INSTALLATION, OPERATIONS, ADJUSTMENT AND REPAIR Rev. 08/01/12 1361 Calle Avanzado San Clemente California 92673 Office: (949) 259-4000 Toll Free: (800) 382-8442 Fax: (949) 276-5500
TABLE OF CONTENTS WARRANTY PROCEDURES........................................... 3 Return Policy.................................................... 3 Warranty Parts and Labor Claims........................................ 3 Warranty Parts.................................................. 3 Labor Claims................................................... 3 Freight Damage Procedures........................................... 4 WARRANTY UPDATES............................................... 5 RV Awnig Products................................................ 5 Limited Lifetime Warranty........................................... 5 Warranty...................................................... 6 PRODUCT DESCRIPTION............................................. 7 How To Order................................................... 7 EVALUATION & NUMBER OF ARTICULATIONS......................... 8 INSTALLATION INSTRUCTIONS........................................ 9 Tools Required................................................... 9 Installation Preparation.............................................. 9 Number Of Mounting Brackets Required................................... 9 Placement Of Mounting Brackets....................................... 10 Installation Sequence............................................... 11 MAINTENANCE INSTRUCTIONS....................................... 12 Tension Change.................................................. 12 Leadrail/Articulation Replacement....................................... 12 Spring Replacement................................................ 13 Fabric Change................................................... 13 Slide Brush Replacement............................................. 14 EXPLODED VIEW FOR G5000 SLIDE-OUT................................ 15 PARTS LIST...................................................... 16 WARRANTY LABOR TIME GUIDLINES.................................. 17 page 2
Freight Damage Procedures Any visible damage to a shipment must be reported immediately, and noted on the shippers Bill of Ladding. Please contact the freight carrier and then report damage to Girard Systems. If possible, please photo document any damaged items. Please retain original packaging for any damage returns. Replacement items may need to be ordered depending on the extent of loss or damage. In the event that a shipment is refused due to damage please file a claim with the carrier. The carrier will return the items to Girard Systems. Please contact Girard Systems immediately for replacement goods.. IMPORTANT ALL CONCEALED DAMAGE MUST BE REPORTED WITHIN 5 DAYS OF RECEIPT. ANY SHORTAGE TO AN ORDER MUST BE REPORTED WITHIN 10 DAYS OF RECEIPT. page 4
PRODUCT DESCRIPTION The G5000 provides protection from the sun, rain, and other elements (leaves, debris, etc.) to the roof area of the slide-out room. Each unit is built to your specifications with the highest quality materials available. The main features and benefits of the G5000 are: 1. This Slide-Out Awning System comes in various lengths to fit accurately any slide-out room. 2. Its top roll design adds increased fabric pitch and favors water run-off. The new design allows for more clearance between the top of the slide-out room and the bottom of the awning. 3. The built in fabric brush eliminates leaves and debris build-up on awning fabric. 4. The G5000 design allows for fabric change without removing the cassette from the side of the coach. 5. The Girard patented G5000 Slide-Out Awning is the only unit that mounts to the coach sidewall, not the slide-out room. The small lead-rail mounted on the slide-out room improves overall appearance. 