Panasonic U-16GE2E5 Main Parts Replacement
  1. Manuals
  2. Brands
  3. Panasonic Manuals
  4. Air Conditioner
  5. U-16GE2E5
  6. Main parts replacement
Panasonic U-16GE2E5 Main Parts Replacement

Panasonic U-16GE2E5 Main Parts Replacement

Gas heat pump, 2way/3way multi/w multi
Hide thumbs Also See for U-16GE2E5:
Table of Contents

Advertisement

Quick Links

Download this manual
Order No. SM7110038-11CE
Gas Heat Pump
Air Conditioner
Main Parts Replacement
Reference No. SM7110038-01
Applicable Models
2WAY MULTI/W MULTI
U-16GE2E5
U-16GEP2E5
U-20GE2E5
U-20GEP2E5
U-25GE2E5
U-25GEP2E5
U-30GE2E5
3WAY MULTI
U-16GF2E5
U-20GF2E5
U-25GF2E5
July 2012

Advertisement

Table of Contents
loading

Related Manuals for Panasonic U-16GE2E5

Summary of Contents for Panasonic U-16GE2E5

  • Page 1 Order No. SM7110038-11CE Gas Heat Pump Air Conditioner Main Parts Replacement July 2012 Applicable Models 2WAY MULTI/W MULTI U-16GE2E5 U-16GEP2E5 U-20GE2E5 U-20GEP2E5 U-25GE2E5 U-25GEP2E5 U-30GE2E5 3WAY MULTI U-16GF2E5 U-20GF2E5 U-25GF2E5 Reference No. SM7110038-01...

  • Page 2: Table Of Contents

    Basic Operation for Shutoff Valves of W MULTI ..........5 Basic Operation for Shutoff Valves of 3 WAY MULTI ......... 6 Table.1 Built-in Engines for GHP Models ( is built-in engine) Engine NissanK25 engine GHP model U-16GE2E5 U-16GEP2E5 U-20GE2E5 2WAY MULTI/ U-20GEP2E5 W MULTI U-25GE2E5...
  • Page 3 Starter Replacement Procedure Required parts and tools used ................21 Preparation for work ....................21 Remove starter .....................21 Install starter ......................21 Preparation for operation ..................21 Final check ......................21 Ignition Electrical Parts Inspection and Maintenance Required parts and tools used ................22 Preparation for work ................... 22 Ignition coils (with built-in power transistors)..........
  • Page 4 Fuel Gas Piping Replacement Procedure Required parts and tools used ................38 Preparation for work ................... 38 Removal........................ 38 Remove the pipe bracket ..................38 Install the pipe bracket ..................38 Installation ......................39 Preparation for operation ................... 39 Final check ......................39 Coolant Three-way Valve and Electric Cooler Three-way Valve Replacement Procedure Required parts and tools used ................
  • Page 5 Coolant Check, Replenishment, and Replacement Procedure Required parts and tools used ................53 Preparation for work ................... 53 Check and replenish coolant ................53 Coolant replacement ................... 54 Coolant pump operation and stopping procedures ......... 58 Compressor Replacement Procedure Required parts and tools used ................60 Prepare to remove the compressors ..............
  • Page 6 Mixer Cleaning Procedure Required parts and tools used ................83 Preparation for work ................... 83 Mixer cleaning procedure ................... 83 Preparation for operation ................... 83 Final check ......................83 Reference Document Refrigerant, Coolant, Fuel, Air Supply and Exhaust, and Engine Oil Filling System ......84 Bolt Tightening Torque Table ..................

  • Page 7: Safety Precautions

    Basic Operation 1. Safety Precautions (1) W MULTI 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, perform the STOP operation for the outdoor unit, check the “...

  • Page 8: Preparation For Work

    Basic Operation 2. Preparation for work (1) Turn off remote controls for all indoor units. (2) Stop outdoor unit W MULTI Move the STOP SW (S001) shown in gure 1 from “NORMAL” to “STOP”.The 7 segment LEDs in gure 2 will display “...

  • Page 9: Basic Operations For Periodic Inspection Work

    Basic Operation 3. 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.
  • Page 10 Basic Operation *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. Check to make sure <<Step 2>>...

