Dometic MANUAL REFRIGERATOR Service Manual
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Dometic MANUAL REFRIGERATOR Service Manual

Dometic MANUAL REFRIGERATOR Service Manual

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8/89
OS1286
DOMETIC
Dometic
M A N U A L R E F R I G E R A T O R
D I A G N O S T I C S E R V I C E
M A N U A L
The Dometic C o r p o r a t i o n
Corporate Office
Warranty
Department
Technical Services
Department
2320 Industrial Parkway
Elkhart, IN 46515
219-295-5228
205 E. Fenn St.
LaGrange, IN 46761
219-463-2191
509 S. Poplar St.
LaGrange, IN 46761
219-463-4858
D-l
Diagnostic Service Manuals

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Summary of Contents for Dometic MANUAL REFRIGERATOR

  • Page 1 D I A G N O S T I C S E R V I C E M A N U A L The Dometic C o r p o r a t i o n 2320 Industrial Parkway Corporate Office...
  • Page 2 NOTES:...
  • Page 3 D-4-4 No Gas Operation (Automatic Reigniter) Operation and Diagnosis D-6- Dometic M a n u a l R e f r i g e r a t o r s ..Glossary Terms D-8-l .

  • Page 4: Diagnostic Flow Chart

    MANUAL REFRIGERATOR DIAGNOSTIC FLOW CHART NO OPERATION Check Supply Voltage C o r r e c t a s N e c e s s a r y 1. 110 Volt Plug 2. Wire Size Correct as Necessary Check Fuse...
  • Page 5 MANUAL REFRIGERATOR DIAGNOSTIC FLOW CHART VOLT AC OPERATION NO 120 1. Check AC Power 2. Refrigerator Plugged in Correct as Necessary 3. Breaker 4. Coach Plug Correct as Necessary Check Selector Switch (Page D-6-20, Para. 66) NOT OK Correct as Necessary...
  • Page 6 MANUAL REFRIGERATOR DIAGNOSTIC FLOW CHART NO GAS OPERATION - Models Equipped with Piezo igniter Check Gas Supply Correct as Necessary Check Switch (Page D-6-20, Para 66) NOT OK Correct as Necessary Check Thermostat Continuity Check NOT OK Correct as Necessary Check Gas Pressure (Page D-6-13, Para.
  • Page 7 MANUAL REFRIGERATOR DIAGNOSTIC FLOW CHART NO GAS OPERATION - Models Equipped with Automatic Reigniter Correct as Necessary Check Gas Pressure (Page D-6-13, Para 37) NOT OK Correct as Necessary Check Gas Supply (Page D-6-14, Para. 40) NOT OK Check 12 Volt D.C.
  • Page 8 NOTES:...

  • Page 9: Operation & Diagnosis

    OPERATION & DIAGNOSIS DOMETIC MANUAL REFRIGERATORS D-6-1...
  • Page 10 This is Dometic’s Manual Refrigeration Diagnosis and Troubleshooting program. In this program we will discuss the way an absorption cooling unit operates, and the diagnostic procedures used to troubleshoot the complete refrigerator system. Before we begin extensive troubleshooting procedures on the cooling unit, let’s take a few minutes to see how it operates.
  • Page 11 The cooling unit parts that accomplish this PUMP ‘cooling’ or heat extraction process, include the: Boiler or Generator BOILER l------------- WATER SEPARATOR Condenser TEMPERATUR EXCHANGER - - - - - - - - - - - - Evaporator D-6-3...
  • Page 12 Absorber ABSORBER THE ABSORPTION SYSTEM CONDENSER EVAPORATOR Because the self-contained cooling unit does not utilize an electric compressor or pump, the cooling coils can be oper- ated from a variety of heat sources. LP TEMPERATURE gas, 120 volts AC and 12 volts DC EXCHANGER heating elements are the most com- monly used heat sources for recreation-...
  • Page 13 (10) WATER We will now take a closer look at how the cooling unit functions in normal operation. When proper heat is supplied to the boiler, ENSER ammonia vapor is produced and rises in the siphon pump, carrying with it a weak liquid ammonia solution.
  • Page 14 U 3) As this process continues, the ammonia and hydrogen vapors become intermixed and flow downward into the absorber vessel. As the ammonia vapor comes in close contact to the liquid ammonia solution in the absorber vessel, the ammonia is absorbed into the liquid solution, allowing the hydrogen vapor to rise up through the absorber coils.
  • Page 15 (16) THREE REQUIREMENTS Since the absorption system utilizes no mechanical pumps or compressors to circulate FOR PROPER OPERATION the refrigerant within the system, proper leveling 1. Level is required to provide correct refrigerant flow in the gravity-feed system. Without proper leveling, refrigerant within the cooling coils will collect and stagnate at certain areas.
  • Page 16 (19) In recent years Dometic has engineered a new type of cooling unit that utilizes an improved siphon pump tube design which drastically PUMP reduces the possibility of permanent damage to the coils if operated in an out-of-level condition, or too much heat is generated at the boiler section.
  • Page 17 The best method for venting the absorption refrigerator is with a lower side vent and a roof vent. Using proper Dometic vents will give you sufficient intake and exhaust areas for ventila- AIR FLOW...

