Service Manual Model RMP 14-6 - RigMaster Powerdealers.rigmasterpower.com/Manuals/ServiceManuals... · 2015-09-13 · These non-binding service instructions apply to all class 8 O.T.R

Service Manual

Model RMP 14-6

RigMaster Power Principals of Operations –Safety RMP14-6

RigMaster On-Board Safety Systems:

ATTENTION: ZERO ENERGY STATE To perform service, maintenance and repairs you must disconnect the RigMaster from its battery source. In the recommended installation configuration the RigMaster shares the battery bank with the vehicles main engine. After disconnecting the battery cables, check the battery posts inside the engine cabinet to confirm there is no voltage to the APU. 1. Safety Cover Switch

ATTENTION: SAFETY COVER SWITCH It is critical that this safety cover switch is never deactivated or bypassed; failure to comply may result in serious injury.

Fig. S-1 The safety cover switch (fig. S-1) is designed to prevent the RigMaster Power APU from starting when the engine cover is loose or has been removed. When the switch is closed the cover is down. When the switch is open the cover has been removed or is loose. The switch is located at the front of the engines enclosure in the lower right hand corner. 2. Perkins Engine Stop Switch

ATTENTION: ENGINE STOP SWITCH

This switch must be rotated clockwise and held until the motor has come to a complete stop. Fig. S-2

Both the Perkins and CAT engines have a switch on them that is capable of shutting the engine off. The switch is located on the engines timing case next to the engine specifications sticker (fig. S-2). This switch is commonly referred to as a stop switch or kill switch. The switch works by disengaging the fuel solenoid and stopping the fuel injection pump. Use the cabin controller to stop the engine during normal operation of the APU. 3. AutoStart Automatic Start/Stop Feature

RigMaster Power Principals of Operations –Safety RMP14-6

ATTENTION: AUTOSTART FEATURE Remember that a properly functioning RigMaster is capable of starting independently of its operator. If the AutoStart feature is enabled, battery voltage, temperature, and time of day can all cause the RigMaster’s engine to start. Please see the cabin controllers operating instructions for further information on the AutoStart feature. You must deactivate this feature prior to refueling. 4. Engine Hoist Points

ATTENTION: ENGINE HOIST POINTS The Perkins and CAT engine has hoist points attached to it that are useful for removal and reinstallation of the engine. Under no circumstances should the entire RigMaster APU assembly be lifted by the engine hoist points as they are not intended to hold the increased weight of the engine with fluids, frame and on-board equipment. 5. Starting Aids

WARNING Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury, and will render the warranty null and void.

6. Starting with the Cover Off

ATTENTION Some installation or repair/diagnosis procedures require that the APU is started with the engine cover off. Do not deactivate or bypass the safety cover switch. Instead, have another individual assist by manually holding the safety cover switch down in the closed position for the duration of the procedure. 7. Inspection of the Safety Systems The safety systems on the RigMaster APU should be examined/tested at 50 hour intervals to ensure that they are in good condition and proper working order. 8. Contact Us If you do not fully understand this safety information contact RigMaster’s Technical Support Department toll free at (888) 208 – 3101 before proceeding with the operation or service of this APU.

RigMaster 14-6 Service Manual Table of Contents

This Service Manual was written for 14-6 model RigMaster’s

Last Updated Oct 10, 2007

Section 1 Technical Information Dimensions 1:1:0 Fluid Capacities and Requirements 1:2:0 Technical Specifications 1:3:0 Air Conditioning System 1:3:1 Maintenance Schedules 1:4:0

Section 2 Enclosure & Engine Components Engine Oil Pans 2:1:0 Enclosure 2:1:1 Disassembly Right Enclosure Assembly 2:1:2 Disassembly Left Enclosure [Radiator/Condenser] Assembly 2:1:3 Disassembly Generator Cover 2:1:4 Enclosure Parts Breakdown 2:2:0 Engine Mounting 2:3:0 Engine Components 2:4:0 Fuel Injectors/Injector Pump Assembly 2:4:1 Cylinder Head Assembly 2:4:2 Oil Seal Replacement 2:4:3 Starter Motor 2:4:4 Drive Belts 2:5:0 Air Conditioning Drive Belt 2:5:1 Generator Drive Belt 2:5:2 Alternator Drive Belt 2:5:3 Filling and Bleeding 2:6:0 Water Pump 2:6:1 By-pass Valve 2:6:2 Thermostat 2:6:3 Electrical Cooling Fan 2:6:4

Section 3 Fuel, Exhaust & Air Filters Fuel System 3:1:0 Bleeding Procedures Low Pressure System 3:1:1 Bleeding Procedures High Pressure System 3:1:2 Typical Fuel System Hook-up 3:1:3 Fuel System Test Procedures 3:1:4 Fuel Filter Service 3:1:5 Exhaust 3:2:0 Flex Pipe Service 3:2:1 Exhaust Flex Replacement 3:2:2 Air Filtering System 3:3:0 Air Filter Replacement 3:3:1 HVAC Box Filter 3:3:2

RigMaster 14-6 Service Manual Table of Contents

Section 4 Electrical System, Controls & Sensors Engine Electrical and Control System 4:1:0 General Electrical Troubleshooting 4:1:1 Engine electrical and control system (General Information) 4:1:2 Engine Harness Wire Colors with Corresponding Pin Locations 4:1:3 Engine Harness Wire Colors with Corresponding Pin Locations 4:1:4 Wiring from the water valve to J2 4:1:5 Alternator 4:2:0 Charging System Diagnostic Procedure 4:2:1 Engine Sensors 4:3:0 Speed Sensor 4:3:1 Oil Pressure Sensor 4:3:2 Safety Cover Switch 4:3:3 High Temperature Sensor and Low Coolant Sensor 4:3:4

Section 5 120 Volt Generator Electrical System Generator Electrical System Specifications 5:1:0 Generator Removal 5:1:1 Generator Electrical Schematic 5:1:2 Flashing The Generator 5:1:3

Section 6 Heating & Air Conditioning HVAC System 6:1:0 Air Conditioning Hose Installation 6:1:1 Evaporator Lines (HVAC to Bulkhead) 6:1:2 Inside RigMaster Unit 6:1:3 Bulkhead to Compressor Hose 6:1:4 Receiver/Drier to Bulk Head Hose’ 6:1:5 Condenser to Receiver/Drier Hose 6:1:6 Air Conditioning Diagnostic 6:1:7 Air Conditioning Flushing Procedure 6:1:8 Air Conditioning System Overview 6:1:9 Compressor 6:1:10 Heating System 6:2:0

Section 7 Troubleshooting Engine 7:1:0 Charging System 7:2:0 Fuel System 7:3:0 Cooling System 7:4:0 HVAC System 7:5:0 120 Volt Electrical System 7:6:0 Electronic Control Operation and Fault Codes 7:7:0 Enhanced Electronic Control Operation and Fault Codes 7:8:0

Section 8 Cross Reference Parts List 8:1:0 Preventative Maintenance Check List 8:2:0

RigMaster 14-6 Service Manual Forward

SCOPE & PURPOSE These non-binding service procedures are intended to support authorized RigMaster Power trained dealers and service personnel in the maintenance and servicing of RigMaster Units. These non-binding service instructions apply to all class 8 O.T.R. vehicles, unless technical modifications on the vehicle influence the serviceability. Depending on the version and vehicle equipment, changes in procedure and diagnosis may be required that are set outside this manual. In any event the directives in the service manual must be followed. Acknowledged engineering conventions must be observed when performing service and maintenance work. DEFINITIONS

NOTE A Note provides information to complete a procedure or information which will make the procedure easier to understand

CAUTION A Caution provides a special procedure or special steps, which must be taken while completing the procedure where the caution is found. Not heeding a Caution may result in damage to the assembly

WARNING A Warning provides a special procedure or steps, which must be taken while completing the procedure where the warning is found. Not heeding a Warning can result in severe injury.

TOOLS REQUIRED Unless otherwise noted, it is expected that the service technician have a comprehensive set of tools suitable for automotive service work. TECHNICAL ASSISTANCE Before calling technical assistance please have ready:

RigMaster Serial Number Unit Hours Service & Repair History (Maintenance Record) RigMaster Service Manual

Technical support is available by calling Mon-Fri 8:30am to 5:00pm EST...................... 416-201-0040 or 1-888-208-3101 (For technical support only)

RigMaster 14-6 Service Manual Forward

ADDITIONAL DOCUMENTATION RigMaster® Power; Auxiliary Power Unit Owners Manual, 2005 Model RMP14-6 RigMaster® Power; Installation Manual; Model RMP14-6 Perkins; User’s Hand Book, 400 Series, Part Number 100816245 Markon, AC Generators From Newage International, Installation, Service & Maintenance Manual; Publication No. M2/0/025ED6E

RigMaster 14-6 Service Manual Section 1

Section 1 Technical Information Dimensions 1:1:0 Fluid Capacities and Requirements 1:2:0 Technical Specifications 1:3:0 Air Conditioning System 1:3:1 Maintenance Schedules 1:4:0 1:1:0 DIMENSIONS Main Unit Bunk Heater/AC Unit Width 27” Width 17.25” Height 29” Height 10.25” Depth 30” Overall (24” off Rail with S brackets) Depth 15.00” Weight 386 lb Air Flow 278 cfm

Figure A Figure B 1:2:0 FLUID CAPACITIES & REQUIREMENTS S.A.E./ (S.I.)

Engine Oil w/filter ............................................... 2 ltr. / 2 USqt. or 3 ltr. / 3 USqt. (See page 9)

Type........................................................ API CD, CF, CF-4, CG-4, CH-4 Viscosity ................................................ (See Chart)

Cooling System .................................................. 50/50 mixture of ethylene Glycol-based antifreeze & water Air Conditioning [R134A] 1.7lbs/27oz/ (0.77Kg)

Compressor Oil....................................... 4.6 fl.oz/ (135 cc) Fuel Type…………………………………...Diesel Fuel Only

WARNING Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury, and will render the warranty null and void.


OIL SPECIFICATIONS BY TEMPERATURE

1:3:0 TECHNICAL SPECIFICATIONS

Engine .................................................................. Perkins 402.5, 2-cylinders, Liquid Cooled Output .................................................................. 13.9 Hp/ (10kW) @2800 RPMs

Glow plugs…………………………………………… Reading should be 1.6 ± 0.16Ω

Alternator............................................................... 14.5 Volts [DC], 60Amp

Generator .............................................................. Newage Intl; BL 105B

Output........................................................ 6kW; 120Volts [AC] 20Amp, 60Hz

A/C compressor..................................................... Sanden

Model: SD7H15, #U4308 Oil pressure ........................................................... 2.8 PSI – 5.7 PSI


1:3:1 AIR CONDITIONING SYSTEM

High Pressure / Temperature Readings High temperatures and pressures are approximate. Readings within 10-15% of the chart readings will deliver acceptable performance. Suction Pressures/Temperature Readings Common low side pressure will be 15-40 PSI depending on the ambient temperature

Figure D


1:4:0 MAINTENANCE SCHEDULES

The first oil change must be performed at 50 hours of service and at 500/1000 hour intervals there after. Please read the following chart for detailed information. Maintenance schedules listed below are for NORMAL road conditions and the specific hour intervals must be adhered to. For SEVERE conditions perform the scheduled maintenance(s) earlier. SCHEDULED INTERVALS IN

HOURS MAINTENANCE ITEMS

50 250 500 1000 X Check coolant level X Check engine lubrication oil level (first oil change) X Check/adjust drive belts, and inspect for wear X Check all fasteners for tightness

X X Change engine lubricating oil (500hrs 2 liter/2 qt.) (1000hrs 3 liter/3 qt.) fill slowly. See Section 2.1.0 for more information.

