LG200 - All Models (with cat/Perkins engines)
Contents
1. 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 SSS aS eee Page 2 LG200 Owners Manual 071714 LG200 Owner s Manual Additional Publications Model LG200 APU Service Manual Model LG200 APU Installation Manual See your Perkins or Caterpillar Dealer for these other publications Perkins Service Manual 400C Series Part Number RENR9825 The tier 4a engine model 400D Series Perkins User s Hand Book 400 Series Part Number 100816245 Caterpillar C0 5 Industrial Engine Service Manual Licensed dealerships may review and download additional publications by logging into their Dealer portal 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 On this web page also note PARTS LISTS ALL MODELS AS OF DATE this lists all parts ever used in our APU s All parts are available to order This Manual is divided into sections by engine and assembly systems with a section dedicated to the preventative maintenance of the APU For detailed2. 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 Page 15 LG200 Owners Manual 071714 LG200 Owner s Manual Cabin Controller Operation of the Cabin Controller Functions To Turn Power On Press the POWER button to activate the system When the power switch is activated the LCD display will light and SYSTEM ON symbol will turn on active mode Press POWER button again for 2 seconds to switch the unit back to low power mode Engine Start Press START button The control panel will display the status of the operation as it occurs Glow Plug and a countdown will display on the screen Once the countdown is complete the display will read Cranking as the APU starts up and the ENGINE RUNNING symbol will blink Once started the 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 display will show the set point instead of internal cabin temperature The set point is stored without a need to
3. information on installation please refer to the model LG200 APU Installation Manual For detailed information on engine service please refer to either the Perkins or Caterpillar 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 amp Repair History if available Technical support is available by Telephone 888 208 3101 or 416 201 0040 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 Page 3 LG200 Owners Manual 071714 LG200 Owner s Manual Table of Contents Table of Contents Principles of Operation Page Preface Additional Publications Technical Assistance 1 Safety 5 Heater 7 Air Conditioner 8 Pre Start Inspection 10 Cabin Controller Description and Operating Instructions 11 Clock and Date Set Up 17 Set Alarm Clock 18 AutoStart Features 19 FAULT CODES 21 Fuel System Description and Bleeding Procedures 25 Preventati
4. press any other buttons The manual temperature control ranges from 59 F to 90 F 15 C to 32 C The system will remember the last set temperature when the APU is turned on If the system is already running the change will take effect a few seconds after the last UP or DOWN key is pressed and the display will switch back from set point to internal cabin temperature EE EE SSE ee Page 16 LG200 Owners Manual 071714 LG200 Owner s Manual Cabin Controller Clock and Date Set Up It is necessary to enter the time and date programming mode if the module has never been programmed or a different time zone is required SET symbol is flashing and CLOCK symbol is turned on during clock setup 1 Press CLOCK button The display will read Set Clock 2 Press SELECT button to continue MODE to exit Clock hour will start flashing 3 Press LEFT or RIGHT scroll button to adjust Clock hour 4 Press SELECT button Clock hour will 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 Day of week will stop flashing and Month will start flashing 11 Press LEFT or
5. use the timing cover fill port to prevent any hydraulic lock of the cylinders Do not use the filler cap on the valve cover at the top of the engine Bottom Cover _ of APU Oil Drain Plate attaches to the Bottom Cover of APU Figure 20 Bottom Cover of APU showing removable Oil Drain Plate 4 Remove the oil drain plate using a 7 16 socket wrench from the bottom plate of the engine enclosure 5 Remove oil drain plug using a 17mm socket wrench and drain the oil Re install the oil drain plug and tighten 6 Remove the oil filter 7 Install new oil filter 8 Inspect drain plug gasket and replace if needed 9 Install and tighten drain plug using a 17mm socket wrench 10 Fill the lubricating oil system with the recommended quantity of engine oil through the fill port on the timing cover E a eee Page 35 LG200 Owners Manual 071714 LG200 Owner s Manual Oil Change Do not use the filler cap on the valve cover at the top of the engine NOTE Use only type CJ 4 engine oil 11 Replace the oil filler 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 Replace engine oil and filter every 1000 Hours TEs Page 36 LG200 Owners Manual 071714 LG200 Owner s Manual Air Filter Change Replacing the Air Filter NO
6. 50 used grades I 30W of oil I 30w I 40W I I I 30 20 10 o 10 20 30 40 50 C 22 4 14 32 50 68 86 104 122 F AMBIENT TEMPERATURE Figure 17 Oil Viscosity vs Temperature Page 33 LG200 Owners Manual 071714 LG200 Owner s Manual Oil Change ENGINE COOLANT TYPE 50 50 mixture of ethylene glycol based low silica diesel specific antifreeze Engine Coolant and distilled water Use only coolants suitable for aluminum core radiators FUEL SPECIFICATIONS Fuel Type Ultra Low Sulfur Diesel ULSD Bio Diesel Tier 4 engines 20 R M E Replacing 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 Procedure Do NOT use upper filler hole 1 Remove front cover ensuring proper operation of the cover safety switch or disconnect battery prior to this step for your safety 2 Remove the oil filler cap from the timing case 3 Remove the oil dipstick from the dipstick tube and wipe clean DO NOT REPLACE THE DIPSTICK AT THIS TIME Figure 18 Oil Fill Cap Figure 19 Dipstick Page 34 LG200 Owners Manual 071714 LG200 Owner s Manual Oil Change Units with the Tier 4 engine have a second fill cap placed on the timing cover When filling oil on Tier 4 engines
7. LG9 402 _ 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 401 L Expansion Valve High Low LG9 003 Page 9 LG200 Owners Manual 071714 LG200 Owner s Manual Pre Start Inspection 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 E E ee Page 10 LG200 Owners Manual 071714 LG200 Owner s Manual Cabin Controller Cabin Controller Operating Instructions Before beginning the start up procedure it is necessary to know how to operate the cabin controller Figure 5 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 semi circular cover The controller also contains a LED indicator When the LED is green the
