Dometic A&E Systems 828 Series Guide

1
USA
SERVICEOFFICE
DometicCorporation
509SouthPoplarStreet
Lagrange,IN46761
260-463-4858
CANADA
DometicDistribution
866LangsDrive
Cambridge,Ontario
CANADAN3H2N7
519-653-4390
For Service Center
AssistanceCall:
800-544-4881
SERVICEINSTRUCTIONS
REVISION
FormNo.3105903.060 8/04
(Replaces3105903.052)
(French3108577.044)
©2004DometicCorporation
LaGrange,IN46761
This manual must be read and un-
derstood before installation, ad-
justment, service, or maintenance
is performed. This unit must be in-
stalled by a qualified service tech-
nician.Modificationofthisproduct
can be extremely hazardous and
could result in personal injury or
property damage.
Lire et comprendre ce manuel avant de
procéderàl'installation,àdesréglages,
de l'entretien ou des réparations.
L'installation de cet appareil doit être
effectuée par un réparateur qualifié.
Toute modification de cet appareil peut
être extrêmement dangereuse et
entraîner des blessures ou dommages
matériels.
REPLACEMENT INSTRUCTIONS FOR
828XXXX, 830XXXX, 833XXXX,
834XXXX, 836XXXX SERIES
MODEL 8300 AND SUNCHASER AWNINGS
FABRIC ROLLER TUBE TORSION ASSEMBLY
MODELS
828(XXXX) 834(XXXX)
830(XXXX) 836(XXXX)
833(XXXX)
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2
SAFETY INSTRUCTIONS
This manual has safety information and instruc-
tionsto helpusers eliminateor reducethe riskof
accidentsand injuries.
RECOGNIZE SAFETY INFORMATION
Thisisthesafety-alertsymbol.Whenyou see this
symbolinthis manual,bealert tothepotentialfor
personalinjury.
Follow recommended precautions and safe op-
eratinginstructions.
UNDERSTAND SIGNAL WORDS
Asignal word ,WARNING ORCAUTION is used
withthesafety-alertsymbol.Theygivethelevelof
riskforpotentialinjury.
Indicatesa potentiallyhazard-
oussituation which, ifnotavoided, couldresultin
deathorseriousinjury.
Indicates a potentially hazard-
ous situation which, if not avoided may result in
minorormoderate injury.
When used without the safety
alertsymbol indicates,apotentiallyhazardoussitu-
ation which, if not avoided may result in property
damage.
Readandfollowallsafetyinformationandinstruc-
tions.
!
WARNING
!
CAUTION
CAUTION
!
A. Removal Of Awning From Coach
Note: Awning removal from the coach is NOT necessary
when replacing a torsion assembly. Proceed to Section B,
Steps 1 & 2, Sections C, Steps 1–3, and Section D, Steps
1–3.
1. Inallinstancesoffabricorrollertubereplacement,
itwillbenecessarytohavealargeworkareatoallow
complete unrolling of the awning. This work area
must be clean and smooth so the fabric will not be
damaged.
TOOLS AND HARDWARE REQUIRED:
EndCapGuide Socket Wrench Set
Screwdriver Pliers
Electric Drill PopRivetTool
3/16" Drill Bit RollofGrayTape
Stepladder Small File
TorsionWindingTool Steel Pin
1/8"CardboardorWoodSpacer
3/16"PopRivet(308171.006)4req.
TheFabricRollerTubeAssembly(FRTA)consists
ofa fabric,a rollertube andtorsion assemblies.
For proper awning operation, the roller tube is
underspringtensionfromthetorsionassemblies.
Improper release of this spring tension can
result in damage to the awning, severe per-
sonal injury, or both.
These instructions must be read and under-
stood before installation of this kit. This kit
must be installed by a Dometic Service Cen-
ter or a qualified service technician. Modifica-
tion of this product can be extremely hazard-
ous and could result in personal injury or
property damage.
GENERAL INSTRUCTIONS
8300 and Sunchaser Service Instructions
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3
AWNING
RAIL
#6 SELF
DRILLING
SCREW
FABRIC
EDGE
2 INCHES
FIG. 1
FIG. 2
FIG. 4
FIG. 3
ROLLER TUBE
END CAP
#14 HEX.
