Gas Heat Pump Air Conditioner - Panasonic PRO Club...(1) Gas Heat Pump Air Conditioner A gas-fueled engine drives the compressor that is the heart of the gas heat pump air conditioner

Gas Heat Pump Air Conditioner

SANYO Electric Co., Ltd.

Applicable Models

W MULTISGP-EW120M2G2WSGP-EW150M2G2WSGP-EW190M2G2WSGP-EW240M2G2W

3WAY MULTISGP-EZ150M2G2SGP-EZ190M2G2SGP-EZ240M2G2

Reference No.SM7110012

Periodic Inspections, Periodic Parts Replacement ManualMarch 2008

CONTENTS

1. Periodic Inspections, Periodic Parts Replacement Work(1) Gas Heat Pump Air Conditioner .............................................................................. I-1(2) Periodic Inspections and Their SchedulingjWarranty Period ...................................................................................................... I-1kInspection Menu for Periodic Inspection Contract .................................................. I-1lMiscellaneous ......................................................................................................... I-1

(3) Outdoor main board switch and LED arrangement diagram .................................... I-2(4) Basic Operations for Periodic Inspection WorkjBackup operation during maintenance work (for W MULTI) ................................... I-3kEngine Stop ............................................................................................................ I-4lCanceling Engine Stop ........................................................................................... I-4mEngine Oil Use Time Reset Method ....................................................................... I-5nOperating the Fuel Gas Solenoid Valve Forced Off Switch .................................... I-5oCoolant Circulation Operation ................................................................................ I-6pForced Rotational Speed Setting Operation ........................................................... I-7qTest Run Procedure ................................................................................................ I-7

2. Periodic Inspection and Periodic Replacement Work Manual(1) Engine Oil Replenishment and Oil Filter Replacement ........................................... II-1(2) Engine oil Inspection, Replenishment, Replacement Work List .............................. II-4(3) Valve Clearance Adjustment .................................................................................. II-5(4) Sparkplug Replacement ......................................................................................... II-8(5) Air Cleaner Element Replacement ........................................................................II-10(6) Coolant Level Check, Replenishment ...................................................................II-12(7) Compressor Drive Belt Replacement ....................................................................II-13(8) Drain Filter Filling Stone Inspection, Replenishment .............................................II-17(9) Gas Leak Inspection ..............................................................................................II-19(10) Control program version check..............................................................................II-19

3. Periodic Replacement Parts List .............................................................. III-1

GHP Periodic Inspection, Periodic Replacement Checklist (Type M2) ........IV-1

I - �

1. Periodic Inspections, Periodic Parts Replacement Work(1) Gas Heat Pump Air Conditioner

A gas-fueled engine drives the compressor that is the heart of the gas heat pump air conditioner (GHP) system. The use of a gas engine offers several advantages:● Becausethereisnodefrostoperation,stableheatingispossibleevenwhenexternaltemperaturesarelow.● Asshownbelow,electricpowerconsumptionisrelativelylow(whenheatingwith60Hzpowersource)andreduces

theloadonpowerreceivingequipment.* Types120,150,190 :1.12kW(approx.)* Type240 :1.58kW(approx.)However,justlikeacarengine,periodicinspectionsbyaspecializedservicepersonarerequiredtoensuretroublefreeoperationofthesystem.Makesureallperiodicinspectionsareperformed.

(2) Periodic Inspections and Their SchedulingjWarrantyPeriod

Theequipmentiscoveredbywarrantyfor1yearaftercompletionoftestrunanddelivery.Howevertheengineitselfandperiodicallyreplaceablepartsarecoveredbywarrantyforoneyearor2,000hoursofoperation(whicheveris shorter) after completion of test run and delivery.

kInspection Menu for Periodic Inspection ContractSinceperiodicinspectionsarenecessarytoensurelong-termtroublefreeuseofthegasheatpumpairconditioner(GHP)afterthewarrantytermends,Sanyohaspreparedthemenuofinspectionsshownbelow.Pleasenotethattheservicecontractforperiodicinspectionsonlyincludestheinspectionsshowninthetablebelow.Servicecallsformalfunctionswillbechargedseparately.

Itemization and Schedule of Periodic Inspections and Periodic Parts ReplacementRemarksNumberofyearspassedortotalhoursofoperation 5yearsor

10,000hours10yearsor20,000hours

Maintenance item Periodic Inspection

Periodic Inspection

� E/G oil jReplacekLeakcheck

2 E/G systeminspection

jValveclearanceadjustmentkStart-upchecklAbnormalnoise,vibrationcheckmHarnesscheck

3 Coolant jCheck(condition,amount),replenishkLeakcheck

4 Drainfilter jReplenish,clean,oilabsorptionsheets change

5 Inspect fuel system jCheckforgasleaks

6 Inspect refrig-eration system jCheckforgasleaks

7 Controlprogramversioncheck Updateasrequired8 Collect and record operation data

9Periodicre-placement parts

jOilfilter jReplacekAir cleaner elementjReplacelSparkplugs jReplacemCompressor drive belt jReplace

nOilabsorbentmat jReplaceoOilabsorbenttube jReplace

Note1:“Periodicinspection”refersto1entireinspectionoftheitemsmarkedwithinthetable,includingreplacementofperiodicallyreplaceableparts.Thisinspectionwillbeperformedateither10,000hoursofoperationorat5years,whichevercomesfirst.

Note2:Theperiodicinspectioncontractisrenewableaslongasthepartsnecessarytousetheequipmentareavailable.Inthiscase,however,ifpartsthatarenotperiodicallyreplaceablepartsmustbereplaced,thecostofthosepartsandtheexpenseofreplacementwillbechargedseparately.

Note3:Whenthehoursofoperationreach30,000hours,Sanyowillarrangefor“refreshmaintenance.”Thismaybere-peatedforupto13years(if13yearsareexceeded,theequipmentisreplaced).Furthermore,aperiodicinspectionisrequiredeither10,000hoursofoperationor5yearsafter“refreshmaintenance,”whichevercomesfirst.Fordetails,contactthepersonresponsibleforinspectingtheequipment.

lMiscellaneousIndoorandoutdoorheatexchangercleaningisgenerallyrequiredonceevery3-4years.However,thisvariesac-cordingtothelevelofcontamination,typeofindustry,andinstallationconditions.Ifforeignmatterordustadherestoindoororoutdoorheatexchangerfins,itwilldegradeperformanceandcausemalfunctions.Cleaningmustbeperformed to ensure proper use of the air conditioner. Cleaning costs are estimated separately.

