Rigmaster 2007 Installation and operating manual

RigMaster Service and Repair Manual
Document # S210909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
S2.1 Maintenance Schedule For RigMaster models 2007 and newer
NOTE
The first oil change must be performed at
50 hours
of service and at 1000 hour intervals
thereafter. 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
XChange engine lubricating oil and oil filter. (First
oil change only.)
XCheck coolant level
X
Check all fasteners for tightness
XCheck/Repair auxiliary power unit for any leaks or
damage
XChange engine lubricating oil; fill slowly.1
X
Change oil filter
XClean generator
XCheck HVAC unit filter, clean if necessary
XClean engine compartment, condenser, and
radiator. Use compressed air or liquid degreaser.
X
Check engine air filter, change if necessary
X
Check fuel filter, change if necessary
XCheck fan belt, change if necessary 2
XCheck serpentine alignment (S3.4)
XCheck serpentine belt, change if necessary 2
X
Check coolant concentration, renew if necessary,
1Please note that the Tier 4 compliant engines uses API oil specification CJ-4, however,
CJ-4 oil is backwards compatible and can be used in earlier Tier 2 engines.
2The use of conditioner may extend the service life of belts; consult the belt
manufacturer for more information on belt maintenance.

RigMaster Service and Repair Manual
Document # S220909
Copyright RigMaster Power by Mobile Thermos Systems Inc. 09-28-09
S2.2 Maintenance Schedule for models 2006 and older
NOTE
The first oil change must be performed at
50 hours
of service and at 500 hour intervals
thereafter. 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
XChange engine lubricating oil and oil filter. (First
oil change only.)
X X X X Check coolant level
X
X
X
Check all fasteners for tightness
X X X X Check/Repair auxiliary power unit for any leaks or
damage
X X Change engine lubricating oil; fill slowly.1
X
X
Change oil filter
X X Clean generator
XCheck HVAC unit filter, clean if necessary
X X Clean engine compartment, condenser, and
radiator. Use compressed air or liquid degreaser.
X
Check engine air filter, change if necessary
X
Check fuel filter, change if necessary
XCheck fan belt, change if necessary 2
XCheck AC compressor belt, change if necessary²
XCheck generator belt, change if necessary 2
X
Check coolant concentration, renew if necessary,
1When filling the engine with oil from the cylinder head, fill the oil slowly so as not to
overflow into the intake and cause hydraulic lock of the cylinders.
CJ-4 oil is backwards compatible and can be used in earlier Tier 2 and older engines.
2The use of conditioner may extend the service life of belts; consult the belt
manufacturer for more information on belt maintenance.

RigMaster Service and Repair Manual
Document # S220909
Copyright RigMaster Power by Mobile Thermos Systems Inc. 09-28-09
S2.2A Oil Pans
Depending on the engine in the RigMaster APU, you can have either a 2 L/2qt oil pan or a
3L/3qt oil pan. Below shows the differences between the two and how to identify which oil pan
the RigMaster is equipped with.
2 Litre/ 2 US qt Oil Pan
3 Litre/3 US qt Oil Pan

RigMaster Service and Repair Manual
Document # S230909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-08-09
S2.3 Preventative Maintenance Check List
Date:
Model No:
Serial No:
Hours:
Performed By:
Work Order No.
Change Oil and Filters
Comments
Change oil and filter
Change fuel filter
Check air filter replace if needed
Use compressed air to clean radiator and condenser
Check for loose brackets, door seals and straps
Compressor mounting bolts
Alternator mounting bolts
Check door seal and tie-down straps
Adjust Drive Belts. Clean Generator and Inspect
the Engine Mounts for Wear
Fan/Alternator belt
Serpentine Belt
Clean out the generator using compressed air
Check the engine mounts for wear
Check Electrical Connections
Positive at negative post studs at the backing plate
on the RigMaster for loose connections or corrosion.
APU engine ground check for loose connections or
corrosion
Check wiring harness for damage/corrosion i.e.
fuses, relays, and other points of connection
Positive and negative cables at the trucks batteries
for loose wires or corrosion
Cooling System
Run APU with heating set to 85°F: check for leaks
Check coolant concentration
HVAC Unit
Clean HVAC filter
Change the temperature on the controller and make
sure the blower motor is blowing heat
Change the temperature on the controller and make
sure the blower motor is blowing cold air
Check all cables at the HVAC unit making sure there
is no stress on the cables
Reassemble and run the unit
Check alternator output (max output 14.8 DCV)
Check the bunks extension cord for (120V) power
Check the trucks block heater extension cord for
(120V) power
Exhaust System – Check for leaks, loose hardware
loose brackets or physical damage to the filter itself
Driver Comments

