NextAire 132.6.00.P.HA Gas Heat Pump Service and Troubleshooting Manual

Model 132.6.00.P.HA
Service and Troubleshooting Manual
2953 Westwood Drive
Las Vegas, NV 89109
702-693-6398 Fax 623-879-4666
11Ton Model 132.6.00.P.HA Service Manual
1
Gas Heat Pump Air Conditioner
PGHP ROOFTOP UNIT SERVICE AND TROUBLESHOOTING
[Model 11 ton (132,000 Btu/h)]
Applicable models
Gas type
Rooftop unit
Natural Gas
High ambient type 11 ton (132,000 Btu/h)
132.6.00.P.HA
A w ord to the person in charge of installation
This service manual for the GHP package unit was written to provide the service and maintenance procedures and precautions for those with a
basic knowledge of gas heat pumps. If this unit is not properly maintained, it will not realize its full performance potential and could cause injury
or damage.
Accordingly, before beginning the maintenance of the GHP outdoor unit, read and fully understand the contents of this manual. If a remote
controller or other options, sold separately, are also to be serviced read and fully understand the contents of those manuals as well.
Important reminder
This unit must be installed by specially trained personnel.
The installation must be performed in accordance with the contents of this
manual.
2953 Westwood Drive
Las Vegas, NV 89109
702-364-3955 Fax 702-364-3955
Introduction
INTRODUCTION
Safety Precautions
The following is an important safety notice you must follow in order to prevent injuries and/or damages that may be
caused by incorrect operation in repair, inspection and maintenance of the NextAire Packaged Rooftop Gas Heat
Pump. Be sure to read this carefully and follow the instructions.
Definition of "
WARNING ", "
WARNING
If the items with this symbol shown in this
manual are not adhered to, serious injury or
death could occur.
CAUTION
If the items with this symbol shown in this
manual are not adhered to, injury or damage to
the unit could occur.
Inspection Precautions
WARNING
[Before starting inspection]
1. Be sure to switch OFF the electric disconnect
in the outdoor control box.
• If not, you could be shocked.
2. Be sure to close the fuel gas valve.
• If not, gas poisoning or gas explosion could
occur.
[During inspection]
1. Check for fuel gas leakage. If there is
anything unusual such as gas odor, be sure to
take proper safety measures.
• If not, gas poisoning or gas explosion could
occur.
2. Be sure to disconnect the igniter connector
before conducting corrective measures against
carbon deposit formation on the valve or valve
seat.
• If not, fire could occur when cranking.
CAUTION
Do not touch the crank pulley or compressor
belts when the [RUN] switch is ON.
•
If not, injury could result.
CAUTION " and NOTE (S):
NOTE: These items are intended to clarify a
situation or add additional general information.
Index
Contents
INTRODUCTION .......................................................................................................................................................... 3
Section I – General Product Information ................................................................................................................. 7
1.
Product Appearance ............................................................................................................................................... 7
2.
Model Name Structure ........................................................................................................................................... 8
3.
Unit Specifications .................................................................................................................................................. 9
4.
Unit External Dimensions..................................................................................................................................... 12
5.
Distance from surrounding objects ..................................................................................................................... 13
6.
Internal Structure................................................................................................................................................... 14
Section II – Operating Principle.................................................................................................................................. 17
1.
Refrigerant System Diagram ............................................................................................................................... 17
2.
Engine Coolant System Diagram ........................................................................................................................ 18
3.
Fuel Gas System Diagram................................................................................................................................... 18
Section III – Siemens TD 200 Hand Held Touch Pad ............................................................................................ 20
1.
Setting the Date/Time ........................................................................................................................................... 20
2.
To Test Blower Rotation ....................................................................................................................................... 20
3.
To Manually Adjust Blower Speed ....................................................................................................................... 20
4.
To Check Indoor Blower Motor Amperages ........................................................................................................ 20
5.
To Check Outdoor Fan Motor Amperages .......................................................................................................... 21
6.
To Start System in Heating or Cooling ................................................................................................................ 21
7.
To Change Stages Between Stages - in Manual Operation Mode ................................................................... 21
8.
To Change from Cooling or Heating .................................................................................................................... 21
9.
To Check Operations ............................................................................................................................................ 21
10.
To Place in Stand-by Mode and Re-Energize Thermostat ............................................................................ 22
11.
To Check Previous Unit Faults ......................................................................................................................... 22
Section IV – System Control ....................................................................................................................................... 23
1.
System Block Diagram ......................................................................................................................................... 23
2.
System Input / Output Specifications.................................................................................................................. 24
3.
Control Details ....................................................................................................................................................... 26
4.
Wiring Diagrams.................................................................................................................................................... 29
Section V – Problems and Diagnosis ........................................................................................................................ 30
1.
Error Code Description and Possible Cause ..................................................................................................... 30
2.
Fault Code Correction Procedures ..................................................................................................................... 32
Section VI – Diagnosis Procedures and Inspection ................................................................................................ 33
1.
System will not operate. ....................................................................................................................................... 34
2.
Starter will not operate.......................................................................................................................................... 35
11Ton Model 132.6.00.P.HA Service Manual
4
Index
3.
Engine will not start ............................................................................................................................................... 37
4.
Engine starts but stalls. ........................................................................................................................................ 42
5.
Engine coolant temperature abnormality ........................................................................................................... 43
6.
Oil pressure abnormality ...................................................................................................................................... 45
7.
Over speed ............................................................................................................................................................ 46
8.
High pressure abnormality in cooling operation ................................................................................................ 46
9.
High pressure abnormality in heating operation................................................................................................ 48
10.
Refrigerant low pressure abnormality ............................................................................................................. 49
11.
Refrigerant discharge temperature abnormality ............................................................................................ 51
12.
Gas heat pump is operating but not cooling. ................................................................................................. 53
13.
Gas heat pump is operating but not heating.................................................................................................. 55
14.
Thermostat is not functioning correctly........................................................................................................... 56
Section VII – REPLACEMENT OF MAIN COMPONENTS ................................................................................... 57
1.
Replacement of Engine Unit ................................................................................................................................ 57
2.