HD. SCREW
PIVOT PIVOT
TOP MOUNTING BRACKET TOP MOUNTING
BRACKET
AWNING RAIL
#14 HEX.
HD. SCREWAWNING
RAIL
2. Removethescrewssecuringtheawningfabricat
each end of the awning rail. See FIG. 1.
ONSQUAREHARDWARE:
3. Placea1/8"cardboardorwoodspacerbetweenthe
armandtherafter.Wrapgraytapearoundthearm
and rafter to hold them together. See FIG. 2.
Repeat onoppositeendofawning.
4. Removebothofthepatiofeetfromtheirmounting
bracketsandextendtheadjustablearmsuntileach
patio foot rests on the ground. Tighten knob to
secure adjustable arm in this position.
5. Tokeeptheawningfromunwindingbesurethelock
leveris in theroll downpositionand a nailinserted
ineach torsionassemblyforpositivelockingof the
rollertube. The left endshouldbedonefirst.Insert
pin into hole on the left end cap. Grasp roller
assembly and release Safe-T-Lock™ lever. Allow
awningtorollupslowlyuntilitstopsagainstthepin.
Insertthepinintotherightendcaptoholditinplace.
See FIG. 3.
6. Removethetwo#14x2"HexHeadscrewsfromthe
topmountingbracket.Repeatfortheoppositeend.
See FIG. 4.
8300 and Sunchaser Service Instructions
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4
FIG. 6
9. Liftthe rightend of the awning androll theFRTA
assembly clockwise one-half turn or until roll
pin (inside end cap) is stopped against the nail.
10. Removetheleftarmassemblyfromthetorsionrod
byremovingthe1/4"–20machinescrewsandlock-
nuts.
11. Proceed to Section B. Removal of Torsion As-
sembly from Roller Tube.
7. Withonepersongraspingeachsupportarm,keep-
ing the two arm assemblies PARALLEL to each
othertoavoidexcessivetwistingandpossibledam-
agetoassembly,walktheawningoutoftheawning
rail. See FIG. 5.
FIG. 5
8. Carefully lay the fabric roller tube assembly on a
clean, well padded "V" trough to prevent fabric
damage.Removetherightarmassemblyfromthe
respective torsion rod, by removing the 1/4"–20
machine screws and 1/4" locknuts. See FIG. 6.
B. Removal Of Torsion Assembly From Roller
Tube
1. Theawningisremovedfromthecoachandisonthe
groundwiththetorsionpinnedandarmsremoved.
a. Insert torsion winding 3/4" hex head stud into
the endofthetorsionrod.Insert1/4"pinthrough
3/4"deepwellsocketoverhexstud.Slidethe3/
4" deep well socket over hex stud until it locks
1/4" pin in place. See FIG. 7.
b. Insertspeedwrenchorbreakerbarintosocket.
c. Remove the pin from the end cap. It may be
necessary to turn torsion rod to release pres-
surefrom pin, making it easier to remove. See
FIG. 8.
Note:Onrighthandtorsion,movetheSafe-T-Lock™leverto
theroll-upposition.
d. Slowly unwind the spring tension from the
torsion.
e. Use 3/16" drill bit to remove the two pop rivets
fromthe end cap.
f. Slide the torsion out of the roller tube.
FIG. 8
FIG. 7
8300 and Sunchaser Service Instructions
Severe injuries can result from the rapid
spin-offofthetorsionspring. Alwayshave
a positive grip on the speed wrench or
breaker bar. Ratchet should not be used
because it may allow rapid spin-off of the
torsion spring.
DONOTREMOVEtheNAILatthistimeand
DONOTattempttorotatetheSafe-T-LockTM
Lock Direction Lever.
Move to roll up position
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5
2. The awning is installed on the coach.
a. Thisisthemethodusedwhenreplacingtorsion
ormainarm.Theawningmustbefullyextended
withrafters locked in place and the Safe-T-
Lock™leverintheroll-downposition.
b. Insert pin in left torsion end cap. It should be
placed in one of the two holes closest to the
counter-clock-wise side of the 1/8" roll pin in
torsion rod. It may be necessary to rotate the
FRTA one way or the other to place the pin
correctly. See FIG. 9.
c. The right hand torsion should also be pinned.