I - 2

(3) Outdoor main board switch and LED arrangement diagram

No. Name No. Name� TerminatingresistanceON/OFFswitch(S010) �7 CN0752 STOPSW(S001) 18 EEPROM3 Indoor/outdoorcommunicationmonitor(D043) 19 CN037(white)4 Fuelgassolenoidvalveforcecloseswitch(S002) 20 CN049(red)Compressoroutlet/inletpressuresensors

PS1:Inlet,PS2:outlet5 SETkey(S007)6 DOWNkey(S006) 2� CN029(blue)7 UPkey(S005) 22 CN014(blue)8 LEVELLED(D053) 23 CN016(black)9 TEST/WARNINGLED(D052) 24 CN062(green)Hotwateroutlettemperature10 HOMEkey(S004) 25 CN060(blue)Clutchcoiltemperature�� CN015(white) 26 CN058(white)Coolanttemperature�2 CN063(yellow) 27 CN059(black)Outdoorairtemperature�3 CN012(red) 28 CN055(blue)Heatexchangerinlettemperature�4 CN011(black) 29 CN064(yellow)Clutch2coiltemperature15 CN010(white) 30 CN053(black)Compressorinlettemperature16 CN006(black) 3� CN054(red)Compressoroutlettemperature

31

20

81710

9

7

6

5

24

25

26

27

28

29

30

19

4

18

3

2

1

13141516

23

22

21

12

11

I - 3

(4) Basic Operations for Periodic Inspection Work

AllworkotherthanwhentheSTOP(allstop)switch(S001)issettoSTOPandtheVG(fuelsolenoidvalveforcedoffswitch)switch(S002)issettoOFFshouldbeperformedwiththeHOME(S004),SET(S007),UP(S005),andDOWN(S006)keys.Itisextremelydangerousifthecustomerperformsanoperationthatrunstheengineduringamaintenanceinspectionorwhennotexpected.Makesureyoustopoperationduringworkinthewaydescribedbelow.* Pressing the HOME (S004) key for 1 second or more forcefully returns the state to the initial state. The

value of a partially set item will be discarded, and the item number will return to “.”* If there is no operation for 10 minutes when other than the “” item number is displayed, the value of

a partially set item will be discarded, and the item number will return to “.”

jBackupoperationduringmaintenancework(forWMULTI)• Whatisbackupoperation?IntheGHPWMULTIseries,multipleoutdoorunitsareconnectedtothesamerefrigeranttube.Therefore,evenduringmaintenanceworkofanoutdoorunit,theotheroutdoorunitnotrequiredinmaintenanceworkcanbeusedtokeeptheindooroperatingconditions.Thisiscalledabackupoperation.

• BackupoperationprocedureToperformbackupoperation,theoutdoorunitformaintenancework(hereafterreferredtoas"targetoutdoorunit")mustbecutofffromthesystemusingthefollowingprocedure.Reviewcontentofthemaintenanceworkandthenselectthemostsuitablemethod.Also,afterthemaintenanceworkisfinished,alwaysreferto[Systemrecovery procedure] and then return the system to its normal state.

[Backup operation procedure]To turn off power of target outdoor unit and then perform maintenance work (basic operation during inspection of outdoor unit)

« Important »Thisisthebasicoperationperformedduringinspectionwork.Ifthisoperationisnotperformedandthepoweroftheoutdoorunitisturnedoff,thiswillcausesystemfaultandpreventbackupoperationtobecar-riedout,andseriousmalfunctionwilloccur.Ifthishappens,see[Systemrecoveryprocedure]torecoverthesystem,andthenonceagainusethefollowingproceduretoperformsetup.Automaticbackupoperationwillkickin.

* �) Sometimes all outdoor units may stop. If there is operationinput,outdoorunitsotherthanthetargetonewillstartoperationagainafterapproximatelyfiveminutes.(Fordetailsonthesettings,seethenextitem.)

* 2) Alwayscarryoutthefollowingthreetasks.

jCheck to make sure « Step 2 » is finished. If the shut-offvalveisopened,refrigerantwillflowfromtheotheroutdoorunittothetargetoutdoorunit,causingseriousmalfunction.

kAfter 3 minutes has elapsed from completion of « Step 1 »,checktomakesuretheoutdoormainboarddisplays" "andthenperformthisoperation.Ifyouturnoffthepowerimmediatelyafterperforming"STOP"setting,theentiresystemwillstop.(Backupoperationcannotbeperformed.)Ifthishappens,see[Systemrecoveryprocedure],recoverthesystem,andthen start over again starting from « Step � ».

lTherewillnotbeanyproblemwhetherthecircuitbreak-er of the outdoor unit in « Step 3 »isONorOFF.Selectoneofthemaccordingtotheworkrequired.

On the outdoor main board of the target outdoor unit, set the STOP switch (S001) to "STOP". *1

(After confirming that the engine of the target outdoor unit is stopped) close the valves of re-frigerant gas tube, refrigerant gas liquid tube, and balance tube.

On the outdoor main board of the target outdoor unit, set the STOP switch (S001) to "STOP". Wait for three minutes or more and then turn off the circuit breaker of the target outdoor unit. *2

Start maintenance work.

« Step 1 »

« Step 2 »

« Step 3 »

I - 4

[Workexample]PerformmaintenanceonWMULTIoutdoorunit2inrefrigerantsystem1.

a) FortheWMULTIoutdoorunit2indicatedintheleftdiagram,perform«Step1»to«Step3»in[Backupoperationprocedure]inthatorder.Then,performmaintenanceworkonWMULTIoutdoorunit2.

b) When«Step3»isfinished,WMULTIoutdoorunit1isreset.(It'llstopeven if it is operating.)

c) Afterapproximatelyfiveminutes,ifthereisoperationinput(indoorremotecontrolleris"Run"ortestrunsettingonoutdoormainboard),WMULTIoutdoorunit1startsup.(Backupoperationstarts.)

d) Iftestrunissetfromoutdoormainboard,WMULTIoutdoorunit1continuestorun.However,ifnormaloperationisstartedbytheindoorremotecontroller,dependingontheload,alloutdoorunitsmaystopdueto thermostat off.

