Dometic A&E Systems 828 Series Leitfaden

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)

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)

“More information https://www.caravansplus.com.au"

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

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

“More information https://www.caravansplus.com.au"

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

“More information https://www.caravansplus.com.au"

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

“More information https://www.caravansplus.com.au"

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

“More information https://www.caravansplus.com.au"

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

ROLL

WIND TO

ADD TORSION

ROLL

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.

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

“More information https://www.caravansplus.com.au"

FIG.16A

WIND TO

ADD TORSION

ROLL

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

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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

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nehwgnirpsnoisrototsnrutlanoitidda6ddA* .dednetxeyllufsigninwa

FIG. 15

FIG. 14

8300 and Sunchaser Service Instructions

“More information https://www.caravansplus.com.au"

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

ROLL

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

ROLL

RIGHT-HAND

END CAP “A’

FIG.16C

WIND TO

ADD TORSION

ROLL

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

“More information https://www.caravansplus.com.au"

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

“More information https://www.caravansplus.com.au"

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