Rigmaster MTS-T4-LG200 Installation Manual
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Rigmaster MTS-T4-LG200 Installation Manual

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MTS-T4-LG200

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Summary of Contents for Rigmaster MTS-T4-LG200

  • Page 1 Installation Manual MTS-T4-LG200...

  • Page 2: Table Of Contents

    Installation of the Fuel Fittings at the Fuel Tanks 7:2:0 Optional Fuel Pick Up Tube (Stand Pipe) 7:2:1 Installation of the Fuel Fittings at the LG200 APU 7:3:0 Prime the Fuel System 7:4:0 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 3 Complete the Installation Check List and Warranty Registration 11:6:1 Diesel Particulate Filter Registration 11:6:2 Section 12 Installation Equipment List Installation Material List 12:1:0 Installation Tools List 12:2:0 Shop Equipment List 12:3:0 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 4 LG200’s engine to start. Please see the cabin controller’s operating instructions for further information on the AutoStart feature. You must deactivate this feature prior to refueling. August 2010 RigMaster Power International Ltd LG200 Service Manual...

  • Page 5: Safety

    LG200. Follow your local regulations and guidelines regarding occupational health and safety. Contact Us If you do not fully understand this safety information, contact RigMaster’s Technical Support Department toll free at (888) 208 – 3101 before proceeding with the operation or service of this APU.

  • Page 6: Introduction To Installation

    In any event, the directives in the installation manual must be followed and accepted engineering principles observed when installing the LG200. Please review the entire manual before beginning the installation. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 7 The main unit (engine enclosure) and HVAC can be mounted on either the driver or passenger side of the vehicle. The optimal location is on the curb side for safety, practicality and ease of installation. The LG200 is also suitable for installation on cab-over vehicles. Please contact RigMaster’s Technical Support Department more...
  • Page 8  In the event that you do not fully understand how to safely and properly mount the APU, contact RigMaster’s Technical Support Department before proceeding with the installation. For part numbers of installation components please see the packing lists enclosed within each box in the LG200. August 2010 RigMaster Power International Ltd LG200 Service Manual...

  • Page 9: Preparation And Frame Rail Mounting

    The following figures illustrate the correct way to install the frame clamps and mounting hardware. See to it that the bolts and clamps are mounted straight with the trucks frame(Fig. 2-1) August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 10 When installing the mounting hardware, make sure that no markings on the flat washers are visible after the washers have been installed (Fig. 2-2). Top of 5/8” Bottom of 5/8” Hardened Washer Hardened Washer NO MARKINGS MARKING Fig. 2-2 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 11 (Fig. 2-4). The anchor will allow the installer to torque the bolt without the use of a wrench or socket on the inside of the unit. Fig. 2-4 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 12 When installing, slotted holes in all mounting brackets must be on the bottom and all bolts must be properly torqued to foot pounds using a torque wrench. 5. Double check that all mounting bolts are secure and remove the lifting device. August 2010 RigMaster Power International Ltd LG200 Service Manual...

  • Page 13: Installing The Bunk Ac Unit

    HVAC unit. It is suggested that the unit serial number and engine serial number be recorded in the Owner’s Manual for the driver’s future reference. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 14 4. Do not secure the HVAC unit to the floor of the vehicle until you are sure that all connections are correct and fully secured. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 15 RigMaster LG200 Installation Manual Section 3 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 16 4” Flexible Ducting the louvered vent at the other. Excess ducting material must be removed to ensure optimal air flow. Method 1: Independent Ducting Fig. 3-5 Fig. 3-5 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 17 It is important that the vent is mounted so that it discharges directly into the sleeper and is unobstructed. Do not allow vents to discharge under the bunk. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 18 Be sure to fold the edges if using sheet metal so not to leave sharp surfaces inside the cab. Painted Aluminum Sheet Metal Air Kicker and Vent Assembly August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 19 HVAC with return air from the sleeper. It is common to port return air vents between the cabinets and the face of the bunk as this leaves them less visible. HVAC Unit August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 20 Integrated Ducting Integrated ducting interconnects the vehicle’s OEM ductwork to the LG200 HVAC box. RigMaster Power does not supply any fittings to perform this type of installation. Custom ductwork is the installer’s responsibility. For further information on this type of installation contact RigMaster’s Technical Support Center.

