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RigMaster LG200 Installation ManualSection 2Preparation and Frame Rail MountingPreparing the LG200Frame Mounting HardwareFrame Rail Mounting2:1:02:2:02:2:1NOTEPlease note that the LG200 model unit is designed so a Diesel ParticulateFilter (DPF) may be installed after it has been mounted on a vehicle. Please allow6 inches on the left side of the unit to accommodate the DPF if it is to be installedat a later date.2:1:0 Preparing the LG200The LG200 unit is shipped on a wooden skid and should be uncrated near theinstallation area with sufficient space to prepare the unit while on the skid.It is much easier to prepare the unit prior to mounting it by installing the batterycables, brass fittings, air conditioning, fuel and coolant hoses. The use of corrugatedsplit loom to protect all cables and hoses is highly recommended. Split loom alsomakes your work look more professional, but will add some cost to the installation. itis much easier to add loom during the preparation phase.Remove the front cover to expose the left and right side panels. These panels shouldthen be removed to gain better access to the frame mounting components.Install the fuel fittings to the bulkhead using thread sealant. Be sure to tighten thereturn fitting fully before attempting to install the supply fitting. See section 7:3:0for further information on fuel fitting installation.2:2:0 Frame Mounting HardwareThe following figures illustrate the correct way to install the frame clamps and mountinghardware. See to it that the bolts and clamps are mounted straight with the trucksframe(Fig. 2-1)August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 2Fig. 2-1When installing the mounting hardware, make sure that no markings on the flatwashers are visible after the washers have been installed (Fig. 2-2).Top of 5/8”Hardened WasherNO MARKINGSBottom of 5/8”Hardened WasherMARKINGFig. 2-2August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 2The nut anchors (Fig 2-3) are designed to hold the two bottom lock nuts in position due tothe lack of space for tools. The anchors must be installed on the inside of the unit so thatthe two offset flanges sit flush against the side of thebulkhead (Fig. 2-4). The anchor will allow theinstaller to torque the bolt without the use of awrench or socket on the inside of the unit.Fig. 2-4August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 22:2:1 Frame Rail MountingOnce the frame rail location has been chosen, and prior to installation, it isimportant that you consult with the owner/operator to ensure they are satisfiedwith the proposed placement of the APU.Installation1. Using a pallet jack (or similar lifting device), position the Main Unit against theframe rail and slowly lower it until the upper bolt locations sit approximately1/8” above the top of the rail.CAUTIONDo not let the mounting bolts carry the weight of the APU until fully tightened.2. Place the four frame grabbers into position. Keep in mind that the boltsmust 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 flatagainst the frame rail and the hardware is straight. Then proceed to use atorque wrench to fully tighten the assembly. Do not use air tools or impactguns during this process; hand tightening with the correct tools will yield muchbetter results. Uneven or over tightening the mounting hardware can causedamage, so exercise caution when performing this step.CAUTIONWhen installing, slotted holes in all mounting brackets must be on thebottom and all bolts must be properly torqued to 75 foot pounds using atorque wrench.5. Double check that all mounting bolts are secure and remove the lifting device.August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 3Installing the Bunk HVAC UnitPreparation to Install the HVAC UnitMounting the HVACDucting the Ventilation SystemIndependent DuctingVent InstallationInstallation of Return Air VentIntegrated Ducting3:1:03:1:13:2:03:2:13:2:23:2:33:3:03:1:0 Preparation to Install the HVAC UnitThe HVAC unit dimensions are 16” wide by 12.5” long by 9.5” tall.Before installing the HVAC unit it is important that you perform the followingsteps:1. Consult with the owner/operator to ensure they are satisfied with the mountinglocation of the HVAC unit.2. Remember to allow space to remove the air filter and service the unit. It is alsoimportant to discuss and decide on a ducting configuration before drilling anyholes.3. Ensure that there are no obstructions under the vehicle (A/C lines, conduit,cross members, exhaust etc.). Do not