6. The durable powder-coated aluminum encasement prevents the fabric from billowing while in transit, and protects the fabric from the elements while not in use. HOW TO ORDER Please specify: 1. Slide-room width: The width should be measured at the top of the slide-out room since room cutout may not be square. Add 3 inches to the width of the slideroom measurement to ensure an overlap of 1 ½ inch on each side of the awning. The minimum width of the awning is 60 inches in order to accommodate the length of the retraction spring and additional hardware. The G5000 comes in widths from 60 to 360 inches. 2. Extension (Fabric projection): The maximum available extension is 42 inches on standard units. 3. Number of articulations needed (See NOTE below). 4. Fabric material and colors. 5. Cassette Color: The standard colors are black and white. Special colors are available on request. NOTE: The awning s cassette can be installed at a vertical distance of 2.5 to 5.5 inches above the upper edge of the slide-out room: The number of required articulations depends on the cassette elevation (See Articulation Chart on page 8). page 7
ELEVATION ARTICULATION CHART NUMBER OF ARTICULATIONS 2.5 to 3.5 3 3.5 to 4.5 4 4.5 to 5.5 5 Weather Seal Pivot Cover Open to release fabric MOUNTING BRACKET Slide Brush CASSETTE ELEVATION Articulations 3/4 distance above Slide-Room edge Slide-Room must be retracted (IN) during Installation LEAD RAIL With slide plates and screw cover Rubber Seal 4.5 4.25.25 Extension max.42 page 8
INSTALLATION INSTRUCTIONS A. TOOLS REQUIRED Electric Drill with Phillips screwdriver bit #2 and #3, and pilot bit for #6 screws. Girard Tension Tool (available upon request) - Girard Part #1511100-19T 3/8 Ratchet Wrench Phillips Screwdriver Chalk Line Measuring Tape Silicone Spring Clamps (2) to block unwanted fabric movement Double Sided Tape Silicon sealant #6 3/4 screws #12 Self-tapping Screws 1 1/2 PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY B. INSTALLATION PREPARATION 1. Verify that the overall length of the cassette is 3 inches greater than the width of the slide-outroom. 2. Verify that the pivot cover (top extrusion) moves freely and closes properly on the magnetic latches. 3. Verify that you have the proper number of Mounting Brackets from the table below. 4. Check that you have received the Rubber Seal to be applied to the top of the housing to complete the installation. 5. Please refer to the Section D (page 10) Placement of Mounting Brackets to determine the proper horizontal location of each bracket along the horizontal line. C. NUMBER OF MOUNTING BRACKETS REQUIRED CASSETTE WIDTH NUMBER OF BRACKETS MODEL TYPE 60 to 149 3 Standard 150 to 204 5 Standard 205 to 275 7 Super Slide 276 to 360 9 Super Slide NOTE: Super Slide models require a centrally located bracket (See Placement of Mounting Brackets on page 10). page 9
D. PLACEMENT OF MOUNTING BRACKETS Mounting Bracket Quantity and Placement Place Outside Bracket 2 Inside the Outer Edge of the Box 60 to 149 = 3 Brackets Place Outside Bracket 2 Inside the Outer Edge of the Box Bracket Centered 150 to 204 = 5 Brackets Bracket Centered Standard Models 205 to 275 = 7 Brackets Bracket Centered 276 to 360 = 9 Brackets Bracket Centered Super Slide Models Standard and Super Slide Models page 10
E. INSTALLATION SEQUENCE 1. Slide-Out Room should be fully retracted to: a. Facilitate the marking and mounting of the Mounting Bracket locations. b. Prevent damage to Slide-Out Room sealing elements. c. Facilitate mounting of the Awning and centering adjustments. 2. Determine and mark on the sidewall the center point of the slide-out-room s width. 3. Draw a horizontal line at least 2 1/2 inches above the top edge of the Slide-Out Room by snapping a chalk line between the specified positions of the outer Mounting Brackets (Part #1511100-08). 4. Mark the horizontal location of each Mounting Bracket required. 5. Using double sided tape, position the Mounting Brackets on the marked spots. This will hold them in place before drilling them with #12 self-tapping screws 1 ½ inches length. Proceed to permanently attach the Mounting Brackets, then seal with silicone caulking the top edge and both sides of each Mounting Bracket. 6. Place the Awning on to the Mounting Brackets; make sure it is centered on previously marked center point. 7. Fix Awning in place with the Mounting Screws located at the bottom of each Mounting Bracket. 8. Remove the Lead Rail End Plate and slide out the Screw Cover. Pull Lead Rail down 1/4 from the top of Slide-Out Room, and attach Lead Rail using #6x3/4 screws. Position screws every 6. 9. Slide back the Screw-Cap Cover into Lead Rail and install the End Plate. 10. Finally, install the Rubber Seal along the top of the housing and against the sidewall of the coach. When doing this procedure, make sure that an effective seal is accomplished. page 11