  • Page 18: Cooling Unit

    THE ABSORPTION SYSTEM (25) Three things must be remembered when diagnosing a cooling unit: CONDENSER First, circulation within the cool- ing unit is totally gravitational. This EVAPORATOF means proper leveling is important. Second, heat - created to boil the ammonia - now has to be dis- sipated into the surrounding air.
  • Page 19 WARM BOILER HOT GAS ONLY (30) The following section of the program examines the Dometic manual refriger- electrical systems. ator’s gas and Dometic refrigerators are designed for both piezo and automatic ignition. Both systems will be covered in this presen- tation.
  • Page 20 UNDERSTANDING (31) Let’s look at the current Dometic refrigerators and see how the gas flows. GAS SYSTEM SHUT-OFF VALVE (32) GAS LINE Gas flows from the gas line to the shut-off valve and to the connection piece. CONNECTION PIECE ( 3 3 )
  • Page 21 (36) and onto the orifice and burner assembly. ORIFICE & BURNER ASSEMBLY Remember that except for the connection piece, all fittings are O-ring sealed. Whenever the system is separated the O-rings must be replaced. (37) To diagnose the gas system, connect a manometer to the test point.
  • Page 22 (40) The most efficient way to diagnose the gas system would be to first connect the gas manometer to the pressure test point. With the thermostat set at maximum you must have 11 to 12 inches water column pressure for the refrigerator to operate properly.
  • Page 23 Turn on the main gas supply and take a reading. If the manometer now reads 11 inches, the thermostat is defective and must be replaced. (45) If the by-pass screw test shows no change in gas pressure, the problem lies with the gas supply to the refrigerator.
  • Page 24 The jet has an orifice made of an industrial ruby which has been laser-beam drilled. Each model of Dometic refrigerator uses a different size orifice in order to maintain the required amount of heat at the siphon pump. To clean the jet and burner, soak them in an alcohol base solvent and allow to air dry.
  • Page 25 (51) The control assembly will now drop down and can be pulled outward for service. (52) Pictured here is the other model design. Make sure the main gas supply has been shut off and disconnect the gas supply line at the refrigerator.
  • Page 26 There are 3 screws in the burner area that must also be removed. Please note - these are machine screws, not sheet metal type. It is important for them to be reinstalled in this area only. (56) The control assernbly will now drop down and can be pulled out..,., On the present line of manual refrigerators we use one of two methods of igniting the burner...
  • Page 27 The igniter reigniter, used on certain Dometic model refrigerators, operates on 12 volt current. On gas operation the igniter senses the resis- tance through the flame between the electrode and burner. When there is no flame at the burner, the resistance is high and the igniter begins sparking to light the burner.
  • Page 28 Technical Service Department at (219) 463- 4858. (69) You are an essential part of a team that con- tributes greatly to the successful future of the RV industry, your dealership and Dometic. Thank you for participating in the training program. D-6-21...
  • Page 29 NOTES:...
  • Page 30 Section of the cooling unit where heat is applied. This is where the ammonia is partially separated from the water. BY-PASS SCREW: Small brass screw located on any Dometic gas thermostat that regulates gas flow in the low flame mode. There are three common sizes of this screw: S-17-350 BTU, S- 14-325 BTU, S-l l-300 BTU.
  • Page 31 (Glossary of Terms . . continued) ORIFICE (JET): A small brass fitting that is mounted on the gas line just prior to the burner. This device incorporates a very small opening to greatly reduce gas flow to the burner. The orifice is cleaned by using an alcohol based solvent and allowing to air dry.
  • Page 32 TYPES OF BLOCKAGE To understand the absorption principle we have set up several refrigerators to inspect and diagnose. Carefully touch the absorber and boiler sections of each unit and record your findings. Proceed with caution as some of these units could be extremely HOT. Listed below are three types of units you will be testing: GOOD COOLING UNIT Carefully touch the unit at the boiler box and the absorber area.
  • Page 33 CHANGING THE Refrigerator HINGE POSITION Bulletin R54/7A March 1987 R 5 4 / 7 A MODELS: 2600,2602,2800,2802, 3600,3601,3800 & 3801 WHEN CHANGING THE HINGE POSITION: If the door(s) open when the latch assembly is in the locked position, adjust the hinge/door I n s u r e t h a t t h e d o o r l a t c h a s s e m b l y o p e r a t e s assembly.
  • Page 34 Dometic refrigerator.

