Rigmaster MTS-T4-LG200 User manual

Installation Manual
MTS-T4-LG200

RigMaster LG200 Installation Manual
Table of Contents
August 2010 RigMaster Power International Ltd LG200 Service Manual
Safety
Safety Information
Preface
Section 1 Introduction to Installation
Introduction to Installation
1:1:0
Definitions
1:1:1
Necessary Tools
1:1:2
Technical Assistance
1:1:3
Placement of the LG200 Components
1:2:0
Section 2 Preparation and Frame Rail Mounting
Preparing the LG200
2:1:0
Frame Mounting Hardware
2:2:0
Frame Rail Mounting
2:2:1
Section 3 Installing the Bunk AC Unit
Preparation to Install the AC Unit
3:1:0
Mounting the AC Unit
3:1:1
Ducting the Ventilation System
3:2:0
Independent Ducting
3:2:1
Vent Installation
3:2:2
Installation of Return Air Vent
3:2:3
Integrated Ducting
3:3:0
Section 4 Mounting the Control Panel
Mounting the Control Panel 4:1:0
Section 5 Installing the Coolant Hoses
Installation of the Coolant Fittings 5:1:0
Installation of the Coolant Hoses 5:2:0
Section 6 Installing the A/C Hoses
Installation of the A/C Refrigerant Hoses
6:1:0
Installing the A/C Hoses in the engine compartment
6:1:1
Installing the A/C hoses from the LG200 to the AC unit
6:1:2
Air Conditioning Specifications
6:1:3
Section 7 Installing the Fuel System
Installation of the Fuel System
7:1:0
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

RigMaster LG200 Installation Manual
Table of Contents
August 2010 RigMaster Power International Ltd LG200 Service Manual
Section 8 Exhaust System
Ultra Quiet Exhaust System 8 :1:0
Diesel Particulate Filter Installation 8:2:0
Section 9 Electrical Connections
Introductions to LG200 Electrical Connections
9:1:0
Connecting the Engine Harness to the Power Module
9:2:0
Evaporator Temperature Switch Wiring Connections
9:3:0
Connecting the Cabin Controller
9:5:0
DPF Backpressure Monitor Wire
9:6:0
Section 10 Installing the Battery Cables
Introduction to Installing the Battery Cables
10:1:0
Installing the Battery Cables to the LG200 Battery Posts
10:2:0
Installing the 100 Amp Battery Fuse
10:3:0
Installing the Battery Cables to the Vehicles Battery Bank
10:4:0
Section 11 Start-Up Procedure
Introduction to Start Up Procedures
11:1:0
Operation of the Electronic Control
11:2:0
Cabin Controller LCD Display
11:2:1
Operation of the Cabin Controller (Functions)
11:2:2
AutoStart Features and Operation
11:2:3
Electronic Control Operation and Fault Codes
11:2:4
Pre-Start Inspection
11:3:0
Test the Air Conditioning System
11:4:0
Test the Alternator
11:5:0
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

RigMaster LG200 Installation Manual
Safety
August 2010 RigMaster Power International Ltd LG200 Service Manual
1. Zero Energy State
ATTENTION: ZERO ENERGY STATE
To perform service, maintenance and repairs you must disconnect the LG200 from its
battery source. In the recommended installation configuration the LG200 shares the battery
bank with the vehicles main engine. Unplug the J1 harness at the power module before
disconnecting the battery cables. After disconnecting the battery cables, check the battery
posts inside the LG200 engine cabinet to confirm there is no voltage to the auxiliary power
unit (APU).
2. Safety Cover Switch
It is critical that this safety cover switch is never deactivated or bypassed. Failure to
comply may result in serious injury.
The safety cover switch is designed to prevent the LG200 from starting when the engine
cover is loose or has been removed. When the switch is in the closed position the cover
is down. When the switch is in the open position the cover has been removed or is loose.
The switch is located at the very top of the unit enclosure on the coolant tank mounting
bracket.
3. AutoStart Automatic Start/Stop Feature
ATTENTION: AUTOSTART FEATURE
Remember that a properly functioning LG200 is capable of starting independently of
its operator. If the AutoStart feature is enabled, battery voltage, temperature and time
of day can all cause the 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.
ATTENTION: SAFETY COVER SWITCH
Cover Safety Switch