  • Page 11: Basic Operation For Shutoff Valves Of W Multi

    Basic Operation 4. Basic Operation for Shutoff Valves of W MULTI (1) Opening and closing of shutoff valves Ball valves are used for the shutoff valves on the outdoor unit, so they can be opened and closed by rotating the tab 90 degrees.

  • Page 12: Basic Operation For Shutoff Valves Of 3 Way Multi

    Basic Operation 5. Basic Operation for Shutoff Valves of 3 WAY MULTI (1) Opening and closing of shutoff valves Ball valves are used for the shutoff valves on the outdoor unit, so they can be opened and closed by rotating the tab 90 degrees.

  • Page 13: Engine Cylinder Head Inspection And Replacement Procedure

    Engine Cylinder Head Inspection and Replacement Procedure 1. Required parts and tools used Part names and tools used Remarks Sparkplug wrench Width across at: 16 mm Valve spring replacer Nissan special tool Gasket stripper spray Nihon Kohzai NX66 or equivalent Scraper Rubber stopper Sponge...

  • Page 14: Disconnect All Lead Wires

    Engine Cylinder Head Inspection and Replacement Procedure 4. Disconnect all lead wires (1) Remove the ignition coil connectors (gray, 3P, 4 locations). (Figure 1) Ignition coil connectors Ignition coil connectors Figure Figure (2) Remove the coolant temperature sensor connector (green, 2P). (Figure 2) Coolant temperature Coolant temperature sensor connector...

  • Page 15: Disconnect All Hoses

    Engine Cylinder Head Inspection and Replacement Procedure 5. Disconnect all hoses Important When each coolant hose is removed, be sure to use a plastic bag to catch the liquid remaining in the hose, keeping it from splashing in the surrounding area. Blow-by hose Blow-by hose (1) Coolant hose (engine outlet side) (Figure 4)
  • Page 16 Engine Cylinder Head Inspection and Replacement Procedure (8) Fuel gas hose (Figure 7) Hose Clamp (width across at) 7 [mm] Air intake hose Air intake hose (9) Intake hose (mixer side) (Figure 7) Hose Clamp (width across at) 7 [mm] Fuel gas hose Fuel gas hose Figure...

  • Page 17: Remove Exhaust Gas Heat Exchanger

    Engine Cylinder Head Inspection and Replacement Procedure 6. Remove exhaust gas heat exchanger (1) Remove the 4 nuts indicated by arrows in Figure 9. Nut (width across at) 17 [mm] Nuts Nuts Figure Figure (2) Remove the 6 nuts, bolts and hexagon socket head bolts indicated by arrows in Figure 10, and remove the exhaust gas heat exchanger.

  • Page 18: Remove Rocker Cover

    Engine Cylinder Head Inspection and Replacement Procedure 8. Remove rocker cover Remove the cap nuts at the 2 locations indicated by arrows in Figure 12, remove rocker cover. Cap nut Cap nut Nut (width across at) 22 [mm] Seal washer Seal washer Cap nuts Cap nuts...

  • Page 19: Remove Spark Plugs

    Engine Cylinder Head Inspection and Replacement Procedure 11. Remove spark plugs Using a spark plug wrench, remove all 4 sparkplugs. (Figure Figure Figure 12. Remove cylinder head assembly Take out push rods. Compress and tie the rocker Compress and tie the rocker Take out and lay out the push rods and each associated Valve rocker bolt Valve rocker bolt...

  • Page 20: Strip And Clean Gasket (Figure18)

    Engine Cylinder Head Inspection and Replacement Procedure 13. Strip and clean gasket (Figure18) (1) Prevent entry of foreign matter by using rubber stoppers or sponges to close off attachment holes, and also coolant and oil circulation holes on top of the cylinder block.

  • Page 21: Attach Cylinder Head

    Engine Cylinder Head Inspection and Replacement Procedure 14. Attach cylinder head (1) Install gasket Install a new cylinder head gasket on the upper Engine front Engine front surface of the cylinder block. There is a front and back to the cylinder head gasket. Install the gasket so that the cut-out hole is on the sparkplug side.