drill through structural members withinor under the trucks floor. Choose a location that requires only the flooringmaterial be drilled.4. The LG200 kit contains an information package in an envelope. Thispackage has an Owner’s Manual and other material that is useful to theoperator of the LG200 APU. Place the information package on thedashboard of the vehicle so the operator of the vehicle receives it. Thisenvelope is in the kit box that contains the HVAC unit. It is suggested that theunit serial number and engine serial number be recorded in the Owner’sManual for the driver’s future reference.August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 33:1:1 Mounting the HVAC UnitThe HVAC unit has a flush mount filter secured by two thumb nuts. Beforeinstallation, see that there is enough room to remove the filter. Leave sufficientclearance on all sides for proper air flow.1. Drill holes for the air conditioning hoses, coolant hoses, condensation draintube and wiring. It is recommended that the holes be piloted with a 3/16” drillbit prior to drilling the 1 1/4” holes with the hole-saw. After drilling use a file toremove any sheet metal burrs that remain and protect edges with grommetsor slit hose. All holes can be drilled individual or grouped together for lessholes in sleeper cab. It is also very important to seal the holes with silicon toprevent and fumes from entering the sleeper cab.2. Attach the condensation drain tube to the bottom of the HVAC box using thesupplied hose clamp, usually found inside the owner’s envelope.3. Lower the HVAC box into the cab of the truck and ensure that the drainhose went through the corresponding hole.4. Do not secure the HVAC unit to the floor of the vehicle until you are sure thatall connections are correct and fully secured.August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualAugust 2010 RigMaster Power International Ltd LG200 Service ManualSection 3

RigMaster LG200 Installation ManualSection 33:2:0 Ducting the Ventilation SystemIndependent and Integrated Ducting are the two methods of providing air from theHVAC box to the bunk area. A great deal of thought and consideration should beused before deciding how to perform the vent installation.3:2:1 Independent DuctingThe first method uses separate ductwork included in the LG200 kit. Werecommend this independent ducting method because it provides the leastrestriction to airflow from the HVAC box.Fig. 3-44” Flexible DuctingInstall the flexible ducting by sliding it over theoutput on the blower motor at one end and overthe louvered vent at the other. Excess ductingmaterial must be removed to ensure optimal airflow.Method 1: Independent DuctingFig. 3-5Fig. 3-5August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 33:2:2 Vent InstallationThe vent kicker is an important component when fitting the independent ductingsystem; it promotes the circulation of vented air from floor to ceiling within thesleeper. It can be installed one of two ways:1. Recess Mounting (fig. 3-8) the air kicker requires that a square hole be cut inthe face of the bunk.2. Surface Mounting (fig. 3-9) the air kicker requires that a 4 1/4 inch hole isdrilled in the face of the bunk.It is important that the vent is mounted so that it discharges directly into thesleeper and is unobstructed. Do not allow vents to discharge under the bunk.August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualFig. 3-10In situations where there is no space tomount the air kicker and vent, a partialfascia may be fabricated and added tothe bunk. Be sure to fold the edges ifusing sheet metal so not to leave sharpsurfaces inside the cab.Painted Aluminum Sheet MetalAir Kicker and Vent AssemblyAugust 2010 RigMaster Power International Ltd LG200 Service ManualSection 4

RigMaster LG200 Installation ManualSection 43:2:3 Installation of Return Air VentsThe LG200 HVAC unit is capable of delivering approximately 278 cubic feet perminute of cooled air. In order to supply the blower motor, a return air vent mustbe installed if not already present. A 4 inch hole, or the equivalent in smallerholes, is sufficient to supply the HVAC with return air from the sleeper. It iscommon to port return air vents between the cabinets and the face of the bunkas this leaves them less visible.HVAC UnitAugust 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 43:3:0 Integrated DuctingIntegrated ducting interconnects the vehicle’s OEM ductwork to the LG200 HVACbox. 