8. is submerged Page 45 LG200 Owners Manual 071714 LG200 Owner s Manual Troubleshooting Troubleshooting Cooling System SYMPTOM PROBABLE CAUSE REMEDY COMMENT Engine Overheating 1 Coolant level low 1 Add coolant and leak test 2 Engine fan belts loose system 3 Radiator fins blocked 2 Tighten or replace fan 4 Electric fan belt 5 Electrical fan 3 Clean radiator fins temperature switch 4 Replace electric fan 6 Faulty engine thermostat 5 Replace switch 7 Engine overloading 6 Replace thermostat 7 Seized belt driven component Engine Overcooling Check coolant mixture Replace coolant 2 Faulty engine thermostat 2 Replace engine thermostat Coolant Loss 1 System over filled 1 Check coolant level 2 External hose leak 2 Check coolant hoses 3 Internal hose leak from main unit to the 4 Failed head gasket HVAC box 3 Check coolant hoses inside the engine compartment 4 Check replace head gasket Poor Circulation 1 Water pump not 1 Check water pump and operating properly belt tension 2 Cooling system 2 Check for weak or kinked restricted hoses Troubleshooting HVAC System SYMPTOM PROBABLE CAUSE REMEDY COMMENT Poor Air Flow 1 HVAC filter clogged 1 Clean filter 2 HVAC air intake 2 Remove obstruction obstructed 3 Reduce the hose length 3 Excessive duct hose 4 Relocate the vent 4 Poor placement of vent 5 Replac
9. lower or more than 5 F 3 C higher than the temperature control setting in auto mode It also engages at least 1 minute after 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 Low Battery AutoStart does not require that it be set by the user in the same way as the time date and temperature based AutoStart features All that is necessary to ensure that low battery AutoStart functions is to leave the APU engine OFF and the cabin controller powered on active mode However the battery voltage that the AutoStart engages at can be reset by a Dealer technician The default voltage is 12V 0 2V Version Display 1 Press MODE button 2 Current version of the Power Module software will appear on the screen 3 Press MODE or SELECT to return Page 20 LG200 Owners Manual 071714 LG200 Owner s Manual FAULT CODES Cabin Controller The LG200 s electronic control will display fault codes on the LCD display if the unit fails to start or shuts down The following table contains fault codes and information on the cause and or remedy These fault codes will display one time only if
10. the positive post on the alternator amp starter is sprayed with battery spray Apply dielectric grease to the low oil sensor high temperature sensor amp the binary switch For all other connections use a silicon based spray product Make sure the boots are installed back on to the sensors Glow Plugs ow Oil Sensor High Temperature Sensor Page 41 LG200 Owners Manual 071714 LG200 Owner s Manual Cleaning HVAC Filter Cleaning the HVAC Filter The HVAC filter does not need to be replaced unless it is damaged The filter should be cleaned every 1000 hours of operation 1 Unscrew the two thumb nuts A Figure 15 and remove the foam air filter from the HVAC box 2 Wash the 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 Figure 15 HVAC Heating amp Cooling Box Cooling Only HVAC Box 1 Unscrew the two thumb nuts A Figure 16 and remove the foam air filter LHW Te immm l Panter s REEL VIENEI 2 Wash the air filter using soapy water or blow clean with compressed air and allow filter to dry completely mm i Hel 3 Re insert the air filter and hand tighten the two thumb nuts Figure 16 HVAC Cooling Only Box a a aS eee Page 42 LG200 Owners Manual 071714 LG200 Owner s Manual Troubleshooting Troubleshooting Technical support is available by cal
11. 3 Repair or replace condition breather tube 4 Replace and or rebuild the engine z EE EEEE a_a EEE eee Page 44 LG200 Owners Manual 071714 LG200 Owner s Manual SYMPTOM Batteries not Charging PROBABLE CAUSE Loose or broken belt ak Troubleshooting Troubleshooting Charging System REMEDY COMMENT Tighten or replace belt 2 Damaged or loose 2 Inspect and or replace battery connection battery connections 3 Poor battery condition 3 Test batteries 4 Faulty alternator 4 Check voltage at alternator field coil wire and truck batteries Batteries Overcharging 1 Faulty alternator 1 Check alternator output Troubleshooting Fuel System SYMPTOM PROBABLE CAUSE REMEDY COMMENT Fuel Odor or Leak 1 Loose fuel fittings 1 Tighten clamps 2 Damaged fuel line 2 Replace fuel hose 3 Damaged fuel filter bowl 3 Replace fuel filter 4 Fuel lift pump leak assembly 4 Replace lift pump No Start Condition 1 Dirty fuel 1 Clean fuel system fuel getting to 2 Clogged fuel filter 2 Replace fuel filter cylinders 15 bio diesel only Air in Fuel System 1 Worn or crack in fuel line 1 Replace fuel line 2 Lose hose clamps 2 Tighten clamps 3 Faulty fuel bowl gasket 3 Replace fuel bowl 4 If pick up tube was gasket installed in tank may 4 Add fuel to tank so pick draw air if fuel too low up tube
12. CHASE AND NOT FROM THE DATE OF CERTIFICATION The Dealer must fill out the warranty check list and fax the check list completed with all of the new Owner s information to 416 293 5104 along with a copy of the original purchase invoice of the APU from RigMaster to validate the warranty period purchased with the APU The Dealer can also have the option to fill out Page 51 LG200 Owners Manual 071714 LG200 Owner s Manual the online form instead and attach a scanned copy of the purchase invoice from RigMaster to validate the warranty purchased with the APU It is the responsibility of the authorized Dealer to inspect and certify that any RigMaster APU has been installed correctly Costs of certification as well as the cost of any repairs to the APU for certification purposes are the responsibility of the Owner 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 RigMaster APU s out of warranty shall be rejected by Rig Master Power International Ltd When Failures Occur due to Improper Installation When a RigMaster Dealer determines a failure to have occurred due to an improper installation by their insta
13. IGHT scroll button to adjust AutoStart Day as required 8 Press SELECT button 9 Press LEFT or RIGHT scroll button to locate On Off 10 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 AutoStart Feature Temperature Allows you to program a comfortable temperature setting the APU regulates the temperature giving you further fuel savings on extended absences from the cab Set Automatic Start Up Shut Down Temperature 1 Press AUTOSTART button twice Temp AutoStart will scroll across the screen SSESSSS_______ _ _ ae SESE eS 2 Page 19 LG200 Owners Manual 071714 LG200 Owner s Manual Cabin Controller 2 Press SELECT button to continue MODE to exit 3 Press LEFT or RIGHT scroll button to select mode of temperature control Mode options include OFF AUTO HEAT or COOL only 4 Press SELECT button to continue MODE to exit 5 Press LEFT or RIGHT scroll button to select AutoStart temperature set point if HEAT or COOL have been selected 6 Press SELECT button to save settings or press MODE to return to menu without saving The Automatic Start temperature range is between 32 F and 95 F 0 C and 77 C When enabled the AutoStart symbol will flash AutoStart temperature start up will engage when the inside temperature is more than 5 F 3 C