X X Change oil filter (500hrs 2 liter/2 qt.) (1000hrs 3 liter/3 qt.) See Section 2.1.0 for more information.

X Clean generator X Check HVAC unit filter, clean if necessary

X Clean engine compartment, condenser, radiator. Use compressed air or liquid degreaser

X Check engine air filter, change if necessary X Check fuel filter, change if necessary X Change drive belts* X Check coolant concentration, renew if necessary,

X Check/Repair auxiliary power unit for any leaks or damage

*The use of conditioner may extend the service life of belts; consult the belt manufacturer for more information on belt maintenance.

RigMaster 14-6 Service Manual Section 2 Section 2 Enclosure & Engine Components Engine Oil Pans 2:1:0 Enclosure 2:1:1 Disassembly Right Enclosure Assembly 2:1:2 Disassembly Left Enclosure [Radiator/Condenser] Assembly 2:1:3 Disassembly Generator Cover 2:1:4 Enclosure Parts Breakdown 2:2:0 Engine Mounting 2:3:0 Engine Components 2:4:0 Fuel Injectors/Injector Pump Assembly 2:4:1 Cylinder Head Assembly 2:4:2 Oil Seal Replacement 2:4:3 Starter Motor 2:4:4 Drive Belts 2:5:0 Air Conditioning Drive Belt 2:5:1 Generator Drive Belt 2:5:2 Alternator Drive Belt 2:5:3 Filling and Bleeding 2:6:0 Water Pump 2:6:1 By-pass Valve 2:6:2 Thermostat 2:6:3 Electrical Cooling Fan 2:6:4 2:1:0 ENGINE OIL PANS This oil pan holds 2 ltr./2 US qt. This engine oil pan is mounted flush with the engine block. Do not go by the color of the engine. The first oil change must be performed at 50 hours of service & 500 hour intervals there after.

Oil Pan

This oil pan holds 3ltr./3US qt. This engine pan is mounted out from the engine block. Do not go by the color of the engine. The first oil change must be performed at 50 hours of service & 500 hour intervals there after.


Oil Pan

2:1:1 ENCLOSURE In order to perform many of the following repair procedures it may be necessary to remove a portion of the enclosure in order to gain access to components and ease repairs.

NOTE Due to the highly corrosive environment the RigMaster is exposed to, it is recommended that an anti-seize type of protection be applied to all hardware upon reassembly. It is also recommended that a corrosion inhibitor be used on electrical and mechanical components.

In order to perform many of the following repair procedures it may be necessary to remove a portion of the enclosure in order to gain access to components and ease repairs. 2:1:2 Disassembly Right Enclosure Assembly (See Figure A)

1. Remove the front cover 2. Remove the four plastic cover plugs. 3. Remove the four (4) 7/16” hex head bolts, lock washers and flat washers that secure the

right side panel to the main frame and remove right side panel. (Re-assembly is reverse of Disassembly) 2:1:3 Disassembly Left Enclosure [Radiator/Condenser] Assembly

1. Evacuate refrigerant for system and disconnect the two (2) air conditioning hoses from the condenser

2. Drain engine coolant 3. Remove radiator hose and two (2) hose from coolant overflow reservoir 4. Remove the eleven (11) 5/16” hex head bolts, lock washers and flat washers that secure

the right louver cover to the left side panel and remove right louver cover.


5. Remove the four (4) 7/16 hex head bolts, lock washers and flat washers that secure the left side panel to the main frame and remove left side panel.

(Re-assembly is reverse of Disassembly) WARNING

Qualified personnel must service this Air Conditioning.

2:1:4 Disassembly Generator Cover TOOLS REQUIRED: 7/16 Wrench 7/16 Socket 5/16 Socket 1. Remove seven 7/16 hex head bolts, lock washers and flat washers that secure the rear generator cover to the RigMaster 3. Remove the generator cover 4. To access the generator wiring remove the 5/16 hex head bolts, lock washers and flat washers that secures the generator connection box lid to the generator connection box. 5/16 Bolt 7/16 Bolts

RigMaster 14-6 Service Manual Section 2 2:2:0 ENCLOSURE PARTS BREAK DOWN


2:3:0 ENGINE MOUNTING

A: Blue Dot vibration mounts [RP11-002] B: Green Dot vibration mounts [RP11-001] C: Shock Pad [RP11-003] Four (4) locations

Figure C D: Oversized 3/8” Flat Washer E: Centre Mount bolt ⅜”-16X2½” F: ⅜”-16 Nut G: ⅜” Lock Washer H: Vibration Mount

CAUTION The engine should be aligned so that the engine cooling fan does not come into contact with the APU fan housing enclosure. Plate removed for clarity only.

Figure B

Figure D


2:4:0 ENGINE COMPONENTS 2:4:1 Fuel Injectors/Injector Pump Assembly

1. Rotate the Fuel Valve handle in a counter-clockwise direction to the Closed Position 2. Remove the four (4) injector pipe fittings and remove the injection pipe assembly. 3. Remove return pipe 4. The fuel injectors can now be removed from the engine. When reinstalling the fuel injectors

it is required that new seals are be used when seating the injectors (Figure E) 5. Remove the two (2) hex head bolts and

carefully pull out the injector pump assembly until the fuel line clip can be accessed without damaging the metal gasket.

131406340

6. Remove the cotter pin from the shaft of the injector slide assembly then carefully slide the connecting link off of the injector slide assembly pin

7. Remove the fuel injection pump and the metal gasket

2:4:2 Cylinder Head Assembly

Figure E 1. Remove cooling fan and pulley 2. Remove water pump 3. Remove breather hose and three cap nuts with washer. Lift rocker cover assembly 4. Loosen and remove the two nuts, one bolt, and lock washers from rocker cover assembly.

Lift rocker assembly. 5. Remove the external oil pipe by removing two banjo bolts at cylinder block main oil

reservoir and cylinder head. 6. Loosen cylinder head bolts starting form the centre in a circular pattern using several steps

of equal torque. Remove head.


2:4:3 Oil Seal Replacement

1. Discharge air conditioning system and remove hoses 2. Drain and disconnect radiator hoses 3. Remove left enclosure assembly 4. Loosen belts and remove drive pulley 5. Remove fly wheel and back-plate noting the position of the alignment dowel (Figure F)

Description Torque

6. Install new seal, using silicon gasket sealant 7. Align back-plate with the dowel 8. Reassemble back-plate, flywheel and pulley in reverse order 9. Reassemble left enclosure assembly, filling with coolant and recharging the air conditioning

system

Flywheel bolts 54 lb-ft (73 Nm)

Back-plate bolts 11 lb-ft (15 Nm)

NOTE When refitting the backplate apply liquid sealer to the block around the screw holes.

NOTE When re-connecting the air conditioning, it will be necessary to replace the reciever dryer.

Figure F


2:4:4 Starter Motor

1. Disconnect battery (see section 5 for removal of the generator) 2. Disconnect wire #5 of cable #1 from the spade terminal of the starter motor by reaching

through the rear opening in the main frame 3. Remove the positive ground cable from the starter motor 4. Remove two (2) hex head bolts, lock washers and flat washers that fasten the starter motor

to the bell housing and remove starter motor (Figure G)

Figure G


2:5:0 DRIVE BELTS 2:5:1 Air Conditioning Drive Belt The air conditioning drive belt can be removed without removing the radiator/condenser assembly. To adjust the air-conditioning belt tension, the pivot must be loosened first then adjust using the air conditioning adjustment bracket.

Figure H

Figure I CAUTION Check when performing

maintenance that the air conditioning compressor pivot bolt is tight otherwise compressor damage may occur.

Air Condition Compressor Pivot Bolt


2:5:2 Generator Drive Belt To replace the generator belt the air conditioning compressor belt must be removed first. TOOLS REQUIRED: 7/16 Wrench 9/16 Wrench 9/16 Socket PROCEDURE:

1. Remove the generator cover using a 7/16 socket. 2. Remove the bottom cover plate using a 7/16 socket. 3. Loosen the two ¼ hex nuts on the generator adjusting bolts (A). 4. Loosen the four 9/16 generator mounting bolts (B). 5. Slide the generator towards the engine then remove the belt. 6. Install the new belt. 7. Tighten the two (2) ¼” hex nuts evenly until the belt is tight making sure the belt is straight. 8. Install the generator cover & the bottom cover plate.

A A

B B


2:5:3 Alternator Drive Belt

D E C

FAN BELT REMOVAL / ADJUSTMENT - FIGURE 9 TOOLS REQUIRED: 12mm Wrench 3/8 Ratchet 12mm Socket 7/16 Socket 16 inch pry bar PROCEDURE: 1) Remove the one piece fan side chamber using a 7/16 socket. 2) Loosen, but DO NOT REMOVE, the adjustment bolt (C) using a 12mm wrench & a 12mm

socket. Then loosen the pivot bolt (D) using a 12mm socket. 3) To remove the fan belt, slide the alternator (E) down towards the back of the engine & remove

the fan belt. 4) Install the new fan belt & slide the alternator (E) up towards the top of the engine using a 16

inch pry bar & until the belt deflection is less than 6 mm. (1/4"). 5) When the fan belt is tight, tighten the adjustment bolt (C) using a 12mm wrench & 12mm

socket. Then tighten the pivot bolt (D) using a 12mm socket. Reinstall the one piece fan side chamber using a 7/16 socket. Make sure the ring on the one piece side chamber does not touch the engine fan blade. NOTE: Inspect the fan blade for broken blades or worn tips; if the blade is damaged check the engine mounts & bottom stiffeners. (Loose bolts or worn engine mounts).


ENGINE COOLING 2:6:0 Filling and Bleeding Method 1

1. Using a radiator pressure tester, pressurize the system to 7 PSI 2. At the HVAC box, loosen the left hose clamp located on the top side of the water

solenoid 3. Carefully insert a flat screwdriver between the hose and tube until air is head

escaping 4. Bleed air until coolant escapes 5. Tighten hose clamp 6. Remove pressure tester and top up coolant reservoir 7. Repeat if necessary 8. Start the engine and turn heat on high setting 9. After the remaining air escapes form the system, top up coolant

Method 2

1. Loosen the radiator cap of the over flow tank 2. Start and run engine allowing the air to escape 3. Top up coolant as need

2:6:1 Water Pump [145017400]

1. Remove four (4) hex head bolts, lock washers and flat washers 2. Remove fan 3. Loosen alternator pivot bolt and the alternator arm tension bolt from engine side

of alternator arm. It is not necessary to remove the bolts unless alternator removal is required.

