2003 SERVICE & REPAIR MANUAL - RigMaster...

2003 SERVICE & REPAIR

MANUAL

Model: RMP-P10-4

RigMaster Power Table of Contents Model: RMP-P10-4

November 05 www.rigmasterpower.com Page 1 11 Diesel Drive, Toronto, ON M8W 4Z7

TABLE OF CONTENTS

Foreword................................................. Page 3

Technical Information ............................... Section 1 Dimensions ....................................................... Pg 5 Fluid Capacities & Requirements ...................... Pg 5 Technical Specifications.................................... Pg 6 Maintenance Schedules..................................... Pg 7

Enclosure & Engine Components ..............Section 2

Enclosure .......................................................... Pg 8 Enclosure Parts Breakdown............................... Pg 9 Engine Mounting ............................................Pg 10 Engine Components .......................................Pg 11 Drive Belts ......................................................Pg 14 Engine Cooling...............................................Pg 16

Fuel, Exhaust & Air .................................Section 3

Fuel System.....................................................Pg 18 Exhaust ...........................................................Pg 22 Air Filtering Systems.......................................Pg 24

Electrical System, Controls, & Sensors .......Section 4

General Information........................................Pg 26 Cabin Controller & Power Module Wiring Guide ..........................Pg 27 Engine Harness Colour Scheme......................Pg 28 Engine Wiring Schematic ...............................Pg 29 Alternator........................................................Pg 31 Charging System Diagnostic...........................Pg 31 Engine Sensors ...............................................Pg 32

AC Electrical System ...............................Section 5

110 Volt Electrical System...............................Pg 35 Generator Electrical Schematic ......................Pg 37

Heating & Air Conditioning ......................Section 6

HVAC System..................................................Pg 38 Air Conditioning Hose Installation ..................Pg 39 Air Conditioning Diagnostic ...........................Pg 42 Air Conditioning Flushing Procedure .............Pg 43 Air Conditioning System Overall ....................Pg 44 Heating System ...............................................Pg 46

Table of Contents RigMaster Power Model: RMP-P10-4

Page 2 www.rigmasterpower.com November 05 11 Diesel Drive, Toronto, ON M8W 4Z7

Troubleshooting......................................Section 7

Engine ............................................................Pg 47 Charging System ............................................Pg 50 Fuel.................................................................Pg 51 Cooling System...............................................Pg 52 HVAC..............................................................Pg 53 110 Volt Electrical System...............................Pg 54 Error Codes ....................................................Pg 55

RigMaster Parts List................................ Appendix A

Cross Reference Chart....................................Pg 61

RigMaster Power Foreword Model: RMP-P10-4

September 03 www.rigmasterpower.com Page 3 11 Diesel Drive, Toronto, ON M8W 4Z7

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 personal injury.

TOOLS REQUIRED Unless otherwise noted, it is expected that the service technician has 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)

Technical support is available by calling Mon-Fri 8:30am to 5:00pm EST ................416-201-0040 or 800-249-6222 Extended Hours Pager ............................416-761-0328 Mon-Fri 5:00pm to 9:00pm EST Sat-Sun 11:00am to 5:00pm EST

Foreword RigMaster Power Model: RMP-P10-4

Page 4 www.rigmasterpower.com November 05 11 Diesel Drive, Toronto, ON M8W 4Z7

ADDITIONAL DOCUMENTATION

RigMaster® Power; Auxiliary Power Unit Owners Manual, 2003 Model RMP-P10-4 RigMaster® Power; Installation Manual; Model RMP-P10-4 Perkins; User’s Hand Book, 100 Series, Part Number 100816245 Markon, AC Generators From Newage International, Installation, Service & Maintenance Manual; Publication No. M2/0/025ED6E Contact RigMaster Power for additional information 800-249-6222

RigMaster Power Section 1 Model: RMP-P10-4

November 05 Technical Information Page 5

1.1 DIMENSIONS Main Unit Bunk Heater/AC Unit Width 27” Width 16” Height 29” Height 9 ¼ Depth 30” Overall (22” off Rail) Depth 9 ¼ Weight 393 lb Air Flow 278 cfm

1.2 FLUID CAPACITIES & REQUIREMENTS

Figure A Figure B

S.A.E./ (S.I.)

Engine Oil w/filter .....................................1.9 Quarts / (1.8 Liter)

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...............................5.1 fl.oz/ (150 cc) Type ................................................PAG-100

Fuel Type..................................................Diesel Fuel Only

Figure C

Section 1 RigMaster Power Model: RMP-P10-4

Page 6 Technical Information November 05

1.3 TECHNICAL SPECIFICATIONS

Engine ........................................................ Perkins 102-05, 2-cylinders, Liquid Cooled

Output .............................................. 9.4 Hp/ (7kW) @2800 RPMs Alternator .................................................... 14.5 Volts [DC], 25Amp Generator .................................................... Newage Intl;BL 105B

Output ............................................... 4kW; 110Volts [AC] 30Amp, 60Hz

A/C compressor .......................................... Seltec; Zexel Model: TM-15HD

Oil pressure................................................. 2.8 PSI – 5.7 PSI 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


November 05 Technical Information Page 7

1.4 MAINTENANCE SCHEDULES

Maintenance schedules listed below are factory recommendations for normal operating and road conditions. For more severe operating and road conditions it may be necessary to shorten the scheduled maintenance intervals.