  • Page 21: Mounting The Control Panel

    (short bolts and cap nuts are preferable in this situation). This will protect the operator’s hands from damage when reaching into the cabinet. Cabin Controller Mounting Bracket Route Wire This Side August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 22 Figure 4-4 The Communication Cable is hidden, giving the control panel installation a professional look. August 2010 RigMaster Power International Ltd LG200 Service Manual...

  • Page 23: Installing The Coolant Hoses

    Figure 5-1 taking care not to pinch the hose. Step 3 Connect the coolant supply and return line to the HVAC box (Figure 5-1).. August 2010 RigMaster Power International Ltd LG200 Service Manual...

  • Page 24: Installing The A/C Hoses

     WD-40 should be used to prevent corrosion between the aluminum and steel fittings. The installation of the A/C refrigerant hoses will require #6, #8, #10 o-rings (Teflon coated o-rings supplied with the LG200 box kit) Fig. 6-1 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 25 AC lines while installing to avoid the possibility of future leaks. Fig. 6-2 There is a slot (A) cut out from the engine plate to support the low side line (Fig. 6-2). Fig. 6-3 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 26 3. The LG9-403 has a swiveling plate that is used to clamp the hoses to the expansion valve. Make sure the hoses are sitting securely before fastening this plate down. Bulkhead HVAC Connections Connections Fig. 6-6 Fig. 6-7 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 27 AC Line - Condenser to Bulkhead - #6 High LG9-402 AC Line - Bulkhead to Evaporator High LG9-404 AC Line - Evaporator to Bulkhead LG9-403 AC Line - Bulkhead to Compressor - #10 LG9-401 Expansion Valve High/Low LG9-003 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 28 F i g u r e 6 - 4 , w i l l d e l i v e r a c c e p t a b l e p e r f o r m a n c e . Suction Pressures – Low Side Common low side pressure will be between 15-40 psi depending on ambient temperature and humidity. Figure 6-4 August 2010 RigMaster Power International Ltd LG200 Service Manual...