4. Release tension on fan belt and remove 5. Remove hex nut and flat washer form crankshaft and remove both the pulley and

key from the crankshaft

NOTE

When refitting water pump, use silicon gasket sealant

Figure L


NOTE

Notice to RigMaster owners with Perkins or Caterpillar 14-6 models with serial numbers 3488 and higher. These 14-6 models do not use the by-pass thermostat [RP5-016]. Instead a thermostat extension kit [RP5-1003K] is added to the motor, and the 75°C [145206062] thermostat is replaced by an 82°C thermostat [145206270]. Please refer to the Thermostat Update Kit Service Bulletin for further information and installation instructions. 2:6:2 By-pass Valve [RP5-016] The by-pass valve is a three-position valve that controls the flow of coolant to the radiator for engine cooling and to the heater core to provide heat to the bunk.

Figure M

The by pass thermostat opens at 180 F 2:6:3 Thermostat 75/82°C [145206062] Since RigMaster incorporates a by-pass valve the engine thermostat is still necessary. If the engine thermostat fails and the engine overheats the thermostat should be removed and replaced.


2:6:4 Electrical Cooling Fan [RP7-228]

Figure N

The electric fan shares power with the compressor clutch wire. Signal voltage to the electric fan relay is taken after the binary switch and before the compressor clutch fuse.


Section 3 Fuel System 3:1:0 Bleeding Procedures Low Pressure System 3:1:1 Bleeding Procedures High Pressure System 3:1:2 Typical Fuel System Hook-up 3:1:3 Fuel System Test Procedures 3:1:4 Fuel Filter Service 3:1:5 Exhaust System 3:2:0 Flex Pipe Service 3:2:1 Exhaust Flex Replacement 3:2:2 Air Filtering System 3:3:0 Air Filter Replacement 3:3:1 HVAC Box Filter 3:3:2 3:1:0 Fuel System The RigMaster incorporates a low/high pressure fuel system with a fuel supply interconnected to the vehicle’s fuel system. The Perkins engine feed pump supplies fuel to the filter/sediment bowl assembly and then to the injection pump. This type of fuel system does not de-aerate itself; all air must be bled from all the hoses and components. There is an air bleed screw located in the filter head assembly (See Figure A) 3:1:1 Bleeding Procedures Low Pressure System 1- Position a container or shop wipe under the fuel sediment bowl to contain any spilled fuel. 2- Using a Philips screwdriver loosen the right-hand bleed screw located in the filter head (location B). 3- Prime the system using the manual primer pump lever located on the fuel feed pump (location F). 4- Continue to pump until the sediment bowl is full and clear flow of fuel is present at the Philips bleed screw. 5- Tighten the Phillips bleed screw in the filter head & the fuel system is bled. (Location B)

NOTE

The low pressure system must be completely free of air before the high pressure system can be bleed properly


3:1:2 Bleeding Procedures High Pressure System

1. Loosen both high-pressure line nuts located at the injectors (location I). 2. Start engine until a clear stream of fuel is observed from the high-pressure line

nuts. 3. If the air bubbles are still present repeat step2. 4. Tighten the injector line nut (Location I), restart engine. 5. Repeat steps 1-4 if unit fails

NOTE It is not necessary to bleed the high-pressure system on installation of a new unit.

Figure A I

B A G C H D

K E J F

Legend: A) Filter Feed Hose B) Air Bleed Screw (Filter Housing) C) Shut-Off Valve D) Fuel Filter Element and Fuel Bowl E) Fuel Supply Pump - Feed Pump F) Manual Primer Pump Lever (Fuel Supply Pump) G) Fuel Supply Hose H) Fuel Return Hose (Injector Bleed-off) I) Fuel Injector Nozzles J) Fuel Injection Pump K) Injector Pump Feed Line


3:1:3 Typical Fuel System Hook-up Fuel can be drawn from one tank without causing any large imbalances in the fuel levels. On some applications the same “T” system can be used for side draw fuel tanks and at dual valves generally located on top of the transmission.

NOTE

A check valve must be installed when tying into the fuel supply line

Figure B

3:1:4 Fuel System Test Procedures (See Figure A)

1. Remove and fill the fuel filter sediment bowl, if the components are full of water or there is sediment, the problem could be dirty fuel or excessive water in the fuel.

2. Prime the high-pressure fuel lines 3. Disconnect the fuel filter feed line from the feed pump (Location A) and install a

length of hose long enough to reach into a can. 4. Start and run the engine. 5. Observe the output from the feed pump; the fuel should be free of air. 6. If air is still present, remove the supply hose from the feed pump and install a

length of hose long enough to reach into a can (Location G). 7. Insert both hoses into a can filled with diesel fuel and start the engine. 8. If there is no air present, check all the fuel hoses and connections between the

fuel feed pump and the fuel tank. 9. If air bubbles are still present, replace the feed pump.

Note: 1) Pressure should be between 30 kpa (4.4 psi) and 69 kpa (10 psi) 2) Replace the lift pump if the pressure is below 21 kpa (3psi)

Lift Pump Pressures


3:1:5 Fuel Filter Service (See Figure A) If proper procedures are followed during filter service, a minimal amount of air bleeding is required.

1. At (location C) the shut off valve must be moved to the closed position 2. Loosen the filter sediment bowl retaining ring and carefully remove the bowl and

filter cartridge 3. Drain and clean the filter sediment bowl 4. Install a new filter with the opening of the filter going over the filter housing inlet

tube 5. Re-install the sediment bowl and retaining ring 6. Open the shut off valve and loosen the right bleed screw in the filter head

assembly (location B) 7. Operate the manual primer pump lever (location F) until the sediment bowl is full

and a clear stream of fuel is observed 8. Tighten the bleed screw and start the engine 9. Check the system for leaks

3:2:0 Exhaust As a safety precaution, an inspection of the complete exhaust system should be performed regularly 1- Condition of flex pipe connecting engine manifold and outlet tube 2- Condition of muffler and exhaust tail pipe (It should be as far from bunk as possible) 3:2:1 Flex Pipe Service

NOTE

In the event the engine has been operated with the flex pipe broken, the air filter may need replacement.

California − Proposition 65 Warning: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm


3:2:2 Exhaust Flex Replacement Step 1 Remove the broken flex pipe & measure the muffler pipe from the inside of the bulkhead to the end of the pipe. If necessary cut off the excess amount so it measures no longer then 1 11/16 Inches. See figure 1.

Figure 1

Cut to 1 11/16 inches long (maximum)

1 11/16”

Step 2 Remove the four bolts from the 90 deg flange and remove the flange (See Figure 2)

Figure 2

Step 3 Install the braided flex pipe (RP6-008) and torque the four bolts to the exhaust manifold to 20-22 ft-lbs.

NOTE The 90 deg flange gasket can be reused. Install the clamp to the left side of the flex pipe making sure the clamp is tight and angled as shown in figure 3.

4 Mounting Bolts

Figure 3

Clamp

90 Deg flange & four bolts


Note

The stainless exhaust flex pipe [RP6-002] shown below has been superseded by the braided exhaust flex pipe [RP6-008].

A. Muffler [RP6-007] Inlet Tube B. Exhaust Clamps 1 ½”

E

DA B

C

[RP6-004] C. Exhaust Flex 1 ½”ID X 6” [RP6-002] D. Engine Exhaust Outlet Elbow C/W Flange [RP6-weld] E. Engine Exhaust Manifold [135616690]

Figure C NOTE:

Extension pipe/elbow (solid pipe not flex pipe) can be added to the exhaust system to direct the exhaust away from the sleeper. A maximum of 10 feet including the muffler can be added to the exhaust system with out having back pressure. Make sure that the extension pipe & muffler is supported using hangers. Figure D Figure E

Make sure the hangers are used Hangers only needed when to support this muffler. adding pipe to this muffler.


3:3:0 AIR FILTERING SYSTEM 3:3:1 Air Filter Replacement (See Figure F)

1. Remove top cover from the air filter assembly 2. Clean the inside of the canister if dirty (Prevent contaminants from entering the

intake manifold). 3. Replace air filter element 4. Install the top cover

NOTE Before installing a new air filter, inspect the filter interconnecting hoses for cracks or hardness.

CAUTION Care must be taken to prevent contaminants from entering the intake manifold.

Figure F


3:3:2 HVAC Box Filter (See Figure G) The heater/air conditioning box also requires service 1. Unscrew the two thumb nuts (A) & remove the air filter out of the HVAC box. 2. Wash the air filter using soapy water or blow clean with compressed air. 3. Re-insert the (dry) air filter to the filter cover & tighten down the two thumb nuts.

Figure G

A A


Section 4 Electrical System, Controls & Sensors Engine Electrical and Control System 4:1:0 General Electrical Troubleshooting 4:1:1 Engine electrical and control system (General Information) 4:1:2 Engine Harness Wire Colors with Corresponding Pin Locations 4:1:3 Engine Harness Wire Colors with Corresponding Pin Locations 4:1:4 Wiring from the water valve to J2 4:1:5 Alternator 4:2:0 Charging System Diagnostic Procedure 4:2:1 Engine Sensors 4:3:0 Speed Sensor 4:3:1 Oil Pressure Sensor 4:3:2 Safety Cover Switch 4:3:3 High Temperature Sensor and Low Coolant Sensor 4:3:4 4:1:0 ENGINE ELECTRICAL & CONTROL SYSTEM General Information The RigMaster electrical system is a 12 Volt DC system in which vehicle and RigMaster electrical accessories are powered by the vehicles battery and in turn charged by the RigMaster alternator. Information on the engine electrical system such as alternator, regulator and starter motor, is also contained in section 2. WARNING

Disconnect the unit from the battery terminals before replacing or repairing the electrical system.

4:1:1 General Electrical Troubleshooting

1. Ensure proper grounding of the RigMaster unit and the vehicles electrical system 2. Check the RigMaster’s electrical connections including battery and vehicle

connections; look for damaged wires, secure connections 3. Check Fuses and Relays (Starter & Glow plugs) 4. Verify that the correct voltage is present and continuity within the circuit

4:1:2 Engine electrical and control system (General Information) The RigMaster control unit is made up of two main components, a Cabin Controller (CC) and a Power Module (PM), which is linked by a communication cable with phone jack style connectors. The Cabin Controller is the user interface sending user commands to the Power Module. The Power Module provides control intelligence to the unit by monitoring inputs and regulating outputs based on commands sent from the Cabin Controller. The cabin controller displays a number of error messages intended to act as a diagnostic aid. These error messages are not indicative of a specific problem, but rather provide general guidelines to aid in the troubleshooting of the RigMaster unit.