RigMaster Service and Repair Manual
Document # S240909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
S2.4 Replacing the Serpentine Belt
2008 and newer models of RigMaster APUs incorporate a serpentine belt and auto tensioner
system to drive the air conditioning compressor and the 120 Volt AC generator from the flywheel
at the back of the engine. The fan belt drives the alternator and water pump from the crank
pulley on the front side of the engine.
#
Component
1 Belt Auto Tensioner RP8-106
2 Drive Pulley Adapter RP8-100
3 Drive pulley RP8-101
4 Compressor RP9-132
5 Idle Pulley RP8-103
6 Generator Pulley RP8-102
NOTE
The serpentine belt should be inspected every 1000 hours of operation.
1
5
2
Figure 2-1
3
6
Belt rotation is
counter clockwise.
4

RigMaster Service and Repair Manual
Document # S240909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
Procedure
1. Remove engine cover.
2. Insert breaker bar or ratchet into serpentine belt auto tensioner as shown in figure 2-2
(recommended method).
3. Lift the breaker bar to release tension on serpentine belt.
4. Remove belt from flywheel pulley while holding tensioner.
5. Release tensioner and remove belt.
6. Replace and route drive belt as shown in figure 2-1.
7. Rotate the engine to ensure that the belt is properly seated on all pulleys before starting the
engine.
Serpentine Belt
CAUTION
You may also use an open ended wrench (figure 2-3), but be sure to protect the radiator in
the event that the wrench slips.
Figure 2-4 Figure 2-5
Figure 2-2 Figure 2-3

RigMaster Service and Repair Manual
Document # S240909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
Pulley Alignment
When replacing the serpentine belt, 120V generator or drive pulley on a serpentine drive system
you must check the alignment of the pulley. Pulleys that are not properly aligned can cause
wear and premature belt failures that are not covered under warranty. Please see Serpentine
Drive Section 3.4 for proper alignment procedures.
WARNING
After changing the belt, but before starting the engine, see that the air conditioning
compressor and 120 Volt generator bolts are properly fastened.

RigMaster Service and Repair Manual
Document # S250909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
2.5 Air Conditioning V Belt Replacement
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.
Tension, lb (kgf)
132 ± 5 (60 ± 2)
CAUTION
Ensure that the air conditioning compressor pivot bolt is tight otherwise damage to the
compressor could result. Check the compressor pivot block for wear or
wallowing of the hole.
This will allow the compressor to ship position and damage the adjuster arm or ears of the
compressor.
Figure I
Air Condition
Compressor Pivot Bolt

RigMaster Service and Repair Manual
Document # S260909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
S2.6 Generator Drive Belt
NOTE
To replace the generator belt, the air conditioning compressor belt must be removed
first.
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 1/4 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) 1/4” 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