14. Install the new fan belt and slide the alternator away from the engine using a 16 inch pry bar until the belt deflection is less than 6 mm 1 4 6 When the fan belt is tensioned tighten the alternator adjustment lock bolt and nut and tighten the alternator pivot bolt to 19 ft lbs 7 Reinstall the engine cover Page 40 LG200 Owners Manual 071714 LG200 Owner s Manual 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 Main Unit General Cleaning 1 Wash the exterior of the main unit making sure that all louvered areas are clear this is especially important so that air may easily enter and exit the APU 2 Remove the front cover and gently 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 amp sensors to prevent the connections amp sensors from corroding Make sure the engine compartment is dry first Using battery sealant spray the positive amp negative post glow plugs and run solenoid see below for areas to spray with battery sealant The following parts are not shown in the picture but make sure that the wire to the starter solenoid amp
15. L OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE No person firm or representative is authorized to assume any obligation or make any warranty on behalf of RigMaster Power other than the limited warranty as stated herein Maintenance The RigMaster Owner s Manual lists all maintenance functions to validate this limited warranty PLEASE NOTE THAT FAILED COMPONENTS DUE TO POOR OR IMPROPER MAINTENANCE WILL NOT BE COVERED BY THIS LIMITED WARRANTY Where a dispute arises regarding proper maintenance the manufacturer reserves the right to request proof in the form of receipts for maintenance and any other records of service to establish that proper maintenance has been performed as per the maintenance schedule and or Dealer communications Installation It is the responsibility of the installer and the Owner to ensure that 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 RigMaster warranty the APU must be inspected and certified by an authorized RigMaster Dealer within 30 days of purchase The cost of inspecting and certifying any Ri
16. Manual CODE REMEDY CAUSE Cabin Controller REMEDY COMMENT Error Code 7 No Communication Error between control panel and power module Re establish communication Engine did not start e Bad glow plugs or relay AutoStart is disabled e Bad starter relay Engine Start until operator presses e Failed glow plug Failure Select button e Possible speed sensor issue Error Code 8 No communication e Cat5e communication cable possibly damaged commonly available Poor connection at terminal try plugging in a few times Error Code 9 Main Engine Running APU will not run if the Truck s main engine is already running This feature is optional If a switched 12 volt DC wire is connected to the J4 Pin 4 red wire at the power module the APU will not run This 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 Battery Charging Failure Battery voltage still low two 2 minutes after cranking Auto and manual starts can occur Faulty charging system failed batteries p
17. RIGHT scroll button to change 12 Press SELECT button Month will stop flashing and Date will start flashing 13 Press LEFT or RIGHT scroll button to change 14 Press SELECT button to save settings and return to menu or press MODE to return to menu without saving Ee ES Page 17 LG200 Owners Manual 071714 LG200 Owner s Manual Cabin Controller Set Alarm Clock 1 Press ALARM button The display will read Set Alarm 2 Press SELECT button to continue MODE to exit Alarm Clock hour will start flashing 3 Press LEFT or RIGHT scroll button to adjust Alarm Clock hour 4 Press SELECT button Alarm Clock hour will stop flashing and Alarm Clock minutes will start flashing 5 Press LEFT or RIGHT scroll button to adjust Alarm Clock minutes 6 Press SELECT button Alarm Clock minutes will stop flashing and AM PM will start flashing 7 Press LEFT or RIGHT scroll button to change 8 Press SELECT button 9 Press LEFT or RIGHT scroll 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 AUTO OFF is for heating effic
18. RigMaster authorized Dealer to validate the remaining portion of this limited warranty Where the original Owner transfers the RigMaster APU to a new vehicle the installation must be completed by an authorized Dealer to validate any remaining portion of this limited warranty Warranty Policy RigMaster Power International Ltd warrants that under normal service and use the RigMaster APU will be free from defects in materials and workmanship as stated Page 50 LG200 Owners Manual 071714 LG200 Owner s Manual During the warranty period RigMaster Power International Ltd will provide the exclusive remedy of ensuring the repair or replacement of those parts which are demonstrated to be defective in material or workmanship RigMaster Power International Ltd will not under any terms replace the entire APU as a means of repair The purpose of this warranty is to provide the Owner of the RigMaster APU with free repair or replacement of defective parts in a manner outlined in the following policy This remedy does not apply to normal wear and tear of service parts improper installation deterioration modification or economic loss Warranty Qualification All RigMaster Power APUs are eligible for warranty repair for a period of 12 months 2000 hours or 24 months 4000 hours from the in service date as stated on the warranty registration form for all RigMaster APU components excluding the engine RigMaster Power International Ltd maint
19. TE The air filter should be inspected every 1000 hours of operation This filter canister accepts ONLY the Mann 00 C1140 Air Filter Do not use unapproved cross referenced parts Figure 14 Air Filter Procedure to Replace the Air Filter 1 Remove the cover from the air filter canister 2 Remove the air filter element and clean the inside of air canister Allow the air canister to dry completely 3 Replace air filter element Use only manufacturer approved filters 4 Reinstall the air canister lid Turn clockwise Before test running the engine inspect the filter hoses for cracks or brittle sections Damaged or deteriorating hose should be replaced SSS aS eee Page 37 LG200 Owners Manual 071714 LG200 Owner s Manual Serpentine Drive Belt Serpentine Drive Belt RigMaster LG200 APU s are equipped with a serpentine drive belt that drives the air conditioning compressor from the flywheel of the engine Belt rotation is Counter clockwise Figure 21 Serpentine Stretch Fit Compressor Belt COMPONENT PART 1 Flywheel Drive Pulley LG8 003 2 Compressor LG9 004 3 Serpentine Belt LG8 006 The Serpentine belt is a stretch fit belt so there is no need for tension adjustment Page 38 LG200 Owners Manual 071714 LG200 Owner s Manual Serpentine Drive Belt Procedure to Replace Serpentine Belt TOOLS REQUIRED an Ratchet 17mm Socket Wrench 7146 Socket Wre
