Rigmaster MTS-T4-LG200 User manual

Owner's Manual
MTS-T4-LG200

LG200 Owner's Manual
Preface
Page 1 MTS-T4-LG200-Owners-Manual-052815
Congratulations on your purchase of the
RigMaster Auxiliary Power Unit.
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. We are confident you will be
satisfied with your new RigMaster Auxiliary Power Unit.
The following pages contain design features, principles of operation,
preventative maintenance procedures and troubleshooting guides. Please
review it carefully prior to starting and operating your RigMaster Unit. For
safety’s sake, please also heed all safety warnings and advisories found within
your Owner’s Manual.
Should you have any questions or concerns please contact your nearest
authorized RigMaster Power Dealer, or RigMaster Power International Ltd. at:
1-888-208-3101
(for Technical Support only)
Monday to Friday from 8:00 a.m. to 5:00 p.m. Eastern Standard Time
Or Visit Our Website:
www.rigmasterpower.com
Click: Customer Support, Support Materials, Technical Support
(for other technical information)

LG200 Owner's Manual
Preface
Page 2 MTS-T4-LG200-Owners-Manual-052815
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 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.

LG200 Owner's Manual
Preface
Page 3 MTS-T4-LG200-Owners-Manual-052815
Additional Publications
- Model LG200 APU Service Manual
- Model LG200 APU Installation Manual
Visit www.kohlerengines.com for Engine Owner & Service Manuals.
Licensed dealerships may review and download additional publications by
logging into their Dealer portal.
NOTE
Owner’s Manuals and APU Parts Lists are publicly accessible and downloadable:
go to www.rigmasterpower.com
hold your cursor over the “customer support tab” and select “support materials”.
This Manual is divided into sections by engine and assembly systems, with a
section dedicated to the preventative maintenance of the APU. For detailed
information on installation please refer to the “model LG200 APU Installation
Manual”. For detailed information on engine service please refer to the Kohler
Service Manual.
Read this entire Manual prior to performing service and maintenance procedures.
If you do not fully understand how to perform a process or procedure, or require
additional help please contact our Technical Support Department before
proceeding.
Technical Assistance
Before calling for technical assistance please have ready the following:
1. Current LG200 Service Manual
2. Model LG200 Serial Number
3. Unit Hour Meter Reading
4. Service & Repair History (if available)
Technical Support is available by
Telephone: [phone] or [phone]
Monday to Friday from 8:00 a.m. to 5:00 p.m. Eastern Standard Time
and
Website: www.rigmasterpower.com
(click: Customer Support, Support Materials, Technical Support)

LG200 Owner's Manual
Table of Contents
Page 4 MTS-T4-LG200-Owners-Manual-052815
Table of Contents
Principles of Operation
Page #
Preface –Additional Publications/Technical Assistance
1
Safety
5
Heater (Only applicable to those models WITH heat)
7
Air Conditioner
11
Pre-Start Inspection
13
Cabin Controller Description and Operating Instructions
14
Clock and Date Set-Up
20
Set Alarm Clock
21
AutoStart Features
22
FAULT CODES
24
Fuel System Description and Bleeding Procedures
28
Preventative Maintenance Schedule
33
Cross Reference Parts List
34
Normal Maintenance & Adjustment Instructions
Oil Change Instructions
35
Air Filter Change Instructions
38
Serpentine Drive Belt –Removal
39
Fan Belt –Removal and Adjustment
41
Cleaning Instructions
43
Cleaning –HVAC Filter
44
Troubleshooting
45
Warranty
RigMaster APU Limited Warranty
50
Maintenance Record
57
Notes
59

LG200 Owner's Manual
Safety
Page 5 MTS-T4-LG200-Owners-Manual-052815
1. Zero Energy State
NOTE: ZERO ENERGY STATE
To perform service, maintenance and repairs you must disconnect the RigMaster
from its battery source. In the recommended installation configuration the
RigMaster shares the battery bank with the vehicle's 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
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; failure to comply may
result in serious injury.
The safety cover switch (Figure 1)
is designed to prevent the
RigMaster Power APU from starting
when the engine cover is loose or
has been removed. When the
cover is down, the switch is in the
closed position. When the cover is
open or loose, the switch is in the
open position. The switch is
located at the very top of the unit
enclosure on the surge tank
bracket.
Figure 1 –Safety Cover Switch
3. AutoStart Automatic Start/Stop Feature
CAUTION: AUTOSTART FEATURE
Remember that a properly functioning RigMaster 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 RigMaster’s engine to start.
Please see the cabin controllers operating instructions for further information on
the AutoStart feature. You must deactivate this feature prior to refueling.
Safety Cover Switch

LG200 Owner's Manual
Safety
Page 6 MTS-T4-LG200-Owners-Manual-052815
4. Engine Hoist Points
NOTE: ENGINE HOIST POINTS
The Kohler engine has 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. Such use could result in an
explosion and personal injury, and will render the APU warranty null and void.
6. Starting with the Cover Off
CAUTION
Some installation or repair/diagnostic procedures require that the APU is started
with the engine cover off. Do not deactivate or 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 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.
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 RigMaster APU. 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.