RigMaster 14-6 Service Manual Section 4 4:1:3 ENGINE HARNESS WIRE COLOURS WITH CORRESPONDING PIN LOCATIONS [J1] Connector

PIN #

TYPE COLOR

1 OUTPUT White - Engine Run Solenoid. Typical V = Vbat when on, 0V off. Max current 2A

2 OUTPUT Green - A/C Clutch Control. Typ V = Vbat on, 0V off. Max current 1A

3 Not Used 4 POWER Black - Ground = 0V

5 POWER Red with black stripe - Positive Supply = 12 or 24V DC

6 OUTPUT Brown - Glow Plug Relay = Vbat on, 0V off. Max current 200 mA

7 OUTPUT White - Block Heater Relay (Optional) = Vbat on, 0V off. Max 200 mA

8 OUTPUT Yellow - Starter Relay =Vbat on, 0V off. Max 200mA

9 POWER Red - Positive Supply V= 12 or 24 V Dc

10 POWER Red - Positive Supply V= Vbat

6 1

7 2

8 3

9 4

10 5

[J4] Connector

PIN # TYPE COLOR

1 INPUT Green – I/S Oil Pressure Sensor. V= 12.92V + - when normal or sensor is disconnected, 0V low oil pressure

2 INPUT Black - I/S Safety Cover Sensor. V= Vbat when cover is off, or sensor disconnected. 0V when cover is on

3 INPUT Green/Yellow – I/S Pickup Speed Sensor 1. V= when engine is running 4V to 6V AC, 0V when engine is off.

4 INPUT Red – I/S Main Engine. (Optional) V= Vbat when engine is running, 0V when engine is off

5 INPUT

Orange - I/S Hi Temp Sensor. V= 12.99 V + - when temp is low or sensor is disconnected, 0V when temp is high.

6 INPUT Not in Use

7 INPUT Red/Orange - I/S Pickup Speed Sensor 2. Is connected to the non-isolated ground

8 Not in Use (Plugged)

5 1 6 2 7 3 8 4

External Temp sensor See note on page 31

RigMaster 14-6 Service Manual Section 4 4:1:4 ENGINE HARNESS WIRE COLOURS WITH CORRESPONDING PIN LOCATIONS [J2] Connector

PIN # TYPE COLOR

1 INPUT

White- Feedback Signal from Water Valve. Typical voltage = 0V when valve is fully closed, 12.40V + - fully open

2 OUTPUT

Black - Fan Control Signal. Max Current 9A, output is 50,75 & 100% duty cycle for low, med & high fan speeds

3 OUTPUT White - Drive DC Motor to Open/Close W. Valve. Max 2A

4 POWER White - Positive Supply for the Water Valve. V= Vbat. Max 7A

5 OUTPUT Black - Fan Control Signal. Shorted to pin #2

6 OUTPUT Black - Fan Control Signal. Shorted to pin #2

7 OUTPUT White - Drive DC Motor to Open/Close W. Valve. Vbat and max 2A

8 Not in Use

4:1:5 Wiring from the water valve to J2 (#1 to #7) (#2 to #3) (# 3 not used) (#4 to #4) (#5 to #1) (#6 to ground)

1

2

3

4

5

6

4 8 3 7 2 6 1 5

The External Temp Sensor works together with the RigMaster optional block heater kit. If this connector is unplugged or damaged a code will appear on the controller. If using the RigMaster block heater kit the damaged sensor will have to be replaced in order for the RigMaster block heater to work. Pres select to clear the code.

4 8 3 7 2 6 1 5

Note: These voltage readings are approximate, pending on condition of batteries, connections and wiring



4:2:0 Alternator The RigMaster is equipped with an automotive style alternator that has a built in regulator.

NOTE

It is recommended that dielectric grease be used on electrical connections.

4:2:1 CHARGING SYSTEM DIAGNOSTIC PROCEDURE

1. Check drive belt tension, ensure the alternator mounting bolts and adjusting belts are tight

2. Check the positive and negative posts are in good condition and that all wiring connections are secure.

3. Check the positive cable between the alternator and the starter for a loose or damaged cable.

4. Before running the system, ensure the regulator power supply (yellow wire) has approximately 12 VDC [Vbat] when system is on.

5. With the unit running check the output at the battery. The battery reading should be approximately 13.5 V DC to 14.5 V DC.


4:3:0 ENGINE SENSORS 4:3:1 Speed Sensor -It sends an alternating current signal proportional to the engine RPM this indicates the engine is running at its proper speed. -The RigMaster will not operate if the speed sensor is disconnected, faulty or disabled.

Speed Sensor to Fly Wheel Gap: 0.025” 625 ± 75 ohms [550-700 ohms] Note: This resistance test can be done at the power module to ensure continuity

Figure B 4:3:2 Oil Pressure Sensor -The power module sends a signal to the oil pressure sensor. When low oil pressure is detected the oil pressure sensor grounds the signal.

Vbat, Normal oil pressure 0 Volts, Low oil pressure

Figure C


4:3:3 Safety Cover Switch Testing the Door Sensor When the door is closed this closes the switch and grounds the signal. 0 volts will be at the power module J4 pin #2 when the door is closed. Battery voltage will be at the power module when the door is open J4 pin #2.

Figure D

- Packard connector = power - Eyelet = ground

4:3:4 High Temperature Sensor and Low Coolant Sensor High Coolant Temperature Sensor

12 Volts, normal temperature 0 Volts, High temperature

Low Coolant Sensor

The low coolant sensor has a 30 second delay, so if coolant levels remain low for greater than 30 seconds the APU will shut down. The low coolant sensor is connected to the same circuit as the high coolant temperature sensor. If low coolant and/or high temperatures are sensed the unit engine will shut down and display a fault code on the cabin controller. 12Volts normal volume, 0Volts Low Coolant volume

Coolant Surge Tank

Low Coolant Sensor


Section 5 120 Volt Generator Electrical System Generator Electrical System Specifications 5:1:0 Generator Removal 5:1:1 Generator Electrical Schematic 5:1:2 Flashing The Generator 5:1:3 5:1:0 Generator Electrical System Specifications [RP7-008A] Newage International, Model B105B AC Generator 6kW 120 Volts 60Hz 20 amp (X2)

Towards Engine

Figure A

LEGEND QTY. A Hold Down Block - 3/8 - 16 Threaded Hole 2 B Generator Mounting Flange C Hold Down Bolts 3/8 - 16 X 11/2” 4 D Hardened Flat Washers 4 E Lock Washer 3/8” 2 F 6 kW. 120 Volt AC. Generator G Flat Washers 3/8” 4 H Lock Nut 3/8” - 16 2 I Adjuster Nylon Lock Nuts 1/4” - 20 4 J Generator Adjuster - Eye Bolt 2 K Generator Mounting Plate


WARNING Do not service or test this generator unless you are familiar with generating systems. Electrical shock can cause severe personal injury or death.

5:1:1 Generator Removal

1. Remove the tape; re-tape the wire nuts when replacing the wire nuts. 2. Disconnect the 2 120V power cables from the generator (see generator electrical

schematic). 3. Remove cables from connection box and secure 4. Loosen adjusting bolts 5. Loosening the two (2) ¼” hex nuts evenly until the belt is slack, then remove both

adjusting nuts 6. Slide forward towards and remove generator belt 7. Remove generator from the mounting plate

NOTE To adjust generator belt tension, loosen the generator tie down bolts that penetrate through the four slots

Upon reinstallation, thoroughly clean rear mounting feet and the corresponding mating surface. Apply a coat of high tack gasket maker to the two (2) rear mounting feet of the generator and corresponding tie down blocks. Re-tape wire nuts to prevent the wire nuts from loosening. In order for the generator to produce the 6kW at 60 Hz, the generator must rotate at 3600 RPM. The proper method for setting this speed is to use a multi-meter equipped with Hz or frequency capabilities. Measure the output at the receptacle by inserting the test leads into the line and neutral openings. With no load on the generator and at approximately 70°F ambient temperature, the Hz should be 61.5 Hz minimum. Ideally the generator should be tested under partial load, such as with the block heater plugged in, and set the speed to 60.5 Hz.

NOTE

It is recommended that a corrosion inhibitor be used on electrical connections


5:1:2 Generator Electrical Schematic

120 Volt AC Generator Wiring Schematic

LEGEND

A 20 Amp Breakers B Small Wire Nut – Twist On C Large Wire Nut – Twist On D 14/2, 120 Volt Electrical Cables E Wiring from Generator F Green Wires Grounded Using Existing Junction Box Mounting Bolt G Breaker Interconnect Wire (Bridge)

Sleeper & Block Heater Electrical Cords:

o Two Green Wires to Ground (F) o Two Black Wires, One to Each Breaker (B) - Black Wires from the Sleeper

or Block Heater Cords can be connected to either breaker. o Two White Wires to the White Tag# U2 and Blue Tag# U6 (C)

CAUTION

Vibrations can cause wire nuts to become loose or fall off. When wiring the generator it is important to use electrical tape to fully secure the wire nuts.


5:1:3 Flashing the Generator If the rotor has been removed, the generator stored for a considerable time or the rotor (field) connections reversed during servicing, the residual magnetism may have been destroyed. Run the generator at normal no-load speed. A 12 volt battery should then be instantaneously ‘flashed’ (that is connected for only one second) across the capacitor. The auxiliary leads must still be connected to the capacitor. The output voltage should then build up to normal no-load level. Auxiliary Leads

RigMaster 14-6 Service Manual Section 6 Section 6 Heating & Air Conditioning HVAC System 6:1:0 Air Conditioning Hose Installation 6:1:1 Evaporator Lines (HVAC to Bulkhead) 6:1:2 Inside RigMaster Unit 6:1:3 Bulkhead to Compressor Hose 6:1:4 Receiver/Drier to Bulk Head Hose’ 6:1:5 Condenser to Receiver/Drier Hose 6:1:6 Air Conditioning Diagnostic 6:1:7 Air Conditioning Flushing Procedure 6:1:8 Air Conditioning System Overview 6:1:9 Compressor 6:1:10 Heating System 6:2:0 6:1:0 HVAC System The RigMaster heating and air conditioning system is similar in design to most OEM automotive systems. General automotive heating and air conditioning diagnostic techniques will apply to the RigMaster. WARNING

This air conditioning system must be serviced by qualified personnel, who are familiar with air conditioning and refrigeration systems, refrigerants and the dangers of pressurized components.

The RigMaster requires a large volume of airflow for proper engine combustion and generator, engine and air conditioning cooling. Running of the air conditioning system with out the covers in place will result in overheating of the system and possible damage. It is recommended that the receiver drier be replaced whenever air conditioning components are replaced or the system is breeched. If the system becomes contaminated or if it is open for an extended period of time, it is recommended that the system be flushed using an air conditioning flushing agent.