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 typeof installation contact RigMaster’s Technical Support Center.Using a Damper ValveA “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 flapwill allow some air to escape through the OEM HVAC unit. A “Y” fitting may alsobe used to direct the air into the vehicles vent system, which will reduce the amountof air that escapes through the OEM HVAC unit if installed correctly.August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 44:1:0 Mounting the Control PanelThe ideal mounting location for the controlpanel is at the head of the bed and about halfway between the floor and the ceiling. Makesure that the chosen location is close enoughto the HVAC unit that the communication cab lewill reach the power module when completelyrouted. Ensure that vented air does notdischarge directly on the controller as this willcause it to register a false temperature reading. Once a location has been chosen itis necessary to either route the cables behind a cabinet or wall, or surface run thecable securing it to prevent damage. When routing the cables, avoid sharp edgesand protect the cable from damage with grommets and/or wire loom. See that thebunk 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. Takeyour time to make sure it is level; the operator will look at their control panelclosely for many years. If the screws protrude through to the inside of a cabinet,use a piece of fuel line or shrink tube to cover the tip (short bolts and cap nuts arepreferable in this situation). This will protect the operator’s hands from damagewhen reaching into the cabinet.Cabin Controller Mounting BracketUPRoute Wire This SideAugust 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 4Figure 4-2Communication CableConnection TerminalFor surface run cables use thischannel in the back of the controllerFigure 4-3The communication cable is a Category5e (shielded) cable with two RJ-45connectors at each end. The cableshould be attached to the control paneland routed to the power module. Coil upthe excess cable and secure it with wireties. Connect the cable to the powermodule. Connecting the electronic controlsystem to live wires may cause damage.Longer Category 5e communicationcables may be purchased at localcomputer equipment supplier if thesupplied cable will not reach the desiredlocation.Figure 4-4The Communication Cable ishidden, giving the control panelinstallation a professional look.August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 5Installing the Coolant HosesInstallation of the Coolant FittingsInstallation of the Coolant Hoses5:1:05:2:05:1:0 Installation of the Coolant FittingsApply thread sealant to the straight brass fittings. Install the fittings taking care notto allow any of the sealant to enter the cooling system. If the distance in front of theMain Unit is heavily restricted it is acceptable to use a 45 male to female brass fittingto accommodate a sharper turn without kinking the coolant hose.5:2:0 Installation of the coolant hosesThe LG200 is a “stand alone” auxiliary power unit which does not share coolantwith the vehicles engine. The coolant hoses from the Main Unit are routeddirectly to the HVAC unit. The coolant must flow in the correct direction for theheating system to function normally. The kit includes the following components:DESCRIPTION12 ft. (3.5 m) heater hoses3/8” NPT to 5/8” hose fittingsHose clamps #10QTY224NOTEMark the coolant supply line at both ends to prevent the two coolant hoses frombeing accidentally reversed when connecting them to the water valve.The connections from the HVAC unit to the engine enclosure are as illustrated inFigure 5-1 and Figure 5-2. Care must be taken not to kink or restrict coolant flowthrough the coolant lines. Be sure to protect the coolant lines from damage usingwire loom and grommets, and do not over tighten the wire ties that secure thehose to the vehicle.Step 1 Connect the coolant supply and return line tothe LG200 bulkhead. The return line is the top coolantfitting and the supply line is the lower coolant fitting.Remember Fuel Supply and Coolant Supply ports on thebulkhead are next to one another.Step 2 Route the coolant lines along the inside of thevehicles frame rail and secure them with wire tiestaking care not to pinch the hose.Step 3 Connect the coolant supply and return line to the HVAC box (Figure 5-1).August 2010 RigMaster Power International Ltd LG200 Service ManualFigure 5-1