LG200 Owner's Manual
Heater
Page 7 MTS-T4-LG200-Owners-Manual-052815
Heater
NOTE
This section is only applicable to those models WITH heat.
The RigMaster heating system is fully automatic. A constant comfort zone is
maintained with the temperature selector (see Cabin Controller Operation –
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).
The heater/air conditioner blower motor (fan) circulates the cab air through the
heater core pushing warm air into the bunk area. The coolant is then re-
circulated back to the RigMaster Unit.
This system is designed to maximize the bunk heating efficiency.
Figure 2 –Heater
Engine
Thermostat 82 °C
Water
Pump
Radiator Heater
Core
Red –High Temperature Supply Lines
Blue –Lower Temperature Return Lines

LG200 Owner's Manual
Heater
Page 8 MTS-T4-LG200-Owners-Manual-052815
Heating System
For heating, the APU’s 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 through the heater core.
Voltage at the J2 Connector Pin-1 on the power module will indicate if the water
valve is open or closed. (Closed=0 volts / Open=12.4 volts).
Figure 3 –Heating System
NOTE
Notice the coolant flow when the valve is open. The coolant will travel to the
HVAC box and then return on the opposite pipe.
Electronic Coolant Control Valve
The electronic coolant control valve motor shaft is a good indication if the valve is
opening when changing temperature modes. 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

LG200 Owner's Manual
Heater
Page 9 MTS-T4-LG200-Owners-Manual-052815
Frame Connection Layout
Figure 6 –Rear of Frame –Connection Layout
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.
SUPPLY from main unit
RETURN to main unit
Wiring Harness
Fuel Supply
(IN)
Fuel Return
(OUT)
#10 A/C Line
Connection
Engine Coolant
SUPPLY to
HVAC Box
#6 A/C Line
Connection
Engine Coolant
RETURN from
HVAC Box
Battery Cables

LG200 Owner's Manual
Heater
Page 10 MTS-T4-LG200-Owners-Manual-052815
Radiator Filling and Purging
Bleed from the
return side of the
heater core.
Figure 8 –HVAC Box
1. Using a radiator pressure tester, pressurize the system to 7 PSI.
2. At the HVAC box, loosen the lower hose clamp located on the heater core.
3. Carefully insert a flat screwdriver between the hose and tube until air starts
escaping.
4. Bleed air until coolant escapes.
5. Tighten hose clamp.
6. Remove pressure tester, and top up radiator and coolant reservoir.
7. Repeat if necessary.
8. Start the engine and turn heat on high setting.
9. 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.

LG200 Owner's Manual
Air Conditioner
Page 11 MTS-T4-LG200-Owners-Manual-052815
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.
WARNING!
ONLY CERTIFIED AIR CONDITIONING TECHNICIANS SHOULD SERVICE
THE AIR CONDITIONER.
HIGH PRESSURE VS. TEMPERATURE READINGS
High temperatures and pressures are approximate.
Readings within 10-15% of Figure 9 will deliver acceptable performance.
Air Conditioning Performance
Figure 9 –A/C Performance
SUCTION PRESSURES –LOW SIDE
Usual low side pressure 15-40 PSI depending on outside temperature and
humidity.
DISCHARGE PRESSURES –HIGH SIDE
Usual high side pressure 150-300+ PSI depending on outside temperature and
humidity.
AIR CONDITIONING
SPECIFICATIONS
Refrigerant Type
R134A
Volume of Refrigerant (24,000 BTU HVAC)
1.0 lb.; (16 oz.; 0.4 Kg.)
Compressor Oil Type
SP46 to 100 PAG Compressor Oil
Compressor Oil Capacity (already filled with
3.3 oz.; add an extra 3 oz. at time of charging)
6.3 fl. oz.; (186.3 cc.; 186.3 mL.)
Evaporator Temperature Switch
Range = 30°F to 42°F (-1°C to 7°C)
Binary Pressure Switch
Range = 28 to 450 psi

LG200 Owner's Manual
Air Conditioner
Page 12 MTS-T4-LG200-Owners-Manual-052815
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. The
heater/air conditioner blower motor (fan) then activates, and cool dry air is forced
into the bunk area.
Figure 10 –Air Conditioner
LEGEND
PRESSURE
PART #
A
Condenser
High
LG9-001
B
Compressor
High/Low
LG9-004
C
Receiver Drier
High
LG9-007
D
Evaporator
High
LG9-002-01
E
Thermostatic Switch
High/Low
RP9-113
F
Bulkhead Section of Frame
N/A
LG10-001
G
A/C Line –Compressor to Condenser –#8
High
LG9-405
H
A/C Line –Condenser to Bulkhead –#6
High
LG9-407
I
A/C Line –Bulkhead to Evaporator
High
LG9-404
J
A/C Line –Evaporator to Bulkhead
Low
LG9-403
K
A/C Line –Bulkhead to Compressor –#10
Low
LG9-406
L
Expansion Valve
High/Low
LG9-003

LG200 Owner's Manual
Pre-Start Inspection
Page 13 MTS-T4-LG200-Owners-Manual-052815
Pre-Start Inspection
with the RigMaster TURNED OFF
1. Remove the cover.
2. Visually inspect the unit for evidence of oil or coolant leakage.
3. Check the oil and add oil if necessary.
4. Check the tension and wear of all belts.
5. Check the mounting bolts and tighten if necessary.
6. Check for broken, corroded, or loose connectors and/or wires.
7. Check the physical condition and tightness of all hoses and hose clamps.
8. Replace and secure the cover.

