Dometic A&E Systems Sunchaser User manual

DIAGNOSTIC SERVICE MANUAL
REVISION
Form No. 3106934.015 9/07
(Replaces 3106934.007)
©2007 Dometic Corporation
LaGrange, IN 46761
A&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 N3T 5L8
519-720-9578

2
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 qualied
mechanic into the service manual pages
to locate and solve symptoms which may
occur. Dometic has continued its commit-
mentinprovidingservicepeoplewiththis,
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
Thisisthesafety-alertsymbol.Whenyouseethis
symbol in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe op-
erating instructions.
UNDERSTAND SIGNAL WORDS
Asignalword,WARNINGORCAUTIONisused
with the safety-alert symbol. They give the level
of risk for potential injury.
Indicatesa potentiallyhazard-
ous situation which, if not avoided, could result
in death or serious injury.
Indicatesa potentially hazard-
ous situation which, if not avoided may result in
minor or moderate injury.
When used without the safety
alert symbol indicates, a potentially hazardous
situationwhich,ifnotavoidedmayresultinprop-
erty damage.
Read and follow all safety information and in-
structions.

3
PAGE NO.
Diagnostic Flow Chart...................................................................4
CONTENTS
Section 1
Operation
1.1 Open...........................................................................................................5
1.2 Close ..........................................................................................................6
Section 2
Hardware Components
2.1 Special Nut.................................................................................................8
2.2 Black Adjustment Knob............................................................................8
2.3 Lift Handle Lock Button............................................................................8
2.4 Adjustable Arm Assembly........................................................................8
2.5 Top Mounting Bracket ..............................................................................9
2.6 Bottom Mounting Bracket........................................................................9
2.7 Stop Plug .................................................................................................10
2.8 Rafters......................................................................................................10
Section 3
Fabric Roller Tube Assembly (FRTA)
3.1 Fabric .......................................................................................................10
3.1.1 Position...........................................................................................10
3.1.2 Tek Screws......................................................................................10
3.1.3 Square............................................................................................. 11
3.1.4 Seams.............................................................................................. 11
3.1.5 Stitches...........................................................................................11
3.1.6 Fabric / Roller / Torsion Change...................................................11
3.2 Pull Strap .................................................................................................17
3.3 Roller Tube...............................................................................................17
3.4 Torsions ...................................................................................................17
3.4.1 Cam Lock........................................................................................17
Section 4
Other
4.1 Awning Rail..............................................................................................17
4.2 Sidewall....................................................................................................17

4
This program will address the most common system problems associated with theA&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.
Symptom Cause Refer To Page
1. Black adjustment knob will not tighten Special Nut
Knob 2.1 2.2 8
8
2. Main support arm will not extend Lift Handle Lock Button
Adjustable Arm 2.3 2.4 8 8
3. Awning will not roll up straight Fabric Position
Fabric Square 3.1.1
3.1.3 10 11
4. Weatherguard wrinkled Seams
Sidewall 3.1.4
4.2 11 17
5. Fabric does not hang well Tek Screws
Tube Deection
Sidewall
Out of square
Stitches
Seams
3.1.2
3.3
4.2
3.1.3
3.1.5
3.1.4
10
17
17
11
11
11
6. Must lift arm (s) to open awning Stop Plug
Bottom Mounting Brackets 2.7 2.6 10 9
7. Awning arm (s) stay up against side of
coach when trying to open awning Top Mounting Brackets Fabric Position
Operation
2.5
3.1.1
1.2
9
10
7
8. Awning will not roll up Rafters
Black Adjustment Knob
Torsions
2.8
2.2
3.4
10
8
17
9. Awning will not stay in rolled down position Cam Lock 3.4.1 17
10. Fabric leaks at roller tube Stitches 3.1.5 11
11.Awning stops at guard when rolling up Rafters
Stop Plug
Torsions
Awning Rail
Top Mounting Bracket
Operation
2.8
2.7
3.4
4.1
2.5
1.2
10
10
17
17
9
7

5
Operation
Loosen
Knob Sunchaser: Squeeze
8500/9000:
Flip
1. Loosen Knob and Unlock Hardware
2. Unlock Fabric Roller Tube Assembily (FRTA)
Pull down.
Ensure the lock lever is not ipped 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
Hook the rod in loop, and pull all the way out.
3
4. Extend and Secure Rafters
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.
1.1 To Open

6
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
Lower arm to shortest position. Press the release lever
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.
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
During light rain, lower end opposite from door to shed
water and prevent pooling.
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.
Ensure that the lock is in the “roll-down” po-
sition prior to swinging arms toward vehicle.
Failureto do so cancausedamageto thelock
mechanism.
Raisethelifthandleto releasethelockbutton. Lowermain
arm to the stop plug. Swing the handle down to engage
the lock button in a hole. Repeat for other side.
1. From Patio Position
2. Lower Arms To Stop Bolts
3. Loosen knob and release slider
1.2 TO CLOSE