MAINTENANCE INSTRUCTIONS NOTE: PLEASE REFER TO EXPLODED VIEW DIAGRAM IN SECION F (Page 15 ) FOR INDEN- TIFICATION OF COMPONENTS BY DESIGNATION NUMBER A. TENSION CHANGE The tension of the Torsion Spring is preset at the factory between 7 and 8 full turns. To adjust the tension, facing the G5000, gently remove the left end (LH) plastic cap. Attach Girard Tension Tool (Part # 1511100-19T) to 3/8 rachet. Insert tension tool in to square tube. Maintain tension on spring. Proceed to remove two center screws (#22). NOTE: Use caution when removing the two (2) center screws (#22) on the slide plate: The spring is under tension and may cause the ratchet to turn violently inflicting injury. Hold the ratchet handle tight as you remove part #22 (two center screws) from part #7 (spring support), and carefully release all tension. Use a 9/16 wrench on the square profile of the spring support section inside the cassette on the opposite side of the side plate to maintain the tension while repositioning the ratchet handle. Now we are ready for tensioning. Take up fabric slack. Apply 7 full turns, or 14 half turns (follow arrows on end plate to tension). Awnings of width greater than 244 inches (G5000 Super-slide) are equipped with two (2) springs (one at each end). In this case, you will need to adjust also the tension of the second spring (right hand) (in this case clockwise more tension, counter-clockwise less tension). Replace the screws and plastic end cap. B. LEAD RAIL/ARTICULATION REPLACEMENT NOTE: TWO PEOPLE ARE NEEDED FOR THIS PROCEDURE Extend slide-out room at least 12. If the lead rail has not been disconnected from the fabric, follow these steps: Apply clamps at either end of the fabric close to the cassette to keep fabric out as far as possible and free to move. Retract slide-out room 6. Remove one lead rail end plate #15 Remove lead rail screw cover #13 (see exploded view page 15). Remove fabric screws at articulation rail #26. Remove screws #24 at ends of lead rail articulation covers. Remove all self-tapping screws that attach lead rail to slide-out room wall. Carefully slide out lead rail assembly that needs replacing. Add or replace one or more articulations. Place lead rail down 1/4 from the top of slide-out room, and attach lead rail using #6x3/4 screws. Position screws every 6 and offset the starting screw to avoid using existing screw holes. Slide back the screw-cap cover into lead rail and re-install the end plate. page 12
C. SPRING REPLACEMENT Facing the G5000, remove part #8 (LH plastic end cap) very gently. Attach Girard Tension Tool (Part # 1511100-19T) to 3/8 rachet. Insert tension tool in to square tube. Maintain tension on spring. Proceed to remove two center screws (#22). NOTE: Use caution when removing the two (2) center screws (on slide plate. The spring is under tension and will cause ratchet to turn violently. Hold the ratchet handle tight as you remove part #22 two center screws from part #7 spring support, and carefully release all tension. Use a 9/16 wrench on the square profile of the spring support section inside the cassette on the opposite side of the side plate to maintain the tension while repositioning the ratchet handle. Remove lead rail screw cover #13 (see exploded view page 15). Remove fabric screws at articulation rail #26. Remove part #23 three (2) screws, also remove part #3 LH side plate. Pull defective spring assembly out of roller tube and insert replacement spring with the drive (stationary fitting) first.. Once spring is reinserted place part #3 LH side plate back into position, and reinserting part #23 (2) screws. Now we are ready for