Sanyo 3WAY MULTI SGP-EZ150M2G2 User manual

Gas Heat Pump

Air Conditioner

SANYO Electric Co., Ltd.

Applicable Models

W MULTI

SGP-EW120M2G2W

SGP-EW150M2G2W

SGP-EW190M2G2W

SGP-EW240M2G2W

3WAY MULTI

SGP-EZ150M2G2

SGP-EZ190M2G2

SGP-EZ240M2G2

Reference No.SM7110012

Periodic Inspections, Periodic Parts Replacement Manual

March 2008

CONTENTS

1. Periodic Inspections, Periodic Parts Replacement Work

(1) Gas Heat Pump Air Conditioner .............................................................................. I-1

(2) Periodic Inspections and Their Schedulin

j

Warranty Period ...................................................................................................... I-1

k

Inspection Menu for Periodic Inspection Contract .................................................. I-1

l

Miscellaneous ......................................................................................................... I-1

(3) Outdoor main board switch and LED arrangement diagram ....................................

I-2

(4) Basic Operations for Periodic Inspection Wor

j

Backup operation during maintenance work (for W MULTI) ................................... I-3

k

Engine Stop ............................................................................................................ I-4

l

Canceling Engine Stop ...........................................................................................I-4

m

Engine Oil Use Time Reset Method ....................................................................... I-5

n

Operating the Fuel Gas Solenoid Valve Forced Off Switch .................................... I-5

o

Coolant Circulation Operation ................................................................................ I-6

p

Forced Rotational Speed Setting Operation ........................................................... I-7

q

Test 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

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:

● Becausethereisnodefrostoperation,stableheatingispossibleevenwhenexternaltemperaturesarelow.

● Asshownbelow,electricpowerconsumptionisrelativelylow(whenheatingwith60Hzpowersource)andreduces

theloadonpowerreceivingequipment.

* Types120,150,190 :1.12kW(approx.)

* Type240 :1.58kW(approx.)

However,justlikeacarengine,periodicinspectionsbyaspecializedservicepersonarerequiredtoensuretroublefree

operationofthesystem.Makesureallperiodicinspectionsareperformed.

(2) Periodic Inspections and Their Scheduling

j

WarrantyPeriod

Theequipmentiscoveredbywarrantyfor1yearaftercompletionoftestrunanddelivery.Howevertheengine

itselfandperiodicallyreplaceablepartsarecoveredbywarrantyforoneyearor2,000hoursofoperation(whichever

is shorter) after completion of test run and delivery.

k

Inspection Menu for Periodic Inspection Contract

Sinceperiodicinspectionsarenecessarytoensurelong-termtroublefreeuseofthegasheatpumpairconditioner

(GHP)afterthewarrantytermends,Sanyohaspreparedthemenuofinspectionsshownbelow.Pleasenotethatthe

servicecontractforperiodicinspectionsonlyincludestheinspectionsshowninthetablebelow.Servicecallsfor

malfunctionswillbechargedseparately.

Itemization and Schedule of Periodic Inspections and Periodic Parts Replacement

Remarks

Numberofyearspassedortotalhoursofoperation

5yearsor

10,000hours

10yearsor

20,000hours

Maintenance item

Periodic

Inspection

Periodic

Inspection

1 E/G oil

Replace

Leakcheck

E/G system

inspection

Valveclearanceadjustment

Start-upcheck

Abnormalnoise,vibrationcheck

Harnesscheck

3 Coolant

Check(condition,amount),replenish

Leakcheck

4 Drainlter

j

Replenish,clean,oilabsorption

sheets change

Inspect fuel

system

Checkforgasleaks

Inspect refrig-

eration system

Checkforgasleaks

7 Controlprogramversioncheck Updateasrequired

8 Collect and record operation data

9Periodicre-

placement

parts

Oillter

Replace

Air cleaner element

Replace

Sparkplugs

Replace

m

Compressor drive

belt

Replace

Oilabsorbentmat

Replace

Oilabsorbenttube

Replace

Note1:“Periodicinspection”refersto1entireinspectionoftheitemsmarkedwithinthetable,includingreplacementof

periodicallyreplaceableparts.Thisinspectionwillbeperformedateither10,000hoursofoperationorat5years,

whichevercomesrst.