7
Slide the rafter arm down to the bottom of the main arm.
Leave black adjustment knob loose. Repeat for other
side.
Grasp the pull strap, pull toward you, and ip the locking
lever up to the ROLL UP position.
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.
4. Roll Up FRTA.
HELPFUL HINTS FOR AWNING CARE
• Whenever the awning is wet while rolled up, as soon
asconditionsallow,rollitoutandletit drybeforerolling
it up again. This will help prevent mildew.
• Mildew does not form on the fabric itself, but on the
accumulated dust and dirt. Periodically clean vinyl or
woven acrylic.
• Alwaysmakesuretheawningisextendedhigh enough
before opening the entry door.
• Apply silicone spray lubricant as needed to keep the
awning’s moving parts operating smoothly. For ease
ofoperationonhardware,rub candle wax on allsliding
surfaces.
8500 and 8300
• 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 ve gallons of warm fresh water.
Soap the top side of the fabric with this mixture, then
roll it up and let stand for ve 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&E 9000
• 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.
• Avoidtouchingtheundersideofthe9000canopywhen
it is wet. To do so will break the surface tension of the
water and encourage seepage through the fabric.
• 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.
Tighten black adjustment knob.
SunchaserAwnings:Squeezerafterinto arms to engage
latch.
8500 & 9000: Flip travel lock latch down.
Repeat for other side. Your awning is now ready for
travel.
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.
Do not release the awning pull strap now. It
isundertensionand couldsnap back against
the vehicle side.

8
SECTION 2
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 rst loosening the black adjustment knobs
can damage the slider of the secondary rafter, making it
difcult 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 lift handle assembly and the adjust-
able arm assembly, making it difcult 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.
Hardware Components
Top Mounting Bracket
Main Rafter
Knob With Nut
Secondary Rafter
Slider
Main Support Arm
Slider Catch
Travel Lock
Lift-Lock Handle
Adjustable Arm
Bottom Mounting
Bracket
2.1 Special Nut
Thespecialnut is simplya threaded fasteningdevice used
to tighten down the black adjustment knob. If the knob
will not tighten, rst 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
2.4 Adjustable Arm Assembly
Theadjustablearmassemblyallowsfortelescopingheight
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.
Knob With Nut
to be cut off for removal. Using a hack saw cut the knob
stud as close to the rafter as possible without hurting the
nish 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 t hardware back
to the rst 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.

9
Removetheadjustablearm assembly andcheckfornicks,
burrs, bends or twists. If any deection 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 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 yearsA&E
has used a variety of Top Mounting Brackets on different
hardware. Today’s Top Mounting Bracket should mount
on the A&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.
2.6 Bottom Mounting Bracket
The bottom mounting brackets are screwed to the oor
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 difcult.
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.
Mount Top Bracket
Over Awning Rail
#14 x 3" Hex
Head Screw
Awning
Rail
Top Pivot
Rafter
Mount Top Bracket
Below Awning Rail
Mount Top Bracket
Over Awning Rail
#14 x 3" Hex
Head Screw
#14 x 3" Hex
Head Screw
Awning Rail With
Drip Channel
Top Pivot
Top Pivot
Rafter
Rafter
Awning Rail With
Drip Channel
Top Bracket Leg
Mounted On Aw-
ning Rail
#14 x 3" Hex
Head Screw
Top Pivot
Rafter
Awning Rail With
Drip Channel

10
Molding
Standoff Kit 3104781.XXX
Bottom Wall Bracket
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.
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 deection. 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.
Fabric Roller Tube Assembly (FRTA)
The fabric roller tube assembly consist of Fabric, Alumi-
num Guard (858 & 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-
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 ve gallons of fresh water.
Soap the open awning with this mixture, then roll it up and
let stand for ve 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.
Section 3
3.1 Fabric
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,removethetekscrews,centerit,andreplacethe
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
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.
3.1.1 Position
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.
5/16" - 18
Lock Nut
5/16" - 18 x 1"
Shoulder Bolt
Inner Arm
Main Arm
3/8” Dia. Hole
Closest To
Main Arm
Inner Arm
Main Arm
3/8" Dia. Hole
Closest To
Main Arm

11
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 the 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
DISTANCE FROM FABRIC TO END CAP (SAME ON EACH END)
ROLLER
TUBE
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, 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 rst. 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
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.

12
8500 & 9000 Torsion Pinning
To keep the awnings from unwinding during 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.
TOP CASTING
COTTER
PIN
MOVE LEVER POSITION TO
ROLL DOWN POSITION RIGHT-HAND SIDE
(VIEWED FROM FRONT)
Improper release of this spring tension
can result in damage to the aw-
ning, severe personal injury, or both.
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.
8500 & 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 & 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 unwound.
Always note and or mark the location of cam lock on roller
tube.
LOCK
LEVER
TOP
CASTING
MAIN SUPPORT
ARM ASSEMBLY
VISE-
GRIPS®
1/4-20 X 1/2" HEX
HD. MACH. SET SCREW
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.
LOCK
LEVER
TOP
CASTING
1/4 - 20 X 1/2" HEX
HD. MACH. SET SCREW
MAIN SUPPORT
ARM ASSEMBLY
CRANK
3107905.006
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.