  • Page 22: Valve Clearance Adjustment Procedure

    Engine Cylinder Head Inspection and Replacement Procedure 15. Valve clearance adjustment procedure. (1) Use a ratchet or the like to turn the crankshaft (Figure 22), and align cylinder no. 1 at compression top dead centre. (Figure 23) The cylinder numbers are counted in order of no.1, no. 2, no. 3, and no.4 from the compressor side. Timing pointer (White paint) (White paint)

  • Page 23: Install The Rocker Cover (Figure 26)

    Engine Cylinder Head Inspection and Replacement Procedure 16. Install the rocker cover (Figure 26) Tighten the rocker cover cap nut. The seal washer under the cap nut must be installed. Cap nut (width across at) 22 [mm] Tightening torque 13.7 ~ 15.7[N·m] 17.

  • Page 24: Install Ignition Coil Bracket

    Engine Cylinder Head Inspection and Replacement Procedure 18. Install ignition coil bracket (1) Install the ignition coil bracket by tightening the securing bolts indicated by arrows in Figure 30. Bolt securing the bracket 12 [mm] (width across at) Tightening torque 15.7 ~ 17.7[N·m] Bolts securing Bolts securing...

  • Page 25: Install Exhaust Gas Heat Exchanger

    Engine Cylinder Head Inspection and Replacement Procedure 21. Install exhaust gas heat exchanger Caution When installing the exhaust gas heat exchanger, rst test assemble everything, then tighten the bolts. (1) Secure the exhaust gas heat exchanger by tightening the 4 nuts indicated by arrows in Figure 33.

  • Page 26: Preparation For Operation

    Engine Cylinder Head Inspection and Replacement Procedure 25. Preparation for operation (1) Turn on the power supply circuit breaker for the outdoor unit. (2) Open the main gas valve, starting the fuel supply. (3) Set the STOP SW (S001) from STOP to NORM. (Figure 35) Figure Figure...

  • Page 27: Starter Replacement Procedure

    Starter Replacement Procedure 1. Required parts and tools used Part names and tools used Parts code and use Starter 623-166-9511 Torque wrench 9.8 ~ 11.8 N · m 32.4 ~ 38.2 N · m Socket wrench set 1 set Extension bar Approx.

  • Page 28: Ignition Electrical Parts Inspection And Maintenance

    Ignition Electrical Parts Inspection and Maintenance 1. Required parts and tools used Part names and tools used Remarks Ignition coil (four) 623 - 197 - 0976 Crank angle sensor 623 - 197 - 6398 Cam angle sensor 623 - 197 - 6404 Spark plug (four) 623 - 018 - 9588 Torque wrench...

  • Page 29: Cam Angle Sensor

    Ignition Electrical Parts Inspection and Maintenance 5. Cam angle sensor (1) Cam angle sensor removal and installation Ignition coils Remove the harness connector. Remove the cam angle sensor. (2) Points to keep in mind during installation Coat the O-ring with engine oil during installation. Make sure that there are no foreign materials adhering to the sensor ange, O-ring, or front cover areas.

  • Page 30: Preparation For Operation

    Ignition Electrical Parts Inspection and Maintenance (9) Check the electrode gap of the sparkplug Reference value 0.4 ~ 0.5 [mm] Caution Do not adjust the gap, because an iridium chip is used. Do not insert a thickness gauge between the electrodes or clean them with a wire brush. (10) Check that there is no looseness in the terminal part.

  • Page 31: Ignition Timing Check And Adjustment

    Ignition Timing Check and Adjustment 1. Preparation for work (1) See “1. Safety Precautions” of “Basic Operation” in this manual. (2) Turn off remote controls for all indoor units. (3) Stop outdoor unit. 2. Distributor mode setting Set the distributor mode by selecting “ ”...

  • Page 32: Start Test Operation And Set Engine Rotational Speed

    Ignition Timing Check and Adjustment 3. Start test operation and set engine rotational speed Start test operation, and select “ ” forced engine rpm setting, and set 800 [min Start test operation. (1) Press the HOME key (S004) for one second or more.

  • Page 33: Ignition Timing Check

    Ignition Timing Check and Adjustment (6) Press the SET key (S007). The LEVEL LED (D053) will be illuminated, and the status with the engine rotating at the forced (set) speed will be displayed at one-second intervals, as shown below. Display Item (10.1400) Forced engine rotational speed (example: 1400 min...

