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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.

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Summary of Contents for MTS-T4-LG200

Page 1: ...Installation Manual MTS T4 LG200 ...

Page 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...

Page 3: ... 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 1...

Page 4: ...sed 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...

Page 5: ... 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 th...

Page 6: ...hnicians 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 di...

Page 7: ...e 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 i...

Page 8: ... 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 fr...

Page 9: ...t 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 Th...

Page 10: ... 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 ...

Page 11: ...ned 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 ...

Page 12: ...olts 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 ti...

Page 13: ... 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 drill...

Page 14: ... 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 HV...

Page 15: ...RigMaster LG200 Installation Manual Section 3 August 2010 RigMaster Power International Ltd LG200 Service Manual ...

Page 16: ...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 m...

Page 17: ...f 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 unobs...

Page 18: ...ervice 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 ...

Page 19: ...ing 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 ...

Page 20: ...er 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 t...

Page 21: ...ary to either route the cables behind a cabinet or wall or surface run the cable securing it to prevent damage When routing the cables avoid sharp edges and protect the cable from damage with grommets and or wire loom See that the bunk and cabinetry will not make contact with the control panel when folding Use some self tapping screws to secure the mounting bracket to the wall Take your time to ma...

Page 22: ...al look Figure 4 4 The communication cable is a Category 5e shielded cable with two RJ 45 connectors at each end The cable should be attached to the control panel and routed to the power module Coil up the excess cable and secure it with wire ties Connect the cable to the power module Connecting the electronic control system to live wires may cause damage Longer Category 5e communication cables ma...

Page 23: ... The kit includes the following components DESCRIPTION QTY 12 ft 3 5 m heater hoses 2 3 8 NPT to 5 8 hose fittings 2 Hose clamps 10 4 NOTE Mark the coolant supply line at both ends to prevent the two coolant hoses from being accidentally reversed when connecting them to the water valve The connections from the HVAC unit to the engine enclosure are as illustrated in Figure 5 1 and Figure 5 2 Care m...

Page 24: ...or optimum heat exchange properties Care should be taken when connecting and removing the air conditioning lines because of the brittle nature of aluminum 6 1 0 Installation of the A C Refrigerant Hoses WARNING Cross contamination with other refrigerants will cause damage to this air conditioning system Avoid breathing air conditioning refrigerants and lubricant vapor mist Exposure may irritate ey...

Page 25: ...sure to leave room between the compressor hoses in the engine enclosure so that they do not rub together There are three AC lines inside the main unit that need to be installed Be sure not to bend any of the hard AC lines while installing to avoid the possibility of future leaks There is a slot A cut out from the engine plate to support the low side line Fig 6 2 A Fig 6 2 Fig 6 3 ...

Page 26: ... bulkhead when tightening the fitting on the outside of the bulkhead this will prevent the fitting on the inside from rotating out of alignment 1 Install the two 6 o rings on the 6 refrigerant hose LG9 404 High Side and connect it to the bulkhead first Hand tighten the fitting and torque to between 21 and 27 ft lbs Route the hose and connect it to the expansion valve 2 Install the two 10 o rings o...

Page 27: ...e filled new 4 3 fl oz 127 cc 127 mL LEGEND PRESSURE Part Number A Condenser High LG9 001 B Compressor High Low LG9 004 C Receiver Dryer High N A D Evaporator High LG9 002 E Thermostatic Switch High Low RP9 113 F Bulkhead Section of Frame N A LG10 001 G AC Line Compressor to Condenser 8 High LG9 400 H AC Line Condenser to Bulkhead 6 High LG9 402 I AC Line Bulkhead to Evaporator High LG9 404 J AC L...

Page 28: ...ual High Pressure vs Temperature Readings High temperatures and pressures are approximate Readings within 150 300psi the chart in Figure 6 4 will deliver acceptable performance Suction Pressures Low Side Common low side pressure will be between 15 40 psi depending on ambient temperature and humidity Figure 6 4 ...

Page 29: ...tion at the fuel tank or the crossover that links both tanks When using this method a check valve must be installed on the LG200 supply hose as close to the source as possible to prevent the vehicles engine from draining the APU fuel supply 7 2 1Fuel Pick Up Tube The standard method is to install a separate fuel pickup This method requires a fuel pickup tube A check valve is not necessary when usi...