Scheduled Intervals [Hours] Maintenance Items

50 200 400 600 800 1000 1600 X Check coolant level X Check engine lubrication oil level X Change engine oil & filter X Check/adjust drive belts X Inspect drive belts for wear X Clean HVAC unit filter

X Clean internal engine compartment, condenser, air in-take RHS panel and LHS exhaust panel (See Owners Manual for Cleaning Instructions)

X Change air filter [Standard] X Change air filter [Long Life] X Change fuel filter X Change drive belts

X Clean generator; (See Owners Manual for Cleaning Instructions)

X Check all fasteners for tightness and engine mounts for alignment

X Check coolant concentration

X Remove LHS louver panel and clean condenser and radiator with pressurized air

X Check fuel injectors for performance

X Service engine cooling system (drain, flush and refill)

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

Many of the recommended maintenance services can be performed more often than scheduled. RigMaster Power encourages the owner/operator to maintain the auxiliary power unit in peak running condition to get the best performance and durability from the unit.


Page 8 Enclosure & Engine Components November 05

2.1 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. 2.1.1 Disassembly Right Enclosure Assembly (See Figure A)

1. Remove the front cover 2. Remove the eleven (11) 5/16” hex head bolts, lock washers and flat washers

that secure the right louver cover to the right side panel and remove right louver cover.

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.

(Reassembly is reverse of Disassembly) 2.1.2 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.

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

WARNING This Air Conditioning must be serviced by qualified personnel.

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.

(Reassembly is reverse of Disassembly)


November 05 Enclosure & Engine Components Page 9

2.1.3 Disassembly Generator Cover

1. Remove twelve (12) hex head bolts, lock washers and flat washer that secure the bottom cover to the frame

2. Remove eight (8) hex head bolts, lock washers and flat washers that secure the rear generator cover to the main frame

3. Remove the generator cover 4. To access the generator wiring remove the hex head bolts, lock washers and

flat washers that secure the generator connection box lid to the generator connection box.

(Reassembly is reverse of assembly) 2.2 ENCLOSURE PARTS BREAK DOWN

A...............Right-Hand Louver Panel B...............Right-Hand Chamber C...............Aluminum Cover (Or optional SS cover) D...............Cover Hold down Buttons E ...............Left-Hand Radiator Chamber F ...............Left hand Louver Panel G...............Electrical Back plate H...............Frame Assembly

I ................Bottom Cover J ................Rear Generator Cover K...............Cover Latch Assembly (includes

the following parts) #10 - 24 Machine Screws Qty. - 3 #10 Flat Washers Qty. - 3 #10 Lock Washers Qty. - 3 Strap Assembly (Frame Side) Strap Assembly Spacer Strap Catch (Cover Side) L ...............Bottom Access Cover M..............Compressor Adjusting Bracket N...............Generator Connection Box and

Lid O...............Receiver Drier Bracket P ...............2 Groove Pulley Q...............Exhaust Outlet Tube R...............Compressor Mounting Block S ...............Mount Plates T ...............Frame Clamping Brackets U...............Air Chamber, Mounted on Left

or Right Side Louver V...............Mount plate supports Panel

NOTE On newer models, the air chamber is mounted to the right hand louver panel.

Figure A



2.3 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 A: Shock Pad B: Mount Hold Down bolt ¼” 20X1¼” C/W lock, Flat washer and nut C: Upper Mount Plate 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.

Figure B

Figure D


November 05 Enclosure & Engine Components

2.4 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 (Section 3.1.1)

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.

0

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 Figu

1. Remove cooling fan and pulley (See Section 2.5.3) 2. Remove water pump (See section 2.6.2) 3. Remove breather hose and three cap nuts with washer. Lift ro

assembly 4. Loosen and remove the two nuts, one bolt, lock washers from

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

block main oil reservoir and cylinder head. 6. Loosen cylinder head bolts starting form the centre in a circu

using several steps of equal torque. Remove head.

13140634

Page 11

re E

cker cover

rocker cover

cylinder

lar pattern



2.4.3 Oil Seal Replacement

1. Discharge air conditioning system and remove hoses (Section 6.2) 2. Drain and disconnect radiator hoses 3. Remove left enclosure assembly 4. Loosen belts and remove drive pulley (Section 2.5) 5. Remove fly wheel and backplate, noting the position of the alignment

dowel (Figure F)

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

the air conditioning system (Section 1.2)

Description Torque

Flywheel bolts 54 lb-ft (73 Nm)

Backplate bolts 11 lb-ft (15 Nm)

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

NOTE When reconnecting the air conditioning, it will be necessary replace the reciever drier.

Figure F



2.4.4 Starter Motor (See section 6.1.2 for generator removal)

1. Disconnect battery 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 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. It may be necessary to adjust the speed sensor gap [0.025”] after this procedure (See section 4.6.1)

Air Condition Compressor Pivot Bolt

Figure I Figure H CAUTION

Ensure that the air conditioning compressor pivot bolt is tight otherwise damage to the compressor could result.

2.5.2 Generator Drive Belt To replace the generator belt the air conditioning compressor belt must be removed first. It is not necessary to remove the radiator/condenser assembly to change the generator drive belt.


November 05 En

2.5.2 Fan & Alternator Drive Belt To replace the fan belt, the right-hand side chamber must be removed. It is also necessary that the engine cooling fan be removed.

CAUTION Ensure that the alternator pivot bolt is secure and the spacer and bushing is in place. Failure to do this will result in premature belt wear and damage to the alternator belt tensioning arm.