WARNING Cross contamination with other refrigerants will cause damage to this air conditioning system. Avoid breathing a/c refrigerants and lubricant vapor mist. Exposure may irritate eyes, nose and throat. To remove R134a from the system, use equipment certified to meet the requirements of SAE j2210. If accidental system discharge occurs, ventilate the area before resuming service.

The RigMaster Unit is shipped with the air conditioning system capped to reduce the possibility of contamination, which may result from extended storage of the unit. In the RigMaster Auxiliary Power Unit, an aluminum condenser is used in air conditioning system for its optimum heat exchange properties. Due to this, care should be taken when connecting and removing the air conditioning lines because of the brittle nature of aluminum.


NOTE

WD-40 should be used to prevent corrosion between aluminum and steel fittings.

6:1:1 Air Conditioning Hose Installation

CAUTION Do not lean on or put excess stress on air conditioning hoses. This may result in breakage of the air conditioning fittings.

NOTE

Ensure all O-rings are in place. Teflon coated O rings are supplied If using non-Teflon coated O-rings,

apply ester oil to replacement O-rings.

6:1:2 Evaporator Lines (HVAC to Bulkhead)

1. Hook-up external air conditioner lines first. Attach both evaporator hoses to bulk head (See installation manual)

6:1:3 Inside RigMaster Unit

1. Compressor to Condenser Hose (RP9-019-8) found in kit box 2

Carefully thread and hand tighten the hose at both ends

Figure A

Align the compressor fitting in an 11 o’clock position so that there will be a ½”gap for compressor clearance and tighten fitting being careful not to crush the O ring. (See Figure B)


2

½” Gap

1

Figure B

Tighten the condenser fitting (15-20 ft-lb). Use two wrenches so excess

stress is not placed on the condenser resulting in damage. 6:1:4 Bulkhead to Compressor Hose (RP9-018-10A)

Attach hose (See Figure A-3), carefully treading and hand tighten fitting ensuring it is facing upward

Leave approximately a ¼” gap between the condenser hose and fitting (See Figure B-2)

Carefully tighten fitting being careful not to crush O-ring (21-27 ft-lb) Tie wrap the hoses together approximately 8” above compressor

6:1:5 Receiver/Drier to Bulk Head Hose’ (RP9-017-6B)

Loosen Receiver Drier clamp. Ensure binary switch is facing toward the bottom right corner of the unit (See Figure D-1)

Attach hose to receiver drier and hand tighten (See Figure A-4). Ensure the compression fitting is properly seated in the receiver drier before tightening (11-13 ft-lb) (See Figure C)


1

Figure C

6:1:6 Condenser to Receiver/Drier Hose (RP9-017-6A)

Attach hose to both ends and hand tighten (See Figure A). Ensure the compression fitting is seated in the Receiver Drier. (See Figure C)

Raise Receiver Drier about 5/8” from frame ensuring no stress is put on the attached air conditioning lines (See Figure D) and tighten clamp.

1

5/8” Gap

Figure D

With the fitting facing downward in the 6 o’clock position (See Figure A). Use two wrenches to tighten the condenser side of the hose, ensuring not to put stress on the condenser.

Tighten the remaining receiver drier hoses ensuring proper placement of the fitting angles (11-13 ft-lb). The receiver drier should be in the 2 & 7 o’clock position with the hoses aligned as to minimize stress on the fittings. (See Figure D)

RigMaster 14-6 Service Manual Section 6 6:1:7 Air Conditioning Diagnostic 1. Get as much information about the unit as possible. e.g. Service history. 2. Carefully inspect entire system; 3. Check Hoses; look for broken or cut hoses, soft and/or oily spots also pay close attention to hose, service fittings and connections 4 Check for bad electrical connections, damaged or frayed wires 5 Check for missing or loose belts or a frozen compressor. 6 Check around compressor clutch and surrounding area for oil and dirt. 7 Check for correct placement of temperature probe, measuring inside the HVAC box from the expansion valve side ( 2” over from the expansion valve and 4” down from the top of the evaporator core. 8 Check the drain tube. If the hose is pinched or the duck bell is missing this will cause the evaporator core to freeze & the vent temperature will start to blow worm air. 9 Check compressor clutch. Ensure that it working properly. Disconnect the clutch wiring Harnesses, using a jumper wire to apply power to the clutch verify that it engages. (If possible run the system and check the cooling performance. Listen for compressor noise; check if the compressor cycles, and the fan works. 10 The electrical fan (mounted on the left side of the RigMaster) engages at the same time as the compressor clutch. This will draw more air flow threw the condenser & radiator. This will help drop the vent temperature in the bunk. This will also help the engine from overheating when operating the air conditioning. CAUTION

Running the compressor excessively while diagnosing a problem may damage the compressor.

If nothing is found in the initial inspection hook up manifold gages and check the system pressure. Check for blocks or leaks. The most common air conditioning problem is leakage. If there are no obvious sign of leaks;

1. Charge the system, (Nitrogen may also be used to charge the system if a large leak is suspected)

2. Listen for hissing, look for bubbling 3. Use a soapy water solution to help identify leaks 4. If leaks are still not obvious, use a tracer dye, and operate the system normally to let

the die work its way through system

NOTE If the air conditioning system was operating with no pressure in the system, the receiver drier will need to be replaced.

RigMaster 14-6 Service Manual Section 6 6:1:8 Air Conditioning Flushing Procedure

1. If the air conditioning system becomes contaminated, all hoses, condenser, evaporator core must be flushed separately.

2. Flush the system in the direction of refrigerant flow with either an A/C flushing agent

or mineral spirits. Flush the component until the flushing agent flows from the opposite end.

A flush kit or some other method may be necessary to get the flushing agent through the system correctly.

NOTE It may also help to place a pail at the opposite end of the component being flushed to collect A/C flushing agent.

3. Using dry nitrogen, flush the system in the opposite direction of the system

refrigerant flow to remove remaining flushing agent and moisture from the system. 4. Drain remaining oil from the compressor using lower compressor drain plug. NOTE

A new compressor is pre-filled with the correct amount oil for the A/C system.

5. Reassemble the air conditioning system, replacing any components as well as the

correct quantity and type of compressor oil. NOTE

If adding oil to the system, it is best to add oil to the low-pressure line at the expansion valve thereby reducing stress on the compressor.

6. Evacuate and recharge system to specified pressure 7. Check for leaks and proper operation of the system

RigMaster 14-6 Service Manual Section 6 6:1:9 AIR CONDITIONING SYSTEM - OVERVIEW

Hot High Pressure Low Pressure Gas (suction)

RP9-019-8

RP9-017-6A

RP9-018-10A

High Pressure Liquid

RP9-017-6B

Figure E A: Condenser [RP9-011] B: Compressor [RP9-128] C: Binary Pressure Switch [RP9-005] D: Receiver Drier [RP9-027] E: Frame Bulkhead Fittings F: Expansion Valve [RP9-112] G: Evaporator Core H: Right-Hand Frame Section I: Low Pressure Service Fitting J: High Pressure Service Fitting K: Evaporator Temperature Switch C/W Core Temperature Probe


6:1:10 Compressor

Figure F

A

C

D B

LEGEND

A Compressor adjusting bolt and oversized washer B Compressor Body C Compressor mounting block D Compressor pivot bolt


6:2:0 Heating System For heating the RigMaster’s coolant flow is directed into the HVAC box mounted inside the bunk. A water valve mounted to the HVAC box regulates the flow of coolant. (See section 4.2) Voltage at the J2 Connector Pin #1 will indicate if the water valve is open or closed. (Closed 0 volts± / open 12.40 volts±) NOTE: Mark the white disk on the back side of the valve with a black marker this will help show you if the disk is rotating. Coolant Return Coolant Supply

Coolant Return Coolant Supply

White Disc

RigMaster 14-6 Service Manual Section 7 Section 7 Troubleshooting Engine 7:1:0 Charging System 7:2:0 Fuel System 7:3:0 Cooling System 7:4:0 HVAC System 7:5:0 120 Volt Electrical System 7:6:0 Electronic Control Operation and Fault Codes 7:7:0 Enhanced Electronic Control Operation and Fault Codes 7:8:0 7:1:0 Engine

SYMPTOM PROBABLE CAUSE REMEDY/COMMENT

Engine does not crank

1. Starter relay 2. Starter motor faulty 3. Broken engine ground

strap 4. Battery connections loose 5. Low battery voltage

1. Check for power at relay during starting sequence (Section 4)

2. Check for power at starter solenoid (Section 4)

3. Replace strap 4. Tighten connections Charge batteries

Engine cranks but does not start

1. Air filter 2. Speed sensor 3. Glow plug or Glow plug

relay 4. Fuel 5. Run solenoid not

operating 6. Governor assembly

(spring) 7. Clogged filter 8. Faulty wiring

1. Check air filter 2. Check resistance & gap (see section 4.6.1) 3. Check for power @ the glow plug relay. (see section 1.3) 4. (see section 3.1) 5. Check 12v at run solenoid (see section 4) 6. See perkins manual

Engine hard to start 1. Air filter clogged 2. Fuel 3. Glow plugs Air filter clogged

1. Replace air filter 2. See section 3.1 3. Check for power @ the glow

plug relay 4. Replace or Tighten

connectors



Engine Cranks Slowly

1. Damaged / corroded battery connections

2. Faulty starter 3. Faulty A/C Compressor Faulty generator

1. Replace or clean the battery connections

2. Check connections at the starter

3. Compressor seized 4. Generator seized

Engine Starts & Stalls

1. Speed sensor 2. Clogged fuel filter 3. Excessive load on the

motor; generator,a/c compressor

4. Damaged or loose wiring connections

1. Check speed sensor Gap: 0.025”, Ohms: 625 +/- 75

(Section 4) 2. Replace filter 3. Unplug the block heater when

using the a/c compressor 4. Inspect wiring connection &

connectors (see section 4)

Engine Shuts Down 1. Clogged air filter 2. Clogged fuel filter 3. Blown fuses 4. Damaged or loose wiring

1. Replace air filter 2. Replace fuel filter 3. Replace fuse 4. Inspect condition of wiring

and wiring connections (Section 4)

White or blue smoke 1. Excess engine oil 2. Coolant in combustion

chamber

1. Inspect & correct oil level Check for blown head gasket

Dark gray/black smoke Over loading Clogged air filter

1.Unplug 110 volt appliances & block heater 2.Check air filter assembly

Engine runs rough

1. Air filter clogged 2. Fuel filter clogged 3. Fuel leak 4. Worn/contaminated fuel

injectors 5. Engine in poor condition

1. Check air filter assembly 2. Replace fuel filter 3. Inspect all hoses & clamps 4. Inspect Injectors 5. Replace or rebuild the engine

