Norcold 3163G User manual

IMPORTANT PRODUCT INFORMATION
Norcoldrefrigeratormodels3163Tand3163GinstalledintheRialtaandEurovanCampermay
experience a cooling deficiency while operating in the gas mode. The cooling deficiency occurs
when the vehicle’s interior ambient temperatures are 90°F or higher. Performance while
operating in the AC or DC modes is not affected.
To rectify this deficiency, Norcold offers a product upgrade kit. This kit is available through the
Winnebago service network. Customers who experience cooling deficiencies while operating
in the gas mode should operate their refrigerator on AC or DC until the upgrade kit is installed.
All product upgrades are to be completed by an authorized dealer or service center.
The refrigerator models 3163T and 3163G installed in the Rialta and Eurovan Camper are the
only Norcold refrigerator models affected with this cooling deficiency. The following is the list of
product serial numbers which are affected.
3163T 3163G
Serial Number Range Serial Number Range
001001CLTPC4 - 001850CLTPH4 001001CMGYC4 - 002150CMGYH4
Accompanying this notice are complete instructions for installing the product upgrade kit, tool
requirements, and time allotted for installation. Removal of the refrigerator from its enclosure is
required.
Part No.: 618081C

Figure 1 - Before Upgrade
Figure 2 - After Upgrade
1

Upgrade Kit Components
1 - Installation Instructions
1 - Burner Box Gasket
3 - #8 Hex SD Screws
4 - Screws (#6 x 3/8")
2 - Metal Screw (#6 x 1 1/4")
1 - 6" Red Wire w/3" Jumper
1 - 6" Yellow Wire
1 - 7" Red Wire
1 - Spade Terminal Connector (Double 45)
1 - #11 Burner Orifice (Red Dot)
1 - Burner Heat Shield
1 - 1.0 AMP Fuse
1 - 1.0 AMP Fuse Label
1 - DC Fuse Holder
1 - Plastic Fuse Cover
1 - 12 Volt DC Fan (With Brackets and wire extensions)
1 - 12 Volt DC Thermostat (Fan)
1 - 20" Red Wire
1 - Exhaust Flexible Vent Tube w/Insulation
1 - Wiring Diagram Label
Tools Required
1 - Pliers
1 - Tin Snips
1 - Screw Gun with Phillips Head or Phillips Screwdriver
1 - 1/4" Hex Head Driver
1 - Volt Ohmmeter
1 - 7/16" Open End-Wrench
1 - 1/2" Open End-Wrench
1 - 5/8" Open End-Wrench
1 - Manometer
1 - 3/8" Power Drill
1 - 3/32" Drill Bit
1 - 1/16" Drill Bit
Specifications
Installation of the upgrade kit will change the rating specifications for the LP gas mode. The
specifications are as follows:
LP Gas Mode: 925 BTU/Hr. input; 11" W.C. Gas Supply; .011" Orifice (LP11)
Time Allowance
The time allotted to upgrade the refrigerator is 2.0 hours. The allotted time is to be multiplied
by the service facility prevailing shop labor rate. The time allowance includes diagnostic times,
upgrade kit installation, refrigerator removal and re-installation, and gas leak test.
NOTE: A gas leak test is required when gas connections, either the main supply line or
the refrigerator gas components, have been disconnected.
2

Refrigerator Removal Procedures
Eurovan Camper
1. Turn off the gas supply at the main tank.
2. Turn the refrigerator’s mode selector to "OFF".
3. Remove the vehicle’s middle bench seat.
4. Remove the refrigerator’s system cover located on the left front of the refrigerator by
removing 5 retaining screws.
5. Remove 5 retaining screws securing refrigerator to enclosure.
6. Remove the monitor panel located directly above the refrigerator by removing 6
retaining screws.
CAUTION: It is not necessary to disconnect wiring from the monitor panel. Pull
panel forward and away from the monitor panel’s mounting bracket.
Lay monitor panel on galley top. Take care not to scratch the galley and
its surrounding surfaces, or the face of the control panel.
7. Remove the monitor panel’s mounting (frame) bracket by removing four retaining screws.
The retaining screws are located on both the left and right sides of the bracket.
Figure 3 - Vent Terminal Housing
3

