Norcold DC-440 User manual

Refrigerator
Service Manual
Models:
DC440, DC451, DC490
DE441, DE451, DE461, DE490
MRFT415, MRFT440, MRFT460
Part No.619730E (01/01)
NORCOLD, INC.
P.O BOX 4248
SIDNEY, OH 45365-4248

2
-- Procedure A - Thermostat “ON” Compressor does not run ........................................................... 3
-- Procedure B - Compressor Resistance ....................................................................................... 4
-- Procedure C - Power Supply Output Voltage ............................................................................... 5
-- Procedure D - Compressor Amp Draw........................................................................................ 6
-- Procedure E - Evaporator Thermister Resistance ....................................................................... 7
-- Procedure F - Insufficient Coolling ............................................................................................... 8
-- Procedure G - Refrigerator to Cold.............................................................................................. 9
-- Procedure H - Auto Shut-OFF Device........................................................................................ 10
-- Wiring Schematic.......................................................................................................................11
-- Procedure I - Ventilation ....................................................................................................... 12-14
-- Quick Reference Repair Sheet ..................................................................................................15
Trouble Shooting - Table of Contents
WARNING
Perform all tests using a fully charged 12 VDC battery. Using other equipment that
supplies DC voltage may cause permanent refrigerator compressor failure.

3
Figure 1 - Temperature Control
Figure 2 - Power Supply
Note:
If 10 Amp fuse is blown, check wiring of vehicle
Trouble Shooting - Procedure A
Red
TP3
Brn
TP1
Blk
TP2
Yel Org
ART01190
Thermostat "ON" Compressor does not run
Is Temperature
Control LED on? YES
NO
Measure terminal
voltage of Temperature
Control between
TP1 & TP2
DC 0 V
DC 5 V
DC 2 V
Short Circuit
Power Supply
Failure
Normal
Change
Temperature
Control
Change
Power Supply
See Procedure B
Good
Check DC Fuse
Bad
Replace fuse if defective
10A (DE/DC)
8A (MRFT)
See Figure 2
Compressor runs YES
NO
OK
Measure
terminal voltage of
Temperature Control
between TP2 & TP3
See Figure 1
DC 0 V
DC 12 to
32 V
Power Supply
Failure
Normal
Change
Power Supply
See Procedure B
Correct DC Voltage
Wrong Compressor runs YES
NO
Good
OK
(10.5 - 32 VDC)
Check Battery
Voltage
Check DC
Polarity Wrong
Reverse Polarity
& Check operation
(Red+/Blk-)
Good

4
Trouble Shooting - Procedure B
Figure 2 - Measuring Compressor Resistance
Turn the refrigerator to OFF.
Remove the black wire to the compressor. Measure
the resistance of the compressor bewteen Point A and
Point B.
AB
Note: Perform procedure at room temperature.
Change
Cooling Unit
Measure
compressor
resistance
0Internal Compressor
Failure
Normal See Procedure C
3
+/-.5
ART01192
Compressor Resistance

5
Power Supply Output Voltage
Power Supply
Failure
Change
Power Supply
Normal See Procedure D
15 - 25
VAC
Measure voltage
between A & B
at the compressor
Below
15 V AC
0 V AC
Power Supply
Failure
Power Supply
Failure
Remove Power
Supply
Measure voltage
between A & B
at the compressor
ART01196
Check F3 fuse
on circuit board
Ohms:
Replace Power
Supply &
Cooling Unit
0Ohms:
Replace
Power Supply
Trouble Shooting - Procedure C
Figure 3 - Measuring Power Supply
Output Voltage
A
A
F3 Fuse
B
Figure 4 - DE Models only - F3
Fuse Location
Figure 4A - DC Models only - F3
Fuse Location

6
Trouble Shooting - Procedure D
Figure 5 - Measuring Amp draw of
Compressor

7
Three Pole Connector
Measure Resistance
Figure 6 - Evaporator Thermister Figure 7 -Evaporator Thermister
Table 1
Turn the refrigerator to OFF to measure resistance
of the Evaporator Thermistor.
Disconnect the three pole connector (Figure 6)
Measure resistance (Figure 7).
The Evaporator Thermistor is checked by measur-
ing the temperature and resistance of the Ther-
mistor (Table 1).
Thermister Check-Out
Trouble Shooting - Procedure E
Ω = openThermistor windings. An open
Thermistor will stop compressor operation.
Replace Thermistor.
1.6K - 29K Ω= good Thermistor.
ecnatsiseRrotsimrehTrotaropavE
rotsimrehT
erutarepmeT
F°
ecnatsiseR elbawollA
egnaRecnatsiseR
0K7.9K7.01-K7.8
01K8.7K6.8-K0.7
02K4.6K0.7-K7.5
03K3.5K7.5-K8.4
04K5.4K9.4-K0.4
05K6.3K0.4-K2.3
06K8.2K1.3-K5.2
07K1.2K3.2-K9.1
08K9.1K0.2-K7.1
09K8.1K9.1-K6.1