Note2:Theperiodicinspectioncontractisrenewableaslongasthepartsnecessarytousetheequipmentareavailable.In

thiscase,however,ifpartsthatarenotperiodicallyreplaceablepartsmustbereplaced,thecostofthosepartsand

theexpenseofreplacementwillbechargedseparately.

Note3:Whenthehoursofoperationreach30,000hours,Sanyowillarrangefor“refreshmaintenance.”Thismaybere-

peatedforupto13years(if13yearsareexceeded,theequipmentisreplaced).Furthermore,aperiodicinspection

isrequiredeither10,000hoursofoperationor5yearsafter“refreshmaintenance,”whichevercomesrst.For

details,contactthepersonresponsibleforinspectingtheequipment.

l

Miscellaneous

Indoorandoutdoorheatexchangercleaningisgenerallyrequiredonceevery3-4years.However,thisvariesac-

cordingtothelevelofcontamination,typeofindustry,andinstallationconditions.Ifforeignmatterordustadheres

toindoororoutdoorheatexchangerns,itwilldegradeperformanceandcausemalfunctions.Cleaningmustbe

performed 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

1 TerminatingresistanceON/OFFswitch(S010) 17 CN075

2 STOPSW(S001) 18 EEPROM

3 Indoor/outdoorcommunicationmonitor(D043) 19 CN037(white)

4 Fuelgassolenoidvalveforcecloseswitch(S002)

CN049(red)Compressoroutlet/inletpressuresensors

PS1:Inlet,PS2:outlet

5 SETkey(S007)

6 DOWNkey(S006) 21 CN029(blue)

7 UPkey(S005) 22 CN014(blue)

8 LEVELLED(D053) 23 CN016(black)

9 TEST/WARNINGLED(D052) 24 CN062(green)Hotwateroutlettemperature

10 HOMEkey(S004) 25 CN060(blue)Clutchcoiltemperature

11 CN015(white) 26 CN058(white)Coolanttemperature

12 CN063(yellow)

27 CN059(black)Outdoorairtemperature

13 CN012(red)

28 CN055(blue)Heatexchangerinlettemperature

14 CN011(black)

29 CN064(yellow)Clutch2coiltemperature

15 CN010(white) 30 CN053(black)Compressorinlettemperature

16 CN006(black) 31 CN054(red)Compressoroutlettemperature

81710

13141516

I - 3

(4) Basic Operations for Periodic Inspection Work

AllworkotherthanwhentheSTOP(allstop)switch(S001)issettoSTOPandtheVG(fuelsolenoidvalveforcedoff

switch)switch(S002)issettoOFFshouldbeperformedwiththeHOME(S004),SET(S007),UP(S005),andDOWN

(S006)keys.

Itisextremelydangerousifthecustomerperformsanoperationthatrunstheengineduringamaintenanceinspection

orwhennotexpected.Makesureyoustopoperationduringworkinthewaydescribedbelow.

* 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 “



.”

j

Backupoperationduringmaintenancework(forWMULTI)

• Whatisbackupoperation?

IntheGHPWMULTIseries,multipleoutdoorunitsareconnectedtothesamerefrigeranttube.Therefore,even

duringmaintenanceworkofanoutdoorunit,theotheroutdoorunitnotrequiredinmaintenanceworkcanbe

usedtokeeptheindooroperatingconditions.Thisiscalledabackupoperation.

• Backupoperationprocedure

Toperformbackupoperation,theoutdoorunitformaintenancework(hereafterreferredtoas"targetoutdoor

unit")mustbecutofffromthesystemusingthefollowingprocedure.Reviewcontentofthemaintenancework

andthenselectthemostsuitablemethod.Also,afterthemaintenanceworkisnished,alwaysreferto[System

recovery 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 »

Thisisthebasicoperationperformedduringinspectionwork.Ifthisoperationisnotperformedandthe

poweroftheoutdoorunitisturnedoff,thiswillcausesystemfaultandpreventbackupoperationtobecar

riedout,andseriousmalfunctionwilloccur.Ifthishappens,see[Systemrecoveryprocedure]torecoverthe

system,andthenonceagainusethefollowingproceduretoperformsetup.Automaticbackupoperationwill

kickin.

* 1) Sometimes all outdoor units may stop. If there is

operationinput,outdoorunitsotherthanthetarget

onewillstartoperationagainafterapproximately

veminutes.(Fordetailsonthesettings,seethenext

item.)

