:a-. Repair Manual. Type 2. 6 l- rfl z. Campmobile. Repair. Troubleshooting ...
procedures for 1976, 1977 and 1978 factory-equipped Campmobile vehicles.
:a -
RepairManual Type2
6 l-
rfl
z
Campmobile Repair Troubleshooting
Thispublication installation, containstheessentialremoval, andadjustment procedures for 1976,1977and1978factory-equipped Campmobile vehicles soldin theUSAandCanada.
CAUTION It is assumedthat the readeris lamiliarwith basicautomotiverepair procedures. Specialtools requiredin performingcertainserviceoperationsare identilied in the manualand recommended lor use. Useof tools or proceduresotherlhan thoserecommended in this repair manualmaybe detrimentalto the vehicle'ssafeoperationas well as the safety ol the personservicingthe vehicle. Partnumberslistedin this manualarelor relerenceonly.Alwayscheckwith yourauthorized dealerto verilypartnumbers.
"'-----i'
w 42-028-965-1 FirstEdition,4/78 Manufactured in the UnitedStatesof America AKTIENGESELLSCHAFT @ 1978VOLKSWAGENWERK All rightsreserved. All information in thispublication contained is basedon the latestproductinformation available at the timeof printing.Therightis reserved to makechanges at anytimewithoutnotice.No partof thispublication maybe reproduced, in anyformor by anymeans, storedin retrieval system,or transmitted, photocopying, mechanical, recording, electronic, or otherwise, withoutthe prior writtenpermission Thisincludes of thepublisher. text,f iguresandtables.
Contents Page
Repair
Ceilingcabinetandcloset Left insidetrim panel Louvered windows Luggagerack Pop-uproof Rearseatandstoragelocker Refrigeratorcabinet Sinkandgasrangecabinet Currentf low diagram(CANADA)
(usA)
Troubleshooting
Cut-offrelayf or auxiliarybattery(USA) Efectricalsystem,generallayout Refrigeratordoesnot cool(CANADA) (usA)
76.2 75.9 76.8 75.2,75. 7 75.2,75. 3 77.2 76.7 76.4
97.12
97.4 97.11 97.2 97.14 97.6
lndex Ceilingcabinet 76.2 Circuitbreaker 97.3 Closet 76.3 Controlpanel 97.3 Currentf low diagram (cANADA) 97.12 (usA) 97.4 battery 97.11 Cut-offrelayforauxiliary Efectricalsystem,generallayout 97.2 Leftsidetrim panel 75.9 Louvered window 76.8 Luggagerack 75.2,75.7 Pop-uproof 75.2,75.3 canvas 75.2,75.4 seal 75.2,75.5 Rearseatandstoragelocker 77.2 Rectifier 97.3 Refrigeratorcabinet76.7 Sinkandgasrangecabinet 76.4
Sinkwaterpump 97.3 Troubleshooting cut-off relayfor auxiliarybattery(USA) 97.11 refrigeratordoesnot cool (cANADA) 97.14 (usA) 97.6 refrigeratordoesnot coolon 110voltA.C. (CANADA) 97.14 (usA) 97.8 refrigeratordoesnot cool on 12volt D.C. (cANADA) 97.14 (usA) 97.10
75
InteriorPanels Roof
751
Roof 75 InteriorPanels,
Seal removi ng/ i nstal l i ngpage75.5
-Foof r e pta cin gp a g e 7 5 .4 r e mo vin gp a g e 7 5 .4 i n sta llin gp a g e 7 5 .5
fiff;i::3r3ii3i
: Luggage rack
fiffnffii:3:i3l
7 5.2
iff :!:?:l;anvas/sea'
KF
InteriorPanels, Roof 75 Pop-uproof,removing Worksequence
j60rdt
>;-.:,'i,:lt.