  • Page 34: Correction For Distorted Amount

    Ignition Timing Check and Adjustment 5. Correction for distorted amount If the value is different than that displayed by “ ” (engine ignition timing) set in item ( ) above, select “ .” (ignition timing offset) in “ ” engine settings, and correct for the distorted amount. (1) Press the HOME key (S004) for one second or more.
  • Page 35 Ignition Timing Check and Adjustment (5) Make the correction Correction example The adjustment value is 10° BTDC, but the observed value was 8° BTDC. Press the UP (S005) or DOWN (S006) key to set a correction of +2 in relation to the current “ ”...
  • Page 36 Ignition Timing Check and Adjustment Correction example The adjustment value is 10°BTDC, but the observed value was 13° BTDC. Press the UP (S005) or DOWN (S006) key to set a correction of -3 in relation to the current “ ” (ignition timing offset) value. 1) Display the current “...

  • Page 37: Cancel Settings

    Ignition Timing Check and Adjustment 6. Cancel settings When ignition timing correction is nished, cancel the forced rotational speed setting and the distributor mode. Make sure to do this. (1) Press the HOME key (S004) for one second or more. Menu item number “...

  • Page 38: Stop Test Run

    Ignition Timing Check and Adjustment (7) Press the SET key (S007). “ ” (Figure.31) will be displayed. The LEVEL LED (D053) and TEST/WARNING LED (D052) will be illuminated. Figure. Figure. (8) Press the UP (S005) or DOWN (S006) key, to display “...

  • Page 39: Front Oil Seal Replacement Procedure

    Parts code and use Oil seal 623 - 166 - 9580 Engine oil Small amount of Panasonic genuine AP. GHP D -125 Small amount of Panasonic genuine GHP Oil 10TH Small amount of Panasonic genuine GHP Oil 10W30C2 Socket wrench...

  • Page 40: Install The Front Cover Oil Seal (Figure 3)

    Front Oil Seal Replacement Procedure 6. Install the front cover oil seal (Figure 3) (1) Coat around the lip part of the new seal with a small amount of engine oil. (2) Insert the new seal partially by hand. (3) Use a pipe of suitable diameter to carefully press in the oil seal until its foremost surface is even with the foremost surface of the front cover while making sure the oil seal enters uniformly and is not...

  • Page 41: Final Check

    Front Oil Seal Replacement Procedure 10. Final check (1) Running condition check Make sure that no abnormal noise or vibration occurs. Make sure there are no oil leaks. Make sure that none of the attached parts are loose. (2) Cleanliness check of the surroundings Make sure no unneeded items or trash is scattered around.

  • Page 42: Rear Oil Seal Replacement Procedure

    Rear Oil Seal Replacement Procedure 1. Required parts and tools used Part names and tools used Remarks Oil seal 638 - 020 - 8128 Oil seal press t jig Nissan Kohki special tool Flywheel stopper Nissan Kohki special tool Torque wrench 15.7 ~ 17.7 N·m 30.4 ~ 36.3 N·m 137.3 N·m...

  • Page 43: Oil Seal Installation

    Rear Oil Seal Replacement Procedure 5. Oil seal installation (1) Wipe any dirt from the bushing ange, align the outside of the new seal within the inside of the retainer, and use the press t jig to press t the seal. (Figure 4) Caution Press the seal until the press t jig comes in contact with the...

  • Page 44: Fuel Gas Piping Replacement Procedure

    Fuel Gas Piping Replacement Procedure 1. Required parts and tools used Part names and tools used Remarks Part names and tools used Remarks Gas piping 623-197-6466 Phillips screwdriver No. 2, 3 Box driver Width across at 7 mm and 10 mm Socket wrench 1 set Hexagonal wrench...

  • Page 45: Installation

    Fuel Gas Piping Replacement Procedure 6. Installation Installation procedure is the reverse of the removal procedure. Caution Make sure that the O-ring does not fall off or get damaged when tightening the hexagon socket head bolt. Hexagon socket head bolt C tightening torque 2 N·m 7.

