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Old 08-10-2023, 04:22 PM   #121
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Has your repair job using the JB weld held up?
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Old 01-04-2024, 04:33 PM   #122
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9200 awning failure

I jumped over here to see what’s going on with this. I’m actually a Keystone Montana owner (2021 model) with the same issue with the same 9200 awning motor. I was able to get a replacement from Keystone through my extended warranty after little help from Dometic, but I decided to do a repair on the one that failed so I have a backup. It did appear to me that the gear was molded to the shaft around a serrated area and a hole in the shaft which the glass filled nylon flowed. This is the point of failure, motor drives the gear but it just slips on the shaft after to fails. My guess is part of the failure comes from retracting the awning and once it touches the side of the camper, if you continue to hold the retract button it puts additional strain and torque on the joint, weakens it and eventually fails. There is no torque limiter or slip clutch to protect it. Not even the breaker trips.
After seeing some others that were repaired, I decided to make a new flanged shaft and modify the gear to marry the two together. I bored out one side of the gear just deep enough to remove the ribs and hub. Also bored the center hole to 10mm. Added holes for the rivets. The new shaft is a replica of the old with a flange integrated into the shaft. It also has holes to accept the rivets. The head of the rivet only protrudes slightly but there is a flange bronze bushing the shaft goes into that provides the clearance needed. It went together quite nicely however I have only bench tested it since I put a new one on the camper. I had a local machine shop make up the shaft and modify the gear for me. Fortunately I know the owner so he gave me a break on the cost. If this is something you are interested in doing I have pdf drawings of the parts made and more photos.
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Old 01-04-2024, 04:49 PM   #123
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Quote:
Originally Posted by Slideplayer View Post
I jumped over here to see what’s going on with this. I’m actually a Keystone Montana owner (2021 model) with the same issue with the same 9200 awning motor. I was able to get a replacement from Keystone through my extended warranty after little help from Dometic, but I decided to do a repair on the one that failed so I have a backup. It did appear to me that the gear was molded to the shaft around a serrated area and a hole in the shaft which the glass filled nylon flowed. This is the point of failure, motor drives the gear but it just slips on the shaft after to fails. My guess is part of the failure comes from retracting the awning and once it touches the side of the camper, if you continue to hold the retract button it puts additional strain and torque on the joint, weakens it and eventually fails. There is no torque limiter or slip clutch to protect it. Not even the breaker trips.
After seeing some others that were repaired, I decided to make a new flanged shaft and modify the gear to marry the two together. I bored out one side of the gear just deep enough to remove the ribs and hub. Also bored the center hole to 10mm. Added holes for the rivets. The new shaft is a replica of the old with a flange integrated into the shaft. It also has holes to accept the rivets. The head of the rivet only protrudes slightly but there is a flange bronze bushing the shaft goes into that provides the clearance needed. It went together quite nicely however I have only bench tested it since I put a new one on the camper. I had a local machine shop make up the shaft and modify the gear for me. Fortunately I know the owner so he gave me a break on the cost. If this is something you are interested in doing I have pdf drawings of the parts made and more photos.
Nice work and a great 1st post!
Thanks for coming here and posting.
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Old 02-20-2024, 03:49 PM   #124
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Plastic gear trouble

Quote:
Originally Posted by Slideplayer View Post
I jumped over here to see what’s going on with this. I’m actually a Keystone Montana owner (2021 model) with the same issue with the same 9200 awning motor. I was able to get a replacement from Keystone through my extended warranty after little help from Dometic, but I decided to do a repair on the one that failed so I have a backup. It did appear to me that the gear was molded to the shaft around a serrated area and a hole in the shaft which the glass filled nylon flowed. This is the point of failure, motor drives the gear but it just slips on the shaft after to fails. My guess is part of the failure comes from retracting the awning and once it touches the side of the camper, if you continue to hold the retract button it puts additional strain and torque on the joint, weakens it and eventually fails. There is no torque limiter or slip clutch to protect it. Not even the breaker trips.
After seeing some others that were repaired, I decided to make a new flanged shaft and modify the gear to marry the two together. I bored out one side of the gear just deep enough to remove the ribs and hub. Also bored the center hole to 10mm. Added holes for the rivets. The new shaft is a replica of the old with a flange integrated into the shaft. It also has holes to accept the rivets. The head of the rivet only protrudes slightly but there is a flange bronze bushing the shaft goes into that provides the clearance needed. It went together quite nicely however I have only bench tested it since I put a new one on the camper. I had a local machine shop make up the shaft and modify the gear for me. Fortunately I know the owner so he gave me a break on the cost. If this is something you are interested in doing I have pdf drawings of the parts made and more photos.
. Like more info on how you had this made
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Old 02-20-2024, 03:58 PM   #125
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Like more info getting this made a friend of mine also works at machine shop like to see if I can get on made also
Thanks bdld
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Old 02-20-2024, 07:28 PM   #126
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Hey bdld! So,I’m unable to post pdf format files on this portal (or at least I haven’t figured out how)but I have pdf drawings of the gear modification and the detailed shaft drawing. If you want to send me a private message with your email address, I can send you the pdf files.
Thanks, slideplayer
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Old 02-21-2024, 11:22 AM   #127
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Quote:
Originally Posted by Slideplayer View Post
Hey bdld! So,I’m unable to post pdf format files on this portal (or at least I haven’t figured out how)but I have pdf drawings of the gear modification and the detailed shaft drawing. If you want to send me a private message with your email address, I can send you the pdf files.
Thanks, slideplayer
When you write a reply, see the little paper clip above the text box? That's what you use for attachments to your post.
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Old 02-21-2024, 02:55 PM   #128
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PDF files

Here are the pdf files for the repair I did. I actually used cold rolled steel for the shaft instead of SS, it’s a little cheaper. Also attached is a pic of the rivots that i used.
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File Type: pdf Awning Drive Gear Modification.pdf (109.4 KB, 27 views)
File Type: pdf New Awning Shaft.pdf (20.7 KB, 26 views)
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Old 02-21-2024, 02:57 PM   #129
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Thanks NJKris, was able to get it to work this time!
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Old 02-21-2024, 03:02 PM   #130
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Nice work. Always good to have this knowledge in my toolbox for if my 9200 ever fails.
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Old 02-21-2024, 07:27 PM   #131
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Thanks slideplayer
Got the pdf files
Thanks
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Old 02-21-2024, 08:15 PM   #132
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Quote:
Originally Posted by Slideplayer View Post
Hey bdld! So,I’m unable to post pdf format files on this portal (or at least I haven’t figured out how)but I have pdf drawings of the gear modification and the detailed shaft drawing. If you want to send me a private message with your email address, I can send you the pdf files.
Thanks, slideplayer
Got your pdf thanks will let you know when I get one made tryed to chance my name to freebird did not take so will keep bdld
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Old 02-22-2024, 02:29 PM   #133
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I think you have to contact one of the site admins to change your user name. Others have done it no problem.
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Old 02-22-2024, 04:02 PM   #134
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Thank you
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