- releaselatch(A)atlock(B) (D) - pushup roofat handle(C)andcrossbar untilstrutsupports(E)at frontarelocked in oosition
at f rameand - pulloff doublebedsnaps(arrows) removemattress
- removecirclip(A)frombolt(B) - pushbolt(B)outof bracket(C) - letstrutsupports(B)restbetweenbothboltsin brackets(C) Note procedures Following require2 mechanics to avoiddamageto vehiclepaint
- remove3 bolts(arrows) on eachsideof rearlinkages andtie themtogether - let pop-uproofrestat rearof vehicleroof - lift pop-uproofoff vehicle (thirdmechanic required) Note Donotdamagepaintwithf rontsupportstruts whenremoving roof
- removescrews(arrows) at channel
Pop.uproof 75.3
75 InteriorPanels, Roof Pop-uproof,installing
Pop-uproofcanvas,replacing
Work sequence
Note
Note
W hen canvasmust be repl acedcut i t al ong vehi cl eroof.Thi s ensureseasv removalof screws i n channel
T o hold s t r ut s u p p o rtsi n p o s i ti o nte mp o ra ri l y staple roof canvasto wooden f rame on left and r ight s ides - lif t pop- upro o f c a n v a so n to v e h i c l ero o f ( 3 m ec han i c sre q u i re d ) - let s t r ut s u p p o rtsre s t b e tw e e nb o th b o l t s of front brackets - m ount r ea rl i n k a g e sto v e h i c l ero o f w i th 3 bol ts and t ight e nth e m l o o s e l y -
Pop-uproofcanvas,removing Worksequence - removepop-uproofandcanvasas describedon page75.3 - placepop-uproofupsidedownon two benches
ins t allbolt s i n s tru t s u p p o rt b ra c k e tsa n d s ec ur ewit h n e w c i rc l i p s r eins t allc h a n n e lo f p o p -u pro o f c a n v a sa nd t ight en s c r e w sf ro m c e n te rto s i d e s c los e pop- u pro o f n o ti n gfo l l o w i n g : o lower po p -u pro o f s o th a t a t fro n t a p p ro x. 200 m m ( 8 i n .)s ta y so p e n . pus h r oo f o n b o th s i d e s to f ro n t . pus h c en te rp a rt o f ro o f to fro n t a l s o a nd let lat c h e n g a g ei n l o c k
removeone screwof handl e(A )and turn aro und removerei nforcement(B )-3 bol ts removestrut support(C )brackets-2 bol ts on each si de - removelock (D)-4 bolts -
- c hec k alig n m e n to f p o p -u pro o f to l u g g a gerack and seating of seal (arrows)
-
-
if nec es s a ryre a l i g nro o f b y mo v i n gre a r link agesA i n e l o n g a te dh o l e sa n d ti g h te nbol ts B
75.4
Pop-uprool canvas
removepl asti cstri p hel d w i th stapl esto wooden frame (arrows) pul l out stapl eshol di ngcanvasto w oodenfr am e
Roof 75 InteriorPanels, Pop-uproofcanvas,installing Worksequence
l 6d-o60I
. seal for front (crosssecti on B -B ) A - i nsertedsteel cl amps B - rubber part of seal
- f it c anv asto a l l fo u r c o rn e rso f w o o d e nf rame wit h s t aol e s - at t ac hc an v a sto f ro n t, re a ra n d s i d e s e c ti onsof woodenf ra m ew i th s ta p l e sg o i n g f ro m c enter of s ec t ion sto c o rn e rs - c ut 4 plas ti cs tri p s a p p ro x .2 0 0m m (8 i n . ) s hor t ert ha n e a c h s i d e o f ro o f - war m up p l a s ti cs tri p s i n w a rm w a te r - s t apleplas ti cs tri p s (s tre tc h i n gth e m to l ength r equir ed)t o w o o d e nf ra m e Note Always start at corners -
r eins t allp o p -u pro o f a n d c a n v a sa s d e s cri bed on page75 .4
Pop-uproof seal,removing - open r oof a n d p u l l o ff s e a l
Pop-uproofseal,installing Worksequence A -A ) seal f or si des and rear(cross-secti on AB-
i nsertedsteel cl amos rubberoart of seal
Note C orrecttensi onof i nsertedsteel cl amos can b e restoredby squeezi ngsealtogether
- ins t alls ea l w i th c ro s s s e c ti o nA-A o n rearand lef t and r ig h t s i d e s - ins t alls ea lw i th c ro s s s e c ti o n B -B o n front
Pop-uproofseal
75.5
Roof 75 InteriorPanels,
- coatsealwithtalcumpowder - slidesealoveredgesof roofstartingat both f rontcorners(arrows)
clampsis - to makesuresealwithinserted seatedproperlyon roofpressit ontoedgeswith plasticwedge(A)
75.6