Replacement of Cylinder Head ........................................................................................................................... 59
3.
Replacement of Compressor............................................................................................................................... 62
4.
Replacement of Compressor Clutch................................................................................................................... 63
5.
Replacement of Indoor Blower Assembly .......................................................................................................... 64
6.
Replacement of Indoor Blower Pulley and Belts ............................................................................................... 64
7.
Replacement of Indoor Blower Shaft .................................................................................................................. 65
8.
Replacement of Outdoor Fan Blade ................................................................................................................... 66
9.
Replacement of Motor .......................................................................................................................................... 66
10.
Replacement of Engine Coolant Pump .......................................................................................................... 67
11.
Replacement of Transformer ........................................................................................................................... 67
12.
Replacement of Line (Refrigerant) .................................................................................................................. 68
13.
Replacement of Capillary Tube ....................................................................................................................... 68
14.
Replacement of Refrigerant Check Valve ...................................................................................................... 68
15.
Replacement of Reversing Valve.................................................................................................................... 69
16.
Replacement of TXV Power Head .................................................................................................................. 69
17.
Replacement of TXV ........................................................................................................................................ 69
18.
Adjustment of TXV ............................................................................................................................................ 70
Section VIII – PERIODIC MAINTENANCE AND INSPECTION ........................................................................... 71
1.
Periodic Maintenance and Inspection Items and Intervals .............................................................................. 72
2.
Parts Requiring Periodic Replacement .............................................................................................................. 73
3.
Procedure and Method of Regular Inspection ................................................................................................... 74
Section VIII – TECHNICAL DATA FOR REPAIR .................................................................................................... 80
1.
Engine System ...................................................................................................................................................... 80
11Ton Model 132.6.00.P.HA Service Manual
5
Index
2.
Refrigerant System ............................................................................................................................................... 82
3.
Engine Coolant System ........................................................................................................................................ 82
4.
Thermistor Characteristics ................................................................................................................................... 83
5.
Electrical System................................................................................................................................................... 83
11Ton Model 132.6.00.P.HA Service Manual
6
Operating Principle
Section I – General Product Information
1. Product Appearance
Front view
Top view
11Ton Model 132.6.00.P.HA Service Manual
Side view
7
Operating Principle
2. Model Name Structure
1) Example
Code
a
b
c
d
e
f
Model name (Example)
132
6
00
P
H
A
2) Model code list
Code
a
b
c
Item
Rated capacity (Hundreds of BTU’s)
Version
Revision
d
Configuration
e
Type
f
Compressor manufacturer
Symbol and description
------P
S
AB
H
S
A
R
: Package unit
: Split system
: Modulated Split system
: Heat pump
: Cooling only
: AISIN
: ROTOVANE
Note: The model name format on the ETL tags is 132-P-6-00-HA.
11Ton Model 132.6.00.P.HA Service Manual
8
Operating Principle
3. Unit Specifications
UNIT
132.6.P.HA
NOMINAL CAPACITY (tons)
OPERATING WEIGHT (lb)
OVERALL DIMENSIONS
ENGINE
ENGINE COOLANT
11
Unit
2200
Economizer
100
Roof curb
140
Height (ft / in)
4’ ½”
Width (ft)
10’ 6” + 1’ 8” for economizer
Depth (ft)
5’ 10”
Type
Water cooled straight 4-cycle OHV
Exhaust volume (L)
0.952
Rated output (Hp)
16.6
Starting system
AC/DC conversion DC starter
Speed range (cooling) (rpm)
1300 ~ 2400
Speed range (heating) (rpm)
1300 ~ 2400
Lubricant type
AISIN Gas Engine Oil L–10,000G
Lubricant amount (L)
35.0
Exhaust port position
Top
Type
AISIN Coolant S
Enclosing capacity (L)
15
Concentration (Vol %)
50
Freezing temperature °F
-4
Pump type
Seal-less magnetic drive
Pump motor output (Hp)
1/3
Type
Open, Scroll
Quantity
2
3
COMPRESSOR
REFRIGERANT
OUTDOOR COIL (Outer)
OUTDOOR COIL (Inner)
Displacement (cm / rev)
52 X 2
Revolution range (rpm)
2805 ~ 4080 (cooling), 2805 ~ 4080
(heating)
Specified refrigerant oil
AISIN NL10
Oil (L)
2
Power transferring method
Poly V-belting (1pc)
Type
R-410a
Operating Charge (lb/oz)
25
Type
Copper tubes with aluminum sine wave fins
Number of rows...Fins/in
2…18
Tube diameter (in)
5/16
Height x length (in)
40 x 55
Total face area (sq ft)
15.3
Circuits
20
Air flow (CFM)
4000
Type
Copper tubes with aluminum sine wave fins
Number of rows...Fins/ in
2…18
Tube diameter (in)
5/16
Height x length (in)
36 x 55
Total face area (sq ft)
13.8
Circuits
20
11Ton Model 132.6.00.P.HA Service Manual
9
Operating Principle
OUTDOOR FAN
EXHAUST HEAT RECOVERY
SYSTEM
EXHAUST GAS HEAT EXCHANGER
DEFROSTING SYSTEM
INDOOR COIL
INDOOR FAN (Blower)
Coolant Pump
Engine Radiator
Air flow (CFM)
4000
Type
Propeller
Rated air amount (CFM)
5000 X 2
Quantity... Propeller Dia. (in)
2…24
Drive
Direct
Motor type
208 VAC 1 phase sheave 2TB80
Motor rated power (Hp) / Speed (rpm)
3/4…1075
Amps (maximum)
4.2
Watts Input (Total)
742 X 2
Type
Plate and Frame
Number of Plates
20
Surface Area (sq. ft.)
4.8
Type
Shell & tube
Air port (intake & outlet)
Front & rear side (intake), top face (outlet)
Type
Hot gas bypass system
Type
Copper tubes with aluminum sine wave fins
Number of rows...Fins/in.