  • Page 46: Coolant Three-Way Valve And Electric Cooler Three-Way Valve

    Coolant Three-way Valve and Electric Cooler Three-way Valve Replacement Procedure 1. Required parts and tools used Part names and tools used Remarks Coolant three-way valveElectric cooler three-way 623-166-8507 valveHot water three-way valve Clamp As needed General tools 1 set 2. Preparation for work (1) See “1.

  • Page 47: Final Check

    Coolant Three-way Valve and Electric Cooler Three-way Valve Replacement Procedure 8. Final check (1) Running condition check Make sure that no abnormal noise or vibration occurs. Make sure there are no coolant leaks. Make sure there is no looseness in any parts attachment area. (2) Cleanliness check of the surroundings Make sure no unneeded items or trash is scattered around.

  • Page 48: Expansion Valve, Liquid Valve, Bypass Valve And Waste Heat Recovery Valve Replacement Procedure

    Expansion Valve, Liquid Valve, Bypass Valve and Waste Heat Recovery Valve Replacement Procedure 1. Required parts and tools used Part names and tools used Remarks Expansion valve 623-301-2001 623-319-7500 (85. OKW Type) Small heat exchanger expansion valve 623-301-1998 (3WAY) Large heat exchange expansion valve 623-301-2001 (3WAY) Waste heat recovery valve 623-301-5743...

  • Page 49: Prepare To Remove The Expansion Valve, Liquid Valve, Bypass Valve. And Waste Heat Recovery Valve

    Expansion Valve, Liquid Valve, Bypass Valve and Waste Heat Recovery Valve Replacement Procedure 4. Prepare to remove the expansion valve, liquid valve, bypass valve. and waste heat recovery valve. (1) Remove the coil from each solenoid valve. (2) Remove the bracket and rubber securing the pipe, along with the thermal insulation. (3) Cover the areas around the welds with pieces of metal and thermal insulation in order to prevent burning inside the unit.

  • Page 50: Install The Expansion Valve, Liquid Valve, Bypass Valve And Waste Heat Recovery Valve

    Expansion Valve, Liquid Valve, Bypass Valve and Waste Heat Recovery Valve Replacement Procedure 5. Install the expansion valve, liquid valve, bypass valve and waste heat recovery valve. (1) Attach the replacement expansion valve, liquid valve, and bypass valve to the piping on the side of the unit. Caution When replacing the expansion valve, liquid valve, bypass valve and waste heat recovery valve, take care not to apply shock to the valves.

  • Page 51: Final Check

    Expansion Valve, Liquid Valve, Bypass Valve and Waste Heat Recovery Valve Replacement Procedure (2) Turn on the power supply circuit breaker for the outdoor unit. (3) Open the main gas valve, starting the fuel supply. (4) Set the STOP SW (S001) from the STOP side to the NORM side.

  • Page 52: Pressure Sensor Replacement Procedure

    Pressure Sensor Replacement Procedure 1. Required parts and tools used Part names and tools used Remarks High pressure Pressuresensor 623-178-7017 Low pressure Torque wrench 15 ~ 20 N·m General tools 1 set 2. Remove pressure sensor (1) Turn off remote controllers for all indoor units. (2) Change the pressure sensor setting.

  • Page 53: Install Pressure Sensor

    Pressure Sensor Replacement Procedure (3) Set the gauge manifold into position. (4) Purge the air in the hose. (5) Perform the pump-down procedure to recover the refrigerant from within the unit to the indoor unit side. For details on the pump-down procedure, see “Pump Down Procedure (Heating)”...
  • Page 54 Pressure Sensor Replacement Procedure (5) After work is complete, cancel pump-down. Set each of the closing valves from the fully closed position to the fully open position. (Figures 7 and 8) Closed Open Refrigerant Refrigerant Refrigerant Refrigerant gas tube liquid tube gas tube liquid tube Figure 7...
  • Page 55 Pressure Sensor Replacement Procedure (8) Restore the pressure sensor settings. To change the setting, press the HOME (S004) key for 1 second or more and select “ ” (ignore pressure sensor) of the “ ” outdoor unit setting. Press the HOME key (S004) for one second or more.