Pop.up roor seal
InteriorPanels, Roof 75
Work sequence
r em ov ebea d i n g(A )p a rti a l l ya fte r re m o v i n g 2 P hillipss c re w s - r em ov eint e ri o rl i g h t (B)a n d i n s u l a teh o t wi re - r em ov eallT Ph i l l i p ss c re w so n re a rp a rt o f f r ont headli n e r(a rro w s ) - r em ov e2 P h i l l i p ss c re w so n f ro n t p a rt o f f ront headliner(arrows) -
-
parti al l ypul l dow n front headl i nerandi nsul at ion removenuts (arrows)
Lussagerack 75.7
Roof 75 lnteriorPanels,
t#
- removeall (four)sheetmetalscrews(arrows) - lift luggage rackoff vehicleroof
Luggagerack,installing Worksequence
-
place rubberwashers(A)on holes lif t luggagera c k o n ro o f a n d a l i g n h o l e s ins er ts hee t m e ta l s c re w sa n d l o o s e l yti g hten in brackets(B)
-
ins t allwas h e rsa n d n u ts f ro m i n s i d eo f v ehi cl e and loos elyti g h te n - f inallyt ight e na l l s h e e t m e ta l s c re w sa n d nuts - r eins t allins u l a ti o n ,fro n t h e a d l i n e r,b e a d ing and int er io rl i g h t
75.8
rack Lussage
Roof 75 lnteriorPanels, Leftinsidetrim panel,removing
$ r'
rWork sequence
IF
W A R N IN G
Not e
B eforestarti ngto performfol l ow i ngrepai r operati onsdi sconnectextensi oncord and removegroundstrapon both batteri es
Rem ov alis onl y p o s s i b l ea fte r re fri g e ra to rc abi net and s ink / gas r a n g ec a b i n e ta re re m o v e d
r-
- loos enc ab l e c l a mp - dis c onnec tw i ri n g f ro m p l u g (A) ) n d p u l l o ut - r em ov eP hi l l i p ss c re w s(a rro w s a c ont r ol pan e l(B )
tri m oanelout of channel
Left insidetr im panel,installing -
install in reverseorder
Left i nsi detri m panel
75.9
76
Cabinets WaterTank Windows
76.1
76 Cabinets, WaterTank,Windows Ceilingcabinet,removing
- open c abin e t l i d - on lef t s ide re mo v efo u r n u ts (a rro w s ) and ous h b o l ts i n to c l o s e t
- on ri ght si de removeP hi l l i psscrew s (arrows) - l i ft cabi netout (2 mechani csneeded)
Ceilingcabinet,installing -
76.2
cabinet ceirins
i nstal l i n reverseorder starti no w i th 2 bol ts i n top of cabi net
Cabinets, WaterTank,Windows76 Closet,removing Work sequence Note Rem ov alonly p o s s i b l ea fte r c e i l i n g c a b i n e t is removed
- removePhillipsscrews(arrows) at bracketon roof frame - tilt closetand remove
Closet,installing - installin reverse order -
r em ov eeng i n ec o m p a rtm e n ti n s u l a ti o n r em ov eP hi l l i p ss c re w s (a rro w s )a l s o h o l d refrigeratorcabinet frame
- remove Phillips screws (arrows)at brackets at enginec om p a rtme n tto p
76.3 croset
76 Cabinets, WaterTank,Windows
76.4
cabinet Sinkandsasranse
Cabinets, WaterTank,Windows76 Sinkand gas rangecabinet,removing Worksequence
- removebolts(arrows)behinddriver'sseat partition
-
r em ov ef r om u n d e rn e a thv e h i c l e : A = br ac k e tfo r s i n k d ra i n B = c ov ef p l a te w i th s e a l C = cov€I plate for water tank drain hose
-
removebol ts (arrow s)i nsi de of cabi net
- removelock bolt (A)for sparetire storage doorfrom bracket(C) compartment - removedoor(B)f rom hinges
Sink and gas range cabinet
76.5
76 Cabinets, WaterTank,Windows
-
removefuse i n i n-l i nefuse hol derfor w ater pump, di sconnecthot w i re (A ) and ground w i re (B ) from f use box, gas rangeconnecti on (C )and ci ty w ater hook-up(D ) (E = si nk drai n pi pe)
- removeshelf retainers(B) - removeshelves(A) - ( leav es hel f s u p p o rts(C ) i n s ta l l e d )
- removesinkandgasrangecabinet Note Do not damagewire(arrow)to fuse box
Sinkand gas rangecabinet,installing order - installin reverse
CAUTION must Waterandgas rangeconnections not leak
-
r em ov ec o v e r p l a te fo r s i n k d ra i n p l a te (A ) removecabinet doors and drawers
76.6
Sink and gas range cabinet
WaterTank,Windows 76 Cabinets, Refrigeratorcabinet,removing
;.