Loss of engine oil

1. Oil seals leaking 2. Leaking drain plug 3. Pinched or clogged

breather tube 4. Engine worn or in poor

condition

1. Replace crankshaft seals (seals leaking is do to having too much oil in the system)

2. Replace oil pan plug gasket 3. Repair or replace the tube 4. Replace or rebuild the engine


7:2:0 CHARGING SYSTEM


Batteries not charging

1. loose or broken belt 2. Damaged or loose

battery connections 3. Faulty alternator 4. Battery in poor condition

1. Tighten or replace belt 2. Inspect wiring

(Section 4) 3. Replace alternator 4. Test batteries

Batteries overcharging 1. Faulty Alternator 1. Check Alternator output

7:3:0 FUEL


Fuel odor/leak 1. Loose fuel fittings 2. Damaged fuel line or fuel

filter bowl 3. Fuel injection pump leak

1. See section 3.1 for fuel system layout

RigMaster 14-6 Service Manual Section 7 7:4:0 COOLING SYSTEM


Engine overheating

1. Coolant level low 2. Engine fan belts loose 3. Radiator fins blocked

(external) 4. Electric fan 5. Faulty engine thermostat 6. Faulty by-pass valve 7. Overloading the engine

1. Add coolant (see section 1.2) 2. Tighten or replace 3. Clean radiator fins 4. The electric fan only engages

when the compressor clutch engages See section 2.6.5

5. See section 2.6.4 6. Replace the by-pass

thermostat valve (see section 2.6.3)

7. Reduce 110v load (eg. Block heater)

Engine overcooling 1. Block heater not plugged

in & working 2. Faulty by-pass valve 3. Faulty thermostat

1. Plug in block heater 2. (See section 2.6.3 Engine

and Enclosure) 3. See section 2.6.4

Coolant loss 1. Coolant system over filled 2. External coolant leak 3. Internal coolant leak 4. Blown head gasket

1. Check coolant level regularly 2. Check coolant hoses from

RigMaster to the HVAC system

3. Check internal coolant hoses inside the engine compartment

4. Replace the head gasket Note: the cylinder head should be machined

Poor circulation 1. Water pump not operating

properly 2. Cooling system restricted

1. Check the belt tension (see section 2.6)

2. Check for kinks in the coolant hoses

RigMaster 14-6 Service Manual Section 7 7:5:0 HVAC


Poor air flow

1. HVAC filter clogged 2. HVAC air intake obstructed

eg. Cloths or plastic bag 3. Excessive duct hose 4. Poor placement of vent 5. Faulty blower motor 6. Ducted through trucks

ventilation system

1. Clean filter 2. Remove obstruction & tell

the drive to keep the filter clear

3. Reduce the hose by extending the hose to maximum length

4. Relocate the vent 5. Check for power & ground 6. See install manual for

ducking the vents

Little or no hot air

1. Engine overcooling 2. Water valve Faulty 3. Airlock in coolant or low in

coolant 4. Faulty coolant by-pass valve 5. Cooling system blocked

1. Main engine block heater not plugged in

2. Check water valve operation (see section 6.6)

3. Bleed system & fill coolant 4. Replace the by-pass valve 5. Flush complete cooling

system

Little or no cold air

1. Compressor not working 2. Compressor drive belt loose

or damaged 3. Condenser or radiator fins

blocked 4. A/C system leak 5. Electric fan not operating 6. Evaporator core frozen

1. Check the compressor clutch fuse

2. Tighten or replace the drive belts

3. Clean radiator/condenser using compressed air

4. Check pressures using gages

5. See section 2.6.5 6. 7. Check the temperature

switch & the location of the probe (see section 6.3)

7:6:0 [120 VOLT] ELECTRICAL SYSTEMS


No power to receptacles (Bunk and block heater)

1. Breakers tripped 2. Generator drive belt loose or damaged 3. Wiring damaged 4. Internal damage to generator

1. (Section 6 [110 VAC] Generator

Generator continually trips

1. Circuit overloaded (15A or 1800 W max) 2. Short circuit

1. Check power rating of appliances

RigMaster 14-6 Service Manual Section 7 CABIN CONTROLLER & POWER MODULE OPERATION CONTROL PANEL OPERATING PROCEDURES

1

2

6

3

CONTROL PANEL-FIGURE 4 5 4

1 The LCD MODULE DISPLAY is used to prompt the user through each operating mode. The display will back light when the user touches any key and will turn off if not used for 30 seconds.

2 The GREEN STATUS light indicates the cabin controller is active and functional.

The RED STATUS light indicates a system problem and an error message will appear on the display. (Refer to error message listing of this supplement). NOTE: No STATUS light indicates the system is inactive (OFF).

3 The POWER key controls whether the module is active. Pushing the Power key will turn on the LCD backlight and activate the menu display or will turn the system off.

4 The MODE key is used to activate the different operational modes and will back you

out of the menu mode to the main display.

5 The ARROW keys are used to locate the desired data and/or adjust those values. 6 The SELECT key enters the data and advances the program to the next menu step.

NOTE: Pressing the select button will save the information inputted when entering operational data.

RigMaster 14-6 Service Manual Section 7 OPERATION OF THE CABIN CONTROLLER Power On When the RigMaster system is off, the cabin controller enters the low power mode and becomes inactive, shutting off all non-critical functions. In low power mode the display shows: the day of the week and date on the top line and the time and total hours of operation on the bottom line. Pressing the POWER key will activate the normal mode turning the system on. The display will light and the status LED will become green. The display will show the day of the week and time on the top line and the system status (on/off) as well as the temperature setting on the bottom line. Pressing the MODE key again will activate the menu mode. The display will show SELECT on the top line and START SYSTEM on the bottom line. Set Time/Date NOTE: It is necessary to enter and date programming mode if the module has never been programmed or a different time zone is required. Press MODE key Press UP or DOWN key to find Set Time / Date mode on the display Press SELECT key Press UP or DOWN key to find Set Time Press SELECT key clock hour will start flashing Press UP or DOWN key to adjust clock hour Press SELECT key clock hour will stop flashing and clock minutes will start flashing Press UP or DOWN key to adjust clock minutes Press SELECT key clock minutes will stop flashing and am/pm will start flashing Press UP or DOWN key to change am/pm Press SELECT key to save settings and return to menu mode Press MODE key to back out of the menu To Set Date Press MODE key Press UP or DOWN key to find Set Time/Date mode on the display Press SELECT key Press UP or DOWN key to find Set Date mode Press SELECT key Month will start flashing Press UP or DOWN key to find the correct month Press SELECT key Month will stop flashing and calendar date will start flashing Press UP or DOWN key until correct date appears Press SELECT key to save settings and return to menu mode Press MODE key to back out of the menu

RigMaster 14-6 Service Manual Section 7 To Set Day Press MODE key. Press UP or DOWN key to find Set Time/Date mode on the display. Press SELECT key Press UP or DOWN key to find Set Day mode. Press SELECT key Press UP or DOWN key to find the correct day of the week. Press SELECT key to save settings and return to menu. Press MODE key to back out of the menu Set Alarm Clock Press MODE key Press UP or DOWN key to find Set Alarm Clock mode. Press SELECT key clock hour will start flashing Press UP or DOWN key to adjust clock hour Press SELECT key clock hour will stop flashing and clock minutes will start flashing Press UP or DOWN key to adjust clock minutes Press SELECT key clock minutes will stop flashing and am/pm will start flashing Press UP or DOWN key to change am/pm Press SELECT key on or off will display Press UP or DOWN key to change setting Press SELECT key to save changes and return to menu mode Press MODE key to back out of the menu Note: The Alarm symbol ‘*’will appear on the screen to indicate that the alarm is on. When the alarm is activated the SELECT button will cancel the alarm and remove the alarm symbol from the screen. If the alarm is not turned off manually it will ring for one minute and then “snooze” for four minutes before sounding again. Engine Start Press MODE key Start System will display Press SELECT key The control panel will display the status of the operation as it occurs:

• Starting System • Glow Plugs and a 15 second countdown • Cranking Engine • Please Wait…… • Engine Running will display for 5 seconds and then return to the normal mode

The normal mode will display System On Engine Stop Press MODE key.

RigMaster 14-6 Service Manual Section 7 Stop System will display. Press SELECT The control panel will display the status of the operation as it occurs:

• Engine Running • Engine Stopped

The control panel after 5 seconds will return to normal mode Temperature Control Press MODE key. Press UP or DOWN key to find the Set Temperature mode Press SELECT key Press UP or DOWN keys to find desired temperature Press SELECT key to save setting Press MODE key to return to normal mode NOTE: Temperature control ranges from 65ºF to 85ºF. The system will

remember the last set temperature when it is turned off Fan Speed Control Press MODE key. Press UP or DOWN key to find the Set Fan Speed mode Press SELECT key Press UP or DOWN key to desired fan setting Press SELECT key to save setting Press MODE key to return to menu NOTE: The system will remember the last fan setting after system is shutdown. To stop

climate control the fan speed MUST be set to the off setting. During warmer months use the automatic on setting to improve air conditioner efficiency. During the cooler months use the automatic off setting to improve heater efficiency.

Low Battery Alarm When the truck battery voltage reaches 12.0 V +/- .2 Volts the low battery alarm will sound

RigMaster 14-6 Service Manual Section 7 AUTOSTART CONTROL OPTION This feature can be purchased at an additional cost. Auto Start Date/Time Allows you to program the Auto Start to the exact date and time you need your RigMaster to start automatically up to seven days in advance. If you are setting this feature to heat or cool the bunk you MUST make sure your fan speed and temperature settings are programmed. This program has a run time of three hours and will override all other auto start features. Once the program is completed it will shut off and the last time/date will be stored. You will need to turn on this feature each time you use it. NOTE: If your RigMaster is running on another auto start program, e.g. Auto Temperature

Control or Low Battery Start-up program and surpasses the time and date set for Auto Start then the unit will not start on this program.

Automatic Temperature Control This control allows you to regulate the temperature in the bunk automatically providing additional fuel savings. Fan and temperature settings MUST be set in order to activate this control. The engine will NOT shut down if the fan setting is set to the off position. If you are setting the Auto-start Temp to heat the bunk, the unit will start at 6 degrees below the set temperature and run until set temperature is reached, then shut off. If you are setting the Auto-start Temp to cool the bunk, the unit will start at 6 degrees above the set temperature and run until set temperature is reached, then shut off. NOTE: Fan speed has to be set to low, medium, high, automatic off, or automatic on

before the engine will shut down when using the auto start feature. The engine will not shut down if the fan setting is set to off.