RigMaster Service and Repair Manual
Document # S270909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
S2.7 Replacing the Fan Belt the 60A Alternator
NOTE
Inspect the fan belt every 1000 Hours and replace as necessary
Procedure
1. Remove the right hand side panel using a 7/16 socket.
2. Loosen the adjustment bolt (3) using a 12mm wrench and a 12mm
socket.
3. Loosen the pivot bolt (1) using a 12mm socket.
4. To remove the fan belt, slide the alternator (2) down towards the
engine and remove the belt.
5. Install the new fan belt and slide the alternator (2) up towards the
top of the engine using a 16 inch pry bar until the belt deflection is less than 6 mm. (1/4").
6. When the fan belt is tensioned, tighten the adjustment bolt (3) using a 12mm wrench and
12mm socket. Then tighten the pivot bolt (1) using a 12mm socket.
7. Reinstall the right hand side panel using a 7/16 socket. Make sure the shroud on the side
panel does not touch the engine fan blade.
CAUTION
Inspect the fan for broken blades or worn tips; if the blade(s) are damaged
check the
engine mounts and bottom stiffeners for damage, loose bolts or worn engine mounts.
Also see that a foreign object did not enter the engine compartment.
TOOLS REQUIRED
12mm Wrench
3/8 Ratchet
12mm Socket
7/16 Socket
16 inch pry bar
1 Pivot Bolt
2 Alternator
3 Adjustment Bolt
Figure 2-6

RigMaster Service and Repair Manual
Document # S280909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
S2.8 Replacing Fan Belt for 25A and 40A Alternators
To replace the fan belt, the right-hand side chamber must be removed. It is also necessary that
the engine cooling fan be removed.
Procedure
1. Remove the right hand side panel using a 7/16 socket.
2. Loosen the adjustment bolt using a 12mm wrench and a 12mm
socket.
3. Loosen the pivot bolt using a 12mm socket.
4. To remove the fan belt, slide the alternator down towards the
engine and remove the belt.
5. Install the new fan belt and slide the alternator up towards the top
of the engine using a 16 inch pry bar until the belt deflection is less than 6 mm. (1/4").
6. When the fan belt is tensioned, tighten the adjustment bolt using a 12mm wrench and 12mm
socket. Then tighten the pivot bolt using a 12mm socket.
7. Reinstall the right hand side panel using a 7/16 socket. Make sure the shroud on the side
panel does not touch the engine fan blade.
CAUTION
Inspect the fan for broken blades or worn tips; if the blade(s) are damaged check the engin
e
mounts and bottom stiffeners for damage, loose bolts or worn engine mounts. Also see
that a foreign object did not enter the engine compartment.
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.
TOOLS REQUIRED
12mm Wrench
3/8 Ratchet
12mm Socket
7/16 Socket
16 inch pry bar

RigMaster Power Service and Repair Manual
Document # S290909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
S2.9 Replacing the Engine Oil and Oil Filter
CAUTION
It is important to follow the recommendations below when changing or filling the lubricating oil
system. This will avoid the possibility of a hydraulic lock within the cylinder(s) occurring.
Remove the oil filler cap from the timing case.
1. Remove the oil dipstick from the dipstick tube and wipe
clean; DO NOT REPLACE THE DIPSTICK AT THIS
TIME.
2. Remove the access hatch from the bottom plate of the
engine enclosure (6 x 7/16” hex head screws, lock
washers and washers).
3. Remove oil drain plug, drain the oil and replace the oil
drain plug.
4. Remove and replace the oil filter.
5. Fill the lubricating oil system with the recommended quantity of oil. On T4-6 models fill oil
through the fill port on the timing cover. On 14-6 and older models, fill oil slowly through the
rocker cover fill port. Filling oil too quickly can result in oil spilling over into the intake
and cylinders causing hydraulic lock.
6. Replace the oil filler cap.
7. Operate the engine until operating temperature has been reached (approx. 5 minutes).
8. Stop the engine for 15 minutes to allow oil to drain down to the pan.
9. Check the lubricating oil level on the dipstick and add oil as necessary.
NOTE
Replace engine oil and filter every 1000 Hours
NOTE
Units with the Tier 4 engine have a second fill cap placed on the timing cover. When filling oil on
Tier 4 engines, use the timing cover fill port to prevent any hydraulic lock of the cylinders.
Oil Filler Cap
on Tier
4a Engine
Figure 2-8
Oil
Dip Stick Marking
Figure 2
-
7