4…16
Tube diameter (in)
5/16
Height x length (in)
42 x 55
Total Face Area (sq ft)
16
Circuit
28
Air flow (CFM)
4400
Type
Centrifugal
Quantity...Size (Dia. x width) (in)
1…15 x 15
Drive
Belt
Rated air amount (CFM)
2500 / 3500 / 4400
Motor, Standard (hp)
2
Amps, standard
6.5
Min/Max duct static pressure (in WC)
1/1.5
Motor Frame Size
145T
Nominal Rpm High/Low
Variable speed
Fan speed Range (rpm)
1255/1755
Motor Bearing Type
Ball
Maximum Allowable speed (rpm)
1755
Motor Pulley Pitch Diameter Min/Max (in)
2.8/3.95
Motor sheave
Browning 2-groov variable pitch 2VP42 7/8
Blower sheave
Browning dual sheave 2TB80-H1
Nominal Motor Shaft Diameter (in)
1
Fan Pulley Pitch Diameter (in)
7.75
Belt, Quantity...Type...Length (in)
2… V-belt ...
Pulley Center Line Distance (in)
10 1/4
Fan Shaft Diameter at Pulley (in)
7/8
HP
1/4
Flow Rate (gpm)
14.5 (at 24.6 ft. of water head)
Type
Copper tubes with aluminum spelling fins
Number of rows...Fins/ in
2…18
Tube diameter (in)
1/2
Height x length (in)
15 x 55
Total Face Area (sq ft)
5.7
11Ton Model 132.6.00.P.HA Service Manual
10
Operating Principle
Air Filters
Fuel
Air flow (CFM)
2000
Size (width x height x thickness) (In.)
20 x 20 x 2
Quantity
6
Fuel
Natural Gas or Propane
Maximum Input BTU/hr
150,000
Gas Line Inlet
¾ NPT
Input Pressure (in WC)
Natural Gas: 7 to 11
Propane: 11
Unit Supply Voltage and phase
208/230—3Φ/1Φ —60Hz
Minimum Circuit Ampacity
1Φ@30amp
3Φ@15amps
1Φ@40amp
3Φ@25amps
15/3Φ
30/1Φ
Maximum Circuit Ampacity (dual element
fuses or HACR circuit breaker)
Operating current (cooling and heating)
(Amps)
Power consumption (cooling and heating)
(kW)
Standard Compressor Internal Relief
(Differential)
Electrical
HIGH---PRESSURE SWITCH (psig)
FREEZE PROTECTION
THERMOSTAT (F)
1
3.3
Cutout (psi)
600
Reset (Auto.)
610
Opens
Closes
Dual element fuses or HACR circuit breaker.
Operating Principle
4. Unit External Dimensions
Top view
Side view – long
11Ton Model 132.6.00.P.HA Service Manual
Side view - short
12
Operating Principle
5. Distance from surrounding objects
Dimensions
Vertical – Up
Vertical–Down
Horizontal
H1
H2
H3
H4
Installation
72
0
36
36
36
36
Servicing
36
0
36
36
36
36
Ventilation
36
0
36
36
36
36
Combustible Materials
36
0
36
36
36
36
Please follow the city guidelines (code) for other surrounding appliance I.E. MUA, window, exhaust etc.
11Ton Model 132.6.00.P.HA Service Manual
13
Operating Principle
6. Internal Structure
11Ton Model 132.6.00.P.HA Service Manual
14
Operating Principle
1:
Fan motor
2:
Coolant
tank
3:
Variable
frequency
drive
13: Indoor coil
8:
Blower
9:
7:
14: Liquid
line
filter
1: Blower 2: Supply air
sensor
Fuel
supply
line
Blower
motor
15: Suction
line
filter
3: Air intake
silencer
4:
Drain filter
condensation lines
10: Damper
assembly(optional
addition)
16: Engine assembly
4: Air intake
panel
5:
NR Regulator
11: Outside air
hood
assembly
17: Ambient air
temperature
sensor
5: Oil
tank
6:
Suction
accumulator
12: Filter rack
assembly
6: Control panel
assembly
Operating Principle
1: Fans
2: Fuel
7: Blower 8: Oil
tank
1: Exhaust
drain filter
box
7: Oil tank
3: Exhaust drain
filter box
9: Engine assembly
4:
Water
pump
10:
5:
Variable frequency
drive
11:
2: Suction
accumulator
3: Oil
separator
4:
Exhaust
canister
8: Engine
assembly
9: Air intake
panel and
tube
10: Oil tank
lines and
dipstick
6:
Blower
motor
12:
5:
Exhaust heat
exchanger
11: Air intake
hose
6:
Starter
12: Transformer
Operating Principle
Section II – Operating Principle
1. Refrigerant System Diagram
1)
2)
Cooling
The refrigerant (R410A) coming out of the
compressors flows into the outdoor heat
exchanger (outdoor coil) after passing through
an oil separator, a four-way changeover valve
and a sub heat exchanger. Heat is dissipated
by the outside air, the refrigerant condenses
into a liquid. The refrigerant then flows
through the pipe to an indoor thermostatic
expansion valve where its pressure is
reduced. It flows into an indoor heat
exchanger (indoor coil) where it is evaporated
by absorbing the indoor heat and continues
through the four-way changeover valve and
an accumulator before returning to the
compressors.
Heating
The refrigerant (R410A) coming out of the
compressors flows into an indoor heat
exchanger (indoor coil) after passing through
an oil separator and a four-way changeover
valve. Dissipating heat to the room, the
refrigerant condenses into a liquid in the
indoor heat exchanger (indoor coil). The
refrigerant pressure is reduced at an indoor
thermostatic expansion valve. It then passes
through a pipe that leads to the outdoor heat
exchanger (outdoor coil), this valve further
reduce the refrigerant pressure, and then the
sub heat exchanger. At the outdoor heat
exchanger (outdoor coil) the refrigerant
evaporates by absorbing heat from the outside
air, while at the sub heat exchanger it
evaporates by absorbing heat from the engine
exhaust. The refrigerant from the sub heat
exchanger flows into the accumulator and
returning to the compressors.
11Ton Model 132.6.00.P.HA Service Manual
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Operating Principle
2. Engine Coolant System Diagram
1) Engine coolant sent from the engine coolant
pump is heated through the exhaust air heat
exchanger and the engine. When engine
coolant temperature is low at operation
eration start
start-up
the heated engine coolant returns to the engine
coolant pump by making a shortcut via the
thermostat.