Work sequence Not e Rem ov alonly p o s s i b l ea fte r s i n k a n d gas r angec ab i n e t i s re mo v e d
removebol t (arrow )l ocatedi n storagel ocke r under rear seat bench - di sconnectel ectri calconnecti onand l i ft out refri geratorcabi net
-
) o l d i n gfr ame - r em ov eP hil l i p ss c re w s(a rro w s h
Refrigerator cabinet,installing -
i nstal l i n reverseorder
N ote C onnectel ectri calw i res
Refrigeratorcabinet
76.7
76 Cabinets, WaterTank,Windows Louveredwindows,removing
Work sequence Not e Removalis only possible after refrigeratorcabinet cover ts removeo
remove2 P hi l l i psscrew s hol di ng curtai n rod and bend rod (A ) dow n careful l y - removeknurl edknob of w i ndow openerand 16 P hi l l i psscrew s (arrow s) - careful l ypress l ouveredw i ndow to outsi de of panel openi ng -
- removecurtain rod cover (arrow)
76.9
Louveredwindows
Cabinets, WaterTank,Windows76 Louvered window,installing Worksequence
ins t all louv e re dw i n d o w i n p a n e l o p e n i n g wit h t wo up p e rc o rn e rsf i rs t - c hec k pr op e rs e a ti n go f ru b b e rs e a l i n g .Recti fy f it of r ubbe r l i p i f n e c e s s a ry - ins t all 16 P h i l l i p ss c re w s a n d k n u rl e d k nob of window op e n e r -
-
ins t all c ur ta i n ro d ins t all c ur ta i n ro d c o v e r
Louvered window76'9
77
Seats Table Beds
771
77 Seats,Tables, Beds Rearseatandstoragelocker,removing
Wfl*@" tu.**m4*W WwW{ W
Worksequence
W A R N IN G
Note
B eforestarti ngto performfol l ow i ng repai r operati onsdi sconnectextensi oncord and removegroundstrap on both batteri es
Removal is onlypossible aftersink/gasrange cabinetandrefrigerator cabinetareremoved
eg-,gugl -
pull s eat be l ts i n to s to ra g el o c k e r r em ov eP hi l l i p ss c re w(a rro w )o n l e ft a n d ri ght s ides at br a c k e ts -
77.2
Rearseat and storage locker
remove2 sel f-l ocki ngnuts (A ),nut f rom anch or bol t (B )and bol t f rom f l oor (C )
Seats,Tables, Beds 77
) n d th e n cover - r em ov eP hi l l i p ss c re w s(a rro w s a f or r ec t ifier
..q
*;-
-
l oosencabl ecl amp at l eft w heel housi ngan d pl aceel ectri calreceptacl eand housi ngon bottom of storage locker - open coverof recti fi er and di sconnectw i ri ng ( A) at connector(B ) - l i ft rearseat out of vehi cl ew i th a hel per Note
t'.::';)F
Makesure w oodenw edge remai nsunder anchorbol t
'".."-.ft.:':\' ,t.; *ril S.--i -,
--*r +.r *lg r-ffi *'F Fg
Rearseatandstoragelocker,installing order - installin reverse I I
I
-
r em ov ebol t a n d w a s h e r(A)a n d d i s c o n n ecl gr oundc ab l e(B)
N ote pl atew i th 2 studs ( A) W hen i nstal l i ngrei nforcement i n ri ght w heel housi ng,makesure rubberseal i ng (B )i s attached.U se new sel f-l ocki ngnuts
r em ov eelec tri c a lre c e p ta c l e(A),d e ta c hf r om hous ing( B ) a n dp u l l to i n s i d eo f v e h i c l e
Rearseat and storage locker
77.3
97
Wiring
971
97 wirins
E xternalel ectri calreceptacl e for 1 10vol t A .C . connecti ons:Fi g. 1
F u s e f o r a u x i l i a r yb a tle r y
C ontrolboard removi ng/i nstal l i ngFi g.4
Re fr ig e r a to rth e rmosl al
Fl uorescenll amp (12vol l D .C .)