* 2) Alwayscarryoutthefollowingthreetasks.

j

Check to make sure « Step 2 » is nished. If the shut-

offvalveisopened,refrigerantwillowfromtheother

outdoorunittothetargetoutdoorunit,causingserious

malfunction.

k

After 3 minutes has elapsed from completion of « Step

1 »,checktomakesuretheoutdoormainboarddisplays

"



"andthenperformthisoperation.If

youturnoffthepowerimmediatelyafterperforming

"STOP"setting,theentiresystemwillstop.(Backup

operationcannotbeperformed.)Ifthishappens,see

[Systemrecoveryprocedure],recoverthesystem,and

then start over again starting from « Step 1 ».

l

Therewillnotbeanyproblemwhetherthecircuitbreak

er of the outdoor unit in « Step 3 »isONorOFF.Select

oneofthemaccordingtotheworkrequired.

On the outdoor main board of the target

outdoor unit, set the STOP switch (S001) to

"STOP". *1

(After conrming 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

[Workexample]PerformmaintenanceonWMULTIoutdoorunit2inrefrigerantsystem1.

a) FortheWMULTIoutdoorunit2indicatedintheleftdiagram,perform«

Step1»to«Step3»in[Backupoperationprocedure]inthatorder.Then,

performmaintenanceworkonWMULTIoutdoorunit2.

b) When«Step3»isnished,WMULTIoutdoorunit1isreset.(It'llstop

even if it is operating.)

c) Afterapproximatelyveminutes,ifthereisoperationinput(indoor

remotecontrolleris"Run"ortestrunsettingonoutdoormainboard),W

MULTIoutdoorunit1startsup.(Backupoperationstarts.)

d) Iftestrunissetfromoutdoormainboard,WMULTIoutdoorunit1

continuestorun.However,ifnormaloperationisstartedbytheindoor

remotecontroller,dependingontheload,alloutdoorunitsmaystopdue

to thermostat off.

[System recovery procedure]

Ifbackupoperationhasbeenperformed,byallmeanscheckthefollowingitemsafterthemaintenancework,andthen

perform settings again to return the system to its normal state.

1)Checktomakesureallshutoffvalvesofrefrigerantgastube,refrigerantliquidtube,andbalancetubeoftheoutdoor

unit are opened.

2)ChecktomakesuretheSTOPswitch(S001)ontheoutdoormainboardissetto"NORM".

3)Ifthepoweroftheoutdoorunithasbeenturnedoff,turnonthecircuitbreaker.

4)If"Testrun"(No.4  -  /  )isset,cancelit.

* WhenadjustingtoNo.4 -  /  ,ifTEST/WARNINGLED(D052)lights,thismeans

"Testrun"isbeingset.Inthisstate,presstheSET(S007)

keyforonesecondormore.Thesettingwillbecanceled

(TEST/WARNINGLED(D052)goesoff.)

k

Engine Stop

Forciblyturnsoffthethermostatofalloperatingindoor

units,andstopsoutdoorunits.

(STOPSW(S001)isnormallysetto“NORMAL.”)

1)MoveSTOPSW(S001)from“NORMAL”to“STOP”

(Figure1).“  ”willappearonthe7-seg-

mentLEDdisplay(Figure2).

OnaWMULTI,the7-segmentLEDdisplayshownin

Figure3(“ “)replacesthatshowninFig-

ure 2 (“   “)when3minuteshaveelapsed.

2) The all stop operation starts.

Note:Duringallstop,theoutdoorunitwillnotstart

evenwhendirectedtodosobytheindoorunit.

3)Turnoffthepowersupplycircuitbreakerfortheout-

door unit.

l

Canceling Engine Stop

1)MovetheSTOPSW(S001)from“STOP”to“NOR-

MAL.”

2)Turnonthepowersupplycircuitbreakerfortheout-

doorunit.Theallstopwillbecanceled,andtheengine

willstart.

Figure 3

Figure 2

Figure 1

Refrigerant system 1

Refrigerant tube

(main tube)

Refrigerant tube

(outdoor branch tube)

Balance tube

W MULTI

outdoor

unit 1

W MULTI

outdoor

unit 2

Indoor/outdoor control wire

«Step 1»

«Step 2»

«Step 3»

I-5

m

Engine Oil Use Time Reset Method

Makesuretoperformthisprocedureafterchecking(re-

plenishing,changing)theengineoil.

1)PresstheHOME(S004)keyforonesecondormore.