  • Page 56: Preparation For Operation

    Pressure Sensor Replacement Procedure 4. Preparation for operation (1) Open the main gas valve, starting the fuel supply. (2) Set the STOP SW (S001) from the STOP side to the NORM side. (Figure 14) Figure 5. Final check (1) Running condition check Make sure that no abnormal noise or vibration occurs.

  • Page 57: Coolant Pump Replacement Procedure

    Coolant Pump Replacement Procedure 1. Required parts and tools used Part names and tools used Remarks Coolant pump 623-175-8376 Clamps As needed Rags As needed General tools 1 set 2. Preparation for work (1) See 1.Safety Precautions 2.Preparation for Work under Basic Operations in this manual.

  • Page 58: Coolant Pump Installation

    Coolant Pump Replacement Procedure 5. Coolant pump installation (1) Tighten the 4 securing bolts shown in Figure 2 and install the coolant pump. Caution Pay careful attention to the coolant ow direction when installing the coolant pump. (2) Connect the coolant hose (on the coolant pump side). (3) Plug the connector for the coolant pump into the circuit board shown in Figure 1 and connect the wiring.

  • Page 59: Coolant Check, Replenishment, And Replacement Procedure

    Figure 1 If the level within the reserve tank is low, replenish the coolant with the speci ed concentration of genuine Panasonic coolant (50 ±5%) up until the H level position. 1) Remove the coolant replenishment port cover on the top panel, and then remove the rubber cap from the reserve tank.

  • Page 60: Coolant Replacement

    Coolant Check, Replenishment, and Replacement Procedure 4. Coolant replacement 4-1. Coolant discharge (1) Connect the hose nipple to the coolant discharge outlet. (Figure 3) (2) Connect a hose (1.2 m) to the hose nipple, and secure it with a hose clamp.
  • Page 61 (2) Prepare coolant at the speci ed concentration. (3) Mix Panasonic genuine coolant and tap water to the speci ed concentration (50 ± 5%), stir well, then check with a brine tester. (See “Table 1 GHP Model and Amount of Coolant” below.)
  • Page 62 Coolant Check, Replenishment, and Replacement Procedure (9) Turn the air-purge stopcock to “Fully opened.” (Figure 9) (10) Replenish the coolant in the coolant circuit by re lling the coolant replenishment container several times with coolant. The coolant replenishment Stopcoc container capacity is 2 litres. Figure 9 4-3.
  • Page 63 Coolant Check, Replenishment, and Replacement Procedure Press the UP (S005) / DOWN (S006) key, and select menu item “ ”. (Figure 14) Figure 14 In the state with “ ” (Figure 14) displayed, press the SET (S007) key for one second or more. The automatic air-purge operation will start, and the TEST/WARNING LED (D052) will be illuminated.

  • Page 64: Coolant Pump Operation And Stopping Procedures

    Coolant Check, Replenishment, and Replacement Procedure 4-4. Restoring to an operable state (1) Use a hand pump to collect the coolant remaining in the coolant replenishment container. (2) Turn the air-purge stopcock to “fully closed”. (Figure 9) (3) Detach the coolant replenishment container from the ller neck. (4) Remove the pinch pliers that are pinching the hose connecting the ller neck and the reserve tank.
  • Page 65 Coolant Check, Replenishment, and Replacement Procedure Press the UP (S005) / DOWN (S006) key, and select menu item “ ”. (Figure 21) In this status, press the SET (S007) key for 1 second or more. The TEST/WARNING LED (D052) will be illuminated, and the coolant pump will begin to operate.

  • Page 66: Compressor Replacement Procedure

    Compressor Replacement Procedure 1. Required parts and tools used Part names and tools used Remarks Compressor 45.0 KW Type 623-201-4938 (SS200VM1A) 56.0/71.0 KW Type 623-318-0359 (SS245VM2A) 85.0 KW Type 623-197-6671 (SS320VMA) Compressor drive belt 45.0-71.0 KW Type 623-317-2903 85.0 KW Type 638-018-9625 Gasket 638-019-8573...
  • Page 67 Compressor Replacement Procedure Remove the bracket securing the pipe (Figures 2 and 3) Bolts Bolts Figure 3 Figure 2 Turn the tension adjustment bolt (anticlockwise), and raise the bracket (Figure 4). Bolt (width across at) 19 [mm] Rotate the tension adjustment bolt until the compressor drive belt can be removed, then remove the belt.
  • Page 68 Compressor Replacement Procedure (5) Rotate the tension adjustment bolt (indicated by the arrow in Figure 4) clockwise, and lower the compressor bracket near to its lowest point. * Prepare by rst spreading a rag underneath the compressor. (6) Remove the bolts securing the compressor (4 locations indicated by arrows in Figure 6).

