SOLERA® CLASSIC AWNING HEAD REPLACEMENT

BT eR

Purpose

This document describes the procedure to replace the idler and/or drive head assemblies for the Solera Classic
Awning. Figure 1 callouts describe the various names of the parts and assemblies used in the instructions.

AWARNING

Always wear eye protection when performing service or maintenance to the unit. Other safety
equipment to consider includes hearing protection, gloves and possibly a full face shield,
depending on the nature of the service.

A CAUTION

Moving parts can pinch, crush or cut. Keep clear and use caution.

Idler
Head
Assembly

Fabric

Drive
Head
Assembly

Drive
Support Arm
Assembly

Rev: 08.01.19 CCD-0002738

SOLERA® CLASSIC AWNING HEAD REPLACEMENT

eT ck

Resources Required

* 1-2 People, depending on task + Zip ties
* Cordless or electric drill or screw gun ¢ Padded locking pliers

¢ Appropriate drill bits ¢ Two hairpin cotter pins
« Non-permanent method of marking

Preparation

NOTE: Some parts are not shown for clarity.

1. Onthe drive head assembly, flip the cam lock (Fig. 2A) into the down position and extend the awning
out approximately one foot.

Adjust the awing so that the drive head shaft (Fig. 3B) hole aligns with the end cap hole (Fig. 3A) to insert a
hairpin cotter pin (Fig. 3C).

Insert the hairpin cotter pin (Fig. 3C) through the drive head end cap into the shaft of the head assembly.
Adjust the awing so that the idler head shaft (Fig. 4A) hole aligns with the end cap hole (Fig. 4B) to insert a
hairpin cotter pin (Fig. 4C).

Insert the hairpin cotter pin (Fig. 4C) through the idler head end cap into the shaft on the head
assembly.

Rev: 08.01.19 CCD-0002738

SOLERA® CLASSIC AWNING HEAD REPLACEMENT

eT ck

NOTE: Marking the position of the cam lock is only necessary if the drive head assembly is being replaced.

6. Makeanon-permanent mark on the roll tube (Fig. 5A) indicating the position of the cam lock
(Fig. 5B). This mark will assist in re-positioning the cam lock from the new drive head assembly on the
Solera Classic Manual Awning roll tube.

NOTE: Marking the position of the idler head assembly is only necessary if the idler head is being replaced.

7. — If replacing the idler head assembly, make a non-permanent mark on the roll tube (Fig. 6A) indicating
the position of the bottom of the idler end cap (Fig. 6B). This mark will assist in re-positioning the new
idler head assembly on the Solera Classic Manual Awning roll tube.

Rev: 08.01.19 CCD-0002738

SOLERA® CLASSIC AWNING HEAD REPLACEMENT

eT ck

Zip tie (Fig. 7A) both support arm assemblies. Place the zip tie around the outer arm (Fig. 7B)
and the support arm (Fig. 7C). This will keep the outer arm in place while replacing the
drive/idler head assemblies.

Procedure

Replacing the Drive Head Assembly

NOTE: If replacing both the drive and the idler head assemblies, replace one side at a time, starting with
the drive head assembly first. The instructions that follow are for replacing the drive head assembly.

NOTE: Some parts are not shown for clarity.

Failure to maintain control of the roll tube or the drive head assembly may result
in serious injury or property damage.

Make sure to do the steps in the Preparation section before proceeding with step 1.

1. While one person holds the roll tube (Fig. 8A), remove the screw (Fig. 8B) holding the drive head
assembly (Fig. 8C) onto the support arm assembly (Fig. 8D). Set the screw aside for future use in the
installation proce

Rev: 08.01.19 CCD-0002738

SOLERA® CLASSIC AWNING HEAD REPLACEMENT

eT ck

Remove the drive head assembly (Fig. 9E) from the support arm assembly (Fig. 9F).

The spring is under extreme tension. Improper handling could cause death, serious injury
or property damage.

3. With an assistant holding the roll tube (Fig. 9C), firmly take hold of the drive head (Fig. 9E) with a pair of
padded locking pliers.

NOTE: Padding the locking pliers will prevent scratching components.

4. Flip the cam lock (Fig. 9D) up to the roll up position.

5. Remove the hairpin cotter pin (Fig. 9A) from the drive head end cap (Fig. 9B).

6. Slowly rotate the drive head assembly (Fig. 9E) to release tension by rotating the drive head with padded
locking pliers.

7. After the tension is released, remove the three screws (Fig. 10A) holding the drive head end cap
(Fig. 10B) onto the roll tube (Fig. 10C). Set the screws aside for future use in the installation process.

Rev: 08.01.19 CCD-0002738

Rev: 08.01.19

SOLERA® CLASSIC AWNING HEAD REPLACEMENT

eT ck

Make sure the cam lock is in the down (roll out) position (Fig. 12D) and the drive head (Fig. 12E) is front facing.
Make sure the new drive head assembly is in the same position as the old drive head assembly when it was
removed from the roll tube. Insert a hairpin cotter pin (Fig. 12F) into the new drive head end cap (Fig. 12A).
Locate the cam lock mark applied in step 6 of the Preparation section. Slide the Solera spring assembly
into the roll tube so that the cam lock lines up with the cam lock marking on the roll tube (Fig. 5).
Confirm the end cap (Fig. 12A) is fully seated on the end of the roll tube (Fig. 12B) and the holes in the
end cap and the roll tube are aligned.

Fasten the new drive head end cap assembly (Fig. 12E) onto the roll tube (Fig. 12B) with the three
previously-removed screws (step 7, Fig. 10). If the screws/screw holes have been stripped, consider
using #10 screws to ensure a secure fit (Fig. 12C).