Themenudisplaywillshowitemnumber“  ”

2)Next,presstheUP(S005)andDOWN(S006)key,

displayingthemenuitemnumbers.Gotomenuitem

“  ”

3)Aftermenuitemnumber“  ”appears,theoil

usetimewillbedisplayed.PresstheSET(S007)key.

4)WhentheSET(S007)keyispressedwiththeoiluse

timedisplayed(Figure3),thenextdisplayappears.By

pressingtheUP(S005)keyorDOWN(S006)keyinthismode,theoilusetimedisplayclearsettingortheforced

oilreplenishmentsettingcanbeselected.Selectthesettingtoclearoilusetimedisplay(“  ” on the

7-segment LED display).

Display Function

↑DOWN

↓UP



Oil use time display clear setting



Forcibleoilreplenishmentsetting

5)ClearingtheOilUseTimeDisplay

WhentheSET(S007)keyispressedfor1secondor

morewhiletheoilusetimedisplayisselected,

“  ”willappearonthe7-segmentLEDdisplay

(Figure4).

6)ReleasetheSET(S007)keyonce“  ” is dis-

played,thenquicklyholditdownagain.“  ”

willbedisplayed(Figure5),andtheoilusetimewill

beresetto0hours.Nexttheoilusetimewillbedis-

playedandcanbechecked.

Note:Iftheoilusetimedoesnotreturnto0hours,

perform the procedure again.

n

OperatingtheFuelGasSolenoidValveForcedOff

Switch

ThisVGswitch(S002)isusedtoforciblyclosethegas

solenoidvalve(Figure6).

«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

o

Coolant Circulation Operation

Thisoperationforciblydrivesthecoolantpumpandthecoolantelectricthree-wayvalve.Itisusedforrellingcool-

ant and for removing air from the coolant circuit.

Note:Checkthatthecoolantcircuitcontainssomecoolantbeforeperformingthisoperation.Thepumpmaybedam-

agedifforcedoperationisstartedwithoutanycoolant.

1)PresstheHOME(S004)keyfor1secondormore.Themenuitemnumber“  ”willbedisplayed.

2)NextpresstheUP(S005),DOWN(S006)keystodisplaymenuitemnumber“  ”

3) After “  ” the test run/forced setting display

“  ”willappear(Figure7).PresstheSET

(S007)keywhile“  ” is displayed.

4)PresstheSET(S007)keyintheforcedcoolingtest

runsettingmodetoselectoneofthedisplaysshownin

thetablebelow.PresstheUP(S005)orDOWN(S006)

keytoselect“  “ (forced coolant circulation

setting).(Figure8)

Display Function

↑DOWN

↓UP



Forcedcoolingtestrunsetting



Forcedheatingtestrunsetting



Forcedvalveopeningsetting



Forcedcoolantcirculationsetting



Forcedbypassvalveclosing



Coolantairbleedmode



Forcedenginedistributormode



Forcedenginefeedback



Forcedengineadjustmentvalveclosing



Forcedcompressoroilreplenish(WMULTI)



Forcedcompressoroilsupply(WMULTI)



Forcedoutdoordefrosting



Ignore pressure sensor



Forcefuelgassolenoidvalveoff

5)SettingandCancelingForcedCoolantCirculationOperation

PresstheSET(S007)keyfor1secondormorewhileforcedcoolantcirculationsettingisselected.Thecoolant

pumpwilloperateandthecoolantelectricthree-wayvalvewillcyclerepeatedlythroughclosingcompletelyfor

3minutes,thenopeningcompletelyfor1minuteand15seconds.Duringthistime,theforcedsettinginprogress

displaywillappear(theTEST/WARNINGLED(D052)willlight).Tocanceltheforcedcoolantcirculationset

ting,presstheSET(S007)keyfor1secondormore.Theforcedsettinginprogressdisplaywillbecleared(the

TEST/WARNINGLED(D052)willgoout)andthedisplaywillreturntotheforcedsettingselectionoperation.

Figure 8

Figure 7

I - 7

p

ForcedRotationalSpeedSettingOperation

Thissettingisusedtoforciblyxtherevolutionofen-

ginewhendoingtestruns.

1)PresstheHOME(S004)keyforonesecondormore.

Themenuitemnumber“  ”willbedis-

played.

2)NextpresstheUP(S005)andDOWN(S006)keysto

displaymenuitemnumber“  ”

3)PresstheSET(S007)keywhile“  ” is dis-

played. The forced engine revolution setting display

“  ”willappear(Figure9).