[System recovery procedure]Ifbackupoperationhasbeenperformed,byallmeanscheckthefollowingitemsafterthemaintenancework,andthenperform settings again to return the system to its normal state.1)Checktomakesureallshutoffvalvesofrefrigerantgastube,refrigerantliquidtube,andbalancetubeoftheoutdoor

unit are opened.2)ChecktomakesuretheSTOPswitch(S001)ontheoutdoormainboardissetto"NORM".3)Ifthepoweroftheoutdoorunithasbeenturnedoff,turnonthecircuitbreaker.4)If"Testrun"(No.4 - / )isset,cancelit.* WhenadjustingtoNo.4 - / ,ifTEST/WARNINGLED(D052)lights,thismeans

"Testrun"isbeingset.Inthisstate,presstheSET(S007)keyforonesecondormore.Thesettingwillbecanceled(TEST/WARNINGLED(D052)goesoff.)

kEngine StopForciblyturnsoffthethermostatofalloperatingindoorunits,andstopsoutdoorunits.(STOPSW(S001)isnormallysetto“NORMAL.”)

1)MoveSTOPSW(S001)from“NORMAL”to“STOP”(Figure1).“ ”willappearonthe7-seg-mentLEDdisplay(Figure2).OnaWMULTI,the7-segmentLEDdisplayshowninFigure3(“ “)replacesthatshowninFig-ure 2 (“ “)when3minuteshaveelapsed.

2) The all stop operation starts.Note:Duringallstop,theoutdoorunitwillnotstart

evenwhendirectedtodosobytheindoorunit.3)Turnoffthepowersupplycircuitbreakerfortheout-

door unit.

lCanceling Engine Stop1)MovetheSTOPSW(S001)from“STOP”to“NOR-

MAL.”2)Turnonthepowersupplycircuitbreakerfortheout-doorunit.Theallstopwillbecanceled,andtheenginewillstart.

Figure 3

Figure 2

Figure 1

Refrigerant system 1R

efrig

eran

t tub

e(m

ain

tube

) Refrigerant tube(outdoor branch tube)

Balance tube

W MULTIoutdoor unit 1

W MULTIoutdoor unit 2In

door

/out

door

con

trol w

ire

«Step 1»«Step 2»«Step 3»

I-5

mEngine Oil Use Time Reset MethodMakesuretoperformthisprocedureafterchecking(re-plenishing,changing)theengineoil.

1)PresstheHOME(S004)keyforonesecondormore.Themenudisplaywillshowitemnumber“ ”

2)Next,presstheUP(S005)andDOWN(S006)key,displayingthemenuitemnumbers.Gotomenuitem “ ”

3)Aftermenuitemnumber“ ”appears,theoilusetimewillbedisplayed.PresstheSET(S007)key.

4)WhentheSET(S007)keyispressedwiththeoilusetimedisplayed(Figure3),thenextdisplayappears.BypressingtheUP(S005)keyorDOWN(S006)keyinthismode,theoilusetimedisplayclearsettingortheforcedoilreplenishmentsettingcanbeselected.Selectthesettingtoclearoilusetimedisplay(“ ” on the 7-segment LED display).

Display Function

↑DOWN

↓UP

Oil use time display clear setting

Forcibleoilreplenishmentsetting

5)ClearingtheOilUseTimeDisplayWhentheSET(S007)keyispressedfor1secondormorewhiletheoilusetimedisplayisselected,“ ”willappearonthe7-segmentLEDdisplay(Figure4).

6)ReleasetheSET(S007)keyonce“ ” is dis-played,thenquicklyholditdownagain.“ ” willbedisplayed(Figure5),andtheoilusetimewillberesetto0hours.Nexttheoilusetimewillbedis-playedandcanbechecked.Note:Iftheoilusetimedoesnotreturnto0hours,

perform the procedure again.

nOperatingtheFuelGasSolenoidValveForcedOffSwitchThisVGswitch(S002)isusedtoforciblyclosethegassolenoidvalve(Figure6).

«This switch should normally be set to “NORMAL”. »

Figure 6

Figure 5

Figure 4

Figure 3

Oil use time (10,100 hours)

“o” is displayed, indicating oil use time

I-6

oCoolant Circulation OperationThisoperationforciblydrivesthecoolantpumpandthecoolantelectricthree-wayvalve.Itisusedforrefillingcool-ant and for removing air from the coolant circuit.Note:Checkthatthecoolantcircuitcontainssomecoolantbeforeperformingthisoperation.Thepumpmaybedam-

agedifforcedoperationisstartedwithoutanycoolant.1)PresstheHOME(S004)keyfor1secondormore.Themenuitemnumber“ ”willbedisplayed.2)NextpresstheUP(S005),DOWN(S006)keystodisplaymenuitemnumber“ ”3) After “ ” the test run/forced setting display

“ ”willappear(Figure7).PresstheSET(S007)keywhile“ ” is displayed.

4)PresstheSET(S007)keyintheforcedcoolingtestrunsettingmodetoselectoneofthedisplaysshowninthetablebelow.PresstheUP(S005)orDOWN(S006)keytoselect“ “ (forced coolant circulation setting).(Figure8)

Display Function

↑DOWN

↓UP

Forcedcoolingtestrunsetting

Forcedheatingtestrunsetting

Forcedvalveopeningsetting

Forcedcoolantcirculationsetting

Forcedbypassvalveclosing

Coolantairbleedmode

Forcedenginedistributormode

Forcedenginefeedback

Forcedengineadjustmentvalveclosing

Forcedcompressoroilreplenish(WMULTI)

Forcedcompressoroilsupply(WMULTI)

Forcedoutdoordefrosting

Ignore pressure sensor

Forcefuelgassolenoidvalveoff

5)SettingandCancelingForcedCoolantCirculationOperationPresstheSET(S007)keyfor1secondormorewhileforcedcoolantcirculationsettingisselected.Thecoolantpumpwilloperateandthecoolantelectricthree-wayvalvewillcyclerepeatedlythroughclosingcompletelyfor3minutes,thenopeningcompletelyfor1minuteand15seconds.Duringthistime,theforcedsettinginprogressdisplaywillappear(theTEST/WARNINGLED(D052)willlight).Tocanceltheforcedcoolantcirculationset-ting,presstheSET(S007)keyfor1secondormore.Theforcedsettinginprogressdisplaywillbecleared(theTEST/WARNINGLED(D052)willgoout)andthedisplaywillreturntotheforcedsettingselectionoperation.