Low Battery Start Up This feature replaces the low battery alarm and automatically starts up the RigMaster to charge the truck batteries if they get below 12 volts ± .2 volts. The engine will shut down after 20 minutes of charging. The engine will then restart after four minutes if the truck batteries are still below 12 volts ± 0.2 volts. When the truck batteries fail to sustain voltage and the truck batteries drop below 11.5V the RigMaster will shut down and a system charging error message will display on the cabin controller. NOTE: Once the RigMaster starts on low battery auto start, it will not operate any system other than the engine, charging system, and the 110V generator regardless of fan speed and temperature settings. Programming Auto Start Code When you purchase the Auto Start feature you will be provided with a 4 character/digit code which must be first programmed in to the cabin controller Ensure the cabin controller is in low power mode. (Status light off)

RigMaster 14-6 Service Manual Section 7 Press and hold the MODE key and SELECT key at the same time for 5 seconds. The display will show Auto Start code 0000 and the first character/digit will be flashing Press UP or DOWN key to locate the first digit/character in the code Press the SELECT key to accept the data and move to the next digit Continue entering the code in the above manner until all four characters have been selected. Once all four digits have been entered the system will accept the code and a message will display………. Code Ok Auto Start Code: ______________ Programming Auto Start Press MODE key. Press UP or DOWN key to find the Set Auto Start mode Press SELECT key and Set Time Auto Start appears Press SELECT key and day of week starts flashing Press UP or DOWN key to adjust day of week Press SELECT key and day of week will stop flashing and clock hour will starts flashing Press UP or DOWN key to adjust clock hour Press SELECT key and clock hour will stop flashing and clock minutes will start flashing Press UP or DOWN key to adjust clock minutes Press SELECT key and clock minutes will stop flashing and am/pm will start flashing Press UP or DOWN key to adjust am/pm Press SELECT key and am/pm will stop flashing and on/off will start flashing Press UP or DOWN key to change on/off Press SELECT key to save settings and return to menu mode Press MODE key to return to normal mode Note: Once you have set the program a # symbol will appear on the normal mode screen. If you touch any keys once this program is activated it will default to OFF. This control will run a continuous 3 hour program and then will default to OFF. You MUST set this program each time you use it.

RigMaster 14-6 Service Manual Section 7 Set Auto Temperature Control Press MODE key. Press UP or DOWN key to find the Set Auto Start mode Press SELECT key and Set Time Auto Start appears Press UP or DOWN key to find the Set Auto Temperature mode Press SELECT key and on/off will start flashing Press UP or DOWN key to turn on/off Press SELECT key to save setting and return to menu mode Press MODE key to return to normal mode Note: This is a one time program and will default to OFF. If you touch any keys once this

program is activated it will default to OFF. You MUST set this program each time you use it. Set Auto Battery Control Press MODE key. Press UP or DOWN key to find the Set Auto Start mode Press SELECT key and Set Time Auto Start appears Press UP or DOWN key to find the Set Auto Battery Press SELECT key and on will display Press SELECT key to exit and return to the menu mode Press MODE key to return to normal mode Note: This setting can not be changed on cabin controller version 1.08 or higher, it is always

set to ON. This setting can be changed on older cabin controller versions. Notes

RigMaster 14-6 Service Manual Section 7 7:7:0 ERROR CODES & TROUBLESHOOTING GUIDELINE

SYMPTOM REMEDY/CAUSE REMEDY/COMMENT

Safety cover open Safety cover of RigMaster unit is open. RigMaster unit will not start or run until the cover is closed

1. Cover not seated 2. Damaged wiring 3. Faulty switch 4. Switch out of

adjustment (See section 4.6.3)

Low oil pressure

Alarm, low oil pressure. RigMaster engine would start but will not continue running unless oil pressure becomes normal with 60 seconds of engine start.

1. Low oil level 2. Wiring damaged 3. Faulty switch

(See section 4.6.2)

Battery Low Voltage Alarm, low battery voltage Start system immediately

1. Damaged or broken battery cables

2. Excessive load on batteries

3. Bad battery 4. Faulty charging system

See section 4.5

Engine run failure Engine started but did not run properly. Manual start attempts can occur.

1. Speed sensor adjustment

2. Damaged speed sensor wiring

(see section 7.1) 3. Faulty speed sensor (see section 4.6.1)

Engine Overheated Engine will not run until temperature becomes normal

1. See troubleshooting 7.4

(cooling system)

Engine Start Failure Engine did not start. Automatic start is disabled until operator presses select button

1. Bad glow plug relay 2. Bad starter relay 3. Faulty glow plug 4. Lack of fuel (see section 7.1)

No Communication Error

Communication between control panel and power module is lost. Engine will not run until communication is re-established

Check communication cable

Main Engine Running Truck engine is running. RigMaster will not run if the main engine is already running

Optional engine wire is connected to DC voltage supply (see power module J4 pin# 4)


SYMPTOM REMEDY/CAUSE REMEDY/COMMENT

Maximum Run Time Shutdown

The RigMaster has shut down since the maximum run time has been exceeded

See Owners Manual - Auto start

features - Engine will only

run 3 hours max

Check Power Module Fuse Very low battery voltage detected, Check and replace fuse if required

1. Check fuses at the power module

Battery Charging Failure Battery voltage still low two minutes after cranking. Auto and manual starts can occur

1. Faulty charging system

2. Bad batteries (See troubleshooting 7.2.0 Charging)

Battery Discharge Alarm, system will enter low power mode. Auto and manual starts can not occur

1. Bad batteries (see section 4.5)

Check external Temperature Sensor

External temperature sensor disconnected

from the power module

See notes Page 29

External Temp Disable Limit

Engine shut down since the external temperature is outside the programmed range

See notes Page 29

Invalid Power Module Version

Incompatible versions of the cabin controller and power module

Do not mixed controller versions

Power up Displayed when the power module is starting up Normal


Operation of the Electronic Control Before beginning the start-up procedure it is necessary to know how to operate the cabin controller.

Controls The Cabin Controller consists of two sections:

1. LCD (Liquid Crystal Display) with basic control buttons. 2. Advanced control buttons

The LCD and basic control buttons are always visible to the user. The advanced control buttons are concealed behind semi-circular cover. The controller also contains a LED indicator. When the LED is green, the system is active, if it glows red then the system is detecting a problem and an error message will scroll across the bottom of the LCD screen. The LED is turned off in low power mode. 1. Basic Controls and Functions Basic controls contain the following buttons:

1. Start system 2. Stop system 3. Up arrow (Red triangular button) 4. Down arrow (Blue triangular button)

If the unit is in advanced mode, pressing any of the basic control buttons will return the unit to basic mode. Alternately, the control panel will return to basic mode after two minutes of inactivity. If the unit shows the current temperature, pressing either the up or down button will show the set point temperature without changing it. Once the set point is


indicated, pressing up or down buttons will adjust the set point. The new set point takes effect only when display is returned to show internal temperature. 2. Advanced Controls and Functions The advanced controls are as follows:

1. Power button controls whether the module is active. In inactive mode all system functions including engine start, climate control and AutoStart are disabled. You can still see the temperature reading, current time and use the alarm clock function.

2. Fan button is used to change fan setting. Pressing the button cycles between auto, high, med, low and off settings.

3. Clear button will take you back to the main screen without saving any information.

4. Clock button is used to set the time/date/day menu features. 5. Alarm button is used to set the alarm menu features. 6. AutoStart button is used to access and set AutoStart menu features. 7. Mode button is used to activate the different operational modes. Pressing

the mode button will back you out of a menu mode, but does not save the information just entered.

8. Ext. Temp button will display the external temperature on the LCD when pressed.

9. Oprtg. Hours button will display the total hours of use. 10. Select button enters the data and advances the program to the next menu

step. Pressing the select button will save the information when entering operational data.

11. Left scroll button (with symbol) 12. Right scroll button (with symbol) The left and right arrow buttons are used to locate the desired data and/or adjust those values.

Cabin Controller LCD Display The Cabin Controller LCD has a white backlight that turns on each time a user presses a button and will remain on for 2 minutes after the last button that has been pushed. The backlight will turn red when there is an alarm condition. A fault code will be displayed if the unit shuts down or fails to start. The LCD displays 4 groups of information:

1. System information 2. Temperature information 3. Clock, day and alarm information 4. Alphanumeric display for additional information


1. System Information:

SYSTEM ALARM symbol will flash if an alarm condition has occurred. The alphanumeric display along the bottom of the display screen will show more information about the alarm. Red status LED will be on. SYSTEM ON symbol will display if the unit is in ON mode. (Green status LED will be on.) ENGINE RUNNING symbol will display when the engine is running. AUTOSTART symbol will display and flash if temperature AutoStart is enabled (when engine is off). If the engine has been started through AutoStart, this symbol is constantly on while the engine is running. HEATING symbol will display when the system is in heating mode. COOLING symbol will display when the system is in cooling mode. FAN AUTO, FAN HIGH, FAN MED, or FAN LOW symbol will display depending on which setting has been selected. Nothing will display in this area if the fan is set to off.


2. Temperature Information:

This area indicates the internal (or external) temperature and can be programmed to display in either “Celsius” or “Fahrenheit” Internal temperature is shown if EXT TEMP and SET TEMP symbols are not illuminated. Pressing the Ext. Temp button will momentarily display the outside temperature. After 5 seconds, the display will default back to showing the internal temperature. EXT TEMP symbol will flash when showing external temperature. After a few seconds the display returns to show internal temperature. SET TEMP symbol appears (and the numeric temperature value will flash) whenever adjusting temperature set point. A few seconds after adjusting the temperature, the display returns to show internal temperature. 3. Clock and Alarm:

This is a 12:00 hour clock system with AM/PM symbols and 7 symbols indicating day of the week: MO, TU, WE, TH, FR, SA, SU. CLOCK symbol appears when the current time is showing.


ALARM symbol appears to indicate that the alarm setting is showing. Pressing the alarm button allows you to set the alarm. The alarm symbol flashes when the alarm has been set. TIME AUTOSTART symbol appears if the display shows time AutoStart setting. It flashes if time AutoStart is set.

4. Additional Information/Message Area:

This line is used to show extra information in the basic mode, error messages to provide interface when going through menus in advanced mode. Longer text lines are scrolled to the left on the display. Operation of the Cabin Controller (Functions) To Turn Power On Press the POWER button to activate the system. When the power switch is activated the LCD display will light and SYSTEM ON symbol will turn on (active mode). Press POWER button again for 2 seconds to switch the unit back to low power mode. Engine Start Press START button. The control panel will display the status of the operation as it occurs: Glow Plug and a countdown will display on the screen. Once the countdown is complete the display will read Cranking as the RigMaster starts up and the ENGINE RUNNING symbol will blink. Once started the control will display Engine Running for 5 seconds (and ENGINE RUNNING symbol will turn on). Engine Stop Press STOP button. The screen will initially display Stopping and then change to Stopped once the operation is complete. The Engine Running symbol will turn off.


Temperature Control Press UP or DOWN (red/blue) buttons to adjust temperature set point on the display. When editing the set point, the LCD display will show the set point instead of internal cabin temperature. The set point is stored without a need to press any other buttons.