3) When engine coolant temperature is higher,
engine coolant flows into the radiator to
dissipate heat, and returns to the engine
coolant pump via the thermostat.
3. Fuel Gas System Diagram
2) As engine coolant temperature increases,
engine coolant flows into the sub heat
exchanger and heats refrigerant to increase
heating efficiency in heating operation. In low
temperature cooling, engine coolant enhances
evaporation efficiency.
Fuel gas flowing through the series of
electromagnetic gas valves is de
de-pressurized
down to atmospheric pressure by the gas
regulator
gulator and supplied to the gas mixer.
Operating Principle
Intake Air and Exhaust
System Diagram
Air
Intake air enters the gas mixer through the
air filter to be mixed with the fuel. The air/fuel
mixture then flows into the en
engine cylinder.
Exhaust air dissipates heat at the exhaust air
heat exchanger, and is emitted into the
atmosphere through an exhaust muffler.
Condensed water generated by exhaust air
heat dissipation is neutralized at the exhaust
water drain filter, and discharged
dis
from the
unit through the exhaust water drain hose.
1 : Engine
2 : Gas mixer
3 : Gas regulator
4 : Electromagnetic gas valve
5 : Air filter
6 : Engine coolant temperature sensor
7 : Exhaust air heat exchanger
8 : Thermostat (153 F (67 °C))
9 : Thermostat (140 F (60 °C))
10 : Radiator cap
11 : Engine coolant pump
12 : Exhaust muffler
13 : Sub heat exchanger
14 : Engine coolant reserve tank
15 : Radiator
16 : Exhaust water drain filter
17 : Exhaust water drain hose
18 : Exhaust water drain trapper
19 : Sub oil pan
20 : Manual valve
21 : Pressure check tap
22 : Pressure check tap
Touch Pad
Section III – Siemens TD 200 Hand Held Touch Pad
Main Screen Display
M/N - (NextAire P132.6.00.P.HA)
S/N - (Axxxxx)
1. Setting the Date/Time
1. Scroll down using down arrow key ( ) until date and
time screen appear Appears- 01/01/2090 - 0 / 0 / 0
(time may be counting)
2. Press ENTER - month will blink
3. Press arrow (AV) key to change to proper MONTH
4. Press ENTER - DAY will blink
5. Press arrow (AV) key to change to proper DAY
6. Press ENTER - YEAR will blink
7. Press arrow (AV) key to change to proper YEAR
8. Press ENTER - HOUR will blink
9. Press arrow (AV) key to change to proper HOUR
10. Press ENTER - MINUTE will blink
11. Press arrow (AV) key to change to proper MINUTE
V
12. Press ENTER - SECONDS will blink
13. Press arrow (AV) key to change to proper
SECONDS
14. Press ESC until main screen appears
NOTE: Using controller will bypass thermostat.
Thermostat will reset after 1 hour. To return to
thermostat operation press F5-F1 on TD 200.
NOTE: The main screen section displays model and
serial number of the unit. Model and serial numbers
will be pre-programmed by manufacturer through the
PLC.
2. To Test Blower Rotation
(CAUTION - check blower compartment prior to
starting for any debris or loose items)
*Beginning from main screen*
1. Press ESC one time
2. Scroll down until MANUAL OPERATION appears
in screen
3. Press ENTER
4. Scroll down using arrow keys until INDOOR
BLOWER SPEED 0% appears
5. Press ENTER
6. Scroll up by using up arrow key until 50% appears
7. Press ENTER - this will energize blower (Check
Blower Rotation) 8. If rotation needs to be reversed, stop unit and refer
to VFD instructions
9. Press F1 to stop
3. To Manually Adjust Blower Speed
(CAUTION - check blower compartment prior to
starting for any debris or loose items)
*Beginning from main screen*
1. Press ESC one time
2. Scroll down until MANUAL OPERATION appears
in screen
3. Press ENTER
4. Scroll down using arrow keys until INDOOR
BLOWER SPEED 0% appears
5. Press ENTER
6. Scroll up by using up/down arrow keys until desired
blower speed XX% appears (Range 0-100%)
7. Press ENTER - this will energize blower
8. Pressing F1 will return indoor blower speed to 0%
4. To Check Indoor Blower Motor Amperages
11Ton Model 132.6.00.P.HA Service Manual
20
Touch Pad
(CAUTION - check blower compartment prior to
starting for any debris or loose items)
*Beginning from main screen*
1. Press ESC one time
2. Scroll down until MANUAL OPERATION appears
in screen
3. Press ENTER 3. Scroll down using arrow keys until
INDOOR BLOWER SPEED 0% appears
4. Press ENTER
5. Scroll up by using up arrow key until 100% appears
6. Press ENTER - this will energize blower
7. Locate power legs entering VFD for Amperage
check of blower motor
8. Check Blower Motor Amperages on L1 (PL-02-3)
L2 (PL-02-4) L3 (PL-02-16) (Write down findings on
Event Sheet / Start up Sheet)
9. Pressing F1 will return indoor blower speed to 0%
5. To Check Outdoor Fan Motor Amperages
(CAUTION - check motor mounts for stability from
shipping and fan tightness)
*Beginning from main screen*
1. Press ESC one time
2. Scroll down until MANUAL OPERATION appears
in screen
3. Press ENTER
4. Scroll down using arrow keys until OUTDOOR
FANS appears "0" = OFF "1" = ON
Press ENTER
Change "0" to "1"
Press ENTER - this will energize outdoor motors
Locate power legs exiting from contactor (CF-01)
Check outdoor motor amperages on BK (PL-02-5) BK (PL-02-6) – RED (PL-02-7) (Write down
findings on Event Sheet / Start up Sheet)
10.Pressing F1 will de-energize outdoor motors
5.
6.
7.
8.
9.