Figure 8

Figure 7

I - 7

pForcedRotationalSpeedSettingOperationThissettingisusedtoforciblyfixtherevolutionofen-ginewhendoingtestruns.1)PresstheHOME(S004)keyforonesecondormore.Themenuitemnumber“ ”willbedis-played.

2)NextpresstheUP(S005)andDOWN(S006)keystodisplaymenuitemnumber“ ”

3)PresstheSET(S007)keywhile“ ” is dis-played. The forced engine revolution setting display “ ”willappear(Figure9).

4)WhentheSET(S007)keyispressedinthismode,thefollowingdisplayswillcycleinsequenceat1-secondintervals.

Display Function

Forcedenginerevolutions(example:1400min-�)

Enginerevolutions(example:1400min-�)

Compressorinletpressure(example:0.56Mpa)

Compressoroutletpressure(example:0.56Mpa)

Compressoroutlettemperature(example:85.0ºC)

5)SettingandCancelingForcedRotationalSpeedSelectforcedenginerevolutionsusingtheUP(S005)andDOWN(S006)keys.Thespeedcanbesetwithintherangefromtheminimumspeedtothemaximumspeedoftheengine,inunitsof100revolutions.Withthespeedselected,presstheSET(S007)keyfor1secondormore.Theselectedspeedwillbefixedastheforcedenginerevolutions.Duringthistime,theforcedsettinginprogressdisplaywillappear(theTEST/WARNINGLED(D052)willlight).Tocanceltheforcedenginerevolutionsetting,presstheSET(S007)keyfor1secondormore.Theforcedsettinginprogressdisplaywillbecleared(theTEST/WARNINGLED(D052)willgoout)andthedisplaywillreturntothe forced setting selection operation.

qTest Run ProcedureThis setting is used to perform a test run from the outdoor unit.1)Setallremotecontrollerswitchesto“Stop”.2) Select ““ (forced cooling test run) or ““(forcedheatingtestrun).Fordetailsseesteps1)to4)

on page I-7.3)SettingandCancelingaForcedTestRunWhen“ “ (forced cooling test run) or “ “(forcedheatingtestrun)isselected,holdingdowntheSET(S007)key1secondorlongercausestheforcedsettingtoappear(TEST/WARNINGLED(D052)beforeatestrunstarts.Tocancelforcedtestrunoperation,holddowntheSET(S007)keyfor1secondorlonger.Thisclearstheforcedsetting(TEST/WARNINGLED(D052)goesoff)andtheforcedsettingselectionreappears.

Figure 9

II - �

2. Periodic Inspection and Periodic Replacement Work ManualPeriodic inspections and replacements are very important for ensuring that users can enjoy long and trouble-free service from Sanyo gas heat pump air conditioners.

(1) Engine Oil Replenishment and Oil Filter Replacement

Safety PrecautionsStopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer operates the remote controller on the indoor unit side. Before carrying out work on the inside of the outdoor unit, make sure you turn off the power supply circuit breaker of the outdoor unit.(However, if a system controller or other centralized control device is being used, an abnormal communications error may be generated.) Alternatively, perform the STOP operation for the outdoor unit.

● EngineandmodelnumberrelationshipEnginename Model No.

K25 (Nissan engine) SGP-EW120/150/190/240M2G2W(WMULTI)SGP-EZ150/190/240M2G2W(3WAYMULTI)

For details on how and when to perform engine oil inspection, replenishment and replacement, see attached table Chapter [2 (2)].

jUseSanyogenuineoilfortheengineoil.● IdemitsuKosan(Co.,Ltd.)SanyoGenuineAP.GHPD-125

●NipponOilCorporationSanyoGenuineGHPOil10TH

● COSMOOILLUBRICANTSCo.,Ltd.SanyoGenuineGHPOil10W30C2

kEngineoilandoilfilterreplacementperiodReplacetheengineoilandoilfiltereveryfiveyearsor10,000operatinghours,whichevercomesfirst.

lThefollowingtools,parts,andmaterialsarerequiredfordoingthiswork.Preparethembeforestarting:Name Specification Q’ty Remarks

Part

s, M

ater

ials

Sanyo genuine oilD-12510TH10W30C2

46liters

·SanyoGenuineAP.GHPD-125·SanyoGenuineGHPOil10TH·SanyoGenuineGHPOil10W30C2

Oilfilter For models with a K25 engine638-012-7993 �

WasteOilcontainer Asneeded

Rags Asneeded

Tools

Screwdrivers No-3Phillips,No-2flat � eachClosed wrench 19mm �Oilpumporhandpump �Filter wrench �Oilcontainerwithnarrowspout 5 liters �

Tray(Oildrainbasin) �Pliers �

Figure 1 SANYO genuine gas engine oil

II - 2

mReplaceoilfilterReplacetheoilfilterwhentheoilischanged.1)Removetheoilfiltera)Becauseoilremaininginthefilterwillspillwhenthefilterisremoved,positionatray(oildrainbasin)belowthefilterwhen removing it.

b)Useafilterwrenchtoremovetheoilfilter(Figure2).Takecarenottodamagethestudboltsthatholdthefilterin place when using a screwdriver or other tool to turn the oilfilterduringfilterremoval.

2)Installthenewoilfiltera)ApplyfreshengineoilthinlyandevenlytotheO-ringofthenewfilter(Figure3).b)Duringoilfilterinstallation,turnthefiltertwo,threeormoretimesafterthepackingisseatedintheenginetotightenit.(SeeFigure4.)

c)Usearagtowipeupspilledoil.

Tighteningtorque:14.7–20.6N•m

Figure 2 Detaching the oil filter

For models with a K25 engine

Figure 4 oil filter install

For models with a K25 engine

CautionNever use a filter wrench to install the oil filter. If the filter is overtightened, the O-ring will be damaged, resulting in oil leaks.

Figure 3 Applying Sanyo genuine oil

II-3

nChange engine oilReplacealloilintheoilpanandthesubtank.

�) Prepare the designated amount of oil.Amountofoilfor10,000hoursOiltank:43litersEngine:3liters

2)Stoptheengineafterwarmingupforbetween10and15minutes.(RefertoSection1.(4)“kStoppingtheEngine”.)