W ire t o v e h i c l e and all e r n a t o r
swilch
c u t . off r e la y A uxilia r yb a lle r y
S i nk w ai er pump Fi g. Reclilier connections and ci rcuit br eaker Fig. 3
In sid ea u xilia r yo u tle ts anci cir cu it b r e a ke rb o x ( 1 1 0vo lt A.C.)F ig . 2
W A RNI NG Nev err em o v e /i n s ta lel x te rn a le l e c tri c a l r ec ept ac l ei,n s i d ea u x i l i a ryo u tl e ts , c ir c uit br e a k e ro r re c ti fi e r i f v e h i c l ei s hook ed- u pto 1' 1 0v o l t A.C .
Note lllus t r at ionss h o w U SAv e rs i o ne q u i p m e n t
Fig. 1
Externalelectricalreceptacle,connections 1-el ectri calreceptacl e 2-bl ack col oredw i re 3-w hi te col oredw i re 4-non-i nsul atedcopperw i re (ground)
97.2
layout Etectricat system, senerat
wirins97
'
F ig. 2
,]1.29e:
Cir c ui t b re a k e ra n d a u x i l i a ryo u tl e ts 1- hous i n g 2- c ir c u i t b re a k e r(1 ' l0 v o l t/ 15 a m p ) 3- s oc ke ts(' 1 1 0v o l t A .C .) 4- wir e f ro m e x te rn a lre c e o ta c l e S - wir e to re c ti fi e r 6- 9r ou n d w i re -m u s t m a k eg o o d c o ntact
rex Fi g.4
C ontrolpanel ,removi ng/i nstal l i ng
C A U TION R emoveonl y w i th externalreceptacl e di sconnectedand i nl i nefuse on auxi l i arv batterv removed
i_rur F ig. 3
Rec t if i e r ( c onv e rts11 0 v o l t A .C .to 1 2 v o l t D .C .) 1- hous i n g 2- f us e o n D .C .s i d e -2 5 a m p s 3- wir e f ro m e x te rn a lre c e o ta c l ev i a c ir c u i t b re a k e r 4- hot w i re -1 2 v o l t D .C . 5- gr ou n d w i re -1 2 v o l t D .C .
lz7:Tazf Fi g.5
S i nk w ater pump, removi ng/i nstal ti ng - removef use i n f use box - removecoverpl ate i n si nk cabi net - di sconnectw i res at connector(4) - l oosencl amp (3) - removew ater pump (' 1)w i thf use housi ng(2)
Circuit breaker R ecti fi er C ontrolpanel S i nk w ater pump
97.3
97 wirins Currentflow wiring diagramcolor code B l ack - B K B row n - B R R ed -R Orange-O Y el l ow -Y
Green-G B l ue - B L V i ol et-V Gray -GY W hi te-W
1'E, fl
B' ll
0,5
c
I 8K
+ l, il
5678
97.4
USA vgrsion currenrfrowdiasram
wiring97
Current track
Description A - to standardbattery 41 - auxiliarybattery B -to waterpumpinlinefuse(8amp)nextto fusebox B1 - to fuse59 in fusebox C - to alternator, terminal61(D+ ) E1 - batterychargingtimer E2 -switch BATTERY/CITY POWER E3 - refrigeratorswitch E4 - switchfor testingbatterycondition E5 - waterpumpswitch E6 - f lourescentlampswitch F - refrigeratorthermostat G - battery(charge) conditionindicator J - batterycut-offrelay K - refrigerator warninglight N - rectifierll0voltA.C.l 12volt D.C. (110volt/15amp)with2 outlets 51 - circuit breaker 52 - fuse-12volll25amp-in rectifier 53 - fuse-12 volt/15amp-for refrigerator 54 - fuse-12 volt/16amp-forauxiliarybattery S5 - fuse-12 volt/16amp-forwaterpump f 2 - wireconnector,double;in rectifier T2a- wireconnector,double;nextto refrigerator thermostat T2b- wireconnector, double;nextto waterpumpswitch T2c- wireconnector,double;nextto waterpump T3 - wireconnector, 3-point;on refrigeratorthermostat T4 - wireconnector,4-point;on controlpanel (citypower)110voltA.C. receptacle U - external
u1 U2 V W Z
-
auxiliary outlets110voltA.C. waterpumpwithfuse12volt/2amp f lourescent lamp12voltD.C. resistorfor refrigerator(12volt D.C.)