13
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 roller tube.
Rollthe awningcompletely out on a clean smooth surface.
With the awning laying at, 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 at 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 located as shown.
Improper release of this spring tension can
result in damage to the awning, severe per-
sonal injury, or both. 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).
ROLLER
TUBE
SLIDE FABRIC
AND
VALANCE
ROPES
THROUGH
GUIDE
NOTCH
VALANCE
ROPE
FABRIC
GROOVE PLACE END
CAP GUIDE
ON ROLLER
TUBE
OPEN
GROOVE
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.

14
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 fabric 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.
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.
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 winding of the torsion. See
Spring Identication Chart.
Heavy Duty
Standard
Wire Dia. 0.135 0.148
No paint on
either end.
Painted yel-
low cap end,
red on stabi-
lizer end.
Painted yel-
low on cap
end, no paint
on stabilizer
end.
SPRING IDENTIFICATION CHART
Painted red
cap end and
blue on stabi-
lizer end.
Painted white
on cap end
and black
on stabilizer
end.
Painted blue
cap end and
no paint on
stabilizer
end.
Painted black
on stabilizer
end and no
paint on cap
end.
RH
LH
Painted red
cap end and
no paint on
stabilizer
end.
break off two
locating tabs
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.
8500 and 9000 Torsion Identication
CUT VALANCE ROPE EVEN WITH
THE END OF THE ROLLER TUBE
VALANCE
FABRIC STRETCH FABRIC ROPE
TIGHTAND PULL DOWN
AND INTO THE CENTER
OF ROLLER TUBE. MAKE
SURE IT IS LOCKED
IN THE NOTCH ON
THE BOTTOM OF THE
GROOVE.
ROLLER TUBE
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.

15
Current guards have a set screw in the channel. Reinstall
the set screw to keep fabric from shifting.

16
8 8 –
8'6" 8 –
9 8 –
10 8 –
10'6" 8 –
10' 8" 8 –
11 8 –
11'6" 8 –
12 8 –
13 9 –
14 9 –
14'6" 9 –
15 10 –
15'6" 10 –
16 10 –
16'1" 10 –
16'6" 12 –
17 12 –
18 12 –
18'6" 12 –
19 12 8
19'6" 12 8
20 12 8
20'6" 12 8
20'9" 12 8
21 12 8
21'9" 12 8
22 12 8
23 12 8
24 12 8
25 12 8
Model 8500 & 9000
Heavy Duty
Awning
Length
(Ft.)
8500&9000 TORSION ASSEMBLY
TORQUE SPECIFICATIONS
Model 8500 & 9000
Standard
Number of Turns Number of Turns
L
TORSION WINDING FOR LARGE STABILIZER 8300
AWNING LENGTH TURNS UP TURNS OPEN
8 FT 5 11
9 FT 5 11
10 FT 5 11
11 FT 5 11
12 FT 5 11
13 FT 6 12
14 FT 6 12
15 FT 7 13
16 FT 7 13
17 FT 9 15
18 FT 9 15
19 FT 10 16
20 FT 10 16
21 FT & ABOVE 10 16
S
TORSION WINDING FOR SMALL STABILIZER 8300
AWNING LENGTH TURNS UP TURNS OPEN
8 FT 8 14
9 FT 8 14
10 FT 8 14
11 FT 8 14
12 FT 8 14
13 FT 9 15
14 FT 9 15
15 FT 10 16
16 FT 10 16
17 FT 12 18
18 FT 12 18
19 FT 12 18
20 FT 12 18
21 FT & ABOVE 12 18
Once the torsion have been wound, lock the tension on
the 8500 - 9000 with a long cotter pin, on the 8300 sun-
chaser awning use a nail. Now the awning can be rein-
stalled back on the coach. Follow the instalation instruc-
tions for the model awning you are working on.
Torque chart for 8500 and 9000 series awnings. Torque chart for Sunchaser 8300 awnings.

17
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 rearward,
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 deection must be taken into consideration.
Depending on the length of the awning, the roller tube can
deect from one to ve inches with the awning in the open
position. Installing a tension rafter will usually remove 80
per cent of sag and roller tube deection. 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.
Section 4
Other
4.1 Awning Rail
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.
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
thetravelposition.Therighthandtorsionendcapcontains
a cam assembly which prevents the awning from billowing
or unrolling during travel. It also allows one-person set-up
of the awning by preventing rollback. When difculties 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 specied 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.
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 ipped. To check the cam lock on the A&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.
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.

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