Rigmaster MTS-T4-LG200 Owner's Manual
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Rigmaster MTS-T4-LG200 Owner's Manual

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Summary of Contents for Rigmaster MTS-T4-LG200

  • Page 1 Owner's Manual MTS-T4-LG200...

  • Page 3: Preface - Additional Publications/Technical Assistance

    RigMaster is a totally self-contained, stand-alone generator, Air Conditioner and Heater System. The only items that are shared with your Truck Systems are fuel and battery supply. The RigMaster unit also trickle charges the Truck batteries while in operation. Superior design and performance have been incorporated into this product to give you trouble-free, economical operation.
  • Page 4 Disregarding a CAUTION may result in damage to the assembly. WARNING! A WARNING describes a special procedure or steps, which must be taken while completing the procedure where the warning is found. Disregarding a WARNING can result in serious personal injury or death. Page 2 MTS-T4-LG200-Owners-Manual-052815...
  • Page 5 Service & Repair History (if available) Technical Support is available by Telephone: (888) 208-3101 or (416) 201-0040 Monday to Friday from 8:00 a.m. to 5:00 p.m. Eastern Standard Time Website: www.rigmasterpower.com (click: Customer Support, Support Materials, Technical Support) Page 3 MTS-T4-LG200-Owners-Manual-052815...

  • Page 6: Table Of Contents

    Normal Maintenance & Adjustment Instructions Oil Change Instructions Air Filter Change Instructions Serpentine Drive Belt – Removal Fan Belt – Removal and Adjustment Cleaning Instructions Cleaning – HVAC Filter Troubleshooting Warranty RigMaster APU Limited Warranty Maintenance Record Notes Page 4 MTS-T4-LG200-Owners-Manual-052815...

  • Page 7: Safety

    Unplug the J1 harness at the power module before disconnecting the battery cables. After disconnecting the battery cables, check the battery posts inside the RigMaster engine cabinet to confirm there is no voltage to the auxiliary power unit (APU). 2. Safety Cover Switch WARNING!: SAFETY COVER SWITCH It is critical that this safety cover switch is never bypassed;...
  • Page 8 7. Inspection of the Safety Systems The safety systems on the RigMaster APU should be examined and tested prior to performing any service work and at 50 hour intervals to ensure that they are in good condition and proper working order.

  • Page 9: Heater (Only Applicable To Those Models With Heat)

    Page 11). The bunk heating system is a complete stand alone system that is not integrated into the vehicle's cooling system. When heat is selected, and the RigMaster is in operation, the hot coolant flows through the heater core (installed under the bunk – see Figure 2).
  • Page 10 Marking the shaft with a black marker which will make the shaft rotation more visible. When the valve is closed coolant will loop back to the engine. Figure 4 – Control Valve Motor Shaft Figure 5 – Loop back to Engine Page 8 MTS-T4-LG200-Owners-Manual-052815...
  • Page 11 Figure 7 – Engine Coolant NOTE When hooking up the engine coolant lines to the HVAC box it is very important to mark the lines and hook them up correctly. Improper connections will result in poor heating in the bunk. Page 9 MTS-T4-LG200-Owners-Manual-052815...
  • Page 12 Run the engine for 15 minutes and then allow engine to cool. Top up the coolant. NOTE When purging the air from the HVAC box use some lubricant on the screw driver to slide between the heater core tube and rubber hose. Page 10 MTS-T4-LG200-Owners-Manual-052815...

  • Page 13: Air Conditioner

    The RigMaster air conditioner is also fully automatic. A constant comfort zone is maintained with the temperature selector setting (see Cabin Controller Operation – Page 14). The RigMaster air conditioner is an R134A system that is not integrated into the vehicle's existing air conditioning system.
  • Page 14 LG200 Owner's Manual Air Conditioner The compressor within the RigMaster unit pumps the refrigerant gas through the condenser that dissipates the heat and changes the refrigerant from a gas to a liquid. The liquid refrigerant passes through a filter (receiver drier), and then through the evaporator core located in the bunk heater/air conditioner unit.

  • Page 15: Pre-Start Inspection

    LG200 Owner's Manual Pre-Start Inspection Pre-Start Inspection with the RigMaster TURNED OFF Remove the cover. Visually inspect the unit for evidence of oil or coolant leakage. Check the oil and add oil if necessary. Check the tension and wear of all belts.