RigMaster LG200 Installation Manual
Safety
August 2010 RigMaster Power International Ltd LG200 Service Manual
4. Engine Hoist Points
ATTENTION: ENGINE HOIST POINTS
The Perkins and Caterpillar engines have hoist points that are useful for removal and
reinstallation of the engine. It is advised that these hoist points should only be used if no
other means of lifting the unit are available.
5. Starting Aids
WARNING
Do not use any type of starting aids such as ether or “Quick Start”. Using any such
starting aid will result in an explosion, personal injury and severe damage to the engine.
The APU warranty will be “voided” by this action.
6. Starting with the Cover Off
ATTENTION
Some installation or repair/diagnostic procedures require that the APU is started with the
engine cover off. Never bypass the safety cover switch. Instead, have another individual
assist by manually holding the safety cover switch down in the closed position for the duration
of the procedure.
7. Inspection of the Safety Systems
The safety systems on the LG200 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.
8. Safe Working Practices
Safe working practices are your responsibility. The use of protective safety equipment is
mandatory when performing inspections, service, diagnostics and repairs on the
LG200. Follow your local regulations and guidelines regarding occupational health and
safety.
9. Contact Us
If you do not fully understand this safety information, contact RigMaster’s Technical
Support Department toll free at (888) 208 –3101 before proceeding with the operation or
service of this APU.

RigMaster LG200 Installation Manual
Section 1
August 2010 RigMaster Power International Ltd LG200 Service Manual
Introduction to Installation
Introduction to Installation
1:1:0
Definitions
1:1:1
Necessary Tools
1:1:2
Technical Assistance
1:1:3
Placement of the LG200 Components
1:2:0
1:1:0 Introduction to Installation
The following information is supplied as a reference to support qualified
technicians during the installation of the LG200. Given the diversity of
vehicles, these installation procedures are general guidelines and will apply
to Class 8 over the road vehicles, unless technical modifications of the
vehicle influence the serviceability. Depending on the version and vehicle
equipment, changes in procedure may be required that are outside the scope
of this manual. 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.
Fig. 1-1

RigMaster LG200 Installation Manual
Section 1
August 2010 RigMaster Power International Ltd LG200 Service Manual
1:1:1 Definitions
NOTE
A NOTE describes important information necessary to properly complete a procedure, or
information which will make the procedure easier to understand.
CAUTION
A CAUTION describes a special procedure or special steps which must be taken while
completing a task. Disregarding a CAUTION may result in damage to the assembly.
WARNING
A WARNING describes a special process or steps, which must be taken while
completing the procedure. Disregarding a WARNING may result in serious injury .
This manual will refer to the LG200 as an auxiliary power unit, which is
abbreviated APU.
1:1:2 Necessary Tools
It is expected that the installing technician(s) have a comprehensive set of tools
suitable for automotive service work. Please see Section 11 for a detailed list of
tools and materials required to complete an installation.
1:1:3 Technical Assistance
Technical Support is available by calling
(888) 208 - 3101 or (416) 201 - 0040
Mon - Fri, 8:30 am to 5:00 pm EST
1:2:0 Placement of the LG200 Components
Deciding on the placement of the LG200 APU components is the first and most
important step. Poor placement of the APU will have a negative impact on the
performance and accessibility of the unit. Remember that the best location is one
that considers practicality, serviceability and aesthetics.
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 for more detailed information on cab-over installations.

RigMaster LG200 Installation Manual
Section 1
August 2010 RigMaster Power International Ltd LG200 Service Manual
The LG200 requires approximately 20 inches of clear frame rail for installation. It has a
projection from the frame of 26”, which allows the unit to be mounted behind a
fairing. It may be necessary to relocate or modify preexisting vehicle components to
accommodate the LG200. (refer to 2:3:0).
Fig. 1-2
Installation factors to consider include the location of the battery box; air tanks,
air dryers, fuel tanks, tool boxes, pumps, main engine exhaust pipe etc. The
location and accessibility of these components will influence the overall
installation time.
Remember when choosing a location that the harder it is to access the unit, the
more difficult it will be to service. Owners are also less likely to perform frequent
maintenance inspections of oil and coolant levels if the unit is severely restricted.
If the configuration of the truck allows, the unit may be bolted directly to frame
using suitable Grade 8 mounting hardware and following the vehicle
manufacturer’s guidelines for drilling or modifying the frame rails. Ensure that the
unit is mounted straight and level on the frame rail.
CAUTION
When installing the unit, regardless of the method used, it is critical that it be
mounted straight and level on the frame rail. Units that are not level with the
frame rail may experience high vibration and subsequent component failures
that are not covered in any way by warranty.
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.

