Improper can result in damage to ning severe personal A WARNING Severe injuries can result from the rapid spin off of the top casting Use Vise Grips NEVER use bare hands to handle a top casting under spring tension Carefully lay the fabric roller tube assembly on a clean well padded V trough to prevent fabric damage Re move the arm assemblies from the respective torsion rod by removing the 1 4 20 machine screws 8500 amp 9000 Clamp a Vise Grip tightly on the top casting or insert the crank 3107905 006 3308334 006U into top casting Remove the 1 4 20 hex head machine screw from the top casting Take the top casting carefully out of the main sup port arm Slowly let the torsion spring unwind completely Repeat Steps 1 amp 2 for the opposite end NOTE If the awning s right hand torsion assembly has been pinned the cotter pin must be removed from the torsion assembly before the spring can be unwound The cam lock lever on the right hand torsion assembly must be turned clockwise to the roll up position before the spring can be un
25. winding of the torsion See Spring Identification Chart Painted red Painted red cap end and cap end and low cap end on cap end no paint on blue on stabi red on stabi and black Position the right hand torsion assembly open hole in the end cap in alignment with the empty groove in the roller tube If a new right hand torsion assembly is being in stalled and the roller tube does not have the notch shown the two tabs inside the right hand torsion end cap must be broken off Secure torsion assemblies to roller using 3 16 dia x 3 8 long pop rivets BREAK OFF TWO LOCATING TABS WINDTop AWNINGRAIL AWNINGRAIL WINDTOP CASTING CASTING GREENDOT RIGHT HAND SIDE VIEW FROM FRONT LEFT HAND SIDE VIEW FROM REAR SPRING IDENTIFICATION CHART Standard Heavy Duty Painted yel Painted white stabilizer lizer end lizer end on stabilizer end end Painted yel Painted black low on cap Jon stabilizer No paint on no paint on end no paint end and no either end stabilizer on stabilizer paint on cap end end end Painted blue cap end and A VINYL STRIP B HINGE SLAT C TOP SLAT D MAIN SLAT E AWNING RAIL Drill out 1 8 pop rivet before sliding out fabric a V V H wee Trim poly rope aa even and crimp end HINGE SLAT B TOP SLAT C VIEW RH END K 3 16 oe a BOTH ENDS MAIN SLAT D VIEW RH END 1 4 CHANNEL 5 16 CHANNEL INSTALL TOWARL INSTA
26. wound Always note and or mark the location of cam lock on roller tube 12 TOP CASTING N N Pa MAIN SUPPORT 1 4 20 X 1 2 HEX ARM ASSEMBLY HD MACH SET SCREW MAIN SUPPORT ARM ASSEMBLY 1 4 HD MACH SET SCREW A WARNING Severe injuries can result from the rapid spin off of the top casting Use Vise Grips NEVER use bare hands to handle a top casting under spring tension Sunchaser 8300 Carefully lay the fabric roller tube assembly on a clean well padded V trough to prevent fabric damage Re move the right arm assembly from the respective torsion rod by removing the 1 4 20 machine screws and 1 4 locknuts Lift the right end of the awning and roll the FRTA assembly clockwise one half turn or until roll pin inside end cap is stopped against the nail Remove the left arm assembly from the torsion rod by removing the 1 4 20 machine screws and locknuts Insert torsion winding 3 4 hex head stud into the end of the torsion rod Insert 1 4 pin through 3 4 deep well socket over hex stud Slide the 3 4 deep well socket over hex stud until it locks 1 4 pin in place Insert speed wrench or breaker bar into socket Remove the pin from the end cap It may be necessary to turn torsion rod to release pressure from pin making it easier to remove Note On right hand torsion move the Safe T Lock le ver to the roll up position Always note and or mark the location of cam lock on rol

9/6/07 Patio Awning Diagnostic Service Manual A & E

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9/6/07 Patio Awning Diagnostic Service Manual A &amp; E

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9/6/07 Patio Awning Diagnostic Service Manual A & E