Figure J 2.5.3 Fan Belt Assembly

Large Fan – 14530Small Fan - 14530

185046300

closure & Engine Components Page 15

Alternator Pivot Bolt

6590 6680

Figure K



2.6 ENGINE COOLING 2.6.1 Filling and Bleeding (See section 1.2)

1. Using a radiator pressure tester, pressurize the system to 7 PSI 2. At the HVAC box, loosen the 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

2.6.2 Water Pump [145017400]

1. Remove four (4) hex head bolts, lock washers and flat washers 2. Remove fan (See section 2.5.3) 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, uses silicon gasket sealant

Figure L



2.6.3 By-pass Valve [RP5-016] The by-pass valve is a three position valve which controls the flow of coolant to the radiator for engine cooling and to the heater core to provide heat to the bunk. Figure M 2.6.4 Thermostat [145206062] Since RigMaster incorporates a by-pass valve the engine thermostat is not necessary. If the engine thermostat fails and the engine overheats the thermostat should be removed and not replaced.

Figure N


Page 18 Fuel, Exhaust,& Air November 05

3.1 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 are air bleed screws located in the filter head assembly and on the inlet fitting to the injection pump. 3.1.1 Bleeding procedure (See Figure A) 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 10 mm bleed screw.

5. Tighten the 10 mm bleed screw in the filter head. (Location B) 6. Loosen the 10 mm air bleed screw on the inlet to the injection pump

(location K). 7. Operate the manual primer pump lever (Location F) until a clear stream of

fuel is present from bleed screw (Location B). Be sure fuel bowl (Location D) is free from air.

8. Carefully tighten the bleed screw.

CAUTION Do not over tighten bleed screw

NOTE

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


November 05 Fuel, Exhaust, & Air Page 19

High Pressure System

1. Disable cover sensor by tape a metal washer over it 2. Loosen both high-pressure line nuts located at the injectors (location I). 3. Turn on the engine control switch and crank the engine until a clear stream

of fuel is observed from the high-pressure line nuts, or crank to a maximum of approximately 30 seconds.

4. If the air bubbles are still present after 30 seconds of cranking, cycle the on/off switch and crank the engine again.

5. Tighten the injector line nut (Location I), cycle the on/off switch and start the engine.

6. Repeat steps 1-4 if unit fails to run.

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

AH

I

J

B

C

D L

K

Figure A

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. 10 mm Hex Bleed Screw L. Injector Pump Feed Line



3.1.2 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 duel valves generally located on top of the transmission.

NOTE A check valve may be installed during installation

Figure B

3.1.3 Fuel System Test Procedures (See Figure A)

1. Remove and fill the fuel filter sediment bowl. 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.



3.1.4 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 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 (See Figure C) The flex pipe may be replaced using two methods:

1. Remove the outlet tube located in the left-hand frame section. Remove and install the new flex pipe through the now exposed hole.

When removal of the exhaust outlet tube is not possible, use the following method:

2. Remove the exhaust manifold flange/elbow from the engine exhaust manifold. (Care must be taken not to break the flange bolts.) Remove and replace the flex pipe from the engine compartment.

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


Nov

possible.

A. Exhaust Outlet Tube B [RP10-001-30]

D B. Exhaust Clamps 1 ½” [RP6-004] C. Exhaust Flex 1 ½”ID X 6” [RP6-002] D. Engine Exhaust Outlet Elbow C/W Flange A [RP6-001] E

Figure C

E. Engine Exhaust Manifold [135616690]

It is recommended that the exhaust be mounted in the following manner. Ensure that the hanger strap and clamps are in good condition. If rerouting of the exhaust is necessary, the exhaust should be mounted as far from the bunk as

CAUTION Do not use flex pipe to reroute

ember 05

the exhaust.

Fuel, Exhaust, & Air Page 23


Page 24

3.3 AIR FILTERING SYSTEM For proper operation the RigMaster a relatively large amount of air flow is required. Air is needed for engine combustion and generator cooling as well as cooling of the air condition condenser and radiator; therefore it is vital to keep the A/C Condenser and Radiator assembly clean and free of debris. 3.3.1 Air Filter Replacement (See Figure E & F)

1. Loosen upper hose clamp and remove old filter 2. Insert new filter to the point were it bottoms on the hose 3. Tighten upper hose clamps 4. Check lower hose clamps for tightness

Figu

CAUTION The enclosure cover must be securely in place for proper air flow otherwise overheating may occur.

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

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

RP3-002

Fuel, Exhaust,& Air November 05

re E Figure F



3.3.2 Heater/Air Conditioning Unit (See Figure G) The heater/air conditioning box also requires service

1. Slide out and clean the air inlet filter 2. Clean the evaporator core regularly using a fin comb or similar device,

carefully removing any buildup. 3. Ensure the air inlet does not become blocked with items such as plastic

bags, shop wipes, etc.

Figure G


Page 26 Electrical System, Controls, & Sensors November 05

4.1 ENGINE ELECTRICAL & CONTROL SYSTEM 4.1.1 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. 4.1.2 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

4.1.3 Electronic Control Module 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.

WARNING

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

NOTE When replacing the cabin controller or power module, the lower number software should be replaced with a corresponding or higher software version.