SeeSection A, Paragraph 5 on Page 3, for
instructions.
d. Thearmcannowberemovedfromeitherright
handorlefthandtorsion.Topreventdamageto
fabricandotherparts,theendoftherollertube
must be supported so it will not swing back
againstthe coach ordrop down.
e. The torsion can now be unwound. Refer to
Section B., Number 1, Steps a. through f.
FIG. 9
C. Removal And Replacement Of Fabric &
Roller Tube
1. The awning must be removed from coach. See
Section A.
2. Thetorsionsmustberemovedfrombothendsofthe
roller tube. See Section B., Number 1, Steps a
throughf.
3. Unrollfabricfromrollertube,withthetop-sidefacing
down.
4. Pull poly ropes out of the notch in each end of the
rollertube.
5. Haveonepersonholdtheedgeofthefabricwhilea
secondperson slidesthe roller tubeoff the fabric.
6. Ifthenewfabricistobeinstalled,layitontopofthe
oldfabricinthesamedirection.Makesurethesize
and color is correct.
7. Dometic requires the use of the end cap guide to
preventdamages to the fabric, when replacing the
fabric/rollertube.Placetheendcapguidesupplied
withthereplacementfabric/rollertubeontheendof
the roller tube. Slide the fabric and valance ropes
throughtheendcapguideandontotherollertube.
Seefigure9A.
8. Centerfabriconrollertube.
9. Install torsion per instructions in Section D.
FIG. 9A
PLACE END
CAP GUIDE
ON ROLLER
TUBE
ROLLER
TUBE
SLIDEFABRIC AND
VALANCE ROPES
THROUGH GUIDE
D. Replacement Of Torsion
1. Insertthelegoftheidleroppositethetorsionspring
screw and washer over the seamed groove of the
rollertube. See FIG. 10.
Note: Theidlerleg opposite thetorsion springscrewhasa
triangleshape.
FIG. 10
8300 and Sunchaser Service Instructions
Fabric is to be rolled out only on a clean
surface to prevent damage.
CAUTION
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6
2. Installationofanewrollertubemayrequireanotch
cutinthesideofthegrooveawayfromlockleverfor
each poly rope. See FIG. 11.
Note:Inserttorsion idlerintorollertubebeforethepolyrope
is stretched. See Section D. Step 1.
3. Use pliers to stretch the poly rope 1/4" – 1/2" and
tuck itinto the notch and place off to the side. See
FIG.16A-16Gonpages7-9. RepeatSteps1and2
onoppositeend.
FIG. 12
CAP A
CAP B
4. Slidetorsion assembly into roller tube.Identify the
endcap"A","B"or"C"(refertoFIG.12).Positionthe
Safety-T-Lock™LeverasshowninFIGS.16A–16F
onpages7-9.
Theleft-handendcapisalwayspositionedwiththe
opennotchovertheopengroove.SeeFIG.16Gon
page9.
WIND TO
ADD TORSION
L
E
F
T
R
I
G
H
T
ROLL
UP
ROLL
DN
WIND TO
ADD TORSION
L
E
F
T
R
I
G
H
T
ROLL
UP
ROLL
DN
CAP C
FIG. 11
5. Mark the location of rivet holes in the end cap on
rollertube. Drill 3/16" hole. Remove any drill burrs
frominsiderollertube.
6. Attach end cap to roller tube with two 3/16" x 3/8"
poprivets.Repeatonoppositeend.
E. Winding Torsions
1. Inserttorsionwindingtoolintotorsionrod.SeeFIG.
7.
2. Always have the speed wrench handle at the 6 O-
clock positions and turn towards the side of the
coach.Left hand endcapis turned clock-wiseand
righthand endcap isturned counter-clock-wise to
addtension.
Note:RighthandtorsionmusthaveSafe-T-Lock™leverin
theroll-downposition.
3. After torsion spring is wound to proper number of
turns, insert a steel pin in the end cap to prevent
rapidspin-offwhenreinstallingoncoach.SeeFIG.
3,page3andTable1&2.Torsionassemblyinfigure
14hasalargerstabilizerthanthetorsionassembly
infigure 15,shownwith bubble1 in bothfigures.