NOTE The manual temperature control ranges from 59ºF-90ºF (15ºC to 32ºC). The system will remember the last set temperature when the RigMaster is turned on. If the system is already running, the change will take effect a few seconds after the last UP or DOWN key is pressed and the display will switch back from set point to internal cabin temperature. Clock & Date Set Up It is necessary to enter the time and date programming mode if the module has never been programmed or a different time zone is required. (SET symbol is flashing and CLOCK symbol is turned on during clock setup) Press CLOCK button: The display will read Set Clock. Press SELECT button to continue, MODE to exit. Clock hour will start flashing. Press LEFT or RIGHT scroll button to adjust Clock hour. Press SELECT button: Clock hour will stop flashing and Clock minutes will start flashing. Press LEFT or RIGHT scroll button to adjust Clock minutes. Press SELECT button: Clock minutes will stop flashing and am/pm will start flashing. Press LEFT or RIGHT scroll button to change. Press SELECT button: am/pm will stop flashing and day of week will start flashing. Press LEFT or RIGHT scroll button to change. Press SELECT button: day of week stop flashing and Month will start flashing. Press LEFT or RIGHT scroll button to change. Press SELECT button: Month stop flashing and Date will start flashing. Set Alarm Clock Press ALARM button: The display will read Set Alarm. Press SELECT button to continue, MODE to exit. Alarm Clock hour will start flashing. Press LEFT or RIGHT scroll button to adjust Alarm Clock hour. Press SELECT button: Alarm Clock hour will stop flashing and Alarm Clock minutes will start flashing. Press LEFT or RIGHT scroll button to adjust Alarm Clock minutes. Press SELECT button: Alarm Clock minutes will stop flashing and am/pm will start flashing.


Press LEFT or RIGHT scroll button to change. Press SELECT button Press LEFT or RIGHT scroll button to turn Alarm clock on/off. Press SELECT button to save settings and return to menu or press MODE to return to menu without saving. When enabled, ALARM symbol is flashing. Fan Speed Control Press FAN button to adjust fan speed: Press the FAN button to cycle through fan settings: AUTO OFF, AUTO ON, FAN LOW, FAN MEDIUM, FAN HIGH, FAN OFF. There is no need to press any other buttons to confirm. AUTO OFF is for heating efficiency during winter operation. AUTO ON is for air conditioning efficiency during summer operation.

NOTE The air conditioning/heating system will only operate when the fan speed is in a setting other than OFF. To stop the operation of the air conditioning/heating system, the fan speed must be set to OFF. If the system was stopped by another method, the air conditioning/heating will start immediately when the system is restarted. AutoStart Features and Operation AutoStart Time/Day Programming –allows you to program a day and time

for the RigMaster for the start automatically up to 7 days in advance. This feature will run for three hours and shut down. At the end of the AutoStart program the cabin controller will display the error code #10, “Run Timeout”; this is normal.

Set AutoStart Timer The user can adjust the time and day for the next timed AutoStart event. (SET symbol is flashing and TIME AUTOSTART symbol is turned on during alarm setup) Press AUTOSTART button: Time AutoStart will scroll across the screen. Press SELECT button to continue, MODE to exit. Press LEFT or RIGHT scroll button to adjust AutoStart hour as required. Press SELECT button Continue to set the AutoStart Minutes and am/pm as you would set the clock. Press SELECT button after each entry. Press LEFT or RIGHT scroll button to adjust AutoStart Day as required. Press SELECT button Press LEFT or RIGHT scroll button to locate On/Off. Press SELECT button to save settings or press MODE button to return to menu without saving. NOTE: When enabled, Time AutoStart symbol will be flashing.


Automatic Temperature Control Start Up/Shut Down-will start and stop the RigMaster to regulate the temperature giving you further fuel savings on extended absences from the cab.

Set AutoStart Temperature Start-Up Press AUTOSTART button twice: Temp AutoStart will scroll across the screen. Press SELECT button to continue, MODE to exit. Press LEFT or RIGHT scroll button to select mode of temperature control. Mode options include OFF, AUTO, HEAT or COOL only. Press SELECT button to continue, MODE to exit. Press LEFT or RIGHT scroll button to select AutoStart temperature set-point if HEAT or COOL have been selected.

NOTE The AutoStart temperature range is between 32°F and 95°F.

Press SELECT button to save settings or press MODE to return to menu without saving. When enabled, the AutoStart symbol will flash. AutoStart temperature start-up will engage when the inside temperature is more than 5°F lower or more than 5°F higher than the temperature control setting (in auto mode). It also engages at least 1 minute after enabling AutoStart temperature. Low Battery Start Up-automatically starts up the RigMaster to charge the

truck battery if it gets low. This option is always enabled in active mode. The voltage sensitivity of the low battery AutoStart feature can be adjusted, however, this is a dealer programmable feature and must be performed at a RigMaster licensed facility.

Set AutoStart Low Battery Start-Up Low Battery AutoStart does not require that it be set by the user in the same way as the time/date and temperature based AutoStart. All that is necessary to ensure that low battery AutoStart functions is to leave the RigMaster engine OFF and the cabin controller powered on (active mode). Version Display Press MODE button. Current version of the Power Module software will appear on the screen Press MODE or SELECT to return. 7:8:0 Electronic Control Operation and Fault Codes The RigMaster’s electronic control will display fault codes on the LCD display if the unit fails to start or shuts down. The following table contains fault codes and information on the cause and/or remedy. These fault codes will display one time


only; if the code is cleared (by pressing select) the failure will have to reoccur for the code to be displayed again.

CODE REMEDY/CAUSE REMEDY/COMMENT

Error Code 1 Safety Cover Open

Engine cover of RigMaster unit is open. APU will not start or run until the cover is closed

• Cover not seated • Damaged wiring • Failed cover switch • Switch out of adjustment

Error Code 2 Low Oil Pressure Low oil pressure

• Low oil level • Wiring damaged • Faulty switch • Dirty Oil Filter

Error Code 3 Battery Low Voltage

Low battery voltage Start system immediately

• Damaged or broken battery cables

• Excessive load on batteries

• Bad battery • Faulty charging system

Error Code 4 Engine Run Failure

Engine started but did not run properly. Manual start attempts can occur.

• Speed sensor adjustment • Damaged speed sensor

wiring • Failed speed sensor

Error Code 5 Low Coolant/

Engine Overheated

• Engine will not run until temperature becomes normal

• Engine will not run until coolant level is full

• Low coolant • High Engine

Temperature • Failed Temperature or

Coolant Level Switch • Damaged Wiring

Error Code 6 Module Failure

Power Module is not responding • Failed Power Module

Error Code 7 Engine Start Failure

Engine did not start. Automatic start is disabled until operator presses select button

• Bad glow plug relay • Bad starter relay • Failed glow plug • Lack of fuel

Error Code 8 No Communication Error

Communication between control panel and power module is lost. Engine will not run until communication is re-established

• Communication Cable Damaged

• Poor Connectivity at the terminals


Error Code 9 Main Engine Running

Truck engine is running. RigMaster will not run if the main engine is already running

• Optional engine wire is connected to DC voltage supply at the power module

Error Code 10 Run Timeout

The RigMaster has shut down as the maximum run time has been exceeded in the AutoStart Time/Day Setting

• Engine will only run 3 hours max when set on AutoStart Time/Day

Error Code 11 Check Power Module Fuse

Very low battery voltage detected at the power module

• Check 20 Amp fuse at the power module (Located under the bunk on the HVAC unit)

Error Code 12 Battery Charging Failure

Battery voltage still low two minutes after cranking. Auto and manual starts can occur

• Faulty charging system • Bad batteries • Engine harness ground

wires disconnected at the HVAC

Error Code 13 Battery Discharge

Alarm, system will enter low power mode. Auto and manual starts can not occur

• Bad batteries

Error Code 14 Check External

Temperature Sensor

External temperature sensor disconnected from the power module

• External Temperature Sensor Disconnected

• Connection loose or damaged

Error Code 15 External Temp Disable

Limit

Engine shut down since the external temperature is outside the programmed range. Set default to OFF from factory.

The RigMaster has been programmed not to start when the external temperature is outside a preprogrammed range.

Error Code 16 Module Reset – Set Clock

Power to the cabin controller has been lost. • Reset clock


8:1:0 Cross Reference Parts List

OIL FILTER

AIR FILTER

BRAND

PART No.

BRAND

PART No.

AC Delco PF1233 RigMaster/Mann 00-C1140 Perkins 140516250 Wix 51396 K-Mart Motorvator K014477 Fram PH4386 ASSEMBLY Baldwin B37 RigMaster 103002 FUEL FILTER

FAN BELT

BRAND

PART No.

BRAND

PART No.

Wix 33262 RigMaster RP8-009 NAPA 3262 Bando 2310 9.5 X 790LA Perkins 130366040 Perkins 080109049 Fram C7516 Baldwin PF937 AC Delco GF771

COMPRESSOR DRIVE BELT

GENERATOR DRIVE BELT

BRAND

BRAND

PART No.

PART No.

Gates 13A0875 RigMaster RP8-006 Dayco 51009

GLOW PLUGS

RECEIVER-DRIER

BRAND

PART No.

BRAND

PART No.

Perkins 185366220 RigMaster (IPS) RP9-027 Four Seasons 34334 Everco (UAP) A78239

RigMaster 14-6 Service Manual Section 8 8:2:0 Preventative Maintenance Check List

RigMaster Preventative Maintenance Check List Date: Model No: Serial No:

Hours: Performed By:

Invoice No.

Change Oil & Filters Comments Change oil & filter Change fuel filter Check air filter replace if needed Use compressed air to clean radiator and condenser

Check for loose brackets, door seals & straps Comments Compressor mounting bolts Alternator mounting bolts Check door seal & hold down straps

Adjust Drive Belts. Clean Generator & Inspect The Engine Mounts For Wear Comments

Fan/Alternator belt A/C compressor belt Generator belt

Clean out the generator using compressed air Check the engine mounts for wear

Check Electrical Connections Comments Positive & negative post studs @ the backing plate on the RigMaster for loose connections or corrosion.

RigMaster engine ground check for loose connections or corrosion

Relays check for corrosion. Positive & negative cables @ the trucks batteries for loose wires or corrosion

Cooling System Comments Run unit with heating set to 85 & check for leaks Check coolant concentration

HVAC Unit Comments Clean filter Change the temperature on the controller & make sure the blower motor is blowing heat

Change the temperature on the controller & make sure the blower motor is blowing cold air

Check all cables @ the HVAC unit making sure there is no stress on the cables

Reassemble and run the unit Comments Check alternator output (max out put 14.8 DCV) Check the bunks extension cord for (120V) power Check the trucks block heater extension cord for (120V) power

Driver Comments


NOTES


NOTES

© 01/2007 RigMaster Power Corp. Printed in Canada

RigMaster Power Corp. 11 Diesel Drive, Toronto, Ontario, Canada, M8W 4Z7 Tel: (416) 201 0040 Toll Free: 1-888-208-3101 Fax: (416) 201-7532 www.rigmasterpower.com

Documents

Service Manual Model RMP 14-6 - RigMaster Powerdealers.rigmasterpower.com/Manuals/ServiceManuals... · 2015-09-13 · These non-binding service instructions apply to all class 8 O.T.R