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LG200 Owner's Manual

Fuel System

Page 29

MTS-T4-LG200-Owners-Manual-052815

Fuel Filter Replacement Procedure

1.  Shut unit off and ensure unit will not start up automatically.

2.  Remove fuel filter on unit.

3.  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.

4. Re-install fuel filter.

5. Tighten filter.

Figure 17

– Fuel Filter

Air Relief Valve

Bearing

Cartridge

Rubber Element

Filtering Element

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Summary of Contents for MTS-T4-LG200

Page 1: ...Owner s Manual MTS T4 LG200 ...

Page 2: ......

Page 3: ...isfied 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 co...

Page 4: ... 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 ...

Page 5: ...led 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 befo...

Page 6: ... 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 Ins...

Page 7: ...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 Fig...

Page 8: ...y 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...

Page 9: ...ated 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 maximi...

Page 10: ...r 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...

Page 11: ...e 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 ...

Page 12: ...e 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...

Page 13: ...s 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 Refrig...

Page 14: ... 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 Condens...

Page 15: ...ally 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 ...

Page 16: ...rol 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...

Page 17: ...e 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 a...

Page 18: ...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 tem...

Page 19: ...T 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 whenev...

Page 20: ...dicate 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 b...

Page 21: ...control will display Engine Running for 5 seconds and ENGINE RUNNING symbol will turn on Engine Stop Press STOP button The screen will initially display Stopping and then change to Stopped once the operation is complete The Engine Running symbol will turn off Temperature Control Press UP or DOWN red blue buttons to adjust temperature set point on the display When editing the set point the LCD disp...

Page 22: ...ll stop flashing and Clock minutes will start flashing 5 Press LEFT or RIGHT scroll button to adjust Clock minutes 6 Press SELECT button Clock minutes will stop flashing and AM PM will start flashing 7 Press LEFT or RIGHT scroll button to change 8 Press SELECT button AM PM will stop flashing and Day of week will start flashing 9 Press LEFT or RIGHT scroll button to change 10 Press SELECT button Da...

Page 23: ...l button to turn Alarm clock on off 10 Press SELECT button to save settings and return to menu or press MODE to return to menu without saving When enabled ALARM symbol is flashing Fan Speed Control 1 Press FAN button to adjust fan speed 2 Press the FAN button to cycle through fan settings AUTO OFF AUTO ON FAN LOW FAN MEDIUM FAN HIGH FAN OFF There is no need to press any other buttons to confirm AU...

Page 24: ...T button to continue MODE to exit 3 Press LEFT or RIGHT scroll button to adjust AutoStart hour as required 4 Press SELECT button 5 Continue to set the AutoStart Minutes and AM PM as you would set the clock See Section Clock and Date Set Up 6 Press SELECT button after each entry 7 Press LEFT or RIGHT scroll button to adjust AutoStart Day as required 8 Press SELECT button 9 Press LEFT or RIGHT scrol...

Page 25: ...fter enabling AutoStart temperature AutoStart Feature Low Battery Automatically starts up the APU to charge the truck battery if it gets low 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 trained facility Set Automatic Start Up Low Battery Lo...

Page 26: ...ssure Low oil pressure Low oil level Wiring damaged Faulty switch Dirty oil filter Error Code 3 Battery Low Voltage Low battery voltage Start system immediately to charge batteries Damaged or broken battery cables failed battery Excessive load on batteries Faulty charging system Error Code 4 Engine Run Failure Engine may have started but didn t run properly AutoStart is disengaged attempt manual s...

Page 27: ...his is optional Error Code 10 Run Timeout APU shuts down at three 3 hours of running when the AutoStart Time Day Setting is used Engine will only run for three 3 hours when set on AutoStart Time Day Error Code 11 Check Power Module Fuse Very low battery voltage detected at the power module Check 20 Amp fuse and J1 connector at the power module located under the bunk on the HVAC unit Error Code 12 ...

Page 28: ... replacement Error Code 18 Replace Exhaust Filter for unit equipped with Diesel Particulate Filters Replace exhaust filter if unit is DPF equipped if not DPF equipped then power module failure likely See authorized Dealer for exhaust filter replacement or power module diagnosis replacement Error Code 19 Please Register Unit Unit will run for four 4 hours after installation Registration code must b...

Page 29: ...g excess current Unplug run solenoid power with jumper wire attempt again If code returns A C clutch problem Error Code 26 BH Overcurrent Phantom Code block heater is not operated by power module output no output on J1 Pin 7 May indicate damage to power module circuit board Possible solution Unplug J1 connector for 30 seconds Error Code 27 Power down to clear overcurrent Power must be turned off w...

Page 30: ... interconnected with the vehicle s fuel lines the APU s fuel supply line requires that a check valve be installed If using the standard pick up tube a check valve is not necessary as the APU s fuel system is now independent of the vehicle NOTE This type of fuel system does not de aerate itself all air must be bled from the hoses and components There is an air bleed screw located on the filter asse...