November 05 Electrical System, Controls, & Sensors Page 27

4.2 CABIN CONTROLLER & POWER MODULE WIRING GUIDE

PIN NAME TYPE FUNCTION CONDITION VOLTAGE

ENGINE IS ON Vbat.-0.2 1 CM OUT ENGINE RUN SOLENOID CONTROL

ENGINE IS OFF 0

A/C IS ON Vbat-0.2 2 AC OUT A/C CLUTCH CONTROL

A/C IS OFF 0

GLOW PLUG IS ON Vbat-0.1 6 GP OUT GLOW PLUG RELAY

GLOW PLUG IS OFF 0

BLOCK HEATER ON Vbat.-0.1 7 BH OUT BLOCK HEATER RELAY

BLOCK HEATER OFF 0 STARTER IS ON Vbat-0.1

8 ES OUT ENGINE STARTER RELAY STARTER IS OFF 0

3

4 GND POWER GROUND CONNECTION FOR COMPLETE

SYSTEM. CONNECTED TO BATTERY 0

5

9

J1

10

VIN POWER POSITIVE CONNECTION FOR COMPLETE SYSTEM. CONNECTED TO BATTERY

(BATTERY VOLTAGE) V battery

FULLY CLOSED Aprox 2 1 HC_F

B INPUT FEEDBACK FROM WATER VALVE FULLY OPENED Aprox 10

2 FC OUT 50% DUTY CYCLE @ LOW SPEED Aprox 6.5

5 FC OUT 75% DUTY CYCLE @ MID. SPEED Aprox 9.75

6 FC OUT

FAN CONTROL SIGNAL. PULSE WIDTH MODULATED (PWM) SIGNAL

100% DUTY CYCLE @ HIGH SPEED Aprox 11.7

3 HC+

7 HC- OUT DRIVING THE DC MOTOR TO OPEN OR

CLOSE THE WATER VALVE POLARITY REVERSES WITH DIRECTION OF TRAVEL

4 VINF POWER POSITIVE SUPPLY FOR THE WATER VALVE V battery

J2

8 GND POWER GROUND FOR THE WATER VALVE 0

1

2 VOUT POWER +5 VOLTS REGULATED POSITIVE

SUPPLY CABIN CONTROLLER 5

3

4 LIN INPUT/

OUTPUT

BI-DIRECTIONAL COMMUNICATION BETWEEN CABIN CONTROLLER & POWER MODULE

HI SPEED DATA CAN ONLY BE OBSERVED WITH OSCILLOSCOPE

5

J3

6 GND POWER GROUND FOR CABIN CONTROLLER

OIL PRESSURE HIGH OR IS CONNECTED 5 1 OP INPUT OIL PRESSURE SENSOR OIL PRESSURE LOW 0 COVER IS OPEN OR DISCONNECTED 5 2 SC INPUT SAFETY COVER COVER IS CLOSED 0

3 MA AC SIGNAL (3.9kHz) @ 2700 RPM Aprox 4-6

7 MB INPUT

SPEED SENSOR SIGNAL IS A SIN WAVE. FREQUENCY IS PROPORTIONAL TO RPM

MAIN ENGINE IS RUNNING V battery 4 A1 INPUT SIGNAL FROM MAIN ENGINE

MAIN ENGINE IS OFF 0

HIGH TEMPERATURE 0 5 HT INPUT SIGNAL FROM HI TEMPERATURE SENSOR LOW TEMP, OR DISCONNECTED 5

LOW TEMP, 30 SECOND GLOW PLUG V battery 6 TS INPUT SIGNAL FROM EXTERNAL TEMPERATURE SENSOR HIGH TEMP, 15 SECOND GLOW PLUG 0

J4

8 A2 NA RESERVED FOR THE MANUFACTURE TEST DO NOT CONNECT 0



4.3 ENGINE HARNESS COLOUR SCHEME After January 2003 4.3.1 [J1] Connector

PIN NUMBER COLOUR 1 White 2 Green 3 Black 4 Black 5 Red with black stripe 6 Orange 7 White 8 Red 9 White with black stripe 0 Green

4.3.2 [J2] Connector

PIN NUMBER COLOUR 1 Green 2 Red 3 White 4 Red 5 Orange 6 Blue 7 Red with Black stripe 8 Not in Use

4.3.3 [J4] Connector

PIN NUMBER COLOUR 1 Green 2 Pink 3 White 4 Red 5 Orange 6 Blue 7 White with Black stripe 8 Not in Use



4.4 ALTERNATOR The alternator and regulator in the RigMaster unit are separate. The alternator generates an AC current which is supplied to the regulator, which produces a DC current.

4.5 CHARGING SYSTEM DIAGNOSTIC PROCEDURE

1. Check condition of regulator ground

strap. The strap should be connected to the negative post and free of corrosion. (See Figure A-1) (If a ground strap is not present or it’s the suspected problem, connect a jumper cable to the RigMaster frame and the body of the regulator)

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

Component Wire Voltage

Blue [X2] 28-38 VAC Alternator [195046300]

White [X2] Neutral

Yellow Vbattery Red Vbattery

Green Not Used

Regulator [185516140]

Black Ground

1

NOTE The maximum output from the regulator is 14.8 VDC, more than this will result in overcharging of the battery.

2. Inspect wiring harness looking for burnt, corroded and damaged wires.

Figure A

3. Before running the system, ensure the regulator power supply (yellow wire) has approximately 12 VDC [Vbat] when system is on and that there is continuity to the ground

4. With unit running, ensure that the alternator generates between 28 to 38 VAC across the blue and white wires.

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



4.6 ENGINE SENSOR There are five (5) sensors which provide feedback to the main engine control unit. 4.6.1 Speed Sensor [RP7-103] (Normally Closed) -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] System Running; 3.9 kHz @ 2650 RPM More than 2 Volts AC [RMS]

Figure B

4.6.2 Oil Pressure Sensor [185246060] (Normally Open) -The power module sends a signal to the oil pressure sensor when the sensor is connected and a high oil pressure is detected. -When low oil pressure is detected the oil pressure sensor ground the signal

5 Volts, High oil pressure 0 Volts, Low oil pressure

Figure C



4.6.3 Safety Cover Sensor [RP7-007] (Normally Closed) -A red light on the back of the sensor indicated the sensor is working and metal is detected -The RigMaster will not operate if a voltage signal is not detected

Input: VBattery 0 Volts (No Metal detected) 5 Volts (Metal detected)

NOTE

The speed sensor has 3 wires Blue: Ground Brown: VBattery Black: Signal to Power Module

Figure D 4.6.4 High Temperature Sensor [385720230] (Normally Open) -The power module sends a voltage signal to the high temperature sensor. -If a high temperature is detected the sensor will ground the signal and the engine will shut down.