4)WhentheSET(S007)keyispressedinthismode,the

followingdisplayswillcycleinsequenceat1-second

intervals.

Display Function

Forcedenginerevolutions(example:1400min

-1

)

Enginerevolutions(example:1400min

-1

)

Compressorinletpressure(example:0.56Mpa)

Compressoroutletpressure(example:0.56Mpa)

Compressoroutlettemperature(example:85.0ºC)

5)SettingandCancelingForcedRotationalSpeed

SelectforcedenginerevolutionsusingtheUP(S005)andDOWN(S006)keys.

Thespeedcanbesetwithintherangefromtheminimumspeedtothemaximumspeedoftheengine,inunitsof

100revolutions.Withthespeedselected,presstheSET(S007)keyfor1secondormore.Theselectedspeedwill

bexedastheforcedenginerevolutions.Duringthistime,theforcedsettinginprogressdisplaywillappear(the

TEST/WARNINGLED(D052)willlight).

Tocanceltheforcedenginerevolutionsetting,presstheSET(S007)keyfor1secondormore.Theforcedsetting

inprogressdisplaywillbecleared(theTEST/WARNINGLED(D052)willgoout)andthedisplaywillreturnto

the forced setting selection operation.

q

Test Run Procedure

This setting is used to perform a test run from the outdoor unit.

1)Setallremotecontrollerswitchesto“Stop”.

2) Select “  “ (forced cooling test run) or ““(forcedheatingtestrun).Fordetailsseesteps1)to4)

on page I-7.

3)SettingandCancelingaForcedTestRun

When“  “ (forced cooling test run) or “  “(forcedheatingtestrun)isselected,holdingdown

theSET(S007)key1secondorlongercausestheforcedsettingtoappear(TEST/WARNINGLED(D052)before

atestrunstarts.Tocancelforcedtestrunoperation,holddowntheSET(S007)keyfor1secondorlonger.This

clearstheforcedsetting(TEST/WARNINGLED(D052)goesoff)andtheforcedsettingselectionreappears.

Figure 9

II - 1

2. Periodic Inspection and Periodic Replacement Work Manual

Periodic 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 Precautions

Stopping 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.

● Engineandmodelnumberrelationship

Enginename Model No.

K25 (Nissan engine)

SGP-EW120/150/190/240M2G2W(WMULTI)

SGP-EZ150/190/240M2G2W(3WAYMULTI)

For details on how and when to perform engine oil inspection, replenishment and replacement, see attached table

Chapter [2 (2)].

j

UseSanyogenuineoilfortheengineoil.

● IdemitsuKosan(Co.,Ltd.)

SanyoGenuineAP.GHPD-125

● NipponOilCorporation

SanyoGenuineGHPOil10TH

● COSMOOILLUBRICANTSCo.,Ltd.

SanyoGenuineGHPOil10W30C2

k

Engineoilandoillterreplacementperiod

Replacetheengineoilandoilltereveryveyearsor10,000

operatinghours,whichevercomesrst.

l

Thefollowingtools,parts,andmaterialsarerequiredfordoingthiswork.Preparethembeforestarting:

Name Specication Q’ty Remarks

Parts, Materials

Sanyo genuine oil

D-125

10TH

10W30C2

liters

·SanyoGenuineAP.GHPD-125

·SanyoGenuineGHPOil10TH

·SanyoGenuineGHPOil10W30C2

Oillter

For models with a K25 engine

638-012-7993

WasteOilcontainer

As

needed

Rags

As

needed

Tools

Screwdrivers No-3Phillips,No-2at 1 each

Closed wrench 19mm 1

Oilpumporhandpump

Filter wrench 1

Oilcontainerwithnarrow

spout

5 liters 1

Tray(Oildrainbasin)

Pliers 1

Figure 1 SANYO genuine gas engine oil

II - 2

m

Replaceoillter

Replacetheoillterwhentheoilischanged.

1)Removetheoillter

a)Becauseoilremaininginthelterwillspillwhenthelter

isremoved,positionatray(oildrainbasin)belowthelter

when removing it.

b)Usealterwrenchtoremovetheoillter(Figure2).

Takecarenottodamagethestudboltsthatholdthelter

in place when using a screwdriver or other tool to turn the

oillterduringlterremoval.