20. ains a complete list of registered RigMaster Owners Dealers are invited to contact RigMaster Power International Ltd to obtain in service date where available The Perkins Caterpillar Engine Both models of engines are warranted by the engine manufacturer for a period of 24 months 2000 hrs for all engine components excluding starter and alternator The starter and alternator are warranted for 12 months 2000 hrs Perkins engine warranty repairs must be performed by a registered Perkins Dealer Caterpillar engine warranty repairs must be performed by a registered Caterpillar Dealer Note to Dealer any RigMaster APU sold with a Caterpillar engine must be registered with Caterpillar to activate the 24 month 2000 hour warranty on the engine To do this the Dealer must go to www cat com go to products select engines and click on register engine warranty on the right side of the screen Fill out the registration form to activate the Caterpillar engine warranty Warranty Registration It is the responsibility of the installing Dealer to register the RigMaster APU installed by the Dealer s trained technicians The installing Dealer must register the in service date of the warranty from the time the Owner takes possession of the Rig Master APU In the event the Owner Fleet have installed the RigMaster APU themselves the APU must be inspected within 30 days of purchase to validate the warranty THE IN SERVICE DATE BEGINS FROM THE DATE OF PUR
21. and return lines interconnected with the vehicle s fuel system The engine lift pump supplies fuel to the filter sediment bowl assembly and then to the injection pump When 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 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 in the filter head assembly and on the inlet fitting to the injection pump Replacing the Fuel Filter If proper procedures are followed during filter service a minimal amount of air bleeding is required after changing the filter Inspect the fuel filter every 500 Hours Bleed Screw Fuel Shut Off Valve Fuel Filter Lift Pump Priming Lever Oil Filter Figure 10 Fuel System Page 25 LG200 Owners Manual 071714 LG200 Owner s Manual Fuel System Fuel Filter Replacement Procedure Fuel System Bleeding Procedure Low Pressure 1 The fuel shut off valve must be moved to the closed position Counterclockwise to 3 o clock position 2 Remove the retaining ring on the filter sediment bowl and carefully remove the bowl and filter cartridge 3 Drain and clean the filter sediment bowl 4 Install a new filter with the opening of the filter going over the
22. 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 0 12 Right scroll button P The left and right arrow buttons are used to locate the desired data and or adjust those values SS____ Eee SES Ee Page 12 LG200 Owners Manual 071714 LG200 Owner s Manual Cabin Controller 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 System information Temperature information Cl
23. e blower motor 5 Faulty blower motor 6 See Installation Manual 6 Ducted through truck s for mounting methods ventilation system a a ee Page 46 LG200 Owners Manual 071714 LG200 Owner s Manual SYMPTOM Little or No Hot Air PROBABLE CAUSE Insufficient engine load 2 Low electronic coolant control valve faulty Troubleshooting REMEDY COMMENT Check if main engine block heater is plugged in 3 Low coolant or air lock 2 Check water valve 4 Cooling system blocked operation 5 Engine overcooling 3 Bleed system of air and fill 4 Flush cooling system 5 Faulty engine thermostat Little or No Cold Air 1 Cabin Controller not set 1 Set Controller to A C mode temperature 2 No Output power to Pin 2 Check for 12V at A C 2 on connector J1 clutch control output 3 A C system leak 3 Check system pressures 4 Condenser radiator dirty 4 Clean 5 Compressor not working radiator condenser 6 Evaporator core frozen 5 Check the compressor 7 Electric fan not and fuse operating 6 Replace thermostatic 8 Electronic coolant control switch valve faulty 7 Check fan relay and fuse 8 Replace electronic coolant control valve Troubleshooting Serpentine Drive Belt SYMPTOM Belt has Premature PROBABLE CAUSE 1 Use of incorrect belt ek REMEDY COMMENT Use correct belt Wear 2 Damage to pulleys 2 Replace damaged 3 Misalignment of p
24. ere 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
25. erty No claim of any kind asserted against RigMaster Power International Ltd whether asserted under legal theories of negligence strict liability warranty or any other common law or statutory basis shall be greater in amount than the purchase price of the RigMaster APU with respect to which damages are claimed Indemnity The user and Owner of the RigMaster APU agree to indemnify and hold RigMaster Power International Ltd harmless from any and all claims expenses suits or liability of any nature whatsoever 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 under this limited warranty It is the Owner s responsibility to act promptly in submitting any such claim Transfer of Warranty Where the vehicle with the RigMaster APU has been sold by the first Owner to a second Owner and the RigMaster has not been removed this limited warranty is transferable from the original Owner to a second Owner with whatever portion of the limited warranty that remains from the date of sale Where the RigMaster APU has been removed and sold by the first Owner to a second Owner re installation is to be completed by a
26. eturns starter BH Overcurrent heater is not operated by power module output no output on J1 Pin 7 Overcurrent relay problem Error Code 25 A C clutch or run solenoid Unplug run solenoid power drawing excess current with jumper wire attempt AC or Run again If code returns A C Overcurrent clutch problem Error Code 26 Phantom Code block 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 with the power button then turned back on This message appears if engine start is attempted without turning POWER OFF Turn power OFF then ON Error Code 28 Output Overcurrent A power module output circuit sees a rise in amperage while trying to activate an electronic component Output circuit shuts off to protect itself Similar to a circuit breaker function caused by a stuck or failed relay solenoid or servo Power OFF with controller for a minute and function will return Test each power module output circuit for amperage draw Page 24 LG200 Owners Manual 071714 LG200 Owner s Manual Fuel System Fuel System Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury and will render the warranty null and void The RigMaster incorporates a low high pressure fuel system with fuel supply