5 Volts, low temperature

Figure E

0 Volts, High temperature



4.6.5 External Temperature Sensor [300029] (Normally Open) -When the engine is warm or the external temperature is above 32°F the glow plugs will glow for 20 seconds -If it is below 32°F then the glow plugs will glow for 30 seconds

RP7-200A – A 12 Volt signal is sent to the power module when a the temperature is below 32°F RP7-500A – A 5 Volt signal is sent from the power module to the sensor. The sensor grounds out the signal when the temperature is below 32°F

Figure F


September 2003 AC Electrical System Page 35

5.1 [110 VOLT] ELECTRICAL SYSTEM 5.1.1 Generator Specifications [RP7-008] Newage International, Model B105B AC Generator 4kW 110 Volts 60Hz 15 amp (X2)

Towards Engine

Figure A

A: Hold Down Block - 3/8 - 16 Threaded Hole B: Generator Mounting Flange C: Hold Down Bolts 3/8 - 16 X 11/2” - Qty. 4 D: Hardened Flat Washers - Qty. 4 E: Lock Washer 3/8” Qty. 2 F: 4 kW. 110 Volt AC. Generator G: Flat Washers 3/8” Qty. 4 H: Lock Nut 3/8” - 16 Qty. 2 I: Adjuster Lock Nuts 1/4” - 20 Qty. 4 J: Generator Adjuster - Eye Bolt - Qty. 2 K: Generator Mounting Plate


Page 36 AC Electrical System November 05

5.1.2 Generator Removal

1. Remove the tape; re-tape the wire nuts when

replacing the wire nuts. 2. Disconnect the 2 110V 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

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 form loosening.

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

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

NOTE

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

In order for the generator to produce the 4 kW 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.


September 2003 AC Electrical System Page 37

5.2 GENERATOR ELECTRICAL SCHEMATIC

A: Generator Connection Box Hold Down Bolt B: 2 Wire Twist- On Connectors C: 4 Wire Twist- On Connector

NOTE There is a breaker boot covering the 15 amp breaker wiring connections.

D: 15 amps – 110 Volt Breaker


Page 38 Heating & Air Conditioning November 05

6.1 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. The RigMaster requires a large volume of air flow 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. 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.

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

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.

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


September 2003

6.2 Air Conditioning Hose Installation

CAUTION Do not put 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.

6.2.1 Evaporator Lines (HVAC to Bulkhead)

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

6.2.2 Inside RigMaster Unit

1. Compressor to Condenser Hose (RP9-019-8)

Carefully thread and hand tighten the hose at both ends (See Figure A-1)

1

3

Align thewill be acareful n

6

Heating & Air Conditioning Page 39

5 4

2

Figure A

compressor fitting in an 11 o’clock position so that there

½”gap for compressor clearance and tighten fitting being ot to crush the O ring. (See Figure B-1)


Page 40 Heating & Air Conditioning

½”Gap

Figure B

Tighten the condenser fitting (15-20 ft-lb). U

excess stress is not placed on the condense 6.2.3 Bulkhead to Compressor Hose (RP9-018-10A

Attach hose (See Figure A-3), carefully treafitting ensuring it is facing upward

Leave approximately a ¼” gap between thfitting (See Figure B-2)

Carefully tighten fitting being careful not tolb)

Tie wrap the hoses together approximately 6.2.4 Receiver/Drier to Bulk Head Hose’ (RP9-017

Loosen Receiver Drier clamp. Ensure binarthe bottom right corner of the unit (See Figu

Attach hose to receiver drier and hand tighEnsure the compression fitting is properly drier before tightening (11-13 ft-lb) (See Fi

1

2

November 05

se two wrenches so r resulting in damage.

)

ding and hand tighten

e condenser hose and

crush O-ring (21-27 ft-

8” above compressor

-6B)

y switch is facing toward re D-1)

ten (See Figure A-4). seated in the receiver gure C-1)


September 2003 Heating & Air Conditioning Page 41

1

Figure C

6.2.5 Condenser to Receiver/Drier Hose (RP9-017-6B)

Attach hose to both ends and hand tighten (See Figure A-5). Ensure the compression fitting is seated in the Receiver Drier. (See Figure C-1)

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-6). 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)



6.3 Air Conditioning Diagnostic 1. Get as much information about the unit as possible. Service history 2. Carefully inspect entire system; 2.1 Check Hoses; look for broken or cut hoses, soft and/or oily spots also pay close attention to hose, service fittings and connections 2.1 Check for bad electrical connections, damaged or frayed wires 2.3 Check for Missing or loose belts or a frozen compressor. 2.4 Check around compressor clutch and surrounding area for oil and dirt. 2.5 Check for correct placement of temperature probe 2.6 Check compressor clutch. Ensure that it working properly. Disconnect the clutch wiring harness, using a jumper wire to apply power to the clutch verify that it engages.

3. If possible run the system. Check the cooling performance. Listen for compressor noise, check if the compressor cycles, and the fan works

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 a leak. If there is no obvious sign of leaks;

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

suspected)

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

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

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



6.4 Air Conditioning Flushing Procedure

1. Remove hoses from the condenser and evaporator core. If air conditioning lines become contaminated, remove them from the air conditioning system and flush 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.