3)Openthecapoftheoiltank(Figure5).

4)Removeoilusingtheoilpump.First,insertthepumpinthenarrowsideoftheoiltankaper-turetoremoveoilfromtheexternaltank.Next,insertthepumpinthewidersideoftheoiltanktoremovetheoilfromtheinternaltank(Figure6).*Caution:Forthenarrowside,atubeofø16mmorbelowis

required.

5)Removethecapsthatareinsertedattheendsofthedischargehose(2intotal)attachedtotheoiltanktoremovethere-mainingoilintheoiltank(Figure7).

6)Oncetheoildischargeiscomplete,useawasteclothtowipeofftheoldoilfromtheoutletoftheoildrainhose.Afterthis,insertthecapsthatwereremovedduringStep5).Bringtheoildrainhosebacktoitsoriginalposition.

7)Usetheoilcontainertoslowlyfill43litersintotheoiltankfromtheoiltankapertureand3litersintotheengineviatheenginehead.Whendoingso,filltheoilfromthewidersideoftheoiltankaperture(Figure6).

8)Closetheoiltankcapandtheengineheadcap.

oOperationcheck�) If oil spilled while adding it, wipe it up.

2)Canceltheenginestop.(RefertoSection1.(4)“l Canceling EngineStop.”)Operatetheenginefor10-15minutesandmakesuretherearenooilleaksaroundtheoilfilteroroildrain hose.

pOillevelgaugecheckMakesurethattheoilisfilleduptillthedividerisnotvisiblefromtheoiltankaperture.

qEngineoilusetimeresetRefertoSection1.(4)“mEngineOilTimeResetMethod.”

Figure 7

Figure 5

Figure 6 Top surface of the oil tank

Oil tank Wider side

Narrow side

II-4

(2) Engine oil Inspection, Replenishment, Replacement Work List

jEngineoilinspection,replenishmentandreplacementschedule1)Engineoilreplacementinterval

YearnumberHoursofoperation

×(1,000hours)

Maintenance item

� 2 3 4 5 6 7 8 9 10 �� 2 13

2 4 6 8 10 �2 14 16 18 20 22 24

Periodic inspection(5yearsor10,000hours)

Replace

2)Whendeliveredthereisenoughoilfor10,000hoursofoperation.3)Oilreplacementareperformedevery10,000operatinghours.4)Theamountofoilsufficientfor10,000operatinghoursisasfollows:

Tanklocation Engine: Oiltank TotalOil

Types120,150,190,240 3liters 43liters 46liters

(Replace) (Replace)

II - 5

(3) Valve Clearance Adjustment


jPre-adjustmentcheckitems1)Thevalveclearanceadjustmentmustbeperformedevery10,000hoursor5years,whichevercomesfirst.2)Thevalveclearanceadjustmentisalsorequiredwhenevertherockerarmshaftisremovedforpartsreplacement

or other reason.3)Performthevalveclearanceadjustmentwhentheengineiswarm.4)Stoptheengineafterwarmingitupfor10to15minutes.(RefertothesafetyprecautionsandSection1.(4)“kEngineStop”.)

Caution● Perform the valve clearance adjustment within 10 minutes of stopping the engine.● The engine will be hot immediately after stopping. Take appropriate precautions.

kThefollowingtoolsandgaugesarerequiredfordoingthiswork.Preparethembeforestarting.Name Specification Q’ty Remarks

Tools

Thicknessgauge 0.45mm � eachRatchetwrench 1/2inchdrive(12.7mm) � eachSocketorclosedwrench 22mm,14mm � each

Screwdriver No-3,No-2Phillips(+),No-2flat(-) � each

Torquewrench31.4 N•m20.6 N•m4.9 N•m2.25 N•m

� each

lRemovetheenginerockerarmcover1)Removethe2enginerockerarmcovercapnuts(22mm)(Figure1).2)Toreleasethegripofthegasketadhesive,movetheenginerockerarmcoverforwardandbacklightlywhile

pressing on it (Figure 2).

Figure 2Figure 1

Cap nuts

II-6

3)Removetheenginerockerarmcoverfromthecylinderhead(Figure3).

mPositionthefirstorfourthcylinderatcompressiontopdeadcenter.1)Removetheignitioncoilandsparkplugsforallcylinders.2)Rotatethecrankshaftwithasocketwrench(ratchet)(Figure4)untilthetopmark(orange)onthecamshaftpul-

ley is aligned with the timing pointer (Figure 5).Thecylindersarenumbered1,2,3,4insequencefromthecompressorside.

3)Rotatetheintakeanddischargesidepushrodsforthefirstcylinderwithyourfingers,checkingthattheymoveeas-ily(Figure6).Iftheymoveeasily,itmeansthatthefirstcylinder is at compression top dead center. Perform the valveclearanceadjustmentsthataremarked●inTable1below(Figure7).

4)Ifthecheckaboveisnotsuccessful,rotatetheintakeand discharge side pushrods for the fourth cylinder with yourfingers,checkingthattheymoveeasily.Iftheserods move easily, it means that the fourth cylinder is at compression top dead center. Perform the valve clearance adjustmentsthataremarked○inTable1below(Figure7).

Table1Cylinder Number 4 3 2 �

Valve Discharge Intake Intake DischargeDischarge Intake Intake Discharge1stcyl.atcompressionTDC ● ● ● ●4thcyl.atcompressionTDC ○ ○ ○ ○

Figure 3

Figure 6 Check the compressor top dead point

Intake sideDischarge side

First cylinder

Figure 4 Timing mark

Figure 5

Timing pointer

Top mark (orange)

Timing indicator details

Top mark (orange)

(white)(white)

(white)

(white)

II-7

5)Afteradjustment3)and4),turnthefly-wheel � revolution, and again align the topmark(orange)onthecamshaftpulleywith the timing pointer. If the valves were adjustedfirstatthefirstcylinderTDCposi-tion,adjusttheremainingvalveswiththe○markinTable1.IfthevalveswereadjustedfirstatthefourthcylinderTDCposition,adjust the clearance of the remaining valves withthe●markinTable1(Figures5,6,7).

nAdjustvalveclearances1)Rotatethepushrodwiththefingers,andcheckthattherodmoveseasily.Ifitdoes,loosenthevalvelocknut(14mm).Slightlyloosentheadjustingboltwithaflat(-)screwdriver,andinsertthethicknessgauge.Turntheadjustingbolttoadjustthevalveclearance.Whentheadjustmentisfinished,securetheadjustingboltwiththeflatscrew-driver so that it does not turn, then tighten thelocknut(Figure8).