RigMaster Power Service and Repair Manual
Document #S2100909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
S2.10 Replacing the Fuel Filter
If proper procedures are followed during filter service, a minimal amount of air bleeding is
required after changing the filter.
NOTE
Inspect the fuel filter every 1000 Hours.
Filter Replacement Procedure
1. The fuel shut off valve must be moved to the closed position. (counter
clockwise to 3 o’clock position)
2. Remove the retaining ring on the filter sediment bowl 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. Reinstall the sediment bowl, and retaining ring.
6. Open the fuel shut-off valve and loosen the right bleed screw on the
filter head assembly.
7. Bleed the low pressure system. (see section S5A-2)
8. Start the engine and check for leaks
Bleed Screw
Fuel Sedim
ent Bowl
Priming Pump
Priming Lever
Fuel
Shut Off
Valve
Figure 2
-
9
Fuel
Filter
Fuel Bowl Retaining Ring
Figure 2
-
10

RigMaster Power Service and Repair Manual
Document # S2110909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
S2.11 Replacing the Air Filter:
CAUTION

Care must be taken to prevent contaminants from entering the intake manifold when
the filter is removed. Remove the housing and change the filter off the engine.
This filter canister accepts the Mann 00–C1140 Air Filter. Consult the cross reference
parts list for approved replacement parts.
Air Filter Assembly
The RigMaster APU uses an air canister and high quality pleated filter to prevent debris from
entering the engine. The air filter element is not washable and requires that it is examined
regularly and replaced as required by the Maintenance Schedule found in section S2
CAUTION
Do not use unapproved air filters as they are not designed to fit properly into the air
canister. Use of unapproved filters and service components may void engine warranty
and cause engine damage.
NOTE
The air filter should be inspected every 500 to 1000 hours of operation and replaced as
necessary.
Figure 2
-
1
A
B

RigMaster Power Service and Repair Manual
Document # S2110909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
Figure 2-2 Figure 2-3
Procedure:
1. Remove the air filter canister from the intake manifold. (loosen the hose clamps at locations
A and B as shown in Figure 2-1)
2. Protect the air intake manifold from dirt or other debris that may enter the engine.
3. Remove top cover from the air filter canister.
4. Remove air filter element and clean the inside of air canister. Allow the air canister to dry
completely.
5. Replace air filter element. (use only manufacturer approved filters)
6. Reinstall the air canister lid. (Turn clockwise).
7. Reinstall the air filter canister assembly.
8. Tighten the hose clamps, and double check the lid is on properly.
NOTE
Before test running the engine inspect the filter hoses for cracks or brittle sections.
Damaged or degraded hose should be replaced.
Mann 00
-
C1140
Air Canister 103002
Inlet Port
To Intake Manifold

RigMaster Power Service and Repair Manual
Document # S2120909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
S2.12 Cleaning the 120 Volt AC Generator:
1. To clean the generator you must remove the generator cover (7 x 7/16” hex head screws,
lock washers and washers), and remove the generators mounting hardware. Please see
section 10 for further information on removal and reinstallation of the generator.
2. Remove the two Phillips head screws and plastic louvered panel that covers the capacitor
and clean the core using compressed air.
3. Continue the cleaning until no more debris is seen leaving the generator. The pulley on the
generator should be rotated so that all surfaces in the generators core are cleaned. Ensure
that you clean both the inlet and exhaust sides of the generator casing.
4. Do not use any liquid cleaners to perform this service.
5. If the generator windings are wet, ensure that the generator is completely dry before using
the generator. Operating the generator with wet windings will result in damage to the
insulation on the windings.
NOTE
The generator should be cleaned every 500 to 1000 hours.

RigMaster Power Service and Repair Manual
Document # S2130909
Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09
S2.13 Cleaning the HVAC Filter:
Procedure:
1. Unscrew the two thumb nuts (A) and
remove the foam air filter from the HVAC
box.
2. Wash the air filter using soapy water or
blow clean with compressed air and allow
filter to dry completely.
3. Reinsert the air filter and hand tighten the
two thumb nuts.
Note
The HVAC filter does not need to be replaced unless it is damaged.
The filter should be cleaned every 1000 hours of operation.
Figure 2
-
12
A