6. To Start System in Heating or Cooling
(CAUTION - check compressor belt area for
electrical, debris or loose items)
*Beginning from main screen*
1. Press ESC one time
2. Scroll down until MANUAL OPERATION
appears in screen
3. Press ENTER
4. Scroll down using arrow keys until Y1, Y2, Y3
appears 1 = Y1 2 = Y2 3 = Y3
5. Press ENTER
6. Scroll up or down to change from "0" to 1 this
will energize system into Y1
7. Pressing F1 will return unit to normal
operation
*Always start the system in Y1
**System will have a 3 min. time delay between
stages
WHILE SYSTEM IS IN OPERATION MODE
7. To Change Stages Between Stages - in Manual Operation Mode
1 . Press ENTER
2 . Change 1, 2 or 3 to "1" - "2" - "3"
3 . Press ENTER (This will energize system into
Y1, Y2 or Y3)
**System will have a 3 min. time delay between
stages
8. To Change from Cooling or Heating
*Beginning from main screen*
1. Press ESC one time
2. Scroll down until MANUAL OPERATION
appears in screen
3. Press ENTER
4. Scroll down using arrow keys until "Cool or
Heat" appear “0" = COOL "1" = HEAT
5. Press ENTER
6. Choose either "0" or "1"
7. Press ENTER
8. Scroll up or down using arrow keys to change
from "0" or "1"
9. Press ENTER (Reversing Valve should
reverse direction of flow)
9. To Check Operations
NOTE: No changes can be made in this section.
*Beginning from main screen*
1. Press ESC one time
11Ton Model 132.6.00.P.HA Service Manual
21
Touch Pad
2. Scroll down using arrow keys until
OPERATIONAL DATA appears in screen
3. Press ENTER
4. Select a function by scrolling up or down
using the arrow keys until the desired function
appears
5. In this area, you can visually observe the
functions of the system: Unit Hours -
Carburetor Mixture Positions - Engine Crank
and Start Commands - RPM'S - Discharge
and Suction Pressures - Ambient
Temperature - Engine Coolant Temperature Discharge Refrigeration Temperature and
Supply Air Temperature
10. To Place in Stand-by Mode and Re-Energize Thermostat
NOTE: No changes can be made in this section.
1. Press ESC until Main screen appears
M/N - NextAire P132.*.P.HA S/N - Axxxxx
2. Press F5-F1 key on TD 200 (Check mark
will appear while key is pushed) Thermostat
will regain control of system
11. To Check Previous Unit Faults
NOTE: No changes can be made in this section.
*Beginning from main screen*
1. Press ESC one time
2. Scroll Down until FAULT HISTORY 1 & 2
appear - Faults are stored in descending
order where fault code 1 is always the most
recent.
3. Press ENTER (Fault code #1 will be
present)
4. Scroll through fault code to get fault data HOUR,
FAULT # & DESCIPTION, RPM'S (the engine
was operating at), DIS – DISCHARGE
PRESSURE, OD (ambient temperature), CT COOLANT TEMP, SUC - SUCTION
PRESSURE, DATE and TIME
5. Continue to scroll down, it will lead to fault
code #2 (with the same data)
6. Press ESC one time
7. Scroll down to FAULT HISTORY 3 & 4
8. Press ENTER (Fault code #3 will be
present)
9. Scroll down and copy down all data onto
back of EVENT SHEET
10.
Continue to scroll down, it will lead
to fault code #4 (with the same data)
11.
Continue the same process through
fault code #8 (All data is to be written down
on EVENT SHEET)
12.
Press ESC until main screen
appears
NOTE: To ENTER - OPERATIONAL DATA or
MANUAL OPERATION screen from FAULT
HISTORY screen - Scroll UP
11Ton Model 132.6.00.P.HA Service Manual
22
Problems and Diagnosis
Section IV – System Control
1. System Block Diagram
11Ton Model 132.6.00.P.HA Service Manual
23
Problems and Diagnosis
2. System Input / Output Specifications
No.Name
Functions
Specifications
1
High pressure
switch
1. Judgment to stop the operation at
abnormally high pressure
2. Detection of disconnection in the refrigerant high
pressure switch.
2
Engine oil
pressure switch
1. Judgment of abnormal oil pressure
2. Detection of disconnection in the engine oil
pressure switch
3
Engine coolant
temperature
sensor
4
Outside air
temperature
sensor
5
Compressor
discharge
temperature
sensors
Supply air
temperature
sensor
6
7
8
9
Compressor
intake temperature
sensors
Accumulator
outlet temperature
sensors 1, 2
Engine room
temperature
sensor
Outdoor
condenser coil
liquid temperature
sensor
Supply voltage: 12
VDC
Circuit OFF: 610 psi
(4.15 MPa)
Circuit ON: 486 psi
(3.35 MPa)
Supply
voltage:12VDC
Circuit OFF: 14.5
psi (0.1 MPa)
Circuit ON: 5.8
psi (0.04 MPa)
1. Judgment of abnormal engine coolant
temperature
2. Judgment of the engine warm-up completion
3. Abnormal engine coolant temperature avoidance
control
4. Preventive control for engine operation without
engine coolant
5. Idling operation for assuring stable oil
temperature
6. Detection of disconnection or short circuit
1. Judgment of ambient temperature under which
the system operation is prohibited (Cooling
operation is prohibited at less than 14°F (-10°C), Refer to P87,
and stopped at less than 10°F (-12°C)
[Thermistor
2. Preventive control for low pressure drop at
Characteristics].
cooling start-up
3. Detection of disconnection or short circuit
1. Detection of disconnection judgment
temperature (detection of 41°F (5°C) or less
for 10 minutes)
2. Detection of short circuit judgment temperature
(detection of 248°F (120°C) or more for 1
minute)
1. Temperature control
2. Indoor blower air volume
3. Room temperature display on the remote
controller
1. Data logging
1. Unit oil equalization control
2. Detection of disconnection or short circuit
Connector
No.
PSH-202
TE-129
TE-213
TE 200
TE-140/141
TE-138/139
1. Data Logging
TE-126
1. Data Logging
TE-113/115
11Ton Model 132.6.00.P.HA Service Manual
24
Problems and Diagnosis
No.Name
Functions
Specifications
Connector
No.