2)Adjustthevalveclearancewhiletheengineiswarm.Intakevalves Dischargevalves

Whenwarm 0.45mm

3)Whenfinishedadjustingthevalveclearance,tightenthelocknuttothespecifiedtorque.

Locknut Tighteningtorque:27.4-34.3N•m

oAfteradjustment1)Reinstalltheenginerockerarmcoverandsparkplugs,andtightentothespecifiedtorques.Firsttightenthe2nutsfortheenginerockerarmcoverevenlyontheleftandrightbyhand,thentightentothespecifiedtorquewithatorquewrench.

Enginerockercovernut Tighteningtorque:13.7-15.7N•m

Sparkplug Tighteningtorque:19.6-29.4N•m

2)Installsparkplugcoilbracketsforallcylinders

Sparkplugcoilbracket Tighteningtorque:15.7-17.7N•m

pOperationcheck1)Canceltheenginestop.(RefertothesafetyprecautionsandSection1.(4)“lCancelingEngineStop.”)2)Makesuretherearenoabnormalnoises(clickingorclatteringsounds).Ifabnormalnoisesarepresent,thevalve

clearances must be readjusted.

Figure 7 Location of each valve

discharge inlet inlet discharge discharge inlet inlet discharge

Figure 8 Valve clearances adjustment

II-8

(4) Sparkplug Replacement


jThesparkplugreplacementmustbeperformedevery10,000hoursor5years,whichevercomesfirst.

kMakesuretousegenuinepartsforthereplacementsparkplugs(Figure1).

lThefollowingtools,gauges,andpartsarerequiredfordoingthiswork.Pre-pare them before starting.

■ PreparationforworkName Specification Q’ty Remarks

Tools

Sparkplugwrench �Torquewrench 9.8-29.4N•m �Screwdriver No-3Phillips(+),No-2Phillips(+) � eachWirebrush �

Sparkplug 623-194-7664(638-018-9588canalsobeused) 4

jEngineStopStoptheengine.(RefertothesafetyprecautionsandSection1.(4)“kEngineStop.”)

kRemovethepanel.Removethefrontpaneloftheunit.

lRemovingthewireharnessplugsRemovethewireharnessplugsfromthesparkplugcoils(Figure5).

Figure 1

II-9

mSparkplugcoilbracketRemovethe2boltsshowninFigure6,andremovethesparkplugcoilbracket.

Figure 5 Removing the wire harness plugs

nSparkplugsUseasparkplugwrench(16mm)toremovethesparkplugs(Figure7).

Figure 7 Removing the sparkplug cover bolts

oInstallationInstallnewsparkplugsbyfollowingthereverseoftheremovalprocedure(froml to j).

Sparkplugs Sparkplugcoilsbracket:19.6-29.4N•m

Sparkplugcoilsbracket Sparkplugcoilsbracket:15.7-17.7N•m

■Operationcheck

jMovetheSTOPSWto“NORMAL.”(RefertoSection1.(4)“lCancelingEngineStop.”)

kOperatetheunit,andperformanenginestartupcheck.

lReinstalltheremovedunitpanelinitsoriginalposition.

Figure 6 Removing the sparkplug coils

II-10

(5) Air Cleaner Element Replacement


jPreworkcheckitems1)Adry-typeaircleanerelementisused.Theintakeportcoverremovescoarseparticles.Astheintakeairisguidedintothebodyoftheairfilter,avortexiscreatedbyacyclonedevice.Thecurrents within the vortex cause particles in the air to collect in adustcup,whilefinerparticlesarefilteredoutbyfoldedpaperfilterelements.

2)Iftheaircleanerelementbecomesclogged,thequantityofairwill be reduced, causing the engine to stall.

●Makesuretoreplacetheelementperiodically.● Replacetheelementmorefrequentlyindustyoroilyenviron-

ments.

kReplacementPeriodReplacetheaircleanerelementevery5yearsor10,000operatinghours,whichevercomesfirst.

lPreparationsThefollowingpartsandtoolsarerequiredfordoingthiswork.Preparethembeforestarting.

Name Specification Q’ty Remarks

Parts Aircleanerelement 623-196-0564(826-2-1245-11300) � Figure �

Tools Nut driver Acrossflats17mm

mPreparationforwork1)Stoptheengine.(RefertoSection1.(4)“kEngineStop.”)2)Removetherearpaneloftheunit.

nRemovetheelementandclean1)Removethescrewthatsecurestheaircleanerelement,slidethe

fastener to the left to remove it and the element. (Figure 2.)2) Clean the inside of the air cleaner case.

Figure 1 air cleaner element

Figure 2

II - ��

oReplaceElementSlideinthenewelementasfarasitwillgo.Makesurethesealdoesnotpreventinsertion.(Figure3.)

Figure 3

Caution● This is a dry element. Do not use oil.● Replace the element earlier in dusty or oily environments.

pFastener attachmentMove the fastener on the air cleaner from the left to the right and secure it in the center using a securing screw. (Figure 2.)

qOperationcheck1)MovetheSTOPSWto“NORMAL.”(RefertoSection1.(4)“lCancelingEngineStop.”)2)Rechecktheaircleanerinstallation.3)Operatetheenginefor10-15minutesandmakesuretherearenochangesintherevolutionsperminute,no

abnormal noises, and no abnormal exhaust smell or color.

II - �2

(6) Coolant Level Check, Replenishment


jPerformthecoolantcheckandreplenishmentevery10,000operatinghoursor5years,whichevercomesfirst.

kUseSanyoGenuineCoolantsolution(Figure1).lThespecifiedconcentrationforcoolantsolutionis50±5%.

Caution● Take care that the coolant solution does not enter the eyes or

mouth during work.

mPreparationsThefollowingtools,gauges,andmaterialsarerequiredfordoingthiswork.Preparethembeforestarting.