27. f the Safety Systems The safety systems on the RigMaster APU should be examined and tested at 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 a SES Page 6 LG200 Owners Manual 071714 LG200 Owner s Manual BE Heater 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 ma
28. fey Fe Hm MASTER PQ Ss ER Owner s Manual Model MTS T4 LG200 LG200 Owner s Manual 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 ee Page 1 LG200 Owners Manual 071714 LG200 Owner s Manual Definitions NOTE A NOTE describes important information necessary to properly complete a procedure or information which will make the procedure easier to understand
29. filter housing inlet tube 5 Reinstall the sediment bowl and retaining ring 6 Open the fuel shut off valve and loosen the right bleed screw on the filter head assembly I 7 Bleed the low pressure system See below for detailed instructions 8 Start the engine and check for leaks Figure 11 Fuel Filter TOOLS REQUIRED Philips Screwdriver 3 The low pressure system must be completely free of air before the high pressure system can be bled properly 1 2 Position a container or shop wipe under the fuel sediment bowl to contain any spilled fuel Using a Phillips screwdriver loosen the right hand bleed screw located in the filter head Location B refer to Figure 13 Prime the system using the manual lift pump lever located on the lift pump Since the pump is mechanical and has a diaphragm it may be necessary to manually turn the engine by hand so that the engine camshaft allows full stroke on the lift pump Location F refer to Figure 13 Continue to pump the lever until the sediment bowl is full and a clear air free stream of fuel is seen passing the bleed screw Tighten the bleed screw in the fuel filter head Location B refer to Figure 13 Bleeding low pressure system is complete Page 26 LG200 Owners Manual 071714 LG200 Owner s Manual Fuel System G0 CY Figure 12 Fuel System Components DESCRIPTION DESCRIPTION 1 Oil Filter Ca
30. gMaster APU is at the Owner s expense and if validated warranty coverage begins from the date of PURCHASE and NOT the date of certification Warranty Voided or Terminated Any modifications to the RigMaster without written authorization from the manufacturer will void this limited warranty Repair replacement or maintenance using other than approved parts may be cause to terminate this limited warranty as will use of starting aids such as ether Exclusions For Limited Warranty The cost of normal maintenance such as but not limited to tune ups adjustments and inspections tightening of clamps fasteners hoses the replacement of belts fuel air and oil filters unless damaged by cause of a warrantable failure are excluded from this limited warranty Page 49 LG200 Owners Manual 071714 LG200 Owner s Manual Limitations of Remedies The remedy of repair or replacement as set forth herein is the exclusive remedy available to the purchaser or user of the RigMaster RigMaster Power International Ltd disclaims and shall not be liable or responsible to the Owner or user of the RigMaster APU or any other person for incidental consequential direct indirect special or general damages of any kind arising out of or in any way related to the use of the RigMaster APU including but not limited to towing charges accident repairs road calls traveling expenses loss of revenue profits loss of truck use or damage to persons or prop
31. iency during winter operation AUTO ON is for air conditioning efficiency during summer operation The air conditioning heating system will only operate when the fan speed is in a setting other than 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 Page 18 LG200 Owners Manual 071714 LG200 Owner s Manual Cabin Controller AutoStart Features and Operation AutoStart Feature Time Day Allows you to program a day and time for the APU to start automatically up to 7 days in advance This feature will run for three hours and shut down At the end of the AutoStart program the cabin controller will display the error code 10 Run Timeout this is normal Set Automatic Start Up Shut Down Time Day The user can adjust the time and day for the next timed AutoStart event SET symbol is flashing and TIME AUTOSTART symbol is turned on during alarm setup 1 Press AUTOSTART button Time AutoStart will scroll across the screen 2 Press SELECT 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 R
32. igerant Single Blower 20 000 BTU HVAC 0 65 Ibs 10 4 oz 0 29 Kg Volume of Refrigerant Dual Blower 24 000 BTU HVAC 1 0 Ib 16 0z 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 ET Page 8 LG200 Owners Manual 071714 LG200 Owner s Manual 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 dryer 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 ae AD DD gt DD ir a a ee SS gt lt gt gt Y XN Figure 4 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 48 High LG9 400 H A C Line Condenser to Bulkhead 6 High
33. ins 140516250 Wix 51396 K Mart Motorvator K014477 AIR FILTER ASSEMBLY Fram PH4386 BRAND PART No Baldwin B37 RigMaster 103002 FUEL FILTER BRAND PART No FAN BELT Wix 33262 BRAND PART No NAPA 3262 RigMaster LG8 005 Perkins 130366040 Fram C7516 Baldwin PF937 GLOW PLUGS AC Delco GF771 BRAND PART No Perkins 185366220 SERPENTINE DRIVE BELT NGK YEO BRAND PART No RigMaster LG8 006 THE USE OF COMPONENTS NOT RECEIVER DRIER ELEMENT LISTED IN THIS TABLE MAY CAUSE DAMAGE TO THE ASSEMBLY AND BRAND PART No VOID THE MANUFACTURERS RigMaster LG9 007 WARRANTY FEE eee Page 32 LG200 Owners Manual 071714 LG200 Owner s Manual Oil Change Oil Change TOOLS REQUIRED Sja Ratchet 17mm Socket Wrench 7146 Socket Wrench OIL S A E S 1 Volume 3 Liter 3 US Quarts Type API CJ4 Oil Viscosity Variable See Figure 17 NOTE API CJ 4 oil is designed for low sulfur diesel fuel Perkins and CAT engines that are backwards compatible with earlier Tier 2 engines Consult a Perkins or CAT Dealer about the use of synthetic oil in your RigMaster Service intervals for oil and oil filter replacements are 1000 hours Synthetic oil is not suitable for use as break in oil during the first 1500 engine operating hours Oil Viscosity vs Temperature ow I 5W 20 15W30 and I I I 10W 30 15W40 are i 1 the most ERE i commonly 20W
34. ions 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 components which consist of 1 The electronic controls 2 The combination heater air conditioning system components Repair or replacement will be completed at an authorized Dealer upon presentation of proof of purchase and determination by RigMaster Power or its authorized Dealer that a component has failed under normal service and use at NO CHARGE to the Owner within the established warranty period of 12 months 2000 hours or 24 months 4000 based on the warranty coverage purchased Engine Warranty Coverage The RigMaster APU comes equipped with either a Perkins or Caterpillar engine Both engines come with a 24 month 2000 hours warranty from the engine manufacturer which covers all engine components excluding alternator and starter The alternator and starter are warranted for a period of 12 months 2000 hours by the engine manufacturers SSS ee ee ee a ee Page 48 LG200 Owners Manual 071714 LG200 Owner s Manual Disclaimer of Other Warranties RIGMASTER POWER INCLUDING ITS AGENTS AND AUTHORIZED DEALERS MAKES NO OTHER WARRANTIES AND EXPRESSLY DISCLAIMS AL
