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REPLACEMENT INSTRUCTIONS FOR AWNINGFabricRoller TubeTorsion AssemblyFor Models 8500 & 9000Tools Required:Vise Grips Socket Wrench Set3/16" Drill Bit1/8" Pop RivetsEnd Cap GuideScrewdriverElectric DrillStep Ladder3/16" PopRivetsPop RivetToolAdjustable Wrench1/8" Drill BitSmall FileA. GENERAL INSTRUCTIONSThe Fabric Roller Tube Assembly (FRTA) consists of a fabric,a roller tube and torsion assemblies.These instructions must be read and understood before installation, adjustment, serviceor maintenance is performed. This unit mustbe installed by a qualified serviceman. Modification of this product can be extremely hazardous and could result in personal injury orproperty damage.Use extreme care. Springs under tension aredangerous. If not controlled they will unwindquickly. Keep hands and clothing clear of topcasting, as personal injury may result.B. REMOVAL OF THE AWNING FROM THE COACH4. Remove both of the patio feet from their mountingbrackets and extend the adjustable arms until each patiofoot rests on the ground and lock button locks in a hole.NOTE: Awning removal from the coach is NOT necessarywhen replacing a torsion assembly. Proceed to SectionC, Steps 1 & 2, Sections D, Steps 1-3, and Section L,Steps 1-3.1. In all instances of fabric or roller tube replacement, it willbe necessary to have a large work area to allowcomplete unrolling of the awning. This work area mustbe clean and smooth so the fabric will not be damaged.5. Slide the awning fabric or roller cover out of the awningrail.a. To keep the awnings from unwinding during thisstep, be sure the cam lock lever is in the roll downposition. A 1/8" cotter pin can be inserted in eachtorsion assembly for positive locking of the rollertube. See FIG. 2.2. Remove the TEK screws securing the awning fabric orroller cover at each end of the awning fabric. See FIG. 1.3. Remove both top mounting brackets on the ends of theawning rail. See FIG. 1MOVE LEVER POSITION TOROLL DOWN POSITION1/2" TEKSCREWREMOVE FROMBOTH SIDESTOP CASTINGRIGHT-HAND SIDE(VIEWED FROM FRONT)AWNINGRAILFIG. 1FIG. 2FABRICSECTIONCOTTERPINTOPBRACKET1REVISIONForm No. 3107299.054 3/02(Replaces 3107299.046)(French 3109898.027) 2002 Dometic CorporationLaGrange, IN 46761
C. UNWINDING A TORSION ASSEMBLY SPRING1. Clamp a Vise Grip tightly on the top casting, or insertthe crank (3107905.006) into top casting. Remove the 1/4-20 hex head machine screw from the top casting. SeeFIG. 3 and FIG. 3A.2. Take the top casting carefully out of the main supportarm (see NOTE below). Slowly let the torsion springunwind completely. Repeat Steps 1 & 2 for the oppositeend.NOTE: If the awning is installed on a coach, complete thefollowing steps on a step ladder, with the awning fabricunrolled two feet from the awning rail. The unwinding can alsobe done while standing on the ground and the awning fullyextended and the opposite side rafter locked in place. Thetorsion spring will be wound with 8/eight more turns in thisposition and is extremely dangerous.NOTE: If the awning's right-hand torsion assembly has beenpinned, the cotter pin must be removed from the torsionassembly before the spring can be unwound. The cam locklever on the right-hand torsion assembly must be turnedclockwise to the roll up position, before the spring can beunwound.Severe injuries can result from the rapid spin-off ofthe top casting. Use Vise Grips - NEVER use barehands - to handle a top casting under spring tension.FIG. ASTINGVISEGRIPS MAIN SUPPORTARM ASSEMBLY1/4-20 X 1/2" HEXHD. MACH. SET SCREWMAIN SUPPORTARM ASSEMBLY1/4-20 X 1/2" HEXHD. MACH. SET SCREWFIG. 3D. HOW TO REMOVE A TORSION ASSEMBLY1. Make sure the torsion spring has been relieved of itstension (see Section C.)2. Mark or make note of the location of the fabric and theend cap on the roller tube. This is necessary to repositionthe new torsion, fabric or roller tube exactly the samewhen the new part is installed.NOTE: Some roller tubes have notches and the end caphas tabs, that will allow the torsion to fit only in oneposition. The fabric must be positioned exactly as shownin FIG. 5 or the lock lever will not be positioned correctlywhen installed on the coach.3. Drill out the two rivets using a 3/16" drill bit. Removetorsion assembly and rivet bodies from roller tube. SeeFIG. 4.2FIG. 4
E. HOW TO REMOVE FABRIC FROM ROLLER TUBE / COVER1. Remove both torsions. See Section D, Steps 1-3 fortorsion removal.crimped to the poly ropes. Use needle nose pliers andflat blade screw dirver to spread open the channel beforeremoving fabric.NOTE: Some 9000 model awning,secured the fabric to theroller cover with 1/8" pop rivets. It is necessary to removethe 1/8" pop rivets from both ends of the roller cover.Once the rivets are removed, you can slide the fabric outof the cover. See FIG. 6 & 7.2. Roll the awning completely out on a clean smoothsurface.3. With the awning laying flat, slide the roller tube out fromfabric.4. The metal roller cover on 8500 and 9000 models areF. INSTALLING FABRIC ON ROLLER TUBE1. Unfold the new fabric and lay it on top of the existingfabric in the exact same position. Be sure the newfabric is the correct size and color. If roller tube is beingreplaced, make sure it is the correct length and positionit with the notch located as shown in FIG. 5.2. Dometic requires the use of the end cap guide to preventdamages to the fabric, when replacing the fabric/rollertube. Place the end cap guide supplied with the replacement fabric/roller tube on the end of the roller tube. Slidethe fabric and valance ropes through the end cap guideand onto the roller tube. See figure 5.4. Center the fabric on the roller tube and hand-roll the entireassembly in the same direction as the original fabric.ROLLERTUBEFIG. 5FABRICGROOVEOPENGROOVENOTE: When changing the fabric, it is vital that the samegroove(s) be used. This eliminates the need to redrill anyholes (i.e. center support).PLACE ENDCAP GUIDEON ROLLERTUBEVALANCEROPE3. Guide the roller tube over the poly-rope(s) of the fabric.Be careful not to damage the roller tube or the fabric.NOTCH3SLIDE FABRIC ANDVALANCE ROPESTHROUGH GUIDE
G. FABRIC REPLACEMENT ON 9000 WITH 7 SLAT ROLLER COVERrope located approximately 12" from the top edge of thefabric.6. Install two pop rivets in the main slat D on both ends toprevent the fabric from shifting in roller cover. If a newroller cover assembly is being installed, a 1/8" hole willneed to be drilled 1-1/2" to 2" from end of the main slatfor the pop rivets. To prevent damage, be sure to removeany burrs left by the drill.NOTE: On 8500 models crimp the channel with pliers tohold fabric.Installing a new replacement fabric on a Model 9000roller cover with 7 slats and a vinyl strip. See FIG. 6:1. Remove vinyl strip A (FIG. 11), and hinge slat B (FIG. 10)from top slat C (FIG. 8). Remove two of Slat D (Fig. 9).Discard vinyl strip A, hinge slat B and the two D slats .2. Remove top slat C (FIG. 8) from roller cover assemblyand keep to be installed later.Note: 9000 awning with 6 slats requires removal of oneslat D. (8500 and 9000 with 5 slats will require one slatD to be remove and discarded if a new roller cover is beingreplaced.)7. Use a small file to round the ends of the 5/16" grooves onthe top slat C (FIG. 8) to prevent tearing of the fabric.Slide the top slat C onto both the 1/4" channel of the fifthmain slat D and the poly-rope 1-1/2" from the edge of thefabric.3. The new replacement fabric will be installed as shown inFIG. 7.4. Use a small file to round the ends of the groove in the5/16" channel of the main slat D (FIG. 9).8. Install the screws into the edge of the roller coverassembly. See FIG. 7.5. Slide the 5/16" channel of the main slat D onto the poly-H. FABRIC REPLACEMENT ON 9000 WITH 6 SLAT ROLLER COVERInstalling a new replacement fabric on 9000 Modelawning roller cover with 6 slats. See FIG. 7.1. Follow steps 2-8 in Section G.I. FABRIC REPLACEMENT ON 8500 AND 9000 WITH 5 SLAT ROLLER COVERInstalling a new replacement fabric on 8500 and 9000model awning roller cover with 5 slats. Use Section G.1. Follow steps 2-8 in Section G.J. INSTALLING NEW ROLLER COVER WITH 6 SLATSInstalling new roller cover on model 9000 with 6 slats.See FIG. 7.1. Follow steps 1-8 in Section G.K. INSTALLING NEW ROLLER COVER WITH 5 SLATSInstalling new roller cover on 8500 model with 5 slats .See FIG. 7.1. Follow steps 1-8 in Section G.4
FIGURES 6 THROUGH 11FIG. 6ECDFOR FIGS. 6–11DDA - VINYL STRIPB - HINGE SLATC - TOP SLATD - MAIN SLATE - AWNING RAILVINYL STRIP "A"DDDrill out 1/8" poprivet, beforesliding out fabricINSTALL A 1/8"POP RIVETEACH ENDTrim poly ropeeven and crimpendHINGE SLAT "B"TOP SLAT "C"VIEW RH ENDFIG. 7FIG. 8E5/16" CHANNELBOTH ENDSCMAIN SLAT "D"VIEW RH ENDDDFIG. 9D5/16" CHANNELINSTALL TOWARDCANOPY1/4" CHANNELINSTALL TOWARDAWNING RAILD3/8" CHANNELFOR VINYLSTRIP "A"DDrill out 1/8" poprivet, or spreadcrimp beforesliding out fabricINSTALL A 1/8"POP RIVETTrimEACHpoly ENDropeeven and crimpend1/4" CHANNELHINGE SLAT "B"FIG. 10VINYL STRIP "A"FIG. 11Note:FIG. 6 shows 9000 model with 7 slats (1 "B" hinge slat, 1 "C" top slat and 5"D" slats).FIG. 7 shows 9000 Model with 6 slats (1 "C" and 5 "D" slats).55/16" ROD INAWNING RAIL
L. REPLACING TORSION ASSEMBLIES1. To reduce the possibility of the poly rope interfering withthe cam lock mechanism, the right-hand torsion requiresthe valance rope to be cut off even with the roller tube.a. Steel Roller Tube: The poly rope on the fabric sidemust be pulled toward the valance groove and cutoff – leaving enough length to tuck it behind thevalance groove. See FIG. 12.b. Aluminum Roller Tubes: The poly rope on thefabric side is cut 2" longer than the roller tube.Stretch the poly rope and pull it toward the centerof the roller tube. Make sure it is locked in thenotch of the groove in the roller tube. See FIG.12A.NOTE: If the roller tube is new, the rivet holes are not drilled.The torsion assemblies must be positioned as follows:The left-hand torsion assembly position has the openslot in the end cap aligned with the empty groove of theroller tube.2. Reinstall the torsion assembly in the roller tube. Alignthe rivet slots on the end cap with the holes in the rollertube - in the exact same position as in Section D, Step2. If a new roller tube is being used make sure the fabrichas been installed as directed in Section "F".NOTE: Placing the end caps as suggested usuallypositions the lock lever in the proper position whenawning is closed. The awning should be opened andclosed several times, and checked. The cam lock levershould be at the "11:00" position . The end cap may haveto be removed and repositioned if it is not in the properlocation. See FIG. 13.Position the right-hand torsion assembly open holein the end cap in alignment with the empty groove in theroller tube.If a new right-hand torsion