  • Page 35: Changing Cooling Unit

    The following categories have been established predicated on similarity of design and procedure for replacement of cooling units. Most Dometic r e f r i g e r a t o r s a r e c o v e r e d one (1) of these categories.
  • Page 36 (Bulletin R55/7A c o n t i n u e d ) INSTALL REPLACEMENT COOLING UNIT: 4. Remove evaporator screws (FIG. B4). 5. Remove screws holding unit from rear (FIG. Trim the Styrofoam portion of the cooling Bl). unit does freely into 6.
  • Page 37 (Bulletin R55/7A) c o n t i n u e d ) Apply sealing permagum (sealing tape) on Remove screws holding unit from rear (FIG. mounting plate (A; FIG. B5). Cl). Apply thermal mastic on the evaporator coil Disconnect green grounding wire (FIG. Cl). (B;...
  • Page 38 (Bulletin R55/7A c o n t i n u e d ) D . C a t e g o r y #4 Apply sealing permagum (sealing tape) on window insulation (A; FIG. D3). RM190 RM2190 RM2 192 Tighten screws securely to obtain proper seal. Install the heating elements completely back into the pocket.
  • Page 39 (Bulletin R55/7A c o n t i n u e d ) SEALING PERMAGUM (Sealing Tape) FIG. E2 FIG. El F. C a t e g o r y #6 RM75 RM76 RM77 REMOVAL OF COOLING UNIT: Remove burner protection cover and remove burner from chimney (FIG.
  • Page 40 (Bulletin R55/7A c o n t i n u e d Tighten screws securely to obtain proper seal. Tighten screws securely to obtain proper seal. 5. Install heating elements completely back into Install the heating elements completely back the pocket and plug in (FIG. Fl). into the pocket.
  • Page 41 Before You Change REFRlGERATOR That Cooling Unit BULLETIN R61/7A DEC. 1987 PART I. PROPER DIAGNOSIS Cooling units are sometimes diagnosed as being For a simple method to check gaskets, close defective when the actual problem is something the door on a dollar bill, then pull the dollar else.
  • Page 42 (Bulletin c o n t i n u e d ) make sure the distance from Also, D. Check the open space above the refrigera- the bottom of the refrigerator to the tor. If this space is 1 1/2 inches roof v e n t i s a t l e a s t t h e m i n i m u m...

  • Page 43: Checking Resistance Of Heating Element

    This could indicate: voltage ratings are known. (These ratings are stamped on all Dometic heating elements.) Liquid trapped in the evaporator sections, caused by out-of-level operation for a Use this Formula: Resetting the refrigerator period of time.

  • Page 44: One Lastcheck

    (Bulletin R61/7A c o n t i n u e d ) ONE LASTCHECK NOTE: The cooling units currently being used are specially designed to prevent overheating of If the previously mentioned test was performed the boiler tube even when operated out-of-level. temperatures above This special design can be identified by the...

  • Page 45: Data

    REFRIGERATOR TECHNICAL DATA RAK1 9286111001 Kerosene RAK1302 9 2 8 6 1 7 9 0 0 8 Kerosene RC15 2 9 2 2 0 0 0 0 0 0 - - - - - - - - RC65G 50 (0061667002) RC65K N / A Kerosene...
  • Page 46 (Bulletin continued) RM3601 0173757022 17.9 RM3604 2934803996 53 (2007419191) 0173754045 0173757022 17.9 R M 3 8 0 0 2934901097 58 (2007419217) 0173742081 Models that use brass heating elements in diameter. D-9-15...
  • Page 47 (Bulletin c o n t i n u e d ) Models that use brass heating elements approximately in diameter. formula for calculating amps NOTE: The Watts Volts = AMPS Volts (120) Amps = D-9-16...
  • Page 48 BULLETIN M A Y 1 9 8 3 Replacement of cooling units in RM760. Cooling unit will replace 530A in production and service. When installing as replacement for 530A three new holes should be drilled in the cooling flange. holes (29 mm) down.
  • Page 49 REFRIGERATOR BULLETIN REVISED AUGUST, 1984 CROSS REFERENCE OF REFRIGERATORS MANUFACTURED BY A.B. ELECTROLUX AND PROCEDURE CHANGES SUBJECT: Dometicare Procedure An out of warranty cooling unit purchased from for installation on an Instamatic, Magic Chef, Hadco or GE refrigerator does not qualify for our three year Dometicare cooling unit coverage.

  • Page 50: Heating Elements

    HEATING ELEMENTS 360-460-660-760 Previous literature covering the following models, lists the wattage of 110 volt heading elements as follows: RM360 120 watts RM460 135 watts RM660 175 watts RM760 250 watts The ratings that are actually stamped on the replacement heating elements are as follows: RM360 135 watts...
  • Page 51 THE ABSORPTION SYSTEM WATER SEPARATOR VAPOR PIPE SOLUTION SOLUTION LIQUID VAPOR HYDROGEN GAS V A P O R D-9-20...
  • Page 52 This Manual is Compliments of Northwest RV Supply 86325 College View Road Eugene, OR 97405 Local: 541-746-9092 Toll-Free: 866-678-7467 Fax: 541-736-5573 http://www.nwrvsupply.com mail@nwrvsupply.com Northwest RV Supply carries a large spectrum of surplus, used, and new RV parts and components. Please feel free to visit our website for additional information.

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