Refrigerant high
pressure
10 transducer
(compressor
discharge)
1. Refrigerant high pressure control (target
control in heating)
2. High refrigerant pressure avoidance control (in
cooling)
3. High refrigerant pressure emergency
avoidance control
5. Detection for inadequate refrigerant
6. Detection for abnormally high refrigerant pressure
7. Detection of disconnection or short circuit in the
refrigerant high pressure sensor
Supply voltage:
24 VDC Pressure
range:
0 to 653 psi
(4.5 MPa)
PP-105
Refrigerant low
pressure
11 transducer
(compressor
suction)
1. Judgment to stop operation at abnormally low
pressure
2. Low pressure control in cooling
3. Low pressure avoidance control in heating
Supply voltage: 5
VDC
Pressure range:
0 to 276 psi
(1.9 MPa)
PP-212
Engine speed
12
sensor
13
Compressor
clutches 1, 2
14 Throttle valve
15
Fuel gas flow
control valve
16 Igniters #1 to # 3
17
Electromagnetic
gas valves 1, 2
18
Four-way
changeover valve
19
Hot bypass gas
valve
20
Compressor
heaters 1,2
1. Engine speed detection
2. Detection of disconnection
3. Detection for engine overspeed abnormality
4. Detection of loss of engine speed control
To turn ON/OFF (clutch
engaged/disengaged)compressors depending on
the calculated refrigerant flow volume for the unit
Control of the engine speed
Control of air/fuel ratio
Power supply cut off to the ignition coil
Engine oil pan
heater
Oil return valves 1
22
,2
To supply or shut off the fuel gas to the outdoor
unit.
To be set to ON in heating.
NOTE: To switch the mode at the start of
operation if the operation mode is different from
the previous one.
1. Low pressure drop preventive control in heating
2. Defrosting operation
3. High pressure avoidance control in heating
4. Low pressure avoidance control in heating
5. Pressure equalizing control at system stop
To set to ON to prevent liquid entrapment in the
compressor if the engine room temperature is low
when the system stops.
To set to ON to prevent engine oil from being too
viscous.
To set to ON/OFF in synchronization with ON/OFF
of the compressor on the same side
23 AC/DC converter
AC/DC conversion (e.g., 230 VAC →12 VDC)
24 Starter
To support the engine for self-operation at startup.
21
25
Outdoor fan
motors 1, 2
To be operated for heat exchange of refrigerant
and for cooling the engine coolant.
26
Engine coolant
pump
To circulate the engine coolant.
27
Indoor blower
motor
To be operated for heat exchange of refrigerant
11Ton Model 132.6.00.P.HA Service Manual
Supply voltage:
12 VDC
Supply voltage:
12 VD
Supply voltage:
12 VDC
Supply voltage:
12 VD
Supply voltage:
12 VDC
Supply voltage:
24 VAC
Supply voltage:
24 VAC
Supply voltage:
200 VAC
Supply voltage:
200 VAC
Supply voltage:
24 VAC
Transformer,
diode
Supply voltage:
12 VDC
Supply voltage:
280 VDC
Supply voltage:
280 VDC DC
brushless
Supply voltage:
280 VDC
25
Problems and Diagnosis
3. Control Details
1) Temperature Control Start/Stop
a.
Starting temperature control
Temperature control starts when the thermostat set temperature control request to "ON".
b.
Temperature control is prohibited when the package unit is stopped
1. When there is a package unit alarm or error.
2. When 3 minutes have not passed, after the power is turned ON or the compressor is turned OFF.
c.
Stopping temperature control during package unit operation
1. When the thermostat set temperature control request to "OFF".
2. When a package unit alarm or error occurs.
2) Starting the Unit
(Starting the Engine and Engaging the Compressor Clutch)
a. Starting the engine
Turn the starter ON to start the engine.
b. Warming up
After starting, engine runs unloaded at 1800 rpm for 20 sec.
c.
Connecting the compressor
After the completion of warm-up, the indicated engine speed is set to the compressor engaging speed and then the
compressor is engaged.
The compressors are engaged at the same time.
3) Engine Speed
a. Engine speed range during temperature control
1. Engine speed at low level : 1850 rpm (min-1)
2. Engine speed at intermediate level : 2000 rpm (min-1)
3. Engine speed at high level : 2400 rpm (min-1)
b. Engine speed in the operation mode
1. Engine speed at start-up : 1800 rpm (min-1)
2. Engine warm-up speed : 1800 rpm (min-1)
3. Compressor engaging speed : 1800 rpm (min-1)
11Ton Model 132.6.00.P.HA Service Manual
26
Problems and Diagnosis
4) Refrigerant Flow Volume
a. Refrigerant flow volume by the engine speed
Engine speed
(rpm (min-1))
1650
2200
2400
Number of
compressors
2
Compressor capacity (cfm)
6.06
8.08
8.8
5) Required engine speed
Set by thermostat based on temperature trend of the conditioned space.
6) Defrosting (in heating only)
In heating, frosting on the outdoor coil blocks heat absorption from the outside air, and causes deterioration of heating
capacity. Defrosting is necessary to prevent such a problem.
a. Judgment for starting defrosting
1. Judgment of frost formation
When the low pressure corresponding temperature has dropped, it is judged that frost has formed and
defrosting starts.
2. Defrosting prohibited conditions
Defrosting does not start if the following conditions are satisfied, even if frosting is judged.
3. Under starting control
4. When the specified length of time has not passed since the last defrosting, or start of remote control operation
or temperature control.
b. Defrosting starting procedure
The control system sends defrosting signal ON to the package units.
c.
Judgment for the end of defrosting
Return to normal heating operation
Operation returns to normal heating mode in either of the following cases:
• The outdoor coil temperature or high pressure corresponding liquid temperature has reached or exceeded the
saturated vapor pressure of 10 psig or more above the suction pressure after the start of defrosting.
• 180 seconds at 2500 rpm has passed after the start of defrosting.
d. Stop of defrosting
Defrosting stops and then operation stops in the normal manner if any of the following cases occurs:
• Operation mode is changed to "stop", "fan", "cooling", or "dehumidifying".
• Any abnormality that requires the package unit to stop running occurs.
1. End of defrosting
Control system sends defrosting signal OFF to all indoor units.
