Solera® Classic Awning Head Replacement Guide for Customer Service and Technical Staff

Overview

This guide outlines the procedures for replacing the idler and/or drive head assemblies of the Solera Classic Awning. It includes detailed steps, required resources, and safety precautions to ensure a successful replacement process.

Safety Precautions

• Always wear eye protection during service or maintenance.
• Consider additional safety equipment like hearing protection, gloves, and a full face shield depending on the task.
• Be cautious of moving parts that can pinch, crush, or cut.

Required Resources

• 1 - 2 People
• Zip ties
• Cordless or electric drill or screw gun
• Padded locking pliers
• Appropriate drill bits
• Two hairpin cotter pins
• Non-permanent marking method

Preparation Steps

1. Unlock the cam lock on the drive head assembly and extend the awning about one foot.
2. Align the drive head shaft hole with the end cap hole to insert a hairpin cotter pin.
3. Insert the hairpin cotter pin through the drive head end cap into the shaft.
4. Repeat the alignment and insertion process for the idler head shaft.
5. Mark the position of the cam lock on the roll tube if replacing the drive head assembly.
6. Mark the position of the bottom of the idler end cap on the roll tube if replacing the idler head assembly.
7. Secure both support arm assemblies with zip ties to keep the outer arm in place during replacement.

Replacing the Drive Head Assembly

1. Remove the screw holding the drive head assembly onto the support arm assembly.
2. Remove the drive head assembly from the support arm.
3. With assistance, hold the roll tube and firmly grip the drive head with padded locking pliers.
4. Flip the cam lock up to the roll-up position.
5. Remove the hairpin cotter pin from the drive head end cap.
6. Slowly rotate the drive head assembly to release tension.
7. Remove the three screws holding the drive head end cap onto the roll tube.
8. Remove the drive head assembly from the roll tube.
9. Ensure the cam lock is in the down position and the drive head is front facing.
10. Insert a hairpin cotter pin into the new drive head end cap.
11. Align the cam lock with the marking on the roll tube.
12. Confirm the end cap is fully seated and aligned with the roll tube.
13. Fasten the new drive head end cap assembly onto the roll tube with the three screws.
14. Apply tension to the spring assembly by turning the drive head in a counterclockwise direction. Refer to the Solera Classic Awnings Drive/Idler Head Assembly Install Turn Chart for the number of turns required based on awning size.
15. Re-insert a hairpin cotter pin after setting the proper tension.
16. Slide the right support arm assembly into the drive head assembly and secure it.
17. Remove both hairpin cotter pins if only installing the drive side. Keep them inserted if also replacing the idler side.
18. Cut the zip ties from the top of the support arms after completing both sides.

Replacing Idler Head Assembly

Follow similar steps as for the drive head assembly, ensuring to:

• Remove the screw holding the idler head assembly onto the outer support arm assembly.
• Remove the idler head assembly from the outer support arm.
• Remove the hairpin cotter pin from the idler end cap.
• Slowly rotate the idler head assembly to release tension.
• Remove the three screws holding the idler head end cap onto the roll tube.
• Insert the new idler head assembly into the roll tube, aligning it with the previously made mark.
• Fasten the new idler head end cap assembly onto the roll tube with the three screws.
• Apply tension to the spring assembly by turning the idler head in a clockwise direction, referring to the turn chart for guidance.
• Re-insert a hairpin cotter pin after setting the proper tension.
• Slide the left support arm assembly into the idler head assembly and secure it.
• Remove both hairpin cotter pins.
• Cut the zip ties from the top of the support arms.

Turn Chart for Drive/Idler Head Assembly Installation

• 6 ft to 10 ft awnings: 4 turns
• 11 ft to 14 ft awnings: 5 turns
• 15 ft to 18 ft awnings: 6 turns
• 19 ft and up awnings: 8 turns

Additional Information

For any questions or further assistance, customer service and technical staff can refer to internal resources or training materials. Always prioritize safety and follow the manufacturer's guidelines during the replacement process.