Parts,Materials

Sanyo genuine coolant 3-9509-1040 Asneeded SSPartcode:1743020826-2-4521-10100 SSPartcode:1743030

Rags Smallq’ty

Tools Dispensingcontainer 2 liters � For coolant (free from oil)Gauges Brinetester For ethylene glycol

nCheckandreplenishcoolant1)Checkthecoolantlevelinsidethereservetankfromthecutoutofthesidepanelonthefillernecksideoftheunit.(Figure2)<SuitableLevels>Whenwarm :LleveltomaximumlevelduringoperationWhencold :LleveltoHlevel

2)Ifthelevelwithinthereservetankislow,replenishthecool-antwiththespecifiedconcentrationofgenuineSanyocoolant(50±5%)upuntiltheHlevelposition.a)Removethecoolantreplenishmentportcoveronthetoppanel,andthenremovetherubbercapofthereservetank.(Figure3)

b)UsethejugtoreplenishthecoolantuntiltheHlevelinthereservetank.

c)Reattachandtightentherubbercapofreservetank.

3)Wipeupanyspiltcoolantwitharagorthelike.

4)Reattachthecoolantreplenishmentportcovertothetoppanel.

Figure 1

Figure 3 Remove the rubber cap of the reserve tank

Coolant refill hole

Rubber cap

Coolant refillhole cover

Figure 2 Checking the coolant level

H level

L level

Maximum level during opera-

tion

II-13

(7) Compressor Drive Belt Replacement


jReplacementPeriodReplacethecompressordrivebeltevery5yearsor10,000operatinghours,whichevercomesfirst.

kPreparationsThefollowingtools,gauges,andpartsarerequiredfordoingthiswork.Preparethembeforestarting.


Parts Compressor drive belt 638-018-9625 �

Tools,Gauges

Openendorclosedwrench 19mm �

Socketwrench 10mm,19mm �

Torquewrench 450QLand900QL �

Linearscale �

Tensionmeter �

lPreparation1)Stoptheengine.(RefertoSection1.(4)“jEngineStop.”)2)Removethefrontandrearpanelsoftheunit.

mBeltremoval1)Loosenthecompressorbracketsecuringbolts.(3locationsindicatedbyarrowsinFigure1)

Figure 1 Compressor bracket securing bolts

II-14

2)Removethetubesecuringbracket(Figures2and3).

CAUTIONThere is also tube-fixing plate on the rear panel side of the unit (Figure 2). Do not forget to remove that plate.

3)Turnthetensionadjustmentbolt(counterclockwise),andraisethebracket.(Figure4,19mmboltindicatedbyarrow)

4)Rotatethetensionadjustmentboltuntilthecompressordrivebeltcanberemoved,thenremovethebelt.

Figure 4 Raising bracket

Figure 2 Removing tube fastener (rear side)

Bolts

Bolts

Figure 3 Removing tube fastener

II - �5

nCompression drive belt tension adjustment1)Installthenewcompressordrivebeltwhenthebracketm has been raised. 2)Loosenthebelttensioningbolttoadjustbelttension.PressthebeltasshowninFigure5topreventitfromcom-ingoffthewheelswhilelooseningtheadjustingbolt.Maintainpressureonthebeltuntiltherequiredamountoftension has been obtained.

CAUTION

Do not grasp the belt as your fingers may then be caught in it. Adjust belt tension by applying pressure to it without grasping it.

Figure 5 Retensioning the belt(be sure to hold the belt steady while doing this)

Be sure to check that there is no slippage at these important places

3)Tightenthetensionadjustmentboltsothatthebelttensionisatthespecifieddeflectionvalue.

Belttension 1670-1720N(NewBelt)

DoctorTensionsetupprocedure

Span 290mmtensionmeasurementlocation

Density 0.018kg/m,rib

Number of ribs 10

DoctorTension:AproductmanufacturedbyMitsuboshiBeltingLtd.thatmeasurestensionbasedonthevibrat-ingsoundproducedwhentensionismeasured.Pressafingeragainstthebeltatthemeasure-mentlocationandtheDoctorTensionmicrophonepicksupthesoundtomeasuretension.

4)Atensionmeasurementmadeafterabelttensionadjustmentbyrotatingtheenginepulleybyhandwillshowthattensionhasdropped.Thentightenthetensionadjustmentboltfurthertoadjusttension.Repeatthisproce-dure until desired tension is achieved.

5)Makesurethatthebeltisnotshiftingorcomingofffromthepulley.

6)Fastenthecompressorbracketsecuringbolt.

Fasteningtorque 78-90N•m

7)Reinstallthetubefixingplate(Seetheitemm).

II-16

oOperationcheck1)MovetheSTOPSWto“NORMAL.”(RefertoSection1.(4)“lCancelingEngineStop.”)2)Afterstartingtheengine,makesurethebeltdoesnotslipormakeabnormalnoises.Ifthebeltdoesslipormake

abnormal noises, readjust the tension.

CAUTIONIf there is belt deflection when you tighten the tension adjustment bolt to adjust the belt tension, the ribs of the belt will be offset from the pulley, which may result in the belt slipping off. In particular, there is a high risk of the belt slipping off if the ribs are offset at the locations indicated by the circles in Figure 5 because of the ro-tation direction after operation starts. Be sure to support the belt with a hand while tightening the tension adjustment bolt. Furthermore, make sure you check that the belt has not come off before performing a test run.

II-17

(8) Drain Filter Filling Stone Inspection, Replenishment


jInspection and replacementPerformdrainfilterfillingstoneinspectionandreplacementevery5yearsor10,000operatinghours,whichevercomesfirst.

kPreparationsThefollowingtools,gauges,andpartsarerequiredfordoingthiswork.Preparethembeforestarting.


Materials,Tools

Drainfilterfillingstones CHEMICAL638-007-4860 Asneeded Calcite5kg.(insideplasticbag)

Gasket 638-012-6149 � For repairingRags Smallq’tyNut driver Acrossflats10mm �Oilabsorbentmat 623-200-4601 10Oilabsorbenttube 623-300-8660 �

jRemovingthedrainfilterA1)Removethedrainhoses(2hoses)thatareattachedtothedrainfilterA(Figure1).* Becarefulofthedraindischargefluidthatsometimescomesoutatthisstage.2)RemovethefourboltsandtwonutsindrainfilterAtoremovethefilterfromtheoutdoorunit.(Figure2.)

kReplenishthedrainfilterAfillingstonesRemovetheupperlidofthecaseandreplacetheoldfillingstoneswithnewstones.Addstonesuntilthecaseiscompletely full. * Fillthecasewithstonesevenlytakingcarenottooverfillthecase,whichcoulddeformtheupperlid,andmak-

ing sure that stone fragments get into the grooves of the case.