7) Oil Return Valve
•
•
•
The oil return valve is controlled to prevent the reduction of the amount of oil returned when the high pressure
goes down.
The main oil valve will be opened when the pressure difference between the compressor discharge and
suction is more than 247 psi
The sub oil valve will be opened when the pressure difference between the compressor discharge and suction
is less than 247 psi but more than 203 psi
The main and sub oil valves will be opened when the pressure difference between the compressor discharge
and suction is less than 203 psi
8) Compressor Heater
When the outside air temperature is low, the compressor heaters are turned ON to protect the compressor
while the engine is stopped.
9) Indoor Blower
Indoor blower motor speed range during temperature control
11Ton Model 132.6.00.P.HA Service Manual
27
Problems and Diagnosis
1. Blower motor speed at low level (Y1): 1255 rpm (min-1)
2. Blower motor speed at intermediate level (Y2): 1520 rpm (min-1)
3. Blower motor speed at high level (Y3): 1725 rpm (min-1)
11Ton Model 132.6.00.P.HA Service Manual
28
Problems and Diagnosis
4. Wiring Diagrams
CA:
CB:
CF:
Capacitor
Circuit Breaker
Contactor
OH:
PL:
RE:
Oil Heater
Plug
Relay
DI:
FU:
MT:
Diode
Fuse
Motor
11Ton Model 132.6.00.P.HA Service Manual
SS:
TB:
TR:
Starter Solenoid
Terminal Block
Transformer
29
Problems and Diagnosis
Section V – Problems and Diagnosis
1. Error Code Description and Possible Cause
NOTE: Repairs to these fault codes are explained in detail following this section according to their repair code
number.
Fault
Code
Fault Name
0
No Fault
1
Faults Were
Reset
11
Engine Over
temperature
12
Engine Stall
13
Engine Under
speed
14
Engine Over
speed
15
Engine Crank
Failure
16
Engine Oil
Press Low
17
Engine Start
failure
17-20
HP Avoidance 1
22
HP Avoidance 2
HPCO
Open
Refrigerant
Low Pressure
25-30
RESERVED
26
24V Power lost
Heat Operation
31
Prevent
24
PLC is reset.
No
If the engine coolant outlet
temperature exceeds 203°F for
more than 5 seconds while
compressors are engaged.
If the unit has a call to run and
the engine speed is below
200 rpm.
If the engine is running, it did
not stall, and the engine speed
falls below 700 rpm.
If the engine speed exceeds
4,000 rpm.
If the engine speed reads
less than 50 rpm three
seconds after the starter
energizes.
If the oil pressure switch
closes after a time delay of
1.5 second.
Engine went through 12
successful crank attempts,
but didn’t start
Unit shutdown by
Programmable
Controller (PLC)
No - Counter for number of
faults in the last 24 hours
erased.
Automated Recovery
Action
Unit will start normally.
Yes
Yes
Fault will reset after the
coolant temperature falls
below 158°F.
Yes
Yes
Fault will reset after a ten
second delay.
Yes
Yes
Fault will reset after a ten
second delay.
Yes
Yes
Fault will reset after the
engine speed drops below
3,000 rpm
Yes
Yes
Fault will reset after three
seconds
Yes
Yes
Fault will reset after ten
seconds
Yes
Yes
Fault will reset after 60
second delay.
RESERVED
21
23
Trigger for Fault
Recording
Counts
toward
24 hour
fault
counter
Cooling Case: If the discharge
pressure exceeds 585 psig,
high-pressure avoidance will
be initiated.
Heating Case: If the discharge
pressure exceeds 450 psig,
high-pressure avoidance is
initiated.
If the discharge pressures
exceed 600 psig.
If the gas valve relay (RE-04)
is energized. (The gas valve
will energize when the
mechanical high-pressure
cutout opens from an input of
610 psig)
If the refrigerant suction
pressure falls below 20 psig.
24 VAC power was interrupted
If the unit calls for heating
while the outdoor ambient
No
The PLC adjusts the engine
speed to decrease discharge
pressures below 535 psig
(cooling) or 400 psig
(heating)
Yes
Yes
Yes
Yes
Yes
Yes
No
Once the operating discharge
pressures fall below 500 psig,
the fault will reset
None. The High Pressure
Cut Out (HPCO) must be
manually reset
Once the pressure exceeds 60
psig, the fault will reset
Yes
11Ton Model 132.6.00.P.HA Service Manual
Once the operating
discharge pressures fall
below 400 psig in heating or
535 psig in cooling, the unit
will exit high-pressure
avoidance
The system will try to restart
after a 30 second delay.
30
Problems and Diagnosis
Fault
Code
Fault Name
Trigger for Fault
Recording
Counts
toward
24 hour
fault
counter
Unit shutdown by
Programmable
Controller (PLC)
Automated Recovery
Action
temperature is greater than or
equal to 75°F for 30 seconds.
32
37
38
39
40
Supply Air
Above 200°F
Discharge
Refrigerant
Above 248°F
RESERVED
5 Faults in
24Hour
DO NOT USE
If the supply air temperature is
above 200°F for 30 seconds.
Yes
Yes
If the discharge temperature
sensor is above 248°F.
Yes
Yes
If 5 countable faults occur in any
given 24 hour interval.
No
Yes – The PLC inhibits the
unit from starting.
Once the supply temperature
falls below 180°F, the fault will
be reset.
Once the discharge
temperature falls below
180°F, the fault will reset
None. The PLC must be
manually reset.
NOTE: The time delay mentioned above only relates to the time required to reset the fault. To initiate the
starting sequence, a time delay of three minutes will occur.
11Ton Model 132.6.00.P.HA Service Manual
31
Problems and Diagnosis
2. Fault Code Correction Procedures
Fault
Code
11
12
13
14
15
16
17
21
22
23
24
26
31
32
37
39
Fault Name
Possible Major Causes
1. Engine coolant circulation failure
(Inadequate engine coolant)
2. Engine heat dissipation failure,
etc.
1.Inadequate engine output
Engine Stall
2. Stepping motor operation failure,
etc
1.Connector contact failure
2.Gas Mixer failure
Engine Under speed 3.Engine compression failure
4.Ignition system failure
5.Clogged engine air filter element
Stepping motor operation failure,
Engine Over speed
etc.