Page 31: ...sure unit will not start up automatically 2 Remove fuel filter on unit 3 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 4 Re install fuel filter 5 Tighten filter Figure 17 Fuel Filter Air Relief Valve Bearing Cartridge Rubber Element Filtering Element ...

Page 32: ...to manually turn the engine by hand so that the engine camshaft allows full stroke on the lift pump 4 Continue to pump the lever until the air relief valve shows signs of fuel passing out of the bleed screw 5 Tighten the air relief valve bolt 6 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 NOTE...

Page 33: ...l Fuel System Page 31 MTS T4 LG200 Owners Manual 052815 Figure 18 Lift Pump WARNING Do not use priming lever when engine is cranking or running Only use priming lever when engine is off Fuel Supply to Filter Priming Lever ...

Page 34: ...an result in the corrosion of metallic components and the premature failure of seals RME is a powerful solvent Damage may occur if it comes into contact with paint CAUTION DO NOT use vegetable oil as a biofuel for this engine No legal liability can be accepted for failure attributable to operating products with fuels for which the products were not designed and no warranties or representations are...

Page 35: ... X Inspect Fan Belt Condition Adjustment X Inspect Serpentine Belt for wear X X X X Check all Fasteners for tightness X Valve Clearance Inspection Intake and Exhaust valve clearance are both 0 0078 X X Vibration Mounts pry up on the engine mount plates there should be less than 1 of upward movement X Change Engine Oil and Filter X X Check HVAC unit filter clean if necessary X X Clean engine compar...

Page 36: ...02 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 SERPENTINE DRIVE BELT BRAND PART No RigMaster LG8 006 FAN BELT BRAND PART No RigMaster KL8 002 Kohler ED0024403160 S RECEIVER DRIER ELEMENT BRAND PART No RigMaster LG9 007K GLOW PLUGS BRAND PART No RigMaster K 004 Kohler ED0021000890 S ...

Page 37: ...ilter 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 Oil Viscosity vs Temperature 15W30 and 15W40 are the most commonly used grades of oil Figure 19 Oil Viscosity vs Temperature NOTE Recommended Lubricant for Fuel with Low Sulfur Content API CF4 CG4 Regions in which diesel normally has a low sulfur con...

Page 38: ...ng 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 from occurring Oil Fill Cap Dipstick Figure 20 Oil Fill Cap and Dipstick Procedure 1 Remove front cover ensuring proper operation of the cover safety switch or disconnect battery pr...

Page 39: ... the lubricating oil system with the recommended quantity of engine oil through the fill port 11 Replace the oil fill cap 12 Run the engine until operating temperature has been reached 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 Make sure engine is stopped on a level grade and cool so oil has...

Page 40: ...place the Air Filter 1 Remove the cover from the air filter 2 Remove the air filter element and clean the inside of the air cover Allow the air cover to dry completely 3 Replace air filter element Use only manufacturer approved filters 4 Reinstall the air filter cover and latches NOTE The air filter should be inspected every 500 hours of operation NOTE Before test running the engine inspect the fi...

Page 41: ... 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 COMPONENT PART 1 Flywheel Drive Pulley LG8 007 2 Compressor LG9 004 3 Serpentine Belt LG8 006 NOTE The Serpentine belt is a stretch fit belt so there is no need for tension adjustment 3 2 1 ...

Page 42: ... with 7 16 Socket Wrench or 12mm Socket Wrench 3 Using a 3 8 ratchet insert into tensioner bracket 4 Lift up on the tensioner bracket while sliding the belt off the main engine pulley Note exercise caution in this step to prevent possible personal injury 5 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 6 Remove...

Page 43: ...ed on all pulleys before starting the engine DO NOT USE YOUR HANDS OR A J BAR 9 Reinstall the belt guard Fan Belt Removal and Adjustment WARNING A DIESEL ENGINE MAY START AT ANY TIME WHEN ITS CRANKSHAFT IS TURNED THIS INCLUDES TURNING BY WRENCH OR BY HAND Figure 25 Alternator NOTE The serpentine belt requires NO adjustments The A C compressor is in a fixed location so there is no need for adjustme...

Page 44: ... 7 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 NOTE The following parts are not shown in the picture but make sure that the wire to the st...

Page 45: ...ly wash the interior of the APU being careful to keep sprayer 2 feet 24 inches from any component 3 Before replacing the front cover you will have to spray all electrical connections 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 spr...

Page 46: ...he 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 There are two models of the HVAC Box with automotive style heating see Figure 27 and without automotive style heating see Figure 28 The HVAC filter does not need to be replaced unless it is damaged The filter should be cleaned every...

Page 47: ... 4 Replace strap 5 Check for power at starter solenoid Engine Cranks but does not Start 1 Clogged air filter 2 Clogged fuel filter 3 Run solenoid not operating 4 Glow plug or glow plug relay 5 Lift pump faulty 6 Governor Assembly 1 Replace air filter 2 Replace fuel filter 3 Check 12V at run solenoid 4 Check for power at the glow plugs and relay 5 See fuel system section 6 See Kohler Service Manual...