35. isplay 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 a aS eee Page 14 LG200 Owners Manual 071714 LG200 Owner s Manual Cabin Controller 3 Clock and Alarm mo TU V mM FR SA sv CLOCK ALARM TIME AUTOSTAR Figure 8 Cabin Controller LCD Display Clock amp 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 M M M nm Ni Ni Ni Nri Wi Ny IN AN DN 28 AN 28 AN JN UN i Figure 9
36. ling 888 208 3101 or 416 201 0040 Monday to Friday from 8 00 a m to 5 00 p m Eastern Standard Time Technical Support can also be accessed via the internet at www rigmasterpower com click Customer Support Support Materials Technical Support Troubleshooting Engine SYMPTOM Engine does not Crank a PROBABLE CAUSE Low battery voltage REMEDY COMMENT Check batteries 2 Battery connections Tighten connections loose Check for power at relay 3 Starter relay problem during starting 4 Broken engine ground sequence strap Replace strap 5 Starter motor faulty Check for power at starter solenoid Engine Cranks but 1 Clogged air filter Replace air filter does not Start 2 Clogged fuel filter Replace fuel filter 3 Run solenoid not Check 12V at run operating solenoid 4 Glow plug or glow plug Check for power at the relay glow plugs and relay 5 Lift pump faulty See fuel system section 6 Governor Assembly See Perkins Service Manual Engine Hard to Start 1 Air filter clogged Replace air filter 2 Fuel See fuel system section 3 Glow plugs Check for power at the 4 Injectors clogged glow plugs Inspect service fuel injectors Engine Cranks Slowly 1 Weak or bad batteries Inspect batteries 2 Damaged corroded Replace or clean the battery connections battery connections 3 Faulty starter Check starter 4 Belt driven component connections problem Compressor
37. lling technician it is the Dealer s responsibility to repair the RigMaster APU and correct the installation error at no cost to the Owner At no time shall RigMaster Power International Ltd warrant any repairs to the RigMaster APU due to improper installation by the installing Dealer When a RigMaster Dealer determines a failure to have occurred due to an improper installation from another installing Dealer it is the Dealer s responsibility to offer the Owner of the RigMaster APU one of two choices 1 Have the Owner return to the installing Dealer to have the APU repaired by the installing Dealer 2 Where the Owner cannot or is unwilling to return to the installing Dealer perform the repairs at the Owner s expense It would then be the Owner s responsibility to obtain a refund for work performed from the installing Dealer If the Dealer is in doubt as the whether the repair is warrantable or not it is the Dealer s responsibility to contact RigMaster Power International Ltd RigMaster Power International Ltd reserves the right to and final determination of whether a repair can be claimed as warranty Use of Aftermarket Components for Warranty Repairs At no time shall a RigMaster Dealer use aftermarket parts for warrantable repairs on a Rig Master APU The use of aftermarket components for warranty repairs is strictly prohibited by RigMaster Power International Ltd At no time shall a Dealer manufacture their own parts including b
38. maintenance sooner SCHEDULED INTERVALS MAINTENANCE ITEMS IN HOURS 50 250 500 1000 X X Xx X Check coolant level X First Engine Oil Change X x xX xX Check APU for leaks damage repair if found X Inspect Fan Belt Condition Adjustment x Inspect Serpentine Belt for wear X x X Check all Fasteners for tightness x Valve Clearance Inspection Intake and Exhaust valve clearance are both 0 0078 Vibration Mounts pry up on the engine x Xx mount plates there should be less than 1 of upward movement X Change Engine Oil and Filter X Check HVAC unit filter clean if necessary Clean engine compartment condenser and X radiator Use compressed air or liquid degreaser Check engine air filter change if necessary Check fuel filter change if necessary Check fan belt change if necessary x x x Xx Check serpentine belt change if necessary Check coolant concentration renew if necessary NOTE The use of conditioner may extend the service life of belts consult the belt manufacturer for more information on the maintenance belt X EET eee eee Page 31 LG200 Owners Manual 071714 LG200 Owner s Manual Cross Reference Parts List RigMaster Power Approved Cross Reference Parts List OIL FILTER AIR FILTER BRAND PART No BRAND PART No AC Delco PF1233 RigMaster Mann 00 C1140 Perk
39. nch Flywheel Drive Pulley A C Compressor Pulley Figure 22 Pulleys A DIESEL ENGINE MAY START AT ANY TIME WHEN ITS CRANKSHAFT IS TURNED THIS INCLUDES TURNING BY WRENCH OR BY HAND 1 Remove front cover ensuring proper operation of the cover safety switch or disconnect battery prior to this step for your safety 2 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 3 Install a new serpentine belt onto the A C compressor pulley then over the flywheel pulley 4 Rotate the engine with a ratchet wrench and socket wrench to ensure that the belt is properly positioned on all pulleys before starting the engine DO NOT USE YOUR HANDS OR A J BAR The A C compressor is in a fixed location so there is no need for adjustment brackets Page 39 LG200 Owners Manual 071714 LG200 Owner s Manual Fan Belt Removal and Adjustment Alternator Pivot Bolt gt gt rare FL FA Alternator NS Fan Belt Alternator Adjuster Lock Bolt and Nut Procedure to Replace the Fan Belt TOOLS REQUIRED 11 Wrench or Ratchet 17mm Socket Wrench 7146 Socket Wrench 8mm Allen Key 1 Remove the APU engine cover 2 Loosen the alternator adjustment bolt and nut about 2 turns 3 Loosen the alternator pivot bolt 4 Slide the alternator down towards the engine and remove the belt 5
40. ock day and alarm information Alphanumeric display for additional information R nne l System Information SYSTEM ALARM SYSTEM ON ENGINE RUHHIHG AUTOSTART HEATING COOLING FAN AUTO FAN HIGH FAH MID FAH LOW Figure 6 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 Page 13 LG200 Owners Manual 071714 LG200 Owner s Manual Cabin Controller 2 Temperature Information SET TEMP EXT TEMP Figure 7 Cabin Controller LCD Display Temperature This area indicates the internal or external temperature and can be programmed to d