  • Page 16: Cabin Controller Description And Operating Instructions

    LCD screen. The LED is turned off in low power mode. Basic Controls and Functions Basic controls contain the following buttons: Start system. Stop system. Up arrow (Red triangular button). Down arrow (Blue triangular button). Page 14 MTS-T4-LG200-Owners-Manual-052815...
  • Page 17 Pressing the select button will save the information when entering operational data. 11. Left scroll button (). 12. Right scroll button (). The left and right arrow buttons are used to locate the desired data and/or adjust those values. Page 15 MTS-T4-LG200-Owners-Manual-052815...
  • Page 18 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. Page 16 MTS-T4-LG200-Owners-Manual-052815...
  • Page 19 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. Page 17 MTS-T4-LG200-Owners-Manual-052815...
  • Page 20 Figure 15 – Cabin Controller LCD Display – 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. Page 18 MTS-T4-LG200-Owners-Manual-052815...
  • Page 21 The system will remember the last set temperature when the APU 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. Page 19 MTS-T4-LG200-Owners-Manual-052815...

  • Page 22: Clock And Date Set-Up

    12. Press SELECT button. (Month will stop flashing and Date will start flashing.) 13. Press LEFT or RIGHT scroll button to change. 14. Press SELECT button to save settings and return to menu or press MODE to return to menu without saving. Page 20 MTS-T4-LG200-Owners-Manual-052815...

  • Page 23: Set Alarm Clock

    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. Page 21 MTS-T4-LG200-Owners-Manual-052815...

  • Page 24: Autostart Features

    Allows you to program a comfortable temperature setting; the APU regulates the temperature giving you further fuel savings on extended absences from the cab. Set Automatic Start-Up/Shut-Down – Temperature Press AUTOSTART button twice. (Temp AutoStart will scroll across the screen.) Page 22 MTS-T4-LG200-Owners-Manual-052815...
  • Page 25 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 trained facility. Set Automatic Start-Up – Low Battery 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 features.

  • Page 26: Fault Codes

    Engine Overheated failed engine temperature sensor (top of water pump, has single wire).  Damaged wire providing ground.  Error Code 6 Power Module is not Failed power module. responding. Module Failure Page 24 MTS-T4-LG200-Owners-Manual-052815...
  • Page 27 Battery Discharge power module.  Error Code 14 External temp. sensor External temperature sensor may not be connected to disconnected or failed.  the power module. Check External Connection loose or damaged. Temperature Sensor Page 25 MTS-T4-LG200-Owners-Manual-052815...
  • Page 28 POWER ON again. Code amperage. should not display when J2 is Water Valve unplugged. Overcurrent  Glow plug relay drawing Error Code 21 Glow plug relay operation is excess amperage. faulty or wire broken. GP Overcurrent Page 26 MTS-T4-LG200-Owners-Manual-052815...
  • Page 29 Output Overcurrent activate an electronic Power OFF with controller for a component. Output circuit minute and function will return. shuts off to protect itself. Test each power module output circuit for amperage draw. Page 27 MTS-T4-LG200-Owners-Manual-052815...

  • Page 30: Fuel System Description And Bleeding Procedures

    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. The RigMaster incorporates a low/high pressure fuel system with fuel supply and return lines interconnected with the vehicle’s fuel system. The engine lift pump supplies fuel to the filter assembly and then to the injection pump.
  • Page 31 If possible fill up new fuel filter with clean diesel fuel to ensure the least amount of air is allowed to enter the fuel system. Re-install fuel filter. Tighten filter. Air Relief Valve Bearing Cartridge Rubber Element Filtering Element Figure 17 – Fuel Filter Page 29 MTS-T4-LG200-Owners-Manual-052815...
  • Page 32 Tighten the air relief valve bolt. Bleeding low pressure system is complete. WARNING! Do not use priming lever when engine is cranking or running. Only use priming lever when engine is off. Page 30 MTS-T4-LG200-Owners-Manual-052815...
  • Page 33 LG200 Owner's Manual Fuel System Fuel Supply to Filter Priming Lever Figure 18 – Lift Pump WARNING! Do not use priming lever when engine is cranking or running. Only use priming lever when engine is off. Page 31 MTS-T4-LG200-Owners-Manual-052815...
  • Page 34 If you require further information, please contact your local RigMaster Dealer. Page 32 MTS-T4-LG200-Owners-Manual-052815...

  • Page 35: Preventative Maintenance Schedule

    Check coolant concentration; renew if necessary. *** 4000 Hrs. - Timing Belt Replacement *** NOTE The use of conditioner may extend the service life of belts; consult the belt manufacturer for more information on the maintenance belt. Page 33 MTS-T4-LG200-Owners-Manual-052815...