Drain filter A

Drain hoses

Figure 1 Removing the drain house Figure 2 Removing the drain filter A

bolts

nut

nut

II-18

lRemovingthedrainfilterB1)Removetheconnectorofthedrainfilterheaterthatisattachedtothedrainfilter.

2)LoosenthesecuringscrewA(4screws)ofthestanduponwhichthedrainfilterBisplaced.

3)Removethefasteningbrackets(inthreeplaces)thatholdthemufflerandthedrainfilterBto-gether.

4)SlidethedrainfilterBandthestanddownward.5)TightenthetwoforemostsecuringscrewsAto

secure the stand. 6)RemovethedrainfilterBfromtheoutdoorunit.

mReplenishthedrainfilterBfillingstones1)Removethesecuringscrews,thefastenerofthe

oil absorbent mats and the oil absorbent mats.2)Replacetheoldoilabsorbentmatswithnewones(10pcs)

3)Removethefillingstonecaseandtakethestonesand oil absorbent tube out of the case.

4)Inserttheoilabsorbenttubeandaddthefillingstones. Addfillingstonesupto1/3ofthecaseandplacetheoilabsorbenttubeonthestones.Thenaddmore stones on top of the oil absorbent tube to fillthecasecompletely.

5)Replacethefillingstonecaseinthedrainfiltercase, place the new oil absorbent mats on top and use the securing screws to attach the fastener of the oil absorbent mats.

nAttachthedrainfilterA1)PlacethedrainfilterAonthestandandusethefourboltsandtwonutstosecureittothestand.2)Attachthedrainhoses(2hoses).

oAttachthedrainfilterB1)PlacethedrainfilterBontheoutdoorunitstandandloosentheforemostsecuringscrewsA.2)SlidethestandandthedrainfilterBupwardstojoinwiththemuffler,andfasteninthreeplacesusingthefasten-ingbrackets.

3)Holdthestandsothatitisplacedhorizontally.Whiledoingso,tightenthesecuringscrewsA(4screws).4)Attachthedrainhoseandtheconnectorofthedrainfilterheatertothedrainfilter.5)LoosenthescrewsB(2screws)andautomaticallydropthemufflersothatthetopsurfaceofthestandandthebottomsurfaceofthedrainfilterareinclosecontact.TightenthescrewsB(2screws).

Figure 3 Removing the drain filter B

Securing screw B

Sastening brackets (in three places)

Srain filter B

Securing screw A

Figure 4 Drain filter B

Fastener of the oil absorbent mats

Securing screw

Oil absorbent mats

Oil absorbent tube

Filling stone case

II-19

(9) Gas Leak Inspection


jCheckforleaksinthefuellineconnections1)Openthemainvalveforthegasline.2)Usingagasleakdetector(Figure1)orsoapywater,makesuretherearenoleaksinthefuellineconnectionsof

the outdoor unit.

Figure 1

(10) Control program version check

Checktheversionofthecontrolprogram.Updatetheprogramifrequired.

III - �

3. Periodic Replacement Parts List

III - �

Replacement rank(Replacement time) Maintenance kit Part code Part name Q'ty

C-5(�0,000 hours or 5 years) SGP-MTK560M

638-0��-7993 Oil filter �

9�3-�96-0565 Air cleaner element �

6�3-�94-7664 Spark plugs 4

938-0�8-96�6 Compressor operation belt �

9�3-�00-460� Oil absorbent mat �0

6�3-300-8660 Oil absorbent tube �

C-�0(�0,000 hours or �0 years) SGP-MTK560M

638-0��-7993 Oil filter �

9�3-�96-0565 Air cleaner element �

6�3-�94-7664 Spark plugs 4

938-0�8-96�6 Compressor operation belt �

9�3-�00-460� Oil absorbent mat �0

6�3-300-8660 Oil absorbent tube �

IV - �

GHP Periodic Inspection, Periodic Replacement Checklist (Type M2)Delivery

Destination · ( ) - Inspection, Replacement

Company name · ( ) -

DeliveryAddress Address

Part

No.

Outdoor SGP- M2 (No. )

Indoor

SGP- M2 SGP- M2 SGP- M2 SGP- M2 · SGP- M2 SGP- M2 SGP- M2 SGP- M2 SGP- M2 · SGP- M2 SGP- M2 SGP- M2 SGP- M2 SGP- M2 · SGP- M2 SGP- M2 SGP- M2 SGP- M2 SGP- M2 · SGP- M2 SGP- M2 SGP- M2 SGP- M2 SGP- M2

Gas company name Inspection date ( / / )

Gas type usedCheck items Work Conclusion

1. Operating hours Hours2. No. of times ON/OFF Times3. Check, replace

j Coolant level check, replenishmentk Drain filter filling stone check, replenishmentl Sparkplug replacementm Engine oil changen Oil filter replacemento Air cleaner element replacementp Compressor drive belt replacementq Valve clearance adjustmentr Oil absorbent mats Oil absorbent tube

Intake valve Exhaust valveBefore adjustment After adjustment Before adjustment After adjustment

1st cylinder2nd cylinder3rd cylinder4th cylinder

4. Replacement parts Q’ty Remarks

(Code) ○:Ok C:Cleaned :Dismantled A:Adjusted L:Replenish X:Changed T:Tightened -:Not applicable

IV - �

Check items Measurement Conclusion5. Engine system checks

6. Control program version Version update available? □ Yes Version □ No

7. Operation data collectionj Data collection time (Time after starting operation) Note: Operate all indoor units and measure. Min.

k Abnormal vibration, noise checks OK/ not Ok

Out

door

uni

t ope

ratio

nal d

ata

Data Code Measurement item (sensor name) Unit Measurement Conclusion

11 Engine revolution speed min-1

12 Compressor inlet pressure MPa13 Compressor outlet pressure MPa14 Compressor inlet temperature °C15 Compressor outlet temperature °C19 External air temperature °C31 Outdoor fan output %34 Outdoor unit electrical valve 1 output Step- Compressor intake superheat/2 outputs Deg /

Indo

or u

nit o

pera

ting

data

Operation mode (cool, heat)

TypeElectric valve

degree ofopening

Intaketemperature

Discharge temperature Coil input temp. Coil output

temp.

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