USA vgrsion
I 8 11 13 10 8 5 5 7 11 14 4 7 9,10 6 1,2 2 2 5 8 11
1,2 1,2 11 12,13 3
rowdiasram 97.5 currenr
97 wirins Ssfusefor refrigerator,checking
Refrigerator doesnot cool
(l ocatedon control panel )
Chec k t hes e f i rs t: o ex t ens ionc o rd to e x te rn a lre c e p ta c l e ( br ok enwir e o r b a d c o n n e c ti o n s ) r c ir c uit br ea k e r . f us es in s y s te m ( s eec ur r en tf l o w d i a g ra mo n p a g e9 7 .4 )
- check for bl ow n fuse
Sofusefor auxiliarybattery,checking (l ocatednext to auxi l i arybatteryi n engi ne compartment) - check for bl ow n f use
Sr circuit breaker,checking - c onnec ta ta b l e l a m p (11 0 v o l t A .C .)to o u t l ets on k ic k boa rd - c hec k t hat c i rc u i t b re a k e ri s i n n o rma lp o si ti on . if t able la mp l i g h ts u p c i rc u i t b re a k e ri s OK . if t able la mp d o e s n o t l i g h t u p , c i rc u i t b reaker is def ec ti v e -re o l a c e
l f al l f uses are checkedand found OK , proceed as fol l ow s: . sw i tch for B A TTE R Y /C ITY P OW E Rsw i tchedt o CITY POWER . ci rcui t breakeri n ON posi ti on o extensi oncord pl uggedi n externalreceptacle
Szfuse in rectifier,checking .j '
;1
rJ1-:i .
2. 'tt,\
1,;
":ffi
si'j:;i!.!T
| 27-308'
jit,;:;
- c onnec ton e l e a do f te s t l i g h t to w i re c o nnector t er m inal1 - c onnec tot h e r l e a do f te s t l i g h t to w i re c o nnector t er m inal2 o if t es t lig h t l i g h ts u p f u s e i s OK - r em ov et es t l i g h t l e a df ro m te rmi n a l2 a n d c onnec tt o f u s e h o l d e rte rm i n a l3 . if t es t lig h t l i g h ts u p f u s e i s d e fe c ti v e
Note lf aux iliar yba tte ryi s re c h a rg e dw i th re c ti fi er,i t i s pos s iblet hat fu s e i n re c ti fi e r b l o w s .In s u c h case c har geaux ilia ryb a tte ryw i th s ta ti o n a ryc h a rger
97.6
USA version rroubreshootinsrefriserator
wirins97 refrigeratorswitchdefective -remove controlpanel Note Do notdisconnect 4-pointconnector - connecttestlightto blueandwhitewire refrigerator warning lightlightsup
refrigerator warning lightdoesnot lightup re p l a c ere fri g e ra tor s w i tc h
wiringto refrigeratorbroken - c onnec tte s t l i g h t to b l u e a n d w h i te w i re of 2- pointwi re c o n n e c to ro n re fri g e ra to r Note Do not dis c o n n e c tw i re c o n n e c to r t es t light lig h ts u p
te s t l i g h t d o e s n ot light up
reoairbrokenwire
wiringof refrigerator thermostat or resistor broken - dis c onne c t2 -p o i n tw i re c o n n e c to r - c onnec to h m m e te ra s s h o w n - t ur n t her m o s ta tfu l l y to ri g h t wir ing not bro k e n ohmmeter reads 0- 2. 5 O hm s
refrigerantf low def ec t iv e,r e p l a c e refrigerator
wiringbroken ohmmeter reads oo Ohms
go to nextpage
USAversionTroubleshootingrefrigerator
97.7
97 wirins loos eor dis c o l o re dw i ri n g o n 3 -p o i n t c onnec t orfo r re fri g e ra to rth e rmo s ta t -
r em ov ere fri g e ra to ra n d c h e c k w i re c onnec ti o n sfo r ti g h tn e s sa n d dis c olo ra ti o n
wiringOK
r ef r iger an ft l o w def ec t iv e,re p l a c e refrigerator
c l e a n a n d re ti g h ten w i ri n g c o n n e c t i ons