8. Turn the manual shut-off valve located on top of the refrigerator to "OFF". See Figure 4.
9. Remove both the positive and negative leads from the vehicle’s battery.
10. Disconnect the vehicle’s 12 volt DC supply wires from the refrigerator’s terminal block
(Figure 1).
11. Disconnect the LP gas supply line from the refrigerator’s manual shut-off valve.
See Figure 4.
CAUTION: To prevent gas leaks or damage to the gas supply lines and fittings,use
two wrenches when connecting or disconnecting gas fittings.
12. Remove the three (3) screws securing the vent cover to the vehicle’s exterior surface.
See Figure 3.
13. Remove the two (2) screws securing the inner disk to the vent terminal housing. See
Figure 3.
14. Carefully push the vent terminal housing inward until free from the vehicle’s wall.
15. Carefully pull the refrigerator forward to gain access to the refrigerator’s AC power cord.
Disconnect the refrigerator’s AC power cord from the wall receptacle.
16. Remove the refrigerator from it’s enclosure.
Valve Shown in
Off Position
LP Gas
Supply Line
U-Tube to
Thermostat OFF
Figure 4 - Manual Shut-Off Valve
4

Rialta
1. Turn off the gas supply at the main tank.
2. Turn the refrigerator’s mode selector to "OFF".
3. Remove the refrigerator’s system cover located on the left front of the refrigerator by
removing 5 retaining screws.
4. Remove 5 retaining screws securing the refrigerator to the enclosure.
5. Remove the drawer directly above the refrigerator.
6. Turn the manual shut-off valve located on top of the refrigerator to "OFF". See Figure 4.
7. Disconnect the vehicle’s 12 volt DC supply wires from the refrigerator’s terminal block
(Figure 1).
8. Disconnect the LP gas supply line from the refrigerator’s manual shut-off valve. See
Figure 4.
CAUTION: To prevent gas leaks and damage to the gas supply lines and fittings,
use two wrenches when connecting or disconnecting gas fittings.
9. Disconnect the refrigerator’s AC power cord from the wall receptacle.
10. Open the cabinet door to the left of the refrigerator. Remove the access panel at the rear
of the cabinet. This will allow access to the refrigerator’s vent-air intake and exhaust piping.
Note: Observe the routing of the existing flexible piping. It will be necessary to
duplicate this configuration with the replacement tube.
11. Remove the phillips head screw and retaining washer which secure the vent-air
exhaust and intake flexible vent piping to the vent terminal housing. See Figure 5.
12. Remove both the intake and exhaust vent piping from the vent terminal housing.
Care must be taken not to damage the "O" ring seals when removing the piping.
13. Remove right dinette assembly cover panel to access the refrigerator retaining bracket.
Reference "Right Dinette Assembly Cover Panel Removal" in the Interior Section
14. Loosen and remove the refrigerator’s retaining screws at rear base of the refrigerator.
15. Position the flexible vent-air intake and exhaust piping to remove the refrigerator from
its enclosure.
Retaining
Washer
Intake Pipe
Exhaust Pipe
(Isolated)
Phillips Head
Screw
Figure 5 - Vent Terminal Housing
5

Installing the Upgrade Kit
Burner Orifice (Rialta and Eurovan Camper) - Reference Figure 6
1. Once the refrigerator is removed from its enclosure, lay the refrigerator on its side with
the cooling unit facing up.
2. Using a 9/16" open-end wrench, loosen and remove the burner tube from the burner orifice.
3. Using a 1/2" open-end wrench, loosen and remove the burner orifice from the burner.
Discard the orifice just removed.
4. Install the orifice received (Red Dot) with the upgrade kit by reversing the above
procedures.
CAUTION: Do not over-tighten the orifice or the burner tube connections. Over-
tightening these connections can result in undue stress and cancreate
gas leaks.
Burner Box Gasket Installation and Thermocouple Alignment
(Rialta and Eurovan Camper) - Reference Figure 6
5. Using a phillips screw driver, remove the 8 screws securing the burner box to the
cooling unit.
Burner Box Flange
(Remove & Install
Gasket Material Here)
Thermocouple
Burner Tube
Connection
Orifice Connection
Figure 6 - View of Burner Box
6