Page 30: ... hose clamps 4 1 4 female NPT to hose fitting 1 The following illustration shows a typical fuel system hook up The same principle can also be applied at the crossover junction NOTE The check valve has an arrow indicating the correct direction of fuel flow Try to keep the arrow on the valve in view this will help when troubleshooting 7 2 0 Installation of the Fuel Fittings at the Fuel Tanks Figure7...

Page 31: ...nual NOTE 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 Figure 7 3 Fuel Fitting Diagram Fuel Fittings at the Crossover Fuel Fittings at the Tank ...

Page 32: ...nual Section 7 August 2010 RigMaster Power International Ltd LG200 Service Manual 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 ...

Page 33: ...he right hand Phillips head bleed screw Figure7 6 4 Place a rag on the underside of the fuel bowl to collect any diesel that spills 5 Manually prime the fuel bowl using the spring loaded priming lever located on the underside of the priming pump 6 Allow all of the air to escape the fuel bowl at the bleed screw 7 Observe a clean stream of diesel leaving the fuel bowl and retighten the bleed screw T...

Page 34: ...ise The flex pipe has been fitted with a thermal blanket which also helps to keep noise levels down NOTE Extension pipe elbow solid pipe not flex pipe can be added to the exhaust system to direct the exhaust away from the sleeper A maximum of 10 feet including the muffler can be added to the exhaust system without creating a harmful back pressure See that any extension pipe is securely fastened 45...

Page 35: ...ecomes available The DPF will take up approximately three more inches in width than the current muffler does Please have this in mind when installing a unit 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...

Page 36: ... LG200 Electrical Connections CAUTION Before making or removing any electrical connections including the power module and the cabin controller ensure that the battery source is not connected to the LG200 Failure to do so may cause damage to the electronic controls The following electrical connections are made between the engine wiring harness and the power module at the AC unit The J terminals are...

Page 37: ...he LG200 will shut down 3 Pin Exterior Temperature Sensor Ext Sensor Figure9 1 Connect the 3 pin temperature sensors J connector to the power module The exterior temperature sensor can be routed to the exterior through the same hole as the 1 20V cable and engine wiring harness If this is not ideal a 3 16 1 4 diameter hole may be drilled independently for the sensor This should be drilled after the...

Page 38: ...er module Coil any excess cable and secure it with wire ties Connect the 8 pin communication cable to the J3 terminal 9 6 0 DPF Backpressure Monitor Wire The LG200 is designed to accommodate a Diesel Particulate Filter as an optional upgrade An exhaust backpressure monitor will be supplied with the kit The back pressure monitor integrates with the silver power module bearing the part number RP50 2...

Page 39: ... Only persons qualified to carry out electrical and mechanical servicing should undertake this work Do not connect the batteries until the installation is completely finished and you are ready to perform the pre start inspection in Section 12 10 1 0 Introduction to Installing the Battery Cables Both battery cables are supplied with eye terminals and shrink tube The smaller eye terminal comes preas...

Page 40: ...ry cable should be located on a separate battery than the negative cable The LG200 positive battery cable should be on an independent post i e there should be no other line or load terminals connected to the same stud as the LG200 s positive battery cable 200 Amp Fuse 1 Install the battery cables on the LG200 engine compartment battery studs and route them to the battery box ensuring that the cabl...

Page 41: ...necting the battery cables to the vehicles batteries make sure all connections are made at the power module and cabin controller first Route the battery cables to the battery compartment and cut the excess cable Fit the shrink tube to the cables and connect the 3 8 terminals Connection 1 Positive cable to the vehicles batteries Figure 11 4 Ensure that the positive battery terminal is clean and con...

Page 42: ...0 Test the Air Conditioning System 11 4 0 Test the Alternator 11 5 0 Mark the Serial Number Placard 11 6 0 Complete the Installation Check List and Warranty Registration 11 6 1 Diesel Particulate Filter Registration 11 6 2 11 1 0 Introduction It is important that you ensure all steps are complete before performing the start up procedure If you require assistance in completing any of the following ...