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.

5. Reassemble the air conditioning system, replacing any components as well as the correct quantity and type of compressor oil.

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

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

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


Page 44

6.5 AIR CONDITIONING SYSTEM - OVERALL

s Low Pressure Gas

Hot High Pressure Ga

Heating & Air Condition

(suction)

RP9-019-8

RP9-017-6A

d Figure E

A: Condenser [RP9-002] B: Compressor [RP9-003] C: Binary Pressure Switch [RP9-005] D: Receiver Drier [RP9-027] E: Frame Bulk-Head 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

High Pressure Liqui

RP9-018-10A

RP9-017-6B

ing November 05



6.5.1 Compressor

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

CAUTION Ensure that the air conditioning compressor pivot bolt is tight otherwise damage to the compressor could result.

CAUTION The air conditioning compressor pivot bolt may loosen with normal usage therefore it is necessary to ensure the tightness of the bolt. Thread lock may be used to stop the bolt from loosening.

D

A

C

Figure F

B



6.6 HEATING SYSTEM For heating the RigMasters 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 2.6)


September 2003 Troubleshooting Page 47

TROUBLESHOOTING 7.1 ENGINE

SYMPTOM PROBABLE CAUSE REMEDY/COMMENT Engine does not crank 1. Battery connections

loose 2. Battery discharged 3. Starter Relay 4. Engine Ground Strap 5. Starter solenoid faulty 6. Starter motor faulty 7. Starter control wiring

damaged

1. Inspect ground strap (Section 4.5)

2. Check for 12V at relay during starting sequence (Section 4)

3. Check for 12V at starter (Section 4)

4. Inspect all electrical connections (Section 4)

Engine cranks but does not start

1. Lack of fuel 2. Glow plug or Glow

plug relay 3. Air in fuel system 4. Run solenoid not

operating 5. Governor assembly

(spring) 6. Faulty power module 7. Faulty wiring

1. Verify 12Vat run solenoid (Section 4)

2. Check fuel supply 3. Bleed air out or fuel

system (Section 3) 4. Inspect all wiring

(Section 4) 5. Try starting with A/C

compressor unplugged 6. Try starting with air

filter off

Engine hard to start

1. Low battery voltage 2. Battery connections

damaged or loose 3. Worn glow plugs 4. Air filter clogged 5. Fuel filter clogged 6. Lack of fuel pressure 7. No compression 8. Faulty wiring 9. Faulty power module

1. Check fuel supply (Section 3)

2. Check for 12V at fuel solenoid (Section 4)

3. Bleed air from fuel system (Section 3)

4. Check for 110V electrical load (Section 5)


Page 48 Troubleshooting November 05

SYMPTOM PROBABLE CAUSE REMEDY/COMMENT Engine Cranks Slowly

1. Low battery voltage 2. Damaged/ Corroded

battery connections 3. Faulty A/C

Compressor 4. Faulty generator 5. Faulty starter

1. Inspect and clean all ground (Section 4)

2. Check condition of batteries

3. Check 110VAC electrical load

4. Inspect A/C system (Section 6)

Engine Starts & Stalls Immediately

1. Damaged or loose wiring connections

2. Excessive load on motor; generator, A/C compressor

3. Blown fuse 4. Low oil level/pressure 5. Clogged fuel filter 6. Irregular and faulty

supply of fuel 7. Speed sensor

1. Check speed sensor Gap: 0.025”, Ohms: 625 +/- 75 (Section 4)

2. Inspect wiring connection and connectors (Section 4)

3. Inspect grounds (Section 4)

Engine Shuts Down 1. Poor grounds

2. Loss of power 3. Blown fuses 4. Faulty wiring 5. Low oil level/pressure 6. Faulty sensors 7. Loose or broken belt 8. Control interference

1. Check speed sensor (See above)

2. Check engine sensors (Section 4)

3. Inspect condition of wiring and wiring connections (Section 4)

White or blue smoke 1. Excess engine oil

2. Viscosity of engine oil too low

3. Faulty injection timing

1. Inspect & correct oil level

2. Check for blown head gasket

Dark grey/black smoke 1. Excess injection 2. Over loading 3. Clogged air filter 4. Engine overheating

1. Unplug 110 volt appliances & block heater

2. Remove air filter & run engine



SYMPTOM PROBABLE CAUSE REMEDY/COMMENT Engine runs rough 1. Fuel filter clogged

2. Air filter clogged 3. Worn/contaminated

fuel injectors 4. Fuel leak 5. Improperly installed

fuel filter 6. Engine in poor

condition

1. Remove air filter & run engine

2. Check for fuel leaks 3. Check service record

for Fuel Filter replacement

Loss of engine oil

1. Oil seals leaking 2. Top pan, oil pan

gaskets leaking 3. Engine oil overfilled 4. Engine worn or in poor

condition 5. Viscosity of oil

incorrect

1. Check for oil leaks 2. Check oil level and

type



7.2 CHARGING SYSTEM

SYMPTOM PROBABLE CAUSE REMEDY/COMMENT Battery’s not charging 1. Damaged or loose

battery connections 2. Faulty alternator 3. Faulty voltage

regulator 4. Battery in poor

condition

1. Check for ground on regulator

2. Inspect alternator wiring harness

3. Inspect wiring 4. Test alternator for 28-

38VAC

Battery Overcharging 1. Faulty Voltage

Regulator

1. Regulator output 14.8VDC max. (Section 4)



7.3 FUEL

SYMPTOM PROBABLE CAUSE REMEDY/COMMENT 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