1.Starter motor failure
Engine Crank Failure 2.Connector disconnected
3.Disconnection of pickup coil
Inadequate oil pressure (inadequate
Engine Oil Press Low
oil amount, etc.)
1.Gas line problem
Engine Start
2.Spark plug problem
failure
3.Intake air blockage
4.Starter voltage not connected
1.Condenser heat dissipation failure
HP Avoidance 1
2.Refrigerant system failure
(Blockage/ Overfilling, etc)
1.Condenser heat dissipation failure
HP Avoidance 2
2.Refrigerant system failure
(Blockage/ Overfilling, etc)
1.Condenser fans not working
HPCO Open
2.Dirty condenser coil
1.Evaporator heat dissipation failure
Refrigerant Low
2.Refrigerant system blockage/
Pressure
leakage etc.
24V Power lost
Heat Operation
Outdoor temperature above 70°F in
Prevent
heating mode
Supply Air Above
Bad sensor
200°F
1.Refrigerant oil level
Discharge Refrigerant
2.Bad sensor
Above 248°F
3.Low refrigerant charge
5 Faults in 24Hour
Engine Over
temperature
Diagnosis/ Repair
Refer to “Engine coolant temperature abnormality”
in Section 5 Diagnosis Procedure
Refer to “Engine Starts But Stalls” in Section 4
Diagnosis Procedure
1.Check connector connection
2.Inspect throttle valve
3.Inspect engine compression pressure
4.Inspect spark plug/ coil/ high voltage cables (spark plug wires)
5.Inspect/ replace air filter element
Refer to “Over Speed” in Section 7 Diagnosis Procedure
1.Replace starter motor
2.Check connector
3.Check pickup coil
Refer to “Oil Pressure Abnormality” in
Section 6 Diagnosis Procedure
1.Check gas line
2.Check the spark plugs
3.Check air intake
4.Check starter voltage connectivity
1.Check for clogging of coil(s) at condenser side or fan operation
2.Check refrigeration amount/ blockage in refrigerant system
1.Check for clogging of coil at condenser side or fan operation
2.Check refrigeration amount/ blockage in refrigerant system
1.Replace coil
2.Clean coils as necessary
Refer to “Refrigerant Low Pressure Abnormality” in
Section 10 Diagnosis Procedure
Do not operate the heating mode above 70°F
Check sensor
1.Correct oil level
2.Change the sensor
11Ton Model 132.6.00.P.HA Service Manual
32
Problems and Diagnosis
Section VI – Diagnosis Procedures and Inspection
Below is a listing of the common problems. Please refer to the corresponding number to see diagnosis and
treatments.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
System will not operate
Starter will not operate
Engine will not start
Engine starts but stalls
Engine coolant temperature abnormality
Oil pressure abnormality
Over speed
High pressure abnormality in cooling operation
High pressure abnormality in heating operation
Refrigerant low pressure abnormality
Refrigerant discharge temperature abnormality
Gas heat pump is operating but not cooling
Gas heat pump is operating but not heating
Thermostat is not functioning correctly
11Ton Model 132.6.00.P.HA Service Manual
33
Problems and Diagnosis
1. System will not operate.
Problem
Possible cause
Specific Example
Inspection and Treatment
Error in connecting the power supply wires
No operation.
No display on the
thermostat.
Fault code # 15
Power supply
system failure
thermostat
failure
Check power supply system
1-1
Control unit failure
Check control unit
1-2
Circuit protector is OFF
Circuit protector
1-2
Check thermostat system
1-3
Contact failure / Disconnection
Contact failure / Disconnection
thermostat failure
Wiring error in the communication line
Thermostat
display functions
but the system
does not
operate.
Inspect the communication line
(wire disconnection, internal short circuit)
Contact failure / Disconnection
Communication
system failure
Wiring error
Contact failure / Disconnection
Check control unit
1-2
Control unit failure
may be faulty. Replace the PLC.
1.1. Check power supply system
a. Check that the power supply wires of the
units are correctly connected as
specified in the installation manual.
b. Check that the power supply voltage
(230 or 208 VAC) is applied to the unit at
the power supply terminal (TB-03).
1.2. Check control unit
Check the input/output voltage of the
transformer at the terminal (TB-03). If 230 or
208 VAC is not applied to the transformer,
the protector (fuse) may be blown.
1.3. Check thermostat system
Inspect the terminals of the unit and the
thermostat for a failure, such as contact
failure, disconnection, etc.
If the LED (green) on the PLC is not lite even
though 230 or 208 VAC is applied, the PLC
11Ton Model 132.6.00.P.HA Service Manual
34
Problems and Diagnosis
2. Starter will not operate
Problem
Possible cause
Specific Example
Inspection and Treatment
Starter pinion does
Pinion drive coil
not work.
failure
Inspect starter
2-1
There is no output
voltage.
* If there is no output voltage applied to the pinion coil and the starter motor, the starter drive
system may be faulty.
Starter drive
Transformer
Inspect transformer
2-2
system failure
Relay (RE-06) failure Operation check of (RE-06) relay
2-3
Engine start
Starter does
failure
not start.
Fault code # 15
2.1. Inspect Starter
1. Check output voltage applied to the
starter
a. Output voltage applied to the starter
motor.
Check the output voltage (12 VDC)
between the "B" terminal of the starter and
the body ground while the starter relay
(RE-06) is ON.
b. Output voltage applied to the pinion
drive coil
Check the output voltage (12 VDC)
between the "S" terminal and the body
ground.
Check if 208/230 VAC is available. If input
voltage at the primary side is normal and
output voltage at the secondary side is not
normal, the transformer is considered to be
faulty.
2. Check secondary output voltage
Check if 12 VDC is available at the
secondary terminals.
3. Check if there is12-16 VDC output
between the primary terminal of the
diode and the ground while the starter
relay (RE-06) is operating.
4. Inspect transformer unit
Check if there is coil disconnection or
internal short circuit in primary and
secondary sides.
2.3. Operation check of relay
1. Operation check of starter relay (RE-06)
2. Inