REPLACEMENT INSTRUCTIONS FOR AWNING
Fabric Roller Tube
For Models 8500 & 9000
Tools Required:
The Fabric Roller Tube Assembly (FRTA) consists of a fabric,
a roller tube and torsion assemblies.
Use extreme care. Springs under tension are
dangerous. If not controlled they will unwind
quickly. Keep hands and clothing clear of top
casting, as personal injury may result.
B. REMOVAL OF THE AWNING FROM THE COACH
Vise Grips®
Socket Wrench Set
3/16" Drill Bit
1/8" Pop Rivets
End Cap Guide
A. GENERAL INSTRUCTIONS
Torsion Assembly
Screwdriver
Electric Drill
Step Ladder
3/16" Pop
RivetsPop Rivet
These instructions must be read and understood before installation, adjustment, service
or maintenance is performed. This unit must
be installed by a qualified serviceman. Modification of this product can be extremely hazardous and could result in personal injury or
property damage.
Tool
Adjustable Wrench
1/8" Drill Bit
Small File
NOTE: Awning removal from the coach is NOT necessary
when replacing a torsion assembly. Proceed to Section
C, 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 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.
2. Remove the TEK screws securing the awning fabric or
roller cover at each end of the awning fabric. See FIG. 1.
3. Remove both top mounting brackets on the ends of the
awning rail. See FIG. 1
REMOVE FROM
BOTH SIDES
AWNING
RAIL
FIG. 1
1/2" TEK
SCREW
4. Remove both of the patio feet from their mounting
brackets and extend the adjustable arms until each patio
foot rests on the ground and lock button locks in a hole.
5. Slide the awning fabric or roller cover out of the awning
rail.
a. 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. See FIG. 2.
MOVE LEVER POSITION TO
ROLL DOWN POSITION
TOP CASTING
FIG. 2
RIGHT-HAND SIDE
(VIEWED FROM FRONT)
SECTION
FABRIC
TOP
BRACKET
COTTER
PIN
1
Form No. 3107299.054 3/02
(Replaces 3107299.046)
(French 3109898.027)
©2002 Dometic Corporation
LaGrange, IN 46761
REVISION
C. UNWINDING A TORSION ASSEMBLY SPRING
NOTE: If the awning is installed on a coach, complete the
following steps on a step ladder, with the awning fabric
unrolled two feet from the awning rail. The unwinding can also
be done while standing on the ground and the awning fully
extended and the opposite side rafter locked in place. The
torsion spring will be wound with 8/eight more turns in this
position and is extremely dangerous.
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.
TOP
CASTING
LOCK
LEVER
1. Clamp a Vise Grip® tightly on the top casting, or insert
the crank (3107905.006) into top casting. Remove the 1/
4-20 hex head machine screw from the top casting. See
FIG. 3 and FIG. 3A.
2. Take the top casting carefully out of the main support
arm (see NOTE below). 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.
FIG. 3A
LOCK
LEVER
CRANK
3107905.006
TOP
CASTING
VISEGRIPS®
1/4-20 X 1/2" HEX
HD. MACH. SET SCREW
MAIN SUPPORT
ARM ASSEMBLY
FIG. 3
D. HOW TO REMOVE A TORSION ASSEMBLY
1. Make sure the torsion spring has been relieved of its
tension (see Section C.)
2. Mark or make note of the location of the fabric and the
end cap on the roller tube. This is necessary to reposition
the new torsion, fabric or roller tube exactly the same
when the new part is installed.
NOTE: Some roller tubes have notches and the end cap
has tabs, that will allow the torsion to fit only in one
position. The fabric must be positioned exactly as shown
in FIG. 5 or the lock lever will not be positioned correctly
when installed on the coach.
1/4-20 X 1/2" HEX
HD. MACH. SET SCREW
MAIN SUPPORT
ARM ASSEMBLY
3. Drill out the two rivets using a 3/16" drill bit. Remove
torsion assembly and rivet bodies from roller tube. See
FIG. 4.
2
FIG. 4
E. HOW TO REMOVE FABRIC FROM ROLLER TUBE / COVER
1. Remove both torsions. See Section D, Steps 1-3 for
torsion removal.
2. Roll the awning completely out on a clean smooth
surface.
3. With the awning laying flat, slide the roller tube out from
fabric.
4. The metal roller cover on 8500 and 9000 models are
F. INSTALLING FABRIC ON ROLLER TUBE
crimped to the poly ropes. Use needle nose pliers and
flat blade screw dirver to spread open the channel before
removing 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. See FIG. 6 & 7.
1. Unfold the new fabric and lay it on top of the existing
fabric 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 in FIG. 5.
2. 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 replacement 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. See figure 5.
NOTE: When changing the fabric, it is vital that the same
groove(s) be used. This eliminates the need to redrill any
holes (i.e. center support).
3. Guide the roller tube over the poly-rope(s) of the fabric.
Be careful not to damage the roller tube or the fabric.
4. Center the fabric on the roller tube and hand-roll the entire
assembly in the same direction as the original fabric.
VALANCE
ROPE
NOTCH
ROLLER
TUBE
FABRIC
GROOVE
OPEN
GROOVE
SLIDE FABRIC AND
VALANCE ROPES
THROUGH GUIDE
FIG. 5
PLACE END
CAP GUIDE
ON ROLLER
TUBE
3
G. FABRIC REPLACEMENT ON 9000 WITH 7 SLAT ROLLER COVER
Installing a new replacement fabric on a Model 9000
roller 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 assembly
and keep to be installed later.
Note: 9000 awning with 6 slats requires removal of one
slat D. (8500 and 9000 with 5 slats will require one slat
D to be remove and discarded if a new roller cover is being
replaced.)
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-
rope located approximately 12" from the top edge of the
fabric.
6. Install two pop rivets in the main slat D on both ends to
prevent the fabric from shifting in roller cover. If a new
roller cover assembly is being installed, a 1/8" hole will
need to be drilled 1-1/2" to 2" from end of the main slat
for the pop rivets. To prevent damage, be sure to remove
any burrs left by the drill.
NOTE: On 8500 models crimp the channel with pliers to
hold fabric.
7. Use a small file to round the ends of the 5/16" grooves on
the top slat C (FIG. 8) to prevent tearing of the fabric.
Slide the top slat C onto both the 1/4" channel of the fifth
main slat D and the poly-rope 1-1/2" from the edge of the
fabric.
8. Install the screws into the edge of the roller cover
assembly. See FIG. 7.
H. FABRIC REPLACEMENT ON 9000 WITH 6 SLAT ROLLER COVER
Installing a new replacement fabric on 9000 Model
awning 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 COVER
Installing a new replacement fabric on 8500 and 9000
model awning roller cover with 5 slats. Use Section G.
J. INSTALLING NEW ROLLER COVER WITH 6 SLATS
Installing new roller cover on model 9000 with 6 slats.
See FIG. 7.
K. INSTALLING NEW ROLLER COVER WITH 5 SLATS
Installing new roller cover on 8500 model with 5 slats .
See FIG. 7.
1. Follow steps 2-8 in Section G.
1. Follow steps 1-8 in Section G.
1. Follow steps 1-8 in Section G.
4
FIGURES 6 THROUGH 11
FIG. 6
E
C
D
D
D
D
VINYL STRIP "A"
FOR FIGS. 6–11
A - VINYL STRIP
B - HINGE SLAT
C - TOP SLAT
D - MAIN SLAT
E - AWNING RAIL
D
Trim poly rope
even and crimp
end
Drill out 1/8" pop
rivet, before
sliding out fabric
INSTALL A 1/8"
POP RIVET
EACH END
HINGE SLAT "B"
TOP SLAT "C"
VIEW RH END
FIG. 7
E
C
D
D
D
D
D
INSTALL A 1/8"
POP RIVET
EACH END
Trim poly rope
even and crimp
end
Drill out 1/8" pop
rivet, or spread
crimp before
sliding out fabric
5/16" CHANNEL
INSTALL TOWARD
CANOPY
3/8" CHANNEL
FOR VINYL
STRIP "A"
1/4" CHANNEL
FIG. 8
5/16" CHANNEL
BOTH ENDS
MAIN SLAT "D"
VIEW RH END
FIG. 9
1/4" CHANNEL
INSTALL TOWARD
AWNING RAIL
HINGE SLAT "B"
FIG. 10
VINYL STRIP "A"
5/16" ROD IN
AWNING RAIL
Note: 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).
5
FIG. 11
L. REPLACING TORSION ASSEMBLIES
1. 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.
a. Steel Roller Tube: The poly rope on the fabric side
must be pulled toward the valance groove and cut
off – leaving enough length to tuck it behind the
valance groove. See FIG. 12.
b. Aluminum Roller Tubes: The poly rope on the
fabric side is cut 2" 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. See FIG.12A.
2. 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 in Section D, Step
2. If a new roller tube is being used make sure the fabric
has been installed as directed in Section "F".
3. The poly ropes on the left-hand end of the roller tube
should be trimmed in the same as the right-hand. See
Section "L" Step 1.
STEEL ROLLER TUBE
FIG. 12
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 open
slot in the end cap aligned with the empty groove of the
roller tube.
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
installed and the roller tube does not have the notch
shown in FIG. 5. The two tabs inside the right-hand
torsion end cap must be broken off. See FIG. 13A.
NOTE: Placing the end caps as suggested usually
positions 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 . The end cap may have
to be removed and repositioned if it is not in the proper
location. See FIG. 13.
Models 8500 and 9000 19' - 25' have been manufactured 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 Identification Chart on page 7.
FIG. 12A
ALUMINUM 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.
4. Secure torsion assemblies to roller using 3/16" dia. x 3/8"
long stainless steel pop rivets.
FIG. 13
FIG. 13A
BREAK OFF TWO
LOCATING
TABS
VALANCE
CUT VALANCE ROPE EVEN WITH THE
END OF THE ROLLER TUBE
6
M. REWINDING TORSION ASSEMBLY SPRING
NOTE: If the awning is installed on a coach, complete the
following steps on a step ladder, with the awning fabric
unrolled two feet from the awning rail. The winding can also
be done while standing on the ground and the awning fully
extended and the oposite side rafter locked in place. The
torsion spring will be wound with 8/eight more turns in this
position and is extremely dangerous.
Severe injury 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.
TORSION ASSEMBLY
TORQUE SPECIFICATIONS
Awning
Length
(Ft.)
88 –
8'6" 8 –
98 –
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
Standard
Number of Turns Number of Turns
Model 8500 & 9000
Heavy Duty
1. Insert the torsion winding crank (Part Number
3108896.006) or clamp a Vise Grip® tightly on the
thickest side of the top casting. See FIG. 3 and FIG. 3A
2. Rewind the torsion assembly to the number of turns
indicated by the torsion assembly Torque Chart and in
the direction shown in FIGS. 14 &15.
3. Place a 1/8" cotter pin through the hole in the end cap
and torsion rod. This will prevent the rapid spin-off of the
top casting during installation of the awning. See FIG. 2.
NOTE: If awning is installed on the coach, place the top
casting in the support arm and secure with the 1/4-20 hex
head bolt.
WIND TOP
CASTING
FIG. 14
RIGHT-HAND SIDE
(VIEW FROM FRONT)
AWNING RAIL AWNING RAIL
HEAVY DUTY
TORSION ASM.
IDENTIFIER
(GREEN DOT)
LEFT-HAND SIDE
(VIEW FROM REAR)
SPRING IDENTIFICATION CHART
Standard
Wire Dia.
RH
LH
Painted red
cap end and
no paint on
stabilizer
end.
No paint on
either end.
0.135
Painted red
cap end and
blue on
stabilizer
end.
Painted blue
cap end and
no paint on
stabilizer
end.
NOTE: Heavy duty torsions can also be identified by a green
dot on the side of the top casting or on the end of the torsion
rod. See Figures 14 and 15.
Before winding the torsion it must be identified for
heavy duty or standard springs. Incorrect winding can
result in damage and improper operation.
Heavy Duty
Painted yellow cap end,
red on stabilizer end.
Painted yellow on cap
end, no paint
on stabilizer
end.
0.148
Painted white
on cap end
and black on
stabilizer
end.
Painted black
on stabilizer
end and no
paint on cap
end.
WIND TOP
CASTING
FIG. 15
N. INSTALLING AWNING ON COACH
1. Follow installation instructions for the awning when replacing on coach.
7
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