7.4 COOLING SYSTEM

SYMPTOM PROBABLE CAUSE REMEDY/COMMENT Overheating

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

(external) 4. Faulty thermostat 5. Faulty by-pass valve 6. Overloading

1. Faulty engine sensors (See section 7.7 for control system troubleshooting)

2. Clean radiator fins

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 Engine and

Enclosure)

Coolant loss 1. Coolant system over

filled 2. External coolant leak 3. Internal coolant leak

1. Check coolant level regularly

Poor circulation 1. Water pump not operating properly

2. Water pump drive belt loose damaged (Fan belt)

3. Cooling system restricted

1. Check belt tension



7.5 HVAC

SYMPTOM PROBABLE CAUSE REMEDY/COMMENT Poor air flow 1. Heater/AC unit

obstructed 2. Heater/AC unit filter

clogged 3. Excessive duct hose 4. Poor placement of vents 5. Faulty blower motor 6. Ducted through trucks

ventilation system

1. Dirty HVAC box filter 2. It is recommended that

the RigMaster ducting be used

Little or no hot air 1. Engine overcooling 2. Faulty coolant by-pass

valve 3. Heater core clogged 4. Coolant not flowing

properly

1. Main engine block heater not plugged in

2. Dirty HVAC box filter

Little or no cold air 1. Radiator/Condenser

assembly fins blocked 2. Compressor drive belt

loose 3. Compressor drive belt

damaged 4. A/C system leak 5. Compressor not

operating properly 6. Engine fan belt loose 7. Unit not sealed properly

1. Dirty HVAC box filter 2. It is recommended that

the RigMaster ducting be used



7.6 [110 VOLT] ELECTRICAL SYSTEMS

SYMPTOM PROBABLE CAUSE REMEDY/COMMENT No power to receptacles (Bunk & Block heater)

1. Breakers tripped 2. Generator drive belt

loose or damaged 3. Wiring damaged 4. Internal damage to

generator

1. (Section 6 [110VAC] Generator)

Generator continually trips

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

2. 2. Short circuit

1. Check power rating of appliances



CABIN CONTROLLER & POWER MODULE OPERATION 7.7 ERROR CODES & TROUBLESHOOTING GUIDELINE

SYMPTOM PROBABLE CAUSE REMEDY/COMMENT

Safety cover open

Engine shuts down & will not start

1. Switch is normally open with cover off

2. Check voltage 3. Check safety cover

sensor; a light on the back indicates that the sensor is working properly (Light is on when metal is detected

4. Check sensor to cover gap is 3/16” (5mm)

Low oil pressure

Engine shuts down & will not start

1. Check engine oil 2. Check oil pressure

switch 3. Switch normally open

while engine running

Battery Voltage Low less than 12.0 Volts Engine is not running and

battery voltage has dropped below 12.0V. An error message is displayed and an alarm will sound for 10 seconds followed by two beeps every 5 minutes

1. Clear message by pressing select

2. Start system to charge battery

3. Check for parasitic electrical loads on battery e.g. lights

4. Test battery

System run failure

Engine shuts down during operation

1. Check speed sensor 2. Check run solenoid 3. Check fuel system for

air or leaks 4. Check battery

connections




Engine Overheated

System shut down due to high engine temperature

1. Check coolant level 2. Check temperature

switch 3. Check engine fan belt

Output malfunction

Output shorted to ground

1. Controls connection problem

2. Check for frayed wires or short circuits

System start failed

Engine cranks but does not start, 3 failed start conditions

1. Check speed sensor signal

2. Check speed sensor gap, 0.015” to 0.030” maximum

Communication malfunction

Cabin controller and power module not operating properly

1. Check that communication cable is connected

2. Check condition of communication cable

Version conflict Software conflict between Cabin controller and Power module

1. Check for software updates

Time limit auto shutdown (auto start mode only)

RigMaster will shut down after 6 hours without operator intervention

Power module reset

Unusual program failure

1. Reset due to unusual system condition possibly due to high power radio transmissions or lightening




Low battery system start (Auto start only)

Low voltage detected, RigMaster started to charge batteries. The RigMaster will monitor the battery voltage, if the voltage drops below 12.2V for more that one minute the RigMaster will start to re-charge the batteries for 20 minutes

1. Check for parasitic electrical loads

2. Check condition of batteries

Battery/Charging failure - 11.5 Volts Engine shuts down &

displays error message

1. Check system voltage 2. Check condition of

alternator and regulator

Battery discharge failure 11.0 Volt

Test battery

Appendix A RigMaster Power Model: RMP-P10-4

Page 58 Parts List November 05

System Part Number Description

A/C System RP9-002 Condenser RP9-103 Evaporator Core RP9-003 A/C Compressor RP9-118 A/C Compressor Clutch Kit RP9-027 Receiver/Dryer RP10-001-22 Receiver/Dryer Bracket RP9-112 Expansion Valve RP9-005 Binary Switch RP9-113 Thermostatic Switch RP9-8-003 Compressor Drive Belt RP10-001-26 Compressor Adjustment Bracket RP10-001-27 Compressor Block RP10-001-38 Threaded Compressor Block RP12-047 Compressor Bolt 6” RP12-054 Compressor Bolt Washer A/C Hoses RP9-017-6A Condenser to Receiver/Dryer RP9-017-6B Receiver/Dryer to Bulkhead RP9-018-10A Bulkhead to Compressor RP9-019-8 Compressor to Condenser A/C Misc. RP9-012 #6 O-Ring RP9-013 #8 O-Ring RP9-014 #10 O-Ring RP9-109 ½ X 5/8 hose Fitting Controls & Sensors