  • Page 29: Installing The Fuel System

    Sealant will need to be used on both the threads for the pick-up tube and the fuel tank vent. Figure 7-1 Fuel supply fitting Fuel return fitting August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 30 7:2:0 Installation of the Fuel Fittings at the Fuel Tanks Figure 7-2 Check Valve Fuel Supply Fittings Fuel Return Fittings August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 31 Mark the fuel supply line at both ends to prevent the two fuel hoses from being accidentally reversed when connecting them to the fuel fittings. Figure 7-4 Figure 7-5 Fuel Fittings at the Crossover Fuel Fittings at the Tank August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 32 RigMaster LG200 Installation Manual Section 7 7:3:0 Installation of the Fuel Fittings at the LG200 APU Fuel Supply from Vehicle Fuel Tank to APU Fuel Return to Vehicle Fuel Tank from APU Figure 6-5 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 33 It may be necessary to turn the engine over approximately 180° to operate the priming pump. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 34 The 45° exhaust tip is not a required Figure 8-6 component in this exhaust system, and may be removed in the event that extension tail pipe must be added (see NOTE above). 45° Exhaust Tip August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 35 The DPF Kit will come with its own installation instructions. These instructions may also be downloaded by authorized Dealers from the RigMaster Power website under “Manuals and Support Material” or can be obtained by contacting RigMaster Power’s Technical Support Department at (888) 208 –...
  • Page 36 Ensure that the J connectors are clean and free of debris that may have entered while routing the cable outside the vehicle. 9:2:0 Connecting the Engine Harness to the Power Module August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 37 Connect the blue wire with the female spade terminal to the evaporator thermostat (bottom position).  Connect the black wire with an eye terminal to ground (AC box mounting hardware is a good ground source) August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 38 DPF kit has been installed. Do not connect this wire unless there is a DPF kit present of the APU. Instead tie the wire off to prevent damage and cover the tip with electrical tape. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 39 LG200’s engine enclosure, and the larger terminal to the vehicle’s battery bank. Figure 10-1 1/4” Terminal to LG200 Shrink Tube 3/8” Terminal to Battery Bank August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 40 2.Once the cables reach the battery box, find a suitable location to mount the in-line fuse. The fuse assembly must be located in an area free of hazards and firmly secured (mounting hardware not included) August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 41 Ensure that the positive battery terminal is clean and connect the red battery cable. Connection 2: Negative cable to the truck batteries (Figure 11-4) Ensure that the negative battery terminal is clean and connect the black battery cable. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 42 Section 1:1:3 for manufacturers Technical Support information. 11:2:0 Operation of the Electronic Control Before beginning the start-up procedure it is necessary to know how to operate the cabin controller. Figure 11-1 August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 43 8. Ext. Temp button will display the external temperature on the LCD when pressed August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 44 Red status LED will be on. SYSTEM ON symbol will display if the unit is in ON mode. (Green status LED will be on.) ENGINE RUNNING symbol will display when the engine is running. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 45 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. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 46 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. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 47 Press LEFT or RIGHT scroll button to adjust Clock hour. Press SELECT button: Clock hour will stop flashing and Clock minutes will start flashing. Press LEFT or RIGHT scroll button to adjust Clock minutes. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 48 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. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 49 HEAT or COOL have been selected. NOTE The AutoStart temperature range is between 32°F and 95°F. Press SELECT button to save settings or press MODE to return to menu without saving. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 50 This option is always enabled in active mode. The voltage sensitivity of the low battery AutoStart feature can be adjusted, however, this is a dealer programmable feature and must be performed at a RigMaster licensed facility.
  • Page 51  Check 20 Amp fuse at Error Code 11 Very low battery voltage Check Power Module Fuse detected at the power the power module module. (located under the bunk on the HVAC unit) August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 52 Error Code 28  Restart the APU to An output on the module Output Overcurrent is drawing too much determine which current moment the error code 28 occurs August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 53 13.5 and 14.5 Volts DC (14.8V DC maximum). This can be done with a volt meter at the batteries of the truck while the unit is running. August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 54 Installation Checklist is only to be completed at the time of inspection by authorized technicians at licensed facilities. The contents of this check list will be submitted via the RigMaster Power website and activate or reactivate whatever portion of warranty remains on the unit. On a new LG200 APU the Installation Checklist is inside a plastic envelope attached to the engine cover.
  • Page 55 Check for heat and air conditioning in the bunk. See that the alternator is charging the batteries. Check for any leaks as in coolant and engine oil. Register this RigMaster Installation Check List at www.rigmasterpower.com/login August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 56 If a Diesel Particulate Filter has been installed it must be independently registered. For further information of DPF registration please refer to the Diesel Particulate Filter Kit Installation Instructions supplied with the DPF Kit. August 2010 RigMaster Power International Ltd LG200 Service Manual...

  • Page 57: Installation Equipment List

    1/4 ” Drive Hand Ratchet 24” Extension [1/2” drive] 8” Square Nose Pliers 3/8 ” Drive Hand Ratchet Channel Lock Pliers 1/2 ” Drive Hand Ratchet 6” Side Cutter Torque Wrench [1/2” drive] Wire Stripper/Crimper August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 58 2 or 4” 4”x 24” Spacer Blocks (if Pallet Truck used). R134 Refrigerant Charge and Recovery System Radiator Pressure Tester Air Impact Gun Pressurized Air Line Supply Portable Extension Light Battery Operated Drill Electric Drill Extension cord Electrical Test Meter August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 59 RigMaster LG200 Installation Manual Notes August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 60 RigMaster LG200 Installation Manual Notes August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 61 RigMaster LG200 Installation Manual Notes August 2010 RigMaster Power International Ltd LG200 Service Manual...
  • Page 62 Toronto, Ontario, Canada M1P2X9 Contact Technical Support Tel: (416) 201 – 0040 ext. 25 Toll Free: 1 (888) – 208 – 3101 Fax: (416) 201 - 7532 www.rigmasterpower.com August 2010 RigMaster Power International Ltd LG200 Service Manual Printed in Canada...

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