Page 48: ...ternator or A C compressor 1 Check speed sensor resistance and gap 2 Replace fuel filter 3 Inspect wiring connection and connectors White or Blue Smoke 1 Engine oil too full 2 Coolant in combustion chamber 1 Inspect correct oil level 2 Possible failed head gasket Engine Runs Rough 1 Air filter clogged 2 Fuel filter clogged 3 Fuel leak 4 Worn clogged fuel injectors 5 Engine in poor condition 1 Chec...

Page 49: ...nator output Troubleshooting Fuel System SYMPTOM PROBABLE CAUSE REMEDY COMMENT Fuel Odor or Leak 1 Loose fuel fittings 2 Damaged fuel line 3 Damaged fuel filter bowl 4 Fuel lift pump leak 1 Tighten clamps 2 Replace fuel hose 3 Replace fuel filter assembly 4 Replace lift pump No Start Condition fuel getting to cylinders 1 Dirty fuel 2 Clogged fuel filter 1 Clean fuel system 2 Replace fuel filter 15...

Page 50: ...engine thermostat Coolant Loss 1 System over filled 2 External hose leak 3 Internal hose leak 4 Failed head gasket 1 Check coolant level 2 Check coolant hoses from main unit to the HVAC box 3 Check coolant hoses inside the engine compartment 4 Check replace head gasket Poor Circulation 1 Water pump not operating properly 2 Cooling system restricted 1 Check water pump and belt tension 2 Check for w...

Page 51: ...lectronic coolant control valve faulty 1 Set Controller temperature 2 Check for 12V at A C clutch control output 3 Check system pressures 4 Clean radiator condenser 5 Check the compressor and fuse 6 Replace thermostatic switch 7 Check fan relay and fuse 8 Replace electronic coolant control valve Troubleshooting Serpentine Drive Belt SYMPTOM PROBABLE CAUSE REMEDY COMMENT Belt has Premature Wear 1 U...

Page 52: ... terms and conditions limitations and provisions of the limited warranty This limited warranty is governed by the laws of the Province of Ontario Canada and any claims or disputes arising out of this limited warranty shall be governed by the laws of the Province of Ontario Canada Warranty Obligation During the warranty period RigMaster Power will repair or replace at its option the RigMaster APU c...

Page 53: ...at ALL RigMaster APU components are in proper working order at the time of installation The manufacturer is not responsible for failed components that are a result of improper installation In the event the Owner Fleet wishes to install the APU themselves it is the Dealer s responsibility to provide installation instructions to the Owner Fleet with the sale of the APU In order to validate your RigM...

Page 54: ...soever asserted against RigMaster Power International Ltd arising out of or in any way related to negligence on the part of the user or Owner of the Rig Master APU Warranty Claims Failed or defective parts must be inspected and their replacement installed by an authorized RigMaster Dealer The manufacturer reserves the right to inspect failed or defective parts prior to a decision on any claim unde...

Page 55: ...ber ready Kohler Engine Warranty The RigMaster s Kohler engine is warrantied against manufacturing defects in materials or workmanship for 3 years from date of purchase or 2000 hours of use whichever occurs first The Kohler engine warranty begins at the same time the RigMaster unit is registered as being in service by an authorized RigMaster Power Dealer see Warranty Registration below RigMaster P...

Page 56: ...er Failure to properly inspect the APU for certification and any damages resulting from improper installation shall render the warranty void The installing Dealer is responsible for all repairs resulting from improper installation It is the Dealer s responsibility to check the warranty registration of any RigMaster APU prior to performing any warranty repairs Any warranty claims filed for RigMaste...

Page 57: ... means of a written notice with both original Owner s information and new Owner s information so all records can be updated for warranty purposes When the APU has been removed and sold to a new Owner with remaining warranty the Dealer must transfer and inspect the APU installation and notify RigMaster Power International Ltd in writing of the transfer of warranty Customer Assistance Procedure To o...

Page 58: ...ult 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 M1P 2X9 Fax 416 293 5104 or Email rigmastertechsupport rigmasterpower com ...

Page 59: ...G200 Owner s Manual Maintenance Record Page 57 MTS T4 LG200 Owners Manual 052815 Maintenance Record Date Hour Meter Reading Maintenance Performed Remarks 200 hrs 400 hrs 600 hrs 800 hrs 1000 hrs 1600 hrs ...

Page 60: ...LG200 Owner s Manual Maintenance Record Page 58 MTS T4 LG200 Owners Manual 052815 Date Hour Meter Reading Maintenance Performed Remarks 200 hrs 400 hrs 600 hrs 800 hrs 1000 hrs 1600 hrs ...

Page 61: ...LG200 Owner s Manual Notes Page 59 MTS T4 LG200 Owners Manual 052815 Notes ...

Page 62: ...LG200 Owner s Manual Notes Page 60 MTS T4 LG200 Owners Manual 052815 Notes ...

Page 63: ......

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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