  • Page 36: Cross Reference Parts List

    LG200 Owner's Manual Cross-Reference Parts List RigMaster Power Approved Cross-Reference Parts List OIL FILTER NOTES BRAND PART No. RigMaster K-002 Kohler ED0021752850-S AIR FILTER BRAND PART No. RigMaster K-001 Kohler ED0021751640-S FUEL FILTER BRAND PART No. RigMaster K-003 Kohler ED0021752880-S...

  • Page 37: Oil Change Instructions

    Europe, North America, and Australia). CAUTION Consult a RigMaster Dealer about the use of synthetic oil in your RigMaster. Service intervals for oil and oil filter replacements are 1000 hours. Synthetic oil is suitable for use; however, it is recommended that mineral-based ois are used for the break-in period.
  • Page 38 Remove front cover ensuring proper operation of the cover safety switch or disconnect battery prior to this step for your safety. Remove the oil fill cap. Remove the oil dipstick from the dipstick tube and wipe clean; DO NOT REPLACE THE DIPSTICK AT THIS TIME. Page 36 MTS-T4-LG200-Owners-Manual-052815...
  • Page 39 (approximately 5 minutes). 13. Stop the engine and allow oil to drain down to the oil pan. 14. Check the oil level on the dipstick and add as necessary. NOTE Replace engine oil and filter every 1000 Hours. Page 37 MTS-T4-LG200-Owners-Manual-052815...

  • Page 40: Air Filter Change Instructions

    Replacing the Air Filter NOTE The air filter should be inspected every 500 hours of operation. CAUTION This unit accepts ONLY the RigMaster P/N KL3-001 (Kohler P/N ED0021751640-S) Air Filter. Do not use unapproved cross-referenced parts. Air Filter Box Figure 22 – Air Filter Procedure to Replace the Air Filter Remove the cover from the air filter.

  • Page 41: Serpentine Drive Belt - Removal

    LG200 Owner's Manual Serpentine Drive Belt Serpentine Drive Belt RigMaster LG200 APU’s are equipped with a serpentine drive belt that drives the air conditioning compressor from the flywheel of the engine. Belt rotation is Counter- clockwise. Figure 23 – Serpentine “Stretch-Fit” Compressor Belt...
  • Page 42 Remove belt from the flywheel drive pulley using the shaft of a wrench or screwdriver to help pry the belt over the edge of the pulley. Remove the belt and inspect for wear and cracking. If the belt looks good, clean and re-install the belt. Page 40 MTS-T4-LG200-Owners-Manual-052815...

  • Page 43: Fan Belt Removal And Adjustment

    A DIESEL ENGINE MAY START AT ANY TIME WHEN ITS CRANKSHAFT IS TURNED. THIS INCLUDES TURNING BY WRENCH OR BY HAND! Alternator Adjuster Lock Bolt and Nut Fan Belt Alternator Alternator Pivot Bolt Figure 25 – Alternator Page 41 MTS-T4-LG200-Owners-Manual-052815...

  • Page 44: Cleaning Instructions

    Reinstall the engine cover. Cleaning Instructions The RigMaster Auxiliary Power Unit should be periodically inspected and any accumulation of road contaminants (such as: paper; plastic; dirt; oil; etc.) must be removed. The main components, as outlined below, must be kept clean and free of contaminants and/or debris.
  • Page 45 & sensors to prevent the connections & sensors from corroding. Make sure the engine compartment is dry first. Using battery sealant, spray the positive & negative post, glow plugs, and run solenoid. (see Figure 26 for areas to spray with battery sealant). Page 43 MTS-T4-LG200-Owners-Manual-052815...

  • Page 46: Cleaning - Hvac Filter

    Unscrew the two thumb nuts (see Figure 29) and remove the foam air filter from the HVAC box. Wash the air filter using soapy water or blow clean with compressed air and allow filter to dry completely. Reinsert the air filter and hand tighten the two thumb nuts. Page 44 MTS-T4-LG200-Owners-Manual-052815...