not coolon110volt Refrigeratordoes A.C.power Chec kt hes e f i rs t: . r efr iger at orc o o l s o n 1 2 v o l t D .C .p o w e r . B A T T E RY /C IT POW E Rs w i tc h i s s w i tc h e dto Y CI T YP O W ER o c ir c uit br ea k e ri s i n O N o o s i ti o n o ex t ens ionc o rd i s p l u g g e di n e x te rn a lre c e ptacl e f us e ( 25am p ) i n re c ti fi e r b l o w n - c onnectte s t l i g h t to te rm i n a l s4 a n d 5 of wir e c on n e c to r t es t light li g h ts u p , f us e O K
I-
te s t l i g h t d o e s not light up
g o to p a g e9 7.9
wir e ( 2. 5m m ' z )to4 -p o i n tc o n n e c to ro n c ont r ol pa n e lb ro k e n - r em ov ec o n tro l p a n e l - c onnectte s t l i g h t to re d a n d w h i te w i r e
97.8
t es t light li g h ts u p
te s t l i g h t d o e s n ot light up
s wit c h def e c ti v e , r eplac e
re p a i rb ro k e nw i re
USA verSiOn rroubteshootinsrefriserator
4r
mr:l
Wiring
97
Continuedf rom page 97.8 f us e ( 25am p)b l o w n c onnec tt e s t l i g h t to te rm i n a l4 i n w i re c onnec t o ra n d f u s e (w h i tea rro w ) t es t light ligh ts u p
testlightdoesnot lightup
f use(25amp) blown,replace
m*
r ec t ifier def e c ti v e - c onnec tt a b l e l a m p(1 1 0v o l t)to a u x i l i a ry out let at ki c k b o a rd t able lam p lig h ts u p
ta b l e l a m p d o e s n ot light up
w i re f ro m e x te rn al re c e p ta c l eto re c ti fi e r b ro k e n , re p a rr
W A R N IN G U npl ugexternalreceptacl ebeforerepai ri ng brokenw i re
USAversionTroubleshooting refrigerator
97.9
97 wirins Refrigerator doesnot cool on 12volt D.C.power Chec k t hes e f i rs t: r r efr iger at o rc o o l s o n 1 1 0v o l t A .C .p o w e r o inlinef us e ( 1 6a mp ) n e x t to a u x i l i a ryb a tteryi n enginec om p a rtm e n ti s OK
aux iIiar y b a tte ryd i s c h a rg e d B A T T E R Y /C IT P Y O W E Rs w i tc h (1 )i n oos it io nBA T T ER Y - r efr iger a to rs w i tc h (2 )i n p o s i ti o nON - r efr iger a to rth e rmo s ta ttu rn e dfu l l y to ri ght -
- c hec k c h a rg eo f b a tte ryw i th s w i tc h (3 ) in oos it i o nBA T T ER Y needleof i n s tru me n t(4 )i s i n : gr eens c al e I
y e l l o ws c a l e
c h a rg e battery
s t andar db a tte ryd i s c h a rg e d r c hec kac i d l e v e l r c hec k s p e c i fi c g ra v i ty . charge battery
B at t er yc an be c h a rg e dw i th : 1- r ec t ifier in v e h i c l e 2- s t at ionar yb a tte ryc h a rg e r 3- alt er nat orw i th v e h i c l ee n g i n eru n n i n g Not e Dis c har gedba tte ryw i l l n o t o n l y b e c a u s e db y oper at ingr efr i g e ra to rto o l o n g o n b a tte ryb ut al so by def ec t iv ecu t-o ff re l a yfo r a u x i l i a ryb a tte ry
971
0
rerriserator USA version rroubreshoor.ns
wirins97 Gut-offrelayfor auxiliarybattery, checking ( s eeals o c ur r e n tf l o w d i a g ra m ,p a g e9 7 .4 ) - r em ov egr o u n ds tra p o f a u x i l i a ryb a tte ry - r em ov ef use (1 6a mp )o f i n l i n efu s e h o l d er - removered wire f rom terminal 87 of relay - c hec k wir e s o t o alt er na to rte rm i n a l6 1 (D + ) r to standardbattery
c ut - of f r ela yfo r a u x i l i a ryb a tte ryd e fe c ti ve br idget e rmi n a l8 7 o f re l a ya n d g ro u n d wit h t es t l i g h t - s t a' r teng i n e . wit h en g i n ea t i d l e ,te s t l i g h t m u s t light u p -
t es t light lig h ts u p