2)Installthenewoillter

a)ApplyfreshengineoilthinlyandevenlytotheO-ringofthenewlter(Figure3).

b)Duringoillterinstallation,turntheltertwo,threeormoretimesafterthepackingisseatedintheengineto

tightenit.(SeeFigure4.)

c)Usearagtowipeupspilledoil.

Tighteningtorque:14.7–20.6N•m

Figure 2 Detaching the oil lter

For models with a K25 engine

Figure 4 oil lter install

For models with a K25 engine

Caution

Never use a lter wrench to install the oil lter.

If the lter is overtightened, the O-ring will be

damaged, resulting in oil leaks.

Figure 3 Applying Sanyo genuine oil

II-3

n

Change engine oil

Replacealloilintheoilpanandthesubtank.

1) Prepare the designated amount of oil.

Amountofoilfor10,000hours

Oiltank:43liters

Engine:3liters

2)Stoptheengineafterwarmingupforbetween10and15

minutes.

(RefertoSection1.(4)“

StoppingtheEngine”.)

3)Openthecapoftheoiltank(Figure5).

4)Removeoilusingtheoilpump.

First,insertthepumpinthenarrowsideoftheoiltankaper-

turetoremoveoilfromtheexternaltank.

Next,insertthepumpinthewidersideoftheoiltankto

removetheoilfromtheinternaltank(Figure6).

*Caution:Forthenarrowside,atubeofø16mmorbelowis

required.

5)Removethecapsthatareinsertedattheendsofthedischarge

hose(2intotal)attachedtotheoiltanktoremovethere-

mainingoilintheoiltank(Figure7).

6)Oncetheoildischargeiscomplete,useawasteclothtowipe

offtheoldoilfromtheoutletoftheoildrainhose.Afterthis,

insertthecapsthatwereremovedduringStep5).Bringthe

oildrainhosebacktoitsoriginalposition.

7)Usetheoilcontainertoslowlyll43litersintotheoiltank

fromtheoiltankapertureand3litersintotheengineviathe

enginehead.Whendoingso,lltheoilfromthewiderside

oftheoiltankaperture(Figure6).

8)Closetheoiltankcapandtheengineheadcap.

o

Operationcheck

1) If oil spilled while adding it, wipe it up.

2)Canceltheenginestop.(RefertoSection1.(4)“

Canceling

EngineStop.”)Operatetheenginefor10-15minutesand

makesuretherearenooilleaksaroundtheoillteroroil

drain hose.

p

Oillevelgaugecheck

Makesurethattheoilislleduptillthedividerisnotvisible

fromtheoiltankaperture.

q

Engineoilusetimereset

RefertoSection1.(4)“

EngineOilTimeResetMethod.”

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

j

Engineoilinspection,replenishmentandreplacementschedule

1)Engineoilreplacementinterval

Yearnumber

Hoursofoperation

×(1,000hours)

Maintenance item

1 2 3 4 5 6 7 8 9 10 11 12 13

2 4 6 8 10 12 14 16 18 20 22 24

Periodic inspection

(5yearsor10,000hours)

Replace

2)Whendeliveredthereisenoughoilfor10,000hoursofoperation.

3)Oilreplacementareperformedevery10,000operatinghours.

4)Theamountofoilsufcientfor10,000operatinghoursisasfollows:

Tanklocation Engine: Oiltank TotalOil

Types120,150,190,240 3liters 43liters 46liters

(Replace) (Replace)

II - 5

(3) Valve Clearance Adjustment

Safety Precautions

Stopping 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.

j

Pre-adjustmentcheckitems

1)Thevalveclearanceadjustmentmustbeperformedevery10,000hoursor5years,whichevercomesrst.

2)Thevalveclearanceadjustmentisalsorequiredwhenevertherockerarmshaftisremovedforpartsreplacement

or other reason.

3)Performthevalveclearanceadjustmentwhentheengineiswarm.

4)Stoptheengineafterwarmingitupfor10to15minutes.

(RefertothesafetyprecautionsandSection1.(4)“

EngineStop”.)

Caution

● Perform the valve clearance adjustment within 10 minutes of stopping the engine.

● The engine will be hot immediately after stopping. Take appropriate precautions.

k

Thefollowingtoolsandgaugesarerequiredfordoingthiswork.Preparethembeforestarting.