CCD-0002738

SOLERA® CLASSIC AWNING HEAD REPLACEMENT

14. Remove the hairpin cotter pin and apply tension to the spring assembly by turning the drive head
(Fig. 12E) in a counterclockwise direction using padded locking pliers. The number of turns is determined by the
position and size of the awning. See the Solera Classic Awnings Drive/Idler Head Assembly Install Turn Chart.

NOTE: Padding the locking pliers will prevent scratching components.

NOTE: If the awning is in the extended position, greater than one foot, the springs will require more turns to set proper
tension.

NOTE: Make sure the drive head (Fig. 13E) is facing the proper direction so that the outer support arm (Fig. 13F)
can be re-inserted.

Solera Classic Awnings Drive/Idler Head Assembly Install Turn Chart
Size Turns
6 ft to 10 ft 4
11 ft to 14 ft 5
15 ft to 18 ft 6
19 ft and up 8

Re-insert a hairpin cotter pin into the drive head end cap (Fig. 13A) after the proper amount of tension
has been set.

Slide the right support arm assembly (Fig. 13F) into the drive head assembly (Fig. 13E) of the roll tube
(Fig. 13B). Align the holes (Fig.13C) and secure using the previously removed screw (Fig. 13D).

Remove both hairpin cotter pins if only installing the drive side. Keep the hairpin cotter pins inserted if
also replacing the idler side.

Cut the zip ties (Fig. 7A) from top of the support arms. If replacing both the drive and idler head
assemblies, wait to cut the zip ties until the idler side is complete.

Rev: 08.01.19 CCD-0002738

SOLERA® CLASSIC AWNING HEAD REPLACEMENT

eT ck

Replacing Idler Head Assembly

Failure to maintain control of the roll tube or the idler head assembly may result
in serious injury or property damage.

NOTE: Some parts are not shown for clarity.

Make sure to do the steps in the Preparation section before proceeding with step 1.

1. While one person holds the roll tube (Fig. 14F), remove the screw (Fig. 14B) holding the idler head
assembly (Fig. 14A) onto the outer support arm assembly (Fig. 14C). Set the screw aside for future use
in the installation process.

The spring is under extreme tension. Improper handling could cause death, serious injury
or property damage.

2. Remove the idler head assembly (Fig. 14A) from the outer support arm assembly (Fig. 14C).
3. With an assistant holding the roll tube (Fig. 14), firmly take hold of the idler head (Fig. 14A) with a pair

of padded locking pliers.
NOTE: Padding the locking pliers will prevent scratching components.

4. Remove the hairpin cotter pin (Fig. 14D) from the idler end cap (Fig. 14).
5. Slowly rotate the idler head assembly (Fig. 14A) to release tension by rotating the idler head with
padded locking pliers.

Rev: 08.01.19 CCD-0002738

SOLERA® CLASSIC AWNING HEAD REPLACEMENT

eT ck

After the tension is released, remove the three screws (Fig. 15A) holding the idler head end cap
(Fig. 15C) onto the roll tube (Fig. 15D). Set the screws aside for future use in the installation process.

7.

Make sure that the new idler head assembly (Fig. 16A) is front facing and re-insert a hairpin cotter pin
(Fig. 14D) into the idler end cap.

Align the idler head with the previously made mark on the roll tube, step 7, Fig. 6 in the Preparation
section of the document. Insert the new idler head assembly into the roll tube.

Confirm the end cap (Fig. 15C) is fully seated on the end of the roll tube (Fig. 15D) and the holes in the
end cap and the roll tube are aligned.

Fasten the new idler head end cap assembly (Fig. 15B) into the roll tube (Fig. 15D) with the three
previously removed screws (step 6, Fig. 15A). If the screws/screw holes have been stripped, consider
using #10 screws to ensure a secure fit.

Rev: 08.01.19 Page 9 CCD-0002738

SOLERA® CLASSIC AWNING HEAD REPLACEMENT

eT ck

12. Remove the hairpin cotter pin and apply tension to the spring assembly by turning the idler head in
a clockwise direction using padded locking pliers. The number of turns is determined by the position
and size of the awning. See the Solera Classic Awnings Drive/Idler Head Assembly Install Turn Chart.

NOTE: Padding the locking pliers will prevent scratching components.

NOTE: If the awning is in the extended position greater than one foot the springs will require more turns to
set proper tension.
NOTE: Make sure the idler head (Fig. 17A) is facing the proper direction so that the outer support arm
(Fig. 17C) can be re-inserted.
Solera Classic Awnings Drive/Idler Head Assembly Install Turn Chart
Size Turns

6 ft to 10 ft 4
11 ft to 14 ft 5
15 ft to 18 ft 6
19 ft and up 8
Insert a hairpin cotter pin (Fig. 17E) into the idler head end cap (Fig. 17A) after the proper amount of

tension has been set.
Slide the left support arm assembly (Fig. 17C) into the idler head assembly (Fig. 17A) of the roll tube
(Fig. 17G). Align the holes (Fig. 17D) and secure using the previously removed screw (step 1) (Fig. 17F).

Remove both the drive head assembly and idler head assembly hairpin cotter pins (Fig. 17E).
Cut the zip ties (Fig. 17B) from top of the support arms.

«7

Tota

As a supplier of components to the RV industry, safety, education and customer satisfaction are our primary concerns. Should you
have any questions, please do not hesitate to contact us at (574) 537-8900 or by email at [email protected]. Self-help tips,
technical documents, product videos and a training class schedule are available at Ici1.com or by downloading the MyLCl app.

Rev: 08.01.19 Page 10 CCD-0002738