6. Pull the burner box away from the refrigerator until the burner, ignition electrode, and
thermocouple are visible.
7. Remove gasket material from the top flange of the burner box.
8. Pull the thermocouple away from the burner box until two clicks are heard.
Do not pull the thermocouple completely out of the burner box.
9. Push the thermocouple into the burner box. The thermocouple tip must be positioned
over the first slot of the burner as illustrated in Figure 6 on page 6.
10. Install the new gasket material around flange of burner box.
Caution: Donotinstalladamagedgasket.Usecarewhenhandlingthereplacement
gasket material. If torn, a new gasket (Part # 617977) must be ordered.
Call 1-800-543-1219 to place order.
11. Re-attach the burner box to the cooling unit. Insure the gasket remains around the
flange of the burner box.
Burner Shield Installation (Rialta and Eurovan Camper) - Reference Figure 7
12. Remove the screw located on the right front face of the burner box and save it for later
installation.
13. Slide the heat shield between the refrigerator’s cabinet and burner box. It may be
necessary to lift the burner box up to position the burner shield in place . Secure
the heat shield to the burner box with the screw removed in Step 12.
14. Align the side of the heat shield with bottom of the refrigerator’s support bracket. Secure
the heat shield with the two self-tapping screws provided with the kit.
Heat Shield
(Side View)
Heat Shield
Remove this screw and
save for re-installation.
Burner Box
Figure 7 - Heat Shield Installation
7

PERFORM ELECTRICAL MODIFICATIONS TO REFRIGERATOR
BEFORE RE-INSTALLING
Terminal Block Modification (Rialta and Eurovan Camper) - Reference Figure 8
1. Remove the white wire from the negative terminal spade at the terminal block.
2. Using a phillips screwdriver, remove the screw securing the single 45°terminal.
Remove and discard the terminal. Attach the supplied double 45°spade terminal with
the screw just removed.
3. Re-attach the white wire to the newly installed spade terminal on the spade closest to
the front of the refrigerator.
Discard this
Terminal
Double 45°
Terminal
Re-attach the
white wire from
the Relighter to
this terminal
Figure 8 - Terminal Block
8

DC Fuse Block Addition (Rialta and Eurovan Camper) - Reference Figure 2
4. Attach the 1 amp fuse label on the left side of the 20 amp fuse.
5. Using the power drill and the 1/16" drill bit, drill a starter hole through the circle on the
label. Do not drill the hole deeper than 1/8".
6. Using a phillips screwdriver, attach the supplied fuse holder with the supplied #6 x 3/8"
screw next to the label.
7. Install the supplied 1 amp fuse in the fuse holder.
8. Install the supplied plastic fuse holder cover over the fuse holder. Insure that all
electrical contact surfaces (except for the spade terminals) are covered.
9. Remove the red wire between the + 12 volt DC terminal and the 20 amp fuse.
10. Locate the supplied 6" red wire with the 3" pigtail. Connect the end with the pigtail to the
input terminal of the 20 amp fuse. Connect the 3" pigtail to the 1 amp fuse holder.
Connect the remaining end to the +12 volt DC terminal of the terminal block.
Modify Wiring of the Refrigerator Electrical Circuit - Reference Figures 1 & 2
11. Remove the red wire with jumper located between the 20 amp fuse and the mode
selection switch and save for later installation.
12. Remove the red wire located between the mode selection switch and the relighter and
discard.
13. Install the supplied 6" yellow wire between the output of the 20 amp fuse to the top DC
spade terminal of the mode selection switch.
14. Install the supplied 7" red wire (without jumper) between the 1 amp fuse and the top
spade terminal of the Gas mode selection switch.
15. Using the wire saved in Step 11, connect the end with the pigtail to the bottom Gas
terminal of the Mode Selection Switch. Connect the pigtail lead of the wire to the open
terminal (exposed terminal when removing wire in Step 12) of the relighter. The other
lead will be used later when connecting the fan.
9

Ventilation Fan Assembly Installation
1. Position the mounting support bracket (B) inside the lower two absorber coils of the
cooling unit. The flanges of the mounting support bracket are to point outward and the
larger flange is to be at the bottom.
2. Position the fan assembly (A) so that the bottom flange is between the bottom absorber
coil and the bottom of the mounting support bracket (B).
3. While holding the fan assembly (A) and the mounting support bracket (B) together, slide
them to the right along the absorber coils leaving a minimum of 1/4" clearance between
the top of the fan and the vent pipe. Insure the two fan wires are not constricted in any way.
4. Insert the two 1 1/4" screws provided with this kit through the clearance holes of the fan
assembly (A) and into the pilot holes in the mounting support bracket (B).
5. Tighten screws to secure ventilation fan assembly to the refrigerator.
Exhaust Vent Pipe Installation
1. Loosen clamp at base of the exhaust pipe.
2. Remove the exhaust pipe and insulation from the refrigerator and discard both items.
3. Install the exhaust pipe and insulation provided with this kit. Tighten clamp to secure
exhaust pipe to refrigerator.
Caution: Do not reuse the original exhaust and insulation removed in Step #2 above.
Exhaust Pipe
Cabinet
"B" Mounting
Support Bracket
"A" Fan
Assembly
1/4" min.
Clearance
Cooling Unit Vent Pipe
Figure 9 - Eurovan Camper & Rialta Fan Assembly Installation
10