Name Specication Q’ty Remarks

Tools

Thicknessgauge 0.45mm 1 each

Ratchetwrench 1/2inchdrive(12.7mm) 1 each

Socketorclosedwrench 22mm,14mm 1 each

Screwdriver

No-3,No-2Phillips(+),

No-2at(-)

1 each

Torquewrench

31.4 N•m

20.6 N•m

4.9 N•m

2.25 N•m

1 each

l

Removetheenginerockerarmcover

1)Removethe2enginerockerarmcovercapnuts(22mm)(Figure1).

2)Toreleasethegripofthegasketadhesive,movetheenginerockerarmcoverforwardandbacklightlywhile

pressing on it (Figure 2).

Figure 2Figure 1

Cap nuts

II-6

3)Removetheenginerockerarmcoverfromthecylinderhead

(Figure3).

m

Positiontherstorfourthcylinderatcompressiontopdeadcenter.

1)Removetheignitioncoilandsparkplugsforallcylinders.

2)Rotatethecrankshaftwithasocketwrench(ratchet)(Figure4)untilthetopmark(orange)onthecamshaftpul-

ley is aligned with the timing pointer (Figure 5).

Thecylindersarenumbered1,2,3,4insequencefromthecompressorside.

3)Rotatetheintakeanddischargesidepushrodsfortherst

cylinderwithyourngers,checkingthattheymoveeas-

ily(Figure6).Iftheymoveeasily,itmeansthattherst

cylinder is at compression top dead center. Perform the

valveclearanceadjustmentsthataremarked●inTable1

below(Figure7).

4)Ifthecheckaboveisnotsuccessful,rotatetheintake

and discharge side pushrods for the fourth cylinder with

yourngers,checkingthattheymoveeasily.Ifthese

rods move easily, it means that the fourth cylinder is at

compression top dead center. Perform the valve clearance

adjustmentsthataremarked○inTable1below(Figure7).

Table1

Cylinder Number 4 3 2 1

Valve Discharge Intake Intake Discharge Discharge Intake Intake Discharge

1stcyl.atcompressionTDC

● ● ● ●

4thcyl.atcompressionTDC

○ ○ ○ ○

Figure 3

Figure 6 Check the compressor top dead point

Intake side

Discharge side

First cylinder

Figure 4 Timing mark

Figure 5

Timing pointer

Top mark (orange)

Timing indicator

details

Top mark (orange)

(white)

II-7

5)Afteradjustment3)and4),turnthey-

wheel 1 revolution, and again align the

topmark(orange)onthecamshaftpulley

with the timing pointer. If the valves were

adjustedrstattherstcylinderTDCposi-

tion,adjusttheremainingvalveswiththe○

markinTable1.Ifthevalveswereadjusted

rstatthefourthcylinderTDCposition,

adjust the clearance of the remaining valves

withthe●markinTable1(Figures5,6,7).

Adjustvalveclearances

1)Rotatethepushrodwiththengers,and

checkthattherodmoveseasily.Ifitdoes,

loosenthevalvelocknut(14mm).Slightly

loosentheadjustingboltwithaat(-)

screwdriver,andinsertthethicknessgauge.

Turntheadjustingbolttoadjustthevalve

clearance.Whentheadjustmentisnished,

securetheadjustingboltwiththeatscrew-

driver so that it does not turn, then tighten

thelocknut(Figure8).

2)Adjustthevalveclearancewhiletheengineiswarm.

Intakevalves Dischargevalves

Whenwarm 0.45mm

3)Whennishedadjustingthevalveclearance,tightenthelocknuttothespeciedtorque.

Locknut Tighteningtorque:27.4-34.3N•m

o

Afteradjustment

1)Reinstalltheenginerockerarmcoverandsparkplugs,andtightentothespeciedtorques.Firsttightenthe2

nutsfortheenginerockerarmcoverevenlyontheleftandrightbyhand,thentightentothespeciedtorque

withatorquewrench.

Enginerockercovernut Tighteningtorque:13.7-15.7N•m

Sparkplug Tighteningtorque:19.6-29.4N•m

2)Installsparkplugcoilbracketsforallcylinders

Sparkplugcoilbracket Tighteningtorque:15.7-17.7N•m

Operationcheck

1)Canceltheenginestop.(RefertothesafetyprecautionsandSection1.(4)“

CancelingEngineStop.”)

2)Makesuretherearenoabnormalnoises(clickingorclatteringsounds).Ifabnormalnoisesarepresent,thevalve

clearances must be readjusted.