  • Page 47: Troubleshooting

    1. Weak or bad batteries. 1. Inspect batteries. 2. Damaged/corroded 2. Replace or clean the battery connections. battery connections. 3. Faulty starter. 3. Check starter 4. Belt driven component connections. problem. 4. Compressor or other belt driven component seized. Page 45 MTS-T4-LG200-Owners-Manual-052815...
  • Page 48 1. Replace crankshaft 2. Leaking drain plug. seals. 3. Pinched or clogged 2. Replace oil pan plug breather tube. gasket. 4. Engine worn or in poor 3. Repair or replace condition. breather tube. 4. Replace and/or rebuild the engine. Page 46 MTS-T4-LG200-Owners-Manual-052815...
  • Page 49 2. Tighten clamps. 3. Faulty fuel bowl gasket. 3. Replace fuel bowl 4. If pick-up tube was gasket. installed in tank, may 4. Add fuel to tank so pick- draw air if fuel too low. up tube is submerged. Page 47 MTS-T4-LG200-Owners-Manual-052815...
  • Page 50 3. Reduce the hose length. 3. Excessive duct hose. 4. Relocate the vent. 4. Poor placement of vent. 5. Replace blower motor. 5. Faulty blower motor. 6. See Installation Manual 6. Ducted through truck's for mounting methods. ventilation system. Page 48 MTS-T4-LG200-Owners-Manual-052815...
  • Page 51 2. Damage to pulleys. 2. Replace damaged during Operation 3. Maladjusted Belt. pulleys. 3. Replace belt. For additional diagnostic and troubleshooting information, please visit www.rigmasterpower.com and click on the “Customer Support” heading, “Support Materials” menu option. Page 49 MTS-T4-LG200-Owners-Manual-052815...

  • Page 52: Warranty

    Rig Master Power International Ltd. warrants that, under normal service and use, the RigMaster APU will be free from defects in material and workmanship for a term of 12 months/2000 hours or a term of 24 months/4000 hours, depending on...
  • Page 53 INCLUDING ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. No person, firm or representative is authorized to assume any obligation or make any warranty on behalf of RigMaster Power other than the limited warranty as stated herein. Maintenance The RigMaster Owner’s Manual lists all maintenance functions to validate this...
  • Page 54 Transfer of Warranty Where the vehicle with the RigMaster APU has been sold by the first Owner to a second Owner and the RigMaster has not been removed, this limited warranty is transferable from the original Owner to a second Owner with whatever portion of the limited warranty that remains from the date of sale.
  • Page 55 International Ltd. will not, under any terms, replace the entire APU as a means of repair. The purpose of this warranty is to provide the Owner of the RigMaster APU with free repair or replacement of defective parts in a manner outlined in the following policy.
  • Page 56 When a RigMaster Dealer determines a failure to have occurred due to an improper installation by their installing technician, it is the Dealer’s responsibility to repair the RigMaster APU and correct the installation error at no cost to the Owner. At no time shall RigMaster Power International Ltd. warrant any repairs to the RigMaster APU due to improper installation by the installing Dealer.
  • Page 57 It is the Dealer’s responsibility to notify RigMaster Power International Ltd. of a change of ownership when a RigMaster APU has been sold by the first Owner to a second Owner. The Dealer must inform RigMaster Power by means of a written notice with both original Owner’s information and new Owner’s...
  • Page 58 Frequently, customer concerns are a result of a breakdown in communications and can be quickly resolved at the Dealer level. If you are still not satisfied, present the entire matter in writing to: RigMaster Warranty Administration 1320 Ellesmere Road, Unit #1 Toronto, Ontario, Canada...

  • Page 59: Maintenance Record

    LG200 Owner's Manual Maintenance Record Maintenance Record Hour Maintenance Performed Date Meter Remarks 1000 1600 Reading hrs. hrs. hrs. hrs. hrs. hrs. Page 57 MTS-T4-LG200-Owners-Manual-052815...
  • Page 60 LG200 Owner's Manual Maintenance Record Hour Maintenance Performed Date Meter Remarks 1000 1600 Reading hrs. hrs. hrs. hrs. hrs. hrs. Page 58 MTS-T4-LG200-Owners-Manual-052815...

  • Page 61: Notes

    LG200 Owner's Manual Notes Notes Page 59 MTS-T4-LG200-Owners-Manual-052815...
  • Page 62 LG200 Owner's Manual Notes Notes Page 60 MTS-T4-LG200-Owners-Manual-052815...
  • Page 64 RigMaster Power International Ltd. 1320 Ellesmere Road, Unit #1 Toronto, ON, Canada M1P 2X9 Tel: 1-416-201-0040 Toll Free: 1-800-249-6222 Fax: 1-416-293-5104 www.rigmasterpower.com...

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