assembly is beinginstalled and the roller tube does not have the notchshown in FIG. 5. The two tabs inside the right-handtorsion end cap must be broken off. See FIG. 13A.3. The poly ropes on the left-hand end of the roller tubeshould be trimmed in the same as the right-hand. SeeSection "L" Step 1.FIG. 12STEEL ROLLER TUBEModels 8500 and 9000 19' - 25' have been manufactured with both standard and heavy duty torsionsprings. Before reinstalling the torsion, properlyidentify (Standard or Heavy Duty) the springs. Thisis necessary for proper winding of the torsion. SeeSpring Identification Chart on page 7.4. Secure torsion assemblies to roller using 3/16" dia. x 3/8"long stainless steel pop rivets.FIG. 13FIG. 13ABREAK OFF TWOLOCATING TABSFIG. 12AALUMINUM ROLLER TUBEFABRICVALANCESTRETCH FABRIC ROPETIGHT AND PULL DOWNAND INTO THE CENTEROF ROLLER TUBE. MAKESURE IT IS LOCKED INTHE NOTCH ON THEBOTTOM OF THEGROOVE.CUT VALANCE ROPE EVEN WITH THEEND OF THE ROLLER TUBE6
M. REWINDING TORSION ASSEMBLY SPRING1. Insert the torsion winding crank (Part Number3108896.006) or clamp a Vise Grip tightly on thethickest side of the top casting. See FIG. 3 and FIG. 3A2. Rewind the torsion assembly to the number of turnsindicated by the torsion assembly Torque Chart and inthe direction shown in FIGS. 14 &15.3. Place a 1/8" cotter pin through the hole in the end capand torsion rod. This will prevent the rapid spin-off of thetop casting during installation of the awning. See FIG. 2.NOTE: If the awning is installed on a coach, complete thefollowing steps on a step ladder, with the awning fabricunrolled two feet from the awning rail. The winding can alsobe done while standing on the ground and the awning fullyextended and the oposite side rafter locked in place. Thetorsion spring will be wound with 8/eight more turns in thisposition and is extremely dangerous.NOTE: If awning is installed on the coach, place the topcasting in the support arm and secure with the 1/4-20 hexhead bolt.Severe injury can result from the rapid spin-off of thetop casting. Use Vise Grips - NEVER use bare hands- to handle a top casting under spring tension.WIND TOPCASTINGAWNING RAILTORSION ASSEMBLYTORQUE SPECIFICATIONSAwningLength(Ft.)88'6"91010'6"10' 10121212121212121212121212121212Number of –––––88888888888WIND TOPCASTINGHEAVY DUTYTORSION ASM.IDENTIFIER(GREENDOT)Model 8500 & 9000 Model 8500 & 9000StandardHeavy DutyNumber of TurnsAWNING RAILFIG. 14RIGHT-HAND SIDE(VIEW FROM FRONT)FIG. 15LEFT-HAND SIDE(VIEW FROM REAR)SPRING IDENTIFICATION CHARTStandard0.135Wire Dia.RHLHPainted redcap end andno paint onstabilizerend.No paint oneither end.Heavy Duty0.148Painted redcap end andblue onstabilizerend.Painted yellow cap end,red on stabilizer end.Painted whiteon cap endand black onstabilizerend.Painted bluecap end andno paint onstabilizerend.Painted yellow on capend, no painton stabilizerend.Painted blackon stabilizerend and nopaint on capend.NOTE: Heavy duty torsions can also be identified by a greendot on the side of the top casting or on the end of the torsionrod. See Figures 14 and 15.Before winding the torsion it must be identified forheavy duty or standard springs. Incorrect winding canresult in damage and improper operation.N. INSTALLING AWNING ON COACH1. Follow installation instructions for the awning when replacing on coach.7
3. The new replacement fabric will be installed as shown in FIG. 7. 4. Use a small file to round the ends of the groove in the 5/16" channel of the main slat D (FIG. 9). 5. Slide the 5/16" channel of the main slat D onto the poly-Installing a new replacement fabric on 8500 and 9000 model awn