Figure 7 Location of each valve

discharge

inlet inlet

discharge

inlet inlet

discharge

Figure 8 Valve clearances adjustment

II-8

(4) Sparkplug Replacement

Safety Precautions

Stopping 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.

j

Thesparkplugreplacementmustbeperformedevery10,000hoursor5years,

whichevercomesrst.

k

Makesuretousegenuinepartsforthereplacementsparkplugs(Figure1).

l

Thefollowingtools,gauges,andpartsarerequiredfordoingthiswork.Pre-

pare them before starting.

■ Preparationforwork

Name Specication Q’ty Remarks

Tools

Sparkplugwrench 1

Torquewrench 9.8-29.4N•m

Screwdriver No-3Phillips(+),No-2Phillips(+) 1 each

Wirebrush

Sparkplug

623-194-7664

(638-018-9588canalsobeused)

j

EngineStop

Stoptheengine.(RefertothesafetyprecautionsandSection1.(4)“

EngineStop.”)

k

Removethepanel.

Removethefrontpaneloftheunit.

l

Removingthewireharnessplugs

Removethewireharnessplugsfromthesparkplugcoils(Figure5).

Figure 1

II-9

m

Sparkplugcoilbracket

Removethe2boltsshowninFigure6,andremovethesparkplugcoilbracket.

Figure 5 Removing the wire harness plugs

n

Sparkplugs

Useasparkplugwrench(16mm)toremovethesparkplugs(Figure7).

Figure 7 Removing the sparkplug cover bolts

o

Installation

Installnewsparkplugsbyfollowingthereverseoftheremovalprocedure(from

Sparkplugs Sparkplugcoilsbracket:19.6-29.4N•m

Sparkplugcoilsbracket Sparkplugcoilsbracket:15.7-17.7N•m

■ Operationcheck

j

MovetheSTOPSWto“NORMAL.”(RefertoSection1.(4)“

CancelingEngineStop.”)

k

Operatetheunit,andperformanenginestartupcheck.

l

Reinstalltheremovedunitpanelinitsoriginalposition.

Figure 6 Removing the sparkplug coils

II-10

(5) Air Cleaner Element Replacement

Safety Precautions

Stopping 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.

j

Preworkcheckitems

1)Adry-typeaircleanerelementisused.Theintakeportcover

removescoarseparticles.Astheintakeairisguidedintothe

bodyoftheairlter,avortexiscreatedbyacyclonedevice.The

currents within the vortex cause particles in the air to collect in

adustcup,whilenerparticlesarelteredoutbyfoldedpaper

lterelements.

2)Iftheaircleanerelementbecomesclogged,thequantityofair

will be reduced, causing the engine to stall.

● Makesuretoreplacetheelementperiodically.

● Replacetheelementmorefrequentlyindustyoroilyenviron-

ments.

k

ReplacementPeriod

Replacetheaircleanerelementevery5yearsor10,000operatinghours,whichevercomesrst.

l

Preparations

Thefollowingpartsandtoolsarerequiredfordoingthiswork.Preparethembeforestarting.

Name Specication Q’ty Remarks

Parts Aircleanerelement

623-196-0564

(826-2-1245-11300)

1 Figure 1

Tools Nut driver Acrossats17mm

m

Preparationforwork

1)Stoptheengine.(RefertoSection1.(4)“

EngineStop.”)

2)Removetherearpaneloftheunit.

n

Removetheelementandclean

1)Removethescrewthatsecurestheaircleanerelement,slidethe

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 - 11

o

ReplaceElement

Slideinthenewelementasfarasitwillgo.Makesurethesealdoesnotpreventinsertion.(Figure3.)

Figure 3

Caution

● This is a dry element. Do not use oil.

● Replace the element earlier in dusty or oily environments.

p

Fastener attachment

Move the fastener on the air cleaner from the left to the right and secure it in the center using a securing screw.

(Figure 2.)

q

Operationcheck

1)MovetheSTOPSWto“NORMAL.”(RefertoSection1.(4)“

CancelingEngineStop.”)

2)Rechecktheaircleanerinstallation.

3)Operatetheenginefor10-15minutesandmakesuretherearenochangesintherevolutionsperminute,no

abnormal noises, and no abnormal exhaust smell or color.

Sanyo 3WAY MULTI SGP-EZ150M2G2, 3WAY MULTI SGP-EZ190M2G2, 3WAY MULTI SGP-EZ240M2G2 User manual

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