RigMaster LG200 Installation ManualSection 5Installing the A/C HosesInstallation of the A/C Refrigerant HosesInstalling the A/C Hoses in the Engine CompartmentInstalling the A/C hoses from the LG200 to the AC unitAir Conditioning Specifications6:1:06:1:16:1:26:1:3WARNINGExercise caution when removing protective caps from the #10 and #8 ports as thecompressor may be under pressure. Wear safety glasses and cover the ports w i t h ashop rag prior to removal of the protective caps.The LG200 unit is shipped with the air conditioning system capped to reduce thepossibility of contamination which may result from extended storage of the unit.The air conditioning system uses an aluminum condenser for optimum heatexchange properties. Care should be taken when connecting and removing theair conditioning lines because of the brittle nature of aluminum.6:1:0 Installation of the A/C Refrigerant HosesWARNINGCross contamination with other refrigerants will cause damage to this airconditioning system. Avoid breathing air conditioning refrigerants and lubricantvapor mist. Exposure may irritate eyes, nose and throat. To charge or recoverR134a from the system, use equipment certified to meet the requirements ofSAE j2210. If accidental system discharge occurs, ventilate the area beforeresuming service.NOTE Ester Oil will be required if using non-Teflon coated o-rings. It isrecommended that ester oil be used to lubricate the o-rings to reduce thelikelihood of tearing upon installation. WD-40 should be used to prevent corrosion between the aluminum and steelfittings.The installation of the A/C refrigerant hoses will require #6, #8, #10 o-rings(Teflon coated o-rings supplied with the LG200 box kit)Fig. 6-1August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 66:1:1 Installing the A/C hoses in the Engine CompartmentNOTEMake sure to leave room between the compressor hoses in the engine en c lo s ur e , s oth a t t h ey d o n ot r u b t og e t he r .There are three AC lines inside the main unit that need to be installed. Be sure notto bend any of the hard AC lines while installing to avoid the possibility of futureleaks.AFig. 6-2There is a slot (A) cut out from the engine plate to support the low side line (Fig. 6-2).Fig. 6-3August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 6Fig. 6-46:1:2 Installing the A/C hoses from the LG200 to the AC unitCAUTIONEvaporator Lines (Bulkhead to HVAC)Excess hose must be secured and allow for movement of the cab. Install the hoses with the cab airsuspension inflated. After installation, deflate the air suspension and inspect hose clearances forpotential problems. A/C hoses should not be under twisting or flexing stresses after installation asthis may cause fittings to leak and/or break.Remember to use a wrench to hold the fitting on the inside of the bulkhead when tightening the fittingon 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 thebulkhead first. Hand-tighten the fitting and torque to between 21 and 27 ft-lbs. Route the hoseand connect it to the expansion valve.2. Install the two #10 o-rings on the #10 refrigerant hose (LG9-403 Low Side) and connect it to thebulkhead first. Hand-tighten the fitting and torque to between 21 and 27 ft-lbs. Route the hoseand connect it to the expansion valve.3. The LG9-403 has a swiveling plate that is used to clamp the hoses to the expansion valve. Makesure the hoses are sitting securely before fastening this plate down.BulkheadConnectionsHVACConnectionsFig. 6-6Fig. 6-7August 2010 RigMaster Power International Ltd LG200 Service Manual

RigMaster LG200 Installation ManualSection 66:1:3 Air Conditioning SpecificationsAIR CONDITIONINGSPECIFICATIONSRefrigerant TypeVolume of RefrigerantCompressor Oil TypeCompressor Oil Volume (pre-filled new)LEGENDABCDEFGHIJKLCondenserCompressorReceiver DryerEvaporatorThermostatic SwitchBulkhead Section of FrameAC Line - Compressor to Condenser - #8AC Line - Condenser to Bulkhead - #6AC Line - Bulkhead to EvaporatorAC Line - Evaporator to BulkheadAC Line - Bulkhead to Compressor - #10Expansion ValveAugust 2010 RigMaster Power International Ltd LG200 Service ManualR134a0.65 lbs ; 9.6 oz ; 0.27kgSP-46 PAG Compressor Oil4.3 fl oz; 127 cc; 127 mLPRESSURE Part 01LG9-400LG9-402LG9-404LG9-403LG9-401LG9-003

RigMaster LG200 Installation ManualSection 6High Pressure vs. Temperature ReadingsHigh temperatures and pressures are approximate. Readings within 150-300

Installing the A/C hoses from the LG200 to the AC unit 6:1:2 Air Conditioning Specifications 6:1:3 Section 7 Installing the Fuel System Installation of the Fuel System 7:1:0 Installation of the Fuel Fittings at the Fuel Tanks 7:2:0 Optional Fuel Pick Up Tube (Stand Pipe) 7:2:1 Installation of the Fuel Fittings at the LG200 APU 7:3:0