RP7-023-D Digital hour meter RP7-024 Start/Glow Switch RP7-025 On/Off Switch RP7-026 Lights RP7-034 Grey Harness RP7-067 CPU RP9-016-5505802 Molded Control Box RP9-101 Fan Harness RP9-106 Fan Switch Knob RP9-108 3 Speed Fan Switch RP9-114 Resistor 3 Speed RP9-115 A/C Filter

RigMaster Power Appendix A Models: RMP-P10-4

September 2003 RigMaster Page 59

Control Unit & Sensors

RP7-200A Cabin Control Kit RP7-103 Speed Sensor 185246060 Oil Sensor RP7-007 Cover Switch Cooling RP5 Radiator Cap RP5-013 Radiator RP9-104 Heater Core RP9-120 Electric Coolant Control RP5-014 Reservoir Tank RP5-001 Radiator Inlet Tube RP5-002 By-Pass Tube RP5-003 Engine Inlet Tube RP5-004 Engine Outlet Tube RP5-016 Thermostat By-Pass RP5-015 By-Pass Adaptor RP5-018 5/8” Heater Hose (per Foot) RP5-009 ½” - # 8 Lola (per Foot) RP5-012 3/8” -#6 Lola (per Foot) RP5-005 Fitting 3/8” X 45 RP5-011 Fitting Hose 5/8”-3/8” NPT Straight Back Plate RP7-004 10 Pin Connector RP7-005 8 Pin Connector RP7-012 8/10 Pin Terminal RP7-076 Packard Male Terminal RP7-077 Packard Female Terminal RP7-078 Packard Cable Seals RP7-079 Packard 2-Cond Male Connection RP7-080 Packard 2-Cond Female Connection RP7-081 Packard 3-Conn Male Connection RP7-082 Packard 3 Conn Female Connection RP7-075 Main Wiring Harness RP7-028 Insulated Stand RP7-036 12 Volt Relay RP7-037 Relay Contact Base RP10-001-16 Electrical Back Plate Enclosure RP10-001-1 Frame Assembly RP10-001-6L Stiffener Left RP10-001-6R Stiffener Right RP10-001-7 Bottom Cover

Appendix A RigMaster Power Model: RMP-P10-4

Page 60 Parts List November 05

RP10-001-8 Frame Clamping Brackets RP10-001-9 Mount Plate Front RP10-001-10 Mount Plate Rear RP10-001-11 Strap Assembly Spacer RP10-001-12 Cover Hold Down Buttons RP10-001-13 Aluminum Cover RP10-003-SS Stainless Steel Cover RP12-023 Sound Insulation- Cover RP12-056 Cover Latch RP12-097 Rear Generator Cover Plugs RP10-001-14 Left-Hand Radiator Chamber RP10-001-15 Left-Hand Louver Panel RP10-001-19 Right-Hand Chamber RP10-001-20 Right- Hand Louver Panel RP10-001-23 Rear Generator Cover RP10-001-39 Air Chamber Louver Panel RP10-001-40 Right Hand Cover, Air Chamber Engine RP6-001 Flange and Exhaust Elbow Starter Refurbished Starter RMP12VSPR RMP 12V Block Heater Kit RP6-002 7” Exhaust Flex Hose RP6-005 Exhaust Hanger RP6-006 Exhaust Silencer RP7-002 Starter Cable RP7-003 Ground Cable RP7-020 Oil Pressure Switch RP8-007 Double Pulley RP12-097 Glow Plugs 185046300 Alternator 145017400 Water Pump 145996420/30 Water Pump Gasket Generator RP7-008 4 kW 110 Generator RP7-014 15 Amp. Breaker RP8-004 Generator Drive Belt RP8-001 Generator “V” Pulley RP8-002 Generator Pulley Bushing RP8-005 Generator Key Stock RP10-001-24 Electrical Box RP10-001-25 Electrical Box Lid RP7-010 ½” Electrical Lock nut RP7-015 Cable Support Straight .312”-.375”

RigMaster Power Appendix A Models: RMP-P10-4


CONSUMABLE PARTS – CROSS REFERENCE LIST OIL FILTER AIR FILTER Brand Part # Brand Part # AC Delco PF1233 RigMaster (IPS) RP3-002 Perkins 140516250 Donaldson CO45001 Wix 51396 Baldwin PA3643 K-Mart Motorvator KO14477 FleetGaurd AH19001 Fram PH4386 Baldwin B37 FUEL FILTER FAN BELT Brand Part # Brand Part # Wix 33262 Perkins 080109083 NAPA 3262 Goodyear FM29 Perkins 130366040 Gates 10A0735 Fram C7516 Baldwin PF937 COMPRESSOR DRIVE BELT GENERATOR DRIVE BELT Brand Part # Brand Part # RigMaster (IPS) RP8-003 RigMaster (IPS) RP8-004 Gates 13A0840 Gates (SPECIAL) 3VX425 GLOW PLUGS RECEIVER-DRIER Brand Part # Brand Part # RigMaster RP12-078 RigMaster (IPS) RP9-027 Perkins 185366060 Four Seasons 34334 NGK Y-107-V Everco (UAP) A78239 **OEM PARTS UNDERLINED

NOTES RigMaster Power Model: RMP-P10-4

Page 62 RigMaster November 05

RigMaster Power NOTES Model: RMP-P10-4


NOTES RigMaster Power Model: RMP-P10-4

Page 64 RigMaster November 05

2003 SERVICE & REPAIR MANUAL - RigMaster...

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