  • Page 69: Install The Compressor

    Compressor Replacement Procedure 5. Install the compressor Before installing the compressor, pour the same amount of new refrigeration oil inside the new compressor as the amount of refrigeration oil that is in the removed compressor. (1) Set the compressor under the engine, turn the tension adjustment bolt (Figure 4) clockwise, lower the bracket and tighten the bolts securing the compressor (4 bolts).
  • Page 70 Compressor Replacement Procedure (8) Install the compressor drive belt Install the compressor drive belt on the main unit of the engine and on the compressor. Turn the tension adjustment bolt (in the clockwise direction) and lower the bracket to tighten the belt. When doing so, tighten the tension adjustment bolt while supporting the belt with a hand as shown in Figure 9 so that it does not slip off.

  • Page 71: Preparation For Operation

    Compressor Replacement Procedure (9) Pass the oil tube through the oil receiver hole, and secure it with a clamp. (10) Connect the crankcase heater, sensor, and clutch connectors. (11) Perform an air tightness test with nitrogen from the low pressure outlet and make sure there are no leaks from the compressor ange.

  • Page 72: Fan Motor Replacement Procedure

    Fan Motor Replacement Procedure 1. Required parts and tools used Part names and tools used Remarks Fan Motor 1FA-4-M4A0-12300 Clamp As needed Torque wrench 6 ~ 8 N·m, 14.7 ~ 16.7 N·m Plastic hammer Loctite As needed (#272) General tools 1 set 2.

  • Page 73: Install The Fan Motor

    Fan Motor Replacement Procedure (6) Remove the four securing bolts indicated by arrows Hub cover Figure 3 and remove the fan motor. Bolt (width across at) 13 [mm] Fixing bolts Fan motor 4. Install the fan motor (1) Tighten the four securing bolts indicated by arrows in Figure 3 and install the fan motor.

  • Page 74: Preparation For Operation

    Fan Motor Replacement Procedure 5. Preparation for operation (1) Turn on the power supply circuit breaker for the outdoor unit. (2) Open the main gas valve, starting the fuel supply. (3) Set the STOP SW (S001) from the STOP side to the NORM side.

  • Page 75: Pump Down Procedure (Common To Cooling And Heating)

    Pump Down Procedure (Common to Cooling and Heating) Safety Precautions Stopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer operates a remote control on the indoor unit. When working on internal parts of the outdoor unit, make sure to cut the power to the outdoor unit at the circuit breaker before starting work.
  • Page 76 Pump Down Procedure (Common to Cooling and Heating) (2) In the case of 3 Way Cooling pump-down Connect the gauge manifold to the service port of the refrigerant discharge shutoff valve and refrigerant suction shutoff valve. Open the valve on the gauge manifold and bypass the refrigerant discharge tube and refrigerant suction tube.

  • Page 77: Operating The Refrigerant Shutoff Valve (* 3 Way Multi Only)

    Pump Down Procedure (Common to Cooling and Heating) 5. Operating the refrigerant shutoff valve (* 3 WAY MULTI only) (1) Cooling pump-down Discharge shutoff valve fully closed (Figures 5 and 6) Open Closed Open Close - up view Closed valve Fully open Fully closed open/close...

  • Page 78: Start The Test Run: Carry Out A Test Run On The Outdoor Unit

    Pump Down Procedure (Common to Cooling and Heating) Items 6 to 8 below describe the work for the outdoor main board. 6. Start the test run: Carry out a test run on the outdoor unit. * Select the test run mode (cooling or heating) in accordance with the pump-down mode. (1) Press the HOME (S004) key for 1 second or more.