RigMaster LG200 Installation Manual
Section 2
August 2010 RigMaster Power International Ltd LG200 Service Manual
Preparation and Frame Rail Mounting
Preparing the LG200
2:1:0
Frame Mounting Hardware
2:2:0
Frame Rail Mounting
2:2:1
NOTE
Please note that the LG200 model unit is designed so a Diesel Particulate
Filter (DPF) may be installed after it has been mounted on a vehicle. Please allow
6 inches on the left side of the unit to accommodate the DPF if it is to be installed
at a later date.
2:1:0 Preparing the LG200
The LG200 unit is shipped on a wooden skid and should be uncrated near the
installation area with sufficient space to prepare the unit while on the skid.
It is much easier to prepare the unit prior to mounting it by installing the battery
cables, brass fittings, air conditioning, fuel and coolant hoses. The use of corrugated
split loom to protect all cables and hoses is highly recommended. Split loom also
makes your work look more professional, but will add some cost to the installation. it
is much easier to add loom during the preparation phase.
Remove the front cover to expose the left and right side panels. These panels should
then be removed to gain better access to the frame mounting components.
Install the fuel fittings to the bulkhead using thread sealant. Be sure to tighten the
return fitting fully before attempting to install the supply fitting. See section 7:3:0
for further information on fuel fitting installation.
2:2:0 Frame Mounting Hardware
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)

RigMaster LG200 Installation Manual
Section 2
August 2010 RigMaster Power International Ltd LG200 Service Manual
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).
Bottom of 5/8”
Hardened Washer
MARKING
Top of 5/8”
Hardened Washer
NO MARKINGS
Fig. 2-2
Fig. 2-1

RigMaster LG200 Installation Manual
Section 2
August 2010 RigMaster Power International Ltd LG200 Service Manual
The nut anchors (Fig 2-3) are designed to hold the two bottom lock nuts in position due to
the lack of space for tools. The anchors must be installed on the inside of the unit so that
the two offset flanges sit flush against the side of the
bulkhead (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

RigMaster LG200 Installation Manual
Section 2
August 2010 RigMaster Power International Ltd LG200 Service Manual
2:2:1 Frame Rail Mounting
Once the frame rail location has been chosen, and prior to installation, it is
important that you consult with the owner/operator to ensure they are satisfied
with the proposed placement of the APU.
Installation
1. Using a pallet jack (or similar lifting device), position the Main Unit against the
frame rail and slowly lower it until the upper bolt locations sit approximately
1/8” above the top of the rail.
CAUTION
Do not let the mounting bolts carry the weight of the APU until fully tightened.
2. Place the four frame grabbers into position. Keep in mind that the bolts
must be level with the trucks frame.
3. Pass the bolts through the components and hardware as shown in figure 2-3.
If the nylon nuts have been tightened and removed they must be replaced.
Do not lubricate the threads in any way.
4. Hand-tighten the four bolts evenly so that the frame spacers are flat
against the frame rail and the hardware is straight. Then proceed to use a
torque wrench to fully tighten the assembly. Do not use air tools or impact
guns during this process; hand tightening with the correct tools will yield much
better results. Uneven or over tightening the mounting hardware can cause
damage, so exercise caution when performing this step.
CAUTION
When installing, slotted holes in all mounting brackets must be on the
bottom and all bolts must be properly torqued to 75 foot pounds using a
torque wrench.
5. Double check that all mounting bolts are secure and remove the lifting device.

RigMaster LG200 Installation Manual
Section 3
August 2010 RigMaster Power International Ltd LG200 Service Manual
Installing the Bunk HVAC Unit
Preparation to Install the HVAC Unit
3:1:0
Mounting the HVAC
3:1:1
Ducting the Ventilation System
3:2:0
Independent Ducting
3:2:1
Vent Installation
3:2:2
Installation of Return Air Vent
3:2:3
Integrated Ducting
3:3:0
3:1:0 Preparation to Install the HVAC Unit
The HVAC unit dimensions are 16” wide by 12.5” long by 9.5” tall.
Before installing the HVAC unit it is important that you perform the following
steps:
1. Consult with the owner/operator to ensure they are satisfied with the mounting
location of the HVAC unit.
2. Remember to allow space to remove the air filter and service the unit. It is also
important to discuss and decide on a ducting configuration before drilling any
holes.
3. Ensure that there are no obstructions under the vehicle (A/C lines, conduit,
cross members, exhaust etc.). Do not drill through structural members within
or under the trucks floor. Choose a location that requires only the flooring
material be drilled.
4. The LG200 kit contains an information package in an envelope. This
package has an Owner’s Manual and other material that is useful to the
operator of the LG200 APU. Place the information package on the
dashboard of the vehicle so the operator of the vehicle receives it. This
envelope is in the kit box that contains the 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.