LG200 Owner's Manual
Cabin Controller
Page 14 MTS-T4-LG200-Owners-Manual-052815
Cabin Controller Operating Instructions
Before beginning the start-up procedure it is necessary to know how to operate
the cabin controller.
Figure 11 –Cabin Controller
Controls
The Cabin Controller consists of two sections:
1. LCD (Liquid Crystal Display) with basic control buttons.
2. Advanced control buttons.
The LCD and basic control buttons are always visible to the user.
The advanced control buttons are concealed behind a semi-circular cover.
The controller also contains a LED indicator. When the LED is green, the system
is active; if it glows red then the system is detecting a problem and an error
message will scroll across the bottom of the LCD screen. The LED is turned off
in low power mode.
1. Basic Controls and Functions
Basic controls contain the following buttons:
1. Start system.
2. Stop system.
3. Up arrow (Red triangular button).
4. Down arrow (Blue triangular button).

LG200 Owner's Manual
Cabin Controller
Page 15 MTS-T4-LG200-Owners-Manual-052815
If the unit is in advanced mode, pressing any of the basic control buttons will
return the unit to basic mode. Alternately, the control panel will return to basic
mode after two minutes of inactivity.
If the unit shows the current temperature, pressing either the up or down button
will show the set point temperature without changing it. Once the set point is
indicated, pressing up or down buttons will adjust the set point. The new set
point takes effect only when display is returned to show internal temperature.
2. Advanced Controls and Functions
The advanced controls are as follows:
1. Power button controls whether the module is active. In inactive mode all
system functions including engine start, climate control and AutoStart are
disabled. You can still see the temperature reading, current time and use
the alarm clock function.
2. Fan button is used to change fan setting. Pressing the button cycles
between auto, high, med, low, and off settings.
3. Clear button will take you back to the main screen without saving any
information.
4. Clock button is used to set the time/date/day menu features.
5. Alarm button is used to set the alarm menu features.
6. AutoStart button is used to access and set AutoStart menu features.
7. Mode button is used to activate the different operational modes. Pressing
the mode button will back you out of a menu mode, but does not save the
information just entered.
8. Ext. Temp button will display the external temperature on the LCD when
pressed.
9. Oprtg. Hours button will display the total hours of use.
10. Select button enters the data and advances the program to the next menu
step. 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.

LG200 Owner's Manual
Cabin Controller
Page 16 MTS-T4-LG200-Owners-Manual-052815
Cabin Controller LCD Display
The Cabin Controller LCD has a white backlight that turns on each time a user
presses a button and will remain on for 2 minutes after the last button has been
pushed. The backlight will turn red when there is an alarm condition. A fault
code will be displayed if the unit shuts down or fails to start.
The LCD displays 4 groups of information:
1. System information.
2. Temperature information.
3. Clock, day and alarm information.
4. Alphanumeric display for additional information.
1. System Information:
Figure 12 –Cabin Controller LCD Display –Controls
SYSTEM ALARM symbol will flash if an alarm condition has occurred. The
alphanumeric display along the bottom of the display screen will show more
information about the alarm. (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.
AUTOSTART symbol will display and flash if temperature AutoStart is enabled
(when engine is off). If the engine has been started through AutoStart, this
symbol is constantly on while the engine is running.
HEATING symbol will display when the system is in heating mode.
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.

LG200 Owner's Manual
Cabin Controller
Page 17 MTS-T4-LG200-Owners-Manual-052815
2. Temperature Information:
Figure 13 –Cabin Controller LCD Display –Temperature
This area indicates the internal (or external) temperature and can be
programmed to display in either “Celsius” or “Fahrenheit”.
Internal temperature is shown if EXT TEMP and SET TEMP symbols are not
illuminated. Pressing the Ext. Temp button will momentarily display the outside
temperature. After 5 seconds, the display will default back to showing the internal
temperature.
EXT TEMP symbol will flash when showing external temperature. After a few
seconds the display returns to show internal temperature.
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.

LG200 Owner's Manual
Cabin Controller
Page 18 MTS-T4-LG200-Owners-Manual-052815
3. Clock and Alarm:
Figure 14 –Cabin Controller LCD Display –Clock & Alarm
This is a 12:00 hour clock system with AM/PM symbols and 7 symbols indicating
day of the week: MO, TU, WE, TH, FR, SA, SU.
CLOCK symbol appears when the current time is showing.
ALARM symbol appears to indicate that the alarm setting is showing. Pressing
the alarm button allows you to set the alarm. The alarm symbol flashes when the
alarm has been set.
TIME AUTOSTART symbol appears if the display shows time AutoStart setting.
It flashes if Time AutoStart is set.
4. Additional Information/Message Area:
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.