  • Page 79: Con Gure The Forced Close Setting Of The Bypass Valve

    Pump Down Procedure (Common to Cooling and Heating) 7. Con gure the forced close setting of the bypass valve. Perform the procedure below to con gure the bypass valve forced close setting approximately 5 minutes after performing the test run on the outdoor unit. (1) Follow the procedure of 5-(1) to (2) to select “...

  • Page 80: Set Engine Rotational Speed

    Pump Down Procedure (Common to Cooling and Heating) 8. Set engine rotational speed Set an engine rotational speed that is suitable for the pump-down. (1) Follow the procedure of 6-(1) to select “ ”. (2) Press the UP (S005) / DOWN (S006) key and select menu item number “...

  • Page 81: Fully Shut Off The Refrigerant Liquid Shutoff Valve

    Pump Down Procedure (Common to Cooling and Heating) • Items 9 to 11 below describe the work for the shutoff valve side (rear of equipment). 9. Fully shut off the refrigerant liquid shutoff valve Using a wrench, fully close the refrigerant liquid shutoff valve for the outdoor unit where the pump-down is to be performed.

  • Page 82: Stop Outdoor Unit

    Pump Down Procedure (Common to Cooling and Heating) • The procedure below describes the work for ending the pump-down. The work is mainly on the outdoor main board. 12. Stop outdoor unit Even if “ ” is displayed and the engine is stopped, if the microcomputer is reset by an instantaneous power failure or the like, the engine will start if an operation is input from, for example, the remote controller.

  • Page 83: Generator Replacement Procedure

    Generator Replacement Procedure 1. Required parts and tools used Table 1 Part names and tools used Remarks Generator 623-173-1362 V-belt 623-172-4463 Non-contact sonic belt tension gauge 1 set Torque wrench See torques in the text Open or box wrench 13 mm and 17 mm Socket wrench 13 mm and 17 mm 2.
  • Page 84 Generator Replacement Procedure (4) See Figure 3. Loosen tension adjustment bolt and nut . Table 6 Bolt/nut size across ats 14 [mm] Figure 3 (5) See Figure 4. Lift up the generator and remove the belt . Figure 4 (6) See Figure 5. Remove the generator’s wiring connector (3P) and connector...
  • Page 85 Generator Replacement Procedure (7) See Figure 6. Remove bolt . Figure 6 (8) See Figure 7. While supporting the generator, remove bolt and the nut, washer and spacer and bolt, washer and spacer nally, remove the generator from the machine. Figure 7...

  • Page 86: Install The Generator

    Generator Replacement Procedure 4. Install the generator (1) See Figure 8. While supporting the generator, install and hand-tighten bolt and spacer, washer and nut in that order. Install and hand-tighten the spacer, washer and bolt in that order and mount the belt on the engine.
  • Page 87 Generator Replacement Procedure (3) See Figure 10. Reconnect the wiring of the generator, namely connectors and . Connector is for electricity produced by the generator Connector is for its temperature sensor (4) See Figure 11. Tighten to their speci ed torques: bolts from Figure 8 and bolts from Figure 9.

  • Page 88: Preparation For Operation

    Generator Replacement Procedure 5. Preparation for operation (1) Turn on the power supply circuit breaker for the outdoor unit. (2) Open the main gas valve, starting the fuel supply. (3) Set the STOP SW (S001) from STOP to NORM. Figure 12 6.
  • Page 89 Mixer Cleaning Procedure 1. Required parts and tools used Table 1 Part names and tools used Remarks Carburetor cleaner Rags As needed 2. Preparation for work (1) See “1. Safety Precautions” and “2. Preparation for work” of “Basic Operation” in this manual. 3.
  • Page 90 Refrigerant, Coolant, Fuel, Air Supply and Exhaust, and Engine Oil Filling System Reference Document · W MULTI...
  • Page 91 Refrigerant, Coolant, Fuel, Air Supply and Exhaust, and Engine Oil Filling System Reference Document · 3 WAY MULTI...
  • Page 92 Bolt Tightening Torque Table Reference Document Refer to this table when you are unsure of a tightening torque. (Basically, use the tightening torque values shown in this manual.) Bolt Tightening Torque Table...

This manual is also suitable for:

U-16gep2e5U-20ge2e5U-20gep2e5U-25ge2e5U-25gep2e5U-30ge2e5 ... Show all

Table of Contents