Thermostat Installation
1. Align the provided template with the kit as illustrated in Figure 10
Warning: Contents of the cooling unit under pressure. Rupturing the cooling unit
will release chemicals which can cause severe damage to the eyes and
skin. Use the provided drill template. Wear protective safety eye glasses
and clothing before drilling the pilot holes.
2. Using the 3/8" drill, 3/32" drill bit, and the provided template, drill two pilot holes as illus-
trated in Figure 10
3. Remove template and save for future installations.
4. Align the thermostat clearance holes with the pilot holes drilled in Step 2.
5. Insert the two #6 x 3/8" screws provided with the kit through the clearance holes of the
thermostat and into the pilot holes in the cooling units condenser fins.
6. Tighten screws to secure thermostat to the condenser fins.
7. Attach the black wire of the fan to the open 45°terminal on the refrigerators terminal block.
8. Attach the red wire of the fan to the bottom terminal of the fan terminal.
9. From the kit, remove the 20" red wire. Attach the female end to the top terminal of the fan
thermostat. Route the male end up and connect to red wire from the mode selection switch.
10. Proceed to the following section before re-installing the refrigerator.
Cooling Unit
Condenser Fins
Template
Thermostat
Mounting Screws
(#6 x 3/8")
Figure 10 - Eurovan Ventilation Fan Installation
11

Test Refrigerator’s Electrical Circuit Before Re-Installing the Refrigerator
DC Circuit
1. With the ohmmeter in the "Ohms" mode, connect the black lead to the - DC input and
the red lead to the + DC input terminals.
2. The following measurements must be observed in each of the selected modes of
operation: (NOTE: These measurements do not depend on thermostat setting.)
Mode Nominal Low Limit High Limit
AC Mode Open Circuit Open Circuit Open Circuit
DC Mode 1.4 ohms 0.5 ohms 3.0 ohms
Gas Mode 365 ohms 190 ohms 664 ohms
3. Remove the ohmmeter from the DC input terminals.
AC Circuit
4. With the Ohmmeter in the "Ohms" mode, Connect the ohmmeter leads to the AC input
terminals on the terminal block.
5. With the thermostat in the start position, the ohmmeter should measure an open circuit
in all of the push-button selector modes of AC, DC, and Gas.
6. With the thermostat at the #2 setting, observe the following measurements in each of
the selected modes:
Mode Nominal Low Limit High Limit
AC Mode 86.5 ohms 65 ohms 105 ohms
DC Mode Open Circuit Open Circuit Open Circuit
Gas Mode Open Circuit Open Circuit Open Circuit
7. Remove the ohmmeter leads from the AC input terminals of the terminal block.
Inspect the power cord
connection to the terminal
block. The hot (smooth)
line of the power cord
must be connected to the
terminal to which the 3
amp fuse is connected.
Figure 11
12

Re-Installing Refrigerator
1. Attach the supplied wiring diagram over the existing diagram located at the top of the
refrigerator.
2. Slide the refrigerator halfway into the enclosure.
3. Proceed to slide the refrigerator into the enclosure while making sure the ventilation fan
wires are not pinched or entangled. Be sure to have 2" minimum clearance to any
wiring or plumbing.
4. Re-install the refrigerator by reversing the removal procedures.
NOTE: Insure that the "O" ring seals are on the ends of the flexible piping which
connects to the vent terminal housing. When connecting the vent-air intake
and exhaust piping to the vent terminal housing, connect the piping as
follows:
Exhaust Pipe - This pipe is insulated and connects to the flue tube of the cooling unit.
Route and connect to the bottom opening of the vent terminal housing.
Intake Pipe - This pipe is not insulated and connects to the burner cover. Route and
connect to top opening of the vent terminal housing.
5. After connecting the vehicle’s gas supply line to the refrigerator’s manual shut-off valve,
turn the valve on. Use a manometer and verify that the input gas pressure is at 11" W.C.
6. Turn off the gas supply at the manual shut-off valve. Observe the manometer to verify that
the gas pressure is maintained for 5 minutes. If a gas leak is noted, apply leak test solution
to all gas fittings and observe for signs of leakage. Do not test for gas leaks with an open
flame. Correct any leaks and retest the system.
When technical assistance is required, call 1-800-543-1219
13