te s t l i g h t d o e s not light up
cut-offrelayOK
c ut - of f r ela yfo r a u x i l i a ryb a tte ryd e fe c ti v e - s t op eng i n e - br idget e rmi n a l8 6 (b l a c kw i re )a n d t er m ina l3 0 (re dw i re )o f c u t-o ff re l a yw ith t es t ligh t relayclicks and test light does n o t light up
re l a yd o e s n o t c li ck
pointsin relay defective, replace
c o i l i n re l a y d e fe c ti v e ,re p l a ce
USA VgfSiOn
rroubteshootinscut-off rerayrorauxiriarybatrery 97.11
97 wirins
C urrentf l ow w i ri ng di agramcol or code
c
I
BK
I 1,. T ll
Av
T Y tl fl Ass
"i
97.12
CANADA version currenrrowdiasram
B l ack - B K B row n - B R -R R ed Orange-O Y el l ow -Y
Green-G B l ue - B L V i ol et-V Gray -GY W hi te-W
wirins97
Current track
Description A - to standardbattery A1 - auxiliarybattery B - to fusepanel,terminal30(incomingside) 81 - to fusepanel,fuse9 terminal61(D+ ) C - to alternator, POWER E - switchBATTERY/CITY E5 - waterpumpswitch E6 - f lourescentlampswitch thermostat(110voltonly) F - refrigerator J - batterycut-offrelay 54 - fuse-12 volt/16amp-forauxiliarybattery 56 - f use- 12volt/2amp-for waterpump T2 - wireconnector,double;nextto refrigeratorswitch T2b- wireconnector,double;nextto waterpumpswitch T2c- wireconnector,double;nextto waterpump thermostat 3-point;nextto refrigerator T3 - wireconnector, outlets110voltA.C. U - auxiliary V - waterpump W - flourescentlamp12volt D.G. Z - resistorfor refrigerator110voltA.C. 21 - resistorfor refrigerator12volt D.C. O
8 7 10 12 9 2-5 10 13 2 8,9 7 10
1-3 10 11 3 4
- groundconnection (green/yellow wiremustmakegoodcontact)
97.1 3 CANADA version currenrrowdiasram
97 wirins doesnot cool Refrigerator - pull out plu g a t 1 1 0v o l t A.C .re c e p ta c l e s - removerefrigerator - removeBATTERY/CITYPOWERswitch - c hec k f or lo o s eo r d i s c o l o re dw i re c o n n e cti ons o if wir es an d c o n n e c ti o n sa re OK , re fri g e rant f low is de fe c ti v e -re p l a c e re fri g e ra to r and s wit c h . r epairloo s eo r d i s c o l o re dw i re c o n n e c ti ons and let r e fri g e ra to ro p e ra teo n ' 11 0 a n d 1 2 vol t power .lf re fri g e ra to rs ti l l d o e s n o t c o o l , replacerefrigerator
Refrigeratorcoolson 12volt D.C. poweronly c hec k t hes e f i rs t: o plug at 110v o l t e x te rn a lre c e p ta c l ep u l l e d . inlinef us e 1 2 v o l t/1 6a m p fo ra u x i l i a ryb a t tery ( nex tt o bat t e ryi n e n g i n ec o mp a rtme n t)
auxiIiary batteryd ischarged -
br idgew h i te a n d b l a c kw i re o f d o u b l ew i re c onnec to ro n re fri g e ra to rw i th te s t l i g h t
testlightlightsup
testlightdoesnot lightup
c hec k as de s c ri b e d above"ref rigerator does not cool"
Po w e rs u PP | Y defective,check cut-off relayfor a u x i l i a ryb a tte r y. C h a rg ea u x i l i a r y battery
Refrigeratordoesnot cool on 110volt A.G.power - pull out plu g a t 1 1 0v o l t A.C .re c e p ta c l e - c hec k ex t e n s i o nc o rd a n d a u x i l i a ryo u tl e ts on k ic k boar dfo r b ro k e nw i re ,w i re s fo r l o o s eand dis c olor edc o n n e c ti o n s - if no f ault s a re fo u n d c h e c k a s d e s c ri b e dabove " r ef r iger at o rd o e s n o t c o o l "
97.14
rerriseraror CANADA version rroubreshoorins