4. ReinstallawningpertheOperatingandInstallation
Manual.Iftheawningisnotremovedfromthecoach,
reversedisassemblyprocedure.
FIG.13
Springpinsonright&left
endsneedtoalignwhen
nails are installed.
TORSION
WIND
8300 and Sunchaser Service Instructions
Selectcorrecttorsionassemblyandwindtor-
sion to the appropriate winds as specified in
table 1 or 2.
CAUTION
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7
FIG.16A
WIND TO
ADD TORSION
L
EF
T
R
IG
H
T
ROLL
UP
ROLL
DN
Place open notch
in alignment with
open groove
See Fig. 11
Open
Groove
Fabric
edge
without
hemmed
Cut Poly Rope flush
with end of tube
Valance
Trim Poly Rope
leaving sufficient
length to tuck in
place behind the
open groove
RIGHT-HAND
END CAP “A”
41ERUGIFROFGNIDNIWNOISROT:1ELBAT
HTGNELGNINWAPUDELLOR *SNRUT DEDNETXE SNRUT
'85 11
'95 11
'015 11
'115 11
'215 11
'316 21
'416 21
'517 31
'617 31
'719 51
'819 51
'910161
'020161
evobadna'120161
nehwgnirpsnoisrototsnrutlanoitidda6ddA* .dednetxeyllufsigninwa
51ERUGIFROFGNIDNIWNOISROT:2ELBAT
HTGNELGNINWA PUDELLOR *SNRUT DEDNETXE SNRUT
'88 41
'98 41
'018 41
'118 41
'218 41
'319 51
'419 51
'510161
'610161
'712181
'812181
'912181
'022181
evobadna'122181
nehwgnirpsnoisrototsnrutlanoitidda6ddA* .dednetxeyllufsigninwa
FIG. 15
FIG. 14
8300 and Sunchaser Service Instructions
11
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8
FIG.16D
Place open notch
in alignment with
valance groove
See Fig. 11
Open
Groove
Fabric
edge
without
hemmed
Cut Poly Rope flush
with end of tube
Valance
Trim Poly Rope
leaving sufficient
length to tuck in
place behind the
open groove
RIGHT-HAND
END CAP “B”
WIND TO
ADD TORSION
L
E
F
T
R
I
G
H
T
ROLL
UP
ROLL
DN
FIG.16B
See Fig. 11
Open
Groove
Fabric edge
folded and
hemmed
Cut Poly Rope flush
with end of tube
Valance
Trim Poly Rope
leaving sufficient
length to tuck in
place behind the
open groove
Place open notch in alignment
with fabric groove
WIND TO
ADD TORSION
LE
F
T
R
I
G
H
T
ROLL
UP
ROLL
DN
RIGHT-HAND
END CAP “A’
FIG.16C
WIND TO
ADD TORSION
L
E
F
T
R
I
G
H
T
ROLL
UP
ROLL
DN
See Fig. 11
Open
Groove
Fabric edge
folded and
hemmed
Cut Poly Rope flush
with end of tube
Valance
Trim Poly Rope
leaving sufficient
length to tuck in
place behind the
open groove
Place open notch in alignment
with fabric groove
RIGHT-HAND
END CAP “B”
8300 and Sunchaser Service Instructions
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9
LEFT-HAND END CAP
Fabric
See
Fig. 11
Valance
Open Groove
The Left-Hand
End Cap is always
placed with open
notch in alignment
with open groove
Trim Poly Rope
leaving sufficient
length to tuck in
place behind groove
FIG.16E
FIG. 16F
Place open notch
in alignment with
Open groove
See Fig. 11
Open
Groove
Cut Poly Rope flush
with end of tube
Valance
Trim Poly Rope
leaving sufficient
length to tuck in
place behind the
open groove
RIGHT-HAND
END CAP “C”
Fabric edge
folded and
hemmed
FIG. 16G
See Fig. 11
Open
Groove
Cut Poly Rope flush
with end of tube
Valance
Trim Poly Rope
leaving sufficient
length to tuck in
place behind the
open groove
Place open notch in alignment
with fabric groove
RIGHT-HAND
END CAP “C”
Fabric
edge
without
hemmed
8300 and Sunchaser Service Instructions
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