41. of fuel is observed from the high pressure line nuts This procedure is only meant to remove air bubbles Unit will not start with nuts loosened 4 Ifthe air bubbles are still present after 30 seconds of cranking reactivate the starter with nuts loose 5 Tighten the left injector line nut using a 17mm wrench Location 6 If the unit fails to start Repeat steps 1 5 7 Asa final measure it is recommended to bleed the fuel system with the engine running Slowly loosen one injector nut at a time using a 17mm wrench left nut first Location 1 and retighten quickly when engine speed drops This will remove any remaining air Be sure to tighten the first injector nut left nut using a 17mm wrench before continuing to the next injector nut right nut It may be necessary to bleed the high pressure system when installing a new unit gt E Page 29 LG200 Owners Manual 071714 LG200 Owner s Manual Fuel System Use of Biodiesel Fuel A Common Statement from Bosch Stanadyne and Lucas FIE manufacturers follows Bio diesel R M E fuel can be used in Perkins Cat direct injection diesel engines however the following conditions apply e The fuel must comply with DIN V 51606 or other approved national standards as they evolve e LG200 Tier 4 engines are rated for mixtures up to 20 RME in mineral oil diesel fuel e No mixture above the listed percentage for the Tier 4 engine is acceptable as this can result in fil
42. oor connection Engine harness ground wires disconnected at the HVAC unit Error Code 13 Battery Discharge Alarm system will enter low power mode No starting options given Failed batteries or connection Possible poor connection at power module Error Code 14 Check External Temperature Sensor External temp sensor may not be connected to the power module External temperature sensor disconnected or failed Connection loose or damaged Page 22 LG200 Owners Manual 071714 LG200 Owner s Manual el 9 REMEDY CAUSE Cabin Controller REMEDY COMMENT Error Code 15 External Temp Disable Limit Engine shut down due to external temperature outside the programmed range The APU 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 unit equipped with Diesel Particulate Filters Service exhaust filter if unit is DPF equipped if not DPF equipped then power module failure likely See authorized Dealer for exhaust filter servicing or power module diagnosis 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 fail
43. or other belt driven component seized Page 43 LG200 Owners Manual 071714 LG200 Owner s Manual Troubleshooting SYMPTOM PROBABLE CAUSE REMEDY COMMENT Engine Shuts Down 1 Clogged air filter 1 Replace air filter 2 Clogged fuel filter 2 Replace fuel filter 3 Blown fuses 3 Replace fuse 4 Damaged or loose 4 Inspect condition of wiring wiring and wiring connections Dark Gray Black 1 Engine over loaded 1 Seized belt driven Smoke 2 Clogged air filter component 2 Check and or replace air filter Engine Starts and 1 Speed sensor 1 Check speed sensor Stalls 2 Clogged fuel filter resistance and gap 3 Damaged or loose wiring 2 Replace fuel filter connections 3 Inspect wiring 4 Excessive load on the connection and engine alternator or connectors A C compressor White or Blue Smoke 1 Engine oil too full 1 Inspect amp correct oil 2 Coolant in combustion level chamber 2 Possible failed head gasket Engine Runs Rough 1 Air filter clogged 1 Check air filter 2 Fuel filter clogged assembly 3 Fuel leak 2 Replace fuel filter 4 Worn clogged fuel 3 Inspect all fuel hoses injectors and clamps 5 Engine in poor condition 4 Inspect service injectors 5 Replace rebuild the engine Loss of Engine Oil 1 Oil seals leaking 1 Replace crankshaft 2 Leaking drain plug seals 3 Pinched or clogged 2 Replace oil pan plug breather tube gasket 4 Engine worn or in poor
44. p 7 Throttle Lever c w adjustment screws 2 Atomizer 8 Coolant Drain Tap 3 Oil Pressure Switch 9 Dip Stick 4 Air Bleed Fuel System 10 Oil Drain Plug also on bottom of pan 5 Fuel Injection Pump 11 Oil Filter 6 ele Stop anes 12 Fuel Lift Pump c w adjustment screws Page 27 LG200 Owners Manual 071714 LG200 Owner s Manual Fuel System Figure 13 Fuel System Other Components LETTER DESCRIPTION A Filter Feed Hose Air Bleed Screw Filter Housing Shut Off Valve Fuel Filter Element and Fuel Bowl Fuel Supply Pump Feed Pump Manual Primer Pump Lever Fuel Supply Pump Fuel Supply Hose IIO J nim olojo Fuel Return Hose Injector Bleed Off Fuel Injector Nozzles J Fuel Injection Pump K Injector Pump Feed Line Page 28 LG200 Owners Manual 071714 LG200 Owner s Manual Fuel System Fuel System Bleeding Procedure High Pressure TOOLS REQUIRED 17MM Wrench NOTE The low pressure system must be completely free of air before the high pressure system can be bled properly It is recommended that a second person assist in the performance of Steps 1 2 3 6 and 7 Never disable or by pass the safety device 1 Have a helper hold down the safety cover switch located on the unit 2 Loosen both high pressure line nuts located at the injectors using a 17mm wrench Location 3 Start engine until a clear stream
45. problem 2 Deliver unit to Dealer for service Upon completion of repairs review and sign the Dealer work order keeping a copy for reference 3 Frequently customer concerns are a result 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 53 LG200 Owners Manual 071714 LG200 Owner s Manual Maintenance Record Maintenance Record Hour Maintenance Performed Date Meter Remarks Reading 200 400 600 800 1000 1600 hrs hrs hrs hrs hrs hrs eee EEE Ee Page 54 LG200 Owners Manual 071714 LG200 Owner s Manual Maintenance Record Hour Maintenance Performed Date Meter Remarks Reading 200 400 600 800 1000 1600 hrs hrs hrs hrs hrs hrs nS Page 55 LG200 Owners Manual 071714 LG200 Owner s Manual LSS Notes NOTES SSS Te re ere oe re me Page 56 LG200 Owners Manual 071714 RigMaster Power International Ltd 1320 Ellesm
46. 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 SSS a aS eee Page 11 LG200 Owners Manual 071714 LG200 Owner s Manual Cabin Controller 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
47. ter blocking e Fuel storage must be to recommended standards to avoid the absorption of water and degradation In any event storage should not exceed twelve 12 months Fuel degradation if allowed to occur can result in the corrosion of metallic components and the premature failure of seals e RME is a powerful solvent Damage may occur if it comes into contact with paint 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 made as to the possible effects of running these products with such fuels Non compliance of the fuel to agreed standards whether being evident by appearance of the known degradation products of these fuels or their effects within the fuel injection equipment will render the manufacturer s guarantee null and void If you require further information please contact your local Perkins or Caterpillar Representative eS SS SSS Page 30 LG200 Owners Manual 071714 LG200 Owner s Manual Preventative Maintenance Preventative Maintenance The first oil change must be performed at 50 hours of service and at 1000 hour intervals thereafter Please read the following chart for detailed information The maintenance schedules are for Normal road conditions and the specific hour intervals must be adhered to in order to maintain the manufacturers warranties For SEVERE conditions perform the scheduled