tensioning. Take up fabric slack. Apply 7 full turns, or 14 half turns (follow arrows on end plate to tension). Re-attach part #22 2-center screws into part #7 spring support and re-attach end cap on each tab NOTE: Please refer to exploded view for part numbers. D. FABRIC CHANGE NOTE: TWO PEOPLE ARE NEEDED FOR THIS PROCEEDURE Remove two 6-32x1 /2 screws part# 21 on both right hand part# 9 and left hand cover side plate part# 3 and remove both cover side plates. Remove two M6x16 PFH screw part# 22 on left hand side plate part# 3 to unwind spring part# 7. Note: Only remove part# 22 on left hand side plate Keeping special tool in place into spring support bracket, maintain tension turning clockwise to unwind fabric: Use a 9/16 wrench on the square profile of the spring support section inside the cassette on the opposite side of the side plate to maintain the tension while repositioning the ratchet handle. Continue unrolling until the tube is exposed and the channel is lined up with the end plate slot for removal of poly rope. Remove the retaining screw of the first articulation on the left hand side part# 24 and remove (pull off) the fabric and the first articulation. page 13
Place removed fabric assembly on appropriate surface and remove two 6x3/8 PPH fabric screws part# 26 located behind articulation fabric channel part#17 to remove from the old fabric. NOTE: When inserting the poly rope and the articulation on the new fabric make sure to start from the end that will prevent these parts from catching or snagging the seams of the fabric. Select the side of the new fabric with sewn in poly rope and insert first articulation then reinstall the two fabric screws. (Pry open slightly articulation channel for freer movement of fabric) Insert 5.6mm roller tube poly rope part# 19 into fabric. Insert the roller tube poly rope with fabric through the full length of the roller tube channel and simultaneously slide the first articulation into the next articulation channel. Once the new fabric is properly positioned re-wind it on the roller tube and set proper tension to the spring using the ratchet and special tool: Use a counter-clockwise motion and apply 7-8 turn to perform this task. Re-attach part #22 2-center screws into part #7 spring support and re-attach end cap on each tab using proper screws. E. SLIDE BRUSH REPLACEMENT Remove the strike plates part# 18 by lifting the pivot cover part #2 and removing screws part # 27. Insert flat head screw driver into brush channel (part# 10) tap lightly on metal fitting until exposed 4-5 inches on opposite end. Grasp with pliers and remove entire length of brush. Insert new brush and ensure both ends of brush are flush with ends of pivot cover. Replace strike plates. page 14
F. EXPLODED VIEW 15 25 24 19 26 2 10 18 27 21 8 5 28 22 23 3 13 16 14 15 12 29 26 17 24 25 1 7 27 18 20 19 11 29 6 12 4 23 9 21 page 15
G. PARTS LIST REF# ITEM CODE DESCRIPTION 1 1110089-50 Box Mainframe 2 1110089-51B Pivot Cover 3 1511100-00L G5000 LH Side Plate Assembly 4 1511100-00R G5000 RH Side Plate Assembly with Gudgeon Support 5 1500121-12 Roller Tube 6 1500142-13 Roller Tube Gudgeon 7 1511100-19 Torsion Spring Assembly (LH) 7A 1511100-19R Torsion Spring Assembly (RH) 8 1511112-012 End Cover LH G5000 9 1511112-022 End Cover RH G5000 10 1511100-41 Brush G-5000 11 1500502-99 Rubber Seal w/adhesive/flush M 12 1511100-08 G5000- Mounting Bracket 13 1110089-20 Slide Screw Cover 14 1110089-30 Slide Lead Rail 15 1511101-22 Lead Rail End Cap LH/RH 16 15111113-03K Slide Cradle 17 1110089-52 Articulation 18 1511100-302 Strike Plate G5000 Plated 19 1500372-00 Poly Rope 20 8000000-00 Fabric-Sunbrella 21 1511103-082 End Cover Screws (MS 6-32-3/8 POH Z/BLK) 22 1511103-05 Spring Support Screws 23 1511103-055 Side Plate Screws (12-14x3/4 PFH SLF TP) 24 1511103-03 Articulation Screws (6x3/4 PH FLT Washer H d) 25 1500530-02 Lead Rail End Cap Screws (6x1/2 FH PHLPS SS) 26 1500182-50 Fabric Screws (6x3/8 PPH SMS SS) 27 1511100-303 Strike Plate Screws (6-20x3/8 PHL FH SS) 28 1511100-45 Retaining Bracket 29 1502085-09 Mounting Bracket Socket Screws page 16
NOTES: page 18