8
Trouble Shooting - Procedure F

9
Trouble Shooting - Procedure G

10
Trouble Shooting - Procedure H
Overheating Shut-off Device Installation
1. Remove the wire [1] from the upper connection [2] of the
POWER SUPPLY [3] (See Art01324).
2. Attach the SHUT-OFF DEVICE to the refrigerator:
NOTE: On some refrigerator models, remove the screw
from the two (2) upper holes [4] of the POWER SUPPLY
(See Art01324).
- Position the SHUT-OFF DEVICE [5] above the POWER
SUPPLY and align the mounting holes of the SHUT-OFF
DEVICE with the upper holes of the POWER SUPPLY
(See Art01325).
- Put a screw through each mounting hole of the SHUT-OFF
DEVICE, through the POWER SUPPLY and into the back
of the refrigerator.
- Tighten each screw.
3. Connect the SHUT-OFF DEVICE wires to the refrigerator
(See Art01325):
- Push the longer wire [6] of the SHUT-OFF DEVICE onto
the upper connection of the POWER SUPPLY.
- Push the shorter wire [7] of the SHUT-OFF DEVICE onto
the wire [1] that you removed in step #1.
Overheating Shut-off Device Operation
The refrigerator will not restart until the refrigerator is manually
turned off and the air temperature is lower than 110°F.
Operating the refrigerator in high ambient temperatures can
overheat the cooling unit and cause premature failure of the
compressor. (Refer to the label inside the refrigerator.)
To protect the cooling unit from overheating, the refrigerator
will automatically shut-off when the vehicle air temperature is
higher than 110°F. If shut off occurs, an audible alarm tone
(an intermittent beeping) from the refrigerator will sound.
To stop the audible alarm tone and restart the refrigerator, you
must turn the thermostat knob counterclockwise to “OFF”and
then clockwise to the desired setting.
Auto-Shut Off Device
Trouble Shooting Shut-Off Device
WARNING
Do not operate refrigerator with Shut-OFF
Device disconnected. Operating the
refrigator without device may cause
compressor failure.
To determine if Shut-OFF Device is functional,
disconnect the Shut-Off Device from the Temperature
Control. Connect the Temperature Control direct to
power supply. IF refrigerator operates, replace the
Shut-OFF Device. If no operation, replace the
Temperature Control.

11
Red
Black
DC 12-32 V
+ DC
AC 85-132 V
Orange
White
+
-
AC/DC
Converter DC 24 V
Red
DC Out +
Black
DC Out -
DC/DC
Converter
Low Temp.
Protector
Battery
Monitor
Electronic
Thermostat
+
-
DC Input
Evaporator
Thermistor
Blue
Blue
Ambient Thermistor
Black
Brown
Yellow
Orange
Red
AC/DC Part
DC/Inverter
Electronic
Current
Protector
Inverter
DC 44.5 V
@ 40 W
DC 51 V
@ 60 W
DC 24V
Fan Motor
Fan
Red +Black
Red Black
Blue
Black
Output
AC - IN (L)
AC - In (N)
Battery In +
Battery In -
- DC
Input High
Voltage
Protector
TP 5
TP 6
TP 7 TP 8
TP 1
TP 2
TP 3
ART01204
Compressor
10 or 8 AMP
Blade Fuse
F3 Fuse
F2
Fuse
Temperature
Control
Trouble Shooting - Wiring Schematic

12
Ventilation - Procedure I
Ventilation is necessary for the correct operation of the refrigerator and to increase the life of the
refrigerator cooling system. Ventilation allows the natural air flow that is necessary for good refrigeration.
Cooler air comes in from the living area of the vehicle through a lower intake vent, goes around the
refrigerator coils where it removes the excess heat from the refrigerator components, and goes out into
the living area of the vehicle through an upper exhaust vent. If this air flow is blocked or decreased, the
refrigerator will not cool correctly. Do not install the vents into areas such as closets or cabinets.
Each refrigerator has specified minimum vent size requirements (See page 12). However, more air
flow over the refrigerator coils increases the cooling performance of the refrigerator. If the construction of
the vehicle does not allow you to install the vents into the living area of the vehicle, use any of the following
approved vent combinations that are at the rear of the refrigerator (See Art01129).
A / B, B / C, C / D, D / E, E / I, F / I, G / I; H / I
A/ D, B / E,,C / I, D / F, E / J, F / J, G / J, H / J
A/ I, B / F, C / J; D / G, A / J, B / G, D / H, B / H
CAUTION:
Each refrigerator has specified minimum vent size re-
quirements. Vent sizes that are less than the minimum
requirements can cause:
- shortened life of the refrigerator cooling unit.
- poor cooling performance of the refrigerator.
- continuous operation of the refrigerator.
- fast battery discharge.
- void of the refrigerator warranty.

13
Ventilation - Procedure I
In addition to the required vents sizes, a fan can be added to increase the refrigerator performance and
to decrease the refrigerator current consumption . A fan kit is available through Norcold part distribution
network. Refer to Fan Kit Assembly chart on page 12.
1. Side view of refrigerator
2. Ventilation Fan
3. Air Intake
4. Exhaust

14
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teltuOsehcnIerauqS05
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teltuOsehcnIerauqS001
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144VE/ED telnIsehcnIerauqS001
teltuOsehcnIerauqS001
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teltuOsehcnIerauqS05 82
164VE/ED telnIsehcnIerauqS001
teltuOsehcnIerauqS001
telnIsehcnIerauqS05
teltuOsehcnIerauqS05 06
rebmuNtraPnoitpircseDledoMPMA
009829061ylnOnaF154CD/ED51.
009829061ylnOnaFV,K,044CD51.
009829061ylnOnaFV,094ED1.
009829061ylnOnaF144ED51.
013929061ylnOnaF164ED51.
Ventilation - Procedure I

15
Trouble Shooting - Quick Reference
2. Check for voltage (15 VAC-25 VAC) at compres-
sor between points A and B. If voltage is not within
range, refer to Procedure C on page 5.
3. Take an Ohm (2.5-3.5 Ohms) reading at com-
pressor between points A and B. If Ohms is not
within range, refer to Procedure B on page 4.
4. Take an Amp (1.5-2.5 Amps) reading at the black
wire (with rubber boot) connected to the compres-
sor. If Ohms is not within range, refer to Procedure
D on page 6.
BA
A
B
1. Check for 12 VDC (supply voltage) at rear of the refrigerator. Turn refrigerator ON, operating volt-
age is between 10.5 VDC to 32 VDC.

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