48. the code is cleared from the cabin controller failure will have to reoccur for the code to be displayed again efe 3 REMEDY CAUSE REMEDY COMMENT Error Code 1 Engine cover of APU unit e Cover not seated is open APU will not start e Damaged wiring Safety Cover Open or run until the cover is e Failed cover switch closed e Switch out of adjustment Error Code 2 Low oil pressure e Low oil level e Wiring damaged Low Oil Pressure e Faulty switch Dirty oil filter Engine Run Failure but didn t run properly AutoStart is disengaged attempt manual starting with START button Error Code 3 Low battery voltage Start e Damaged or broken battery system immediately to cables failed battery Battery Low charge batteries e Excessive load on batteries Voltage e Faulty charging system Error Code 4 Engine may have started e Speed sensor adjustment set air gap at 0 015 Damaged speed sensor wiring Failed speed sensor Error Code 5 Low Coolant Engine Overheated Engine will not run until temperature becomes normal or coolant level is at full in surge tank Low coolant or failed coolant level switch High engine temperature or failed engine temperature sensor top of water pump has single wire Damaged wire providing ground Error Code 6 Module Failure Power Module is not responding Failed power module Page 21 LG200 Owners Manual 071714 LG200 Owner s
49. tion 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 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 SSS a a ees Page 5 LG200 Owners Manual 071714 LG200 Owner s Manual 4 Engine Hoist Points NOTE ENGINE HOIST POINTS The Perkins and CAT 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 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 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 o
50. ulleys pulleys 3 Realign pulleys Belt is Loose and or 1 Use of incorrect belt 1 Use correct belt comes off repeatedly 2 Damage to pulleys 2 Replace damaged during Operation 3 Maladjusted Belt pulleys 3 Replace belt For additional diagnostic and troubleshooting information please visit www rigmasterpower com and click on the Customer Support heading Support Materials menu option Page 47 LG200 Owners Manual 071714 LG200 Owner s Manual RigMaster Power APU Warranty Policy The Limited Warranty This limited warranty applies to the RigMaster Auxiliary Power Unit RigMaster APU which consists of the following components 1 The generator set 2 The generator set control panel 3 The combination heater air conditioning system Warranty Coverage Rig Master Power International Ltd warrants that under normal service and use the RigMaster APU will be free from defects in material and workmanship for a term of 12 months 2000 hours or a term of 24 months 4000 hours depending on the term of the warranty coverage purchased for the APU components listed excluding the engine Refer to the engine warranty coverage section of the policy The RigMaster APU warranty coverage shall begin from the date of installation or from the time the Owner takes possession of the RigMaster APU if the APU is installed with a new vehicle purchase whichever comes first and is subject to all terms and conditions limitat
51. ure 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 be entered into the cabin controller display keypad To obtain registration code please call the APU Manufacturer 1 800 249 6222 with the serial of your unit There is no charge for this service GP Overcurrent excess amperage Error Code 20 Electronic coolant control Unplug J2 connector turn valve drawing excess POWER ON again Code Water Valve amperage should not display when J2 is Overcurrent unplugged Error Code 21 Glow plug relay drawing Glow plug relay operation is faulty or wire broken Page 23 LG200 Owners Manual 071714 LG200 Owner s Manual el 9 REMEDY CAUSE Cabin Controller REMEDY COMMENT Error Code 22 Run solenoid or glow plug relay drawing excess Unplug run solenoid power with jumper wire attempt Run Overcurrent excess amperage Run or GP amperage again If code returns glow Overcurrent plug relay problem Error Code 23 Run solenoid is drawing Unplug run solenoid power with jumper wire attempt again measure Amps If code returns broken wire Error Code 24 Start or Run Starter relay or run solenoid drawing excess current Unplug run solenoid power with jumper wire attempt again If code r
52. ut not limited to air conditioning hoses brackets and fittings SS ey ee eS ee ee sed Page 52 LG200 Owners Manual 071714 LG200 Owner s Manual Transfer of Warranty It is the Dealer s responsibility to notify RigMaster Power International Ltd of a change of ownership when a RigMaster APU has been sold by the first Owner to a second Owner The Dealer must inform RigMaster Power by 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 obtain warranty repairs you must request the needed repairs within the warranty period from an authorized RigMaster Dealer A reasonable time must be allowed to perform the warranty repair after taking the unit to an authorized Dealer location Repairs will be performed during normal business hours To ensure your complete satisfaction the following procedures must be followed in the event you have a problem 1 Contact the nearest most convenient RigMaster Dealer to schedule a warranty service appointment Prior to contact have the following information available i Unit serial number ii Hour meter reading iii In service Purchase date iv Nature of
53. ve Maintenance Schedule 31 Cross Reference Parts List 32 Normal Maintenance amp Adjustment Instructions Oil Change Instructions 33 Air Filter Change Instructions 37 Serpentine Drive Belt Removal 38 Fan Belt Removal and Adjustment 40 Cleaning Instructions 41 Cleaning HVAC Filter 42 Troubleshooting 43 Warranty RigMaster APU Limited Warranty 48 Maintenance Record 54 Notes 56 Page 4 LG200 Owners Manual 071714 LG200 Owner s Manual 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 a Safety Cover Switch 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 posi
54. ximize the bunk heating efficiency Thermostat 82 C Radiator Red High Temperature Supply Lines Blue Lower Temperature Return Lines Figure 2 Heater SSS eS eee Page 7 LG200 Owners Manual 071714 LG200 Owner s Manual 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 11 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 3 will deliver acceptable performance Air Conditioning Performance 400 350 300 H GH HUMIDITY AREAS PRESSURE PSI 250 200 LOW HUMIDITY AREAS 150 100 60 70 80 30 100 110 120 Figure 3 A C Performance TEMPERATURE F 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 Refr
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