RigMaster LG200 Installation Manual
Section 3
August 2010 RigMaster Power International Ltd LG200 Service Manual
3:1:1 Mounting the HVAC Unit
The HVAC unit has a flush mount filter secured by two thumb nuts. Before
installation, see that there is enough room to remove the filter. Leave sufficient
clearance on all sides for proper air flow.
1. Drill holes for the air conditioning hoses, coolant hoses, condensation drain
tube and wiring. It is recommended that the holes be piloted with a 3/16” drill
bit prior to drilling the 1 1/4” holes with the hole-saw. After drilling use a file to
remove any sheet metal burrs that remain and protect edges with grommets
or slit hose. All holes can be drilled individual or grouped together for less
holes in sleeper cab. It is also very important to seal the holes with silicon to
prevent and fumes from entering the sleeper cab.
2. Attach the condensation drain tube to the bottom of the HVAC box using the
supplied hose clamp, usually found inside the owner’s envelope.
3. Lower the HVAC box into the cab of the truck and ensure that the drain
hose went through the corresponding hole.
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.

RigMaster LG200 Installation Manual
Section 3
August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation Manual
Section 3
August 2010 RigMaster Power International Ltd LG200 Service Manual
3:2:0 Ducting the Ventilation System
Independent and Integrated Ducting are the two methods of providing air from the
HVAC box to the bunk area. A great deal of thought and consideration should be
used before deciding how to perform the vent installation.
3:2:1 Independent Ducting
The first method uses separate ductwork included in the LG200 kit. We
recommend this independent ducting method because it provides the least
restriction to airflow from the HVAC box.
Install the flexible ducting by sliding it over the
output on the blower motor at one end and over
the louvered vent at the other. Excess ducting
material must be removed to ensure optimal air
flow.
4” Flexible Ducting
Fig. 3-4
Fig. 3-5
Method 1: Independent Ducting
Fig. 3-5

RigMaster LG200 Installation Manual
Section 3
August 2010 RigMaster Power International Ltd LG200 Service Manual
3:2:2 Vent Installation
The vent kicker is an important component when fitting the independent ducting
system; it promotes the circulation of vented air from floor to ceiling within the
sleeper. It can be installed one of two ways:
1. Recess Mounting (fig. 3-8) the air kicker requires that a square hole be cut in
the face of the bunk.
2. Surface Mounting (fig. 3-9) the air kicker requires that a 4 1/4 inch hole is
drilled in the face of the bunk.
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.

RigMaster LG200 Installation Manual
Section 4
August 2010 RigMaster Power International Ltd LG200 Service Manual
In situations where there is no space to
mount the air kicker and vent, a partial
fascia may be fabricated and added to
the bunk. Be sure to fold the edges if
using sheet metal so not to leave sharp
surfaces inside the cab.
Fig. 3-10
Painted Aluminum Sheet Metal
Air Kicker and Vent Assembly

RigMaster LG200 Installation Manual
Section 4
August 2010 RigMaster Power International Ltd LG200 Service Manual
3:2:3 Installation of Return Air Vents
The LG200 HVAC unit is capable of delivering approximately 278 cubic feet per
minute of cooled air. In order to supply the blower motor, a return air vent must
be installed if not already present. A 4 inch hole, or the equivalent in smaller
holes, is sufficient to supply the 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

RigMaster LG200 Installation Manual
Section 4
August 2010 RigMaster Power International Ltd LG200 Service Manual
3:3:0 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.
Using a Damper Valve
A “T” fitting with a flap to direct the air flow can be used to ensure proper air flow.
This is commonly referred to as a damper valve. Using a “T”fitting without a flap
will allow some air to escape through the OEM HVAC unit. A “Y”fitting may also
be used to direct the air into the vehicles vent system, which will reduce the amount
of air that escapes through the OEM HVAC unit if installed correctly.