Page 43: ...e 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 m...

Page 44: ...ach time a user presses a button and will remain on for 2 minutes after the last button that 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 additiona...

Page 45: ... in this area if the fan is set to off 2 Temperature Information 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 sho...

Page 46: ...mbol 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 This line is used to show extra information in the basic mode error messages to provid...

Page 47: ... 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 display will show the set point instead of internal cabin temperature The set point is stored without a need to press any other buttons NOTE The manual temperature control ranges from 59 F 90 F 15 C to 32 C The system will remember the last set temperature wh...

Page 48: ... or RIGHT scroll button to adjust Alarm Clock minutes Press SELECT button Alarm Clock minutes will stop flashing and am pm will start flashing Press LEFT or RIGHT scroll button to change Press SELECT button Press LEFT or RIGHT scroll button to turn Alarm clock on off Press SELECT button to save settings and return to menu or press MODE to return to menu without saving When enabled ALARM symbol is ...

Page 49: ...uld set the clock Press SELECT button after each entry Press LEFT or RIGHT scroll button to adjust AutoStart Day as required Press SELECT button Press LEFT or RIGHT scroll button to locate On Off Press SELECT button to save settings or press MODE button to return to menu without saving NOTE When enabled Time AutoStart symbol will be flashing Automatic Temperature Control Start Up Shut Down will st...

Page 50: ...ate and temperature based AutoStart All that is necessary to ensure that low battery AutoStart functions is to leave the LG200 engine OFF and the cabin controller powered on active mode Version Display Press MODE button Current version of the Power Module software will appear on the screen Press MODE or SELECT to return Electronic Control Operation and Fault Codes The LG200 s electronic control wi...

Page 51: ...responding Failed Power Module Error Code 7 Engine Start Failure Engine did not start Automatic start is disabled until operator presses select button Bad glow plug relay Bad starter relay Failed glow plug Lack of fuel Error Code 8 No Communication Error Communication between control panel and power module is lost Engine will not run until communication is re established Communication Cable Damage...

Page 52: ...he programmed range Set default to OFF from factory The LG200 has been programmed not to start when the external temperature is outside a preprogrammed range Error Code 16 Module Reset Set Clock Power to the cabin controller has been lost Reset clock Error Code 17 Service Exhaust Filter for units equipped with Diesel Particulate Filters Level 1 Service Filter requires maintenance Proceed to an aut...

Page 53: ...ace and secured See that the belts are in place and tensioned 11 4 0 Test the Air Conditioning System CAUTION Do not operate the unit in the air conditioning mode with any cover removed High pressures and temperatures will result from reduced air flow across the condenser and radiator Set the controller for a temperature lower than that in the cab to activate the air conditioning Start the engine ...

Page 54: ...plete a thorough inspection and file a warranty registration electronically The 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 Chec...

Page 55: ...when using the tie cables Make sure there is loom around the cables hoses that might have a chance to rub on the truck s frame or brackets Muffler Assembly If the muffler tail pipe is located under the bunk then additional piping must be added to avoid exhaust entering the cab HVAC Box Control Panel Make sure all ground wires are secured to the HVAC box Make sure a grommet or loom is used to prote...

Page 56: ... 2 Diesel Particulate Filter Registration 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 ...

Page 57: ... Optional See Section 2 2 1 Assorted Self Tapping Screws Electrical Tape 12 2 0 Installation Tools List Wrenches Sockets1 4 Drive Screwdrivers 5 16 1 4 Flat Head small thin 3 8 5 16 Flat Head small 7 16 3 8 Flat Head medium 9 16 8mm Flat Head large 5 8 10mm Philips Head medium 11 16 3 4 Sockets 3 8 Drive Hole Saws 7 8 7 16 1 1 2 diameter 1 1 2 4 1 2 diameter 1 1 16 9 16 Arbor with 3 16 pilot 1 1 8...

Page 58: ...t transmission jack or equivalent lifting device with a minimum weight capacity of 650 lbs approx 300kg 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 ...

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: ...td LG200 Service Manual Printed in Canada RigMaster Power International Ltd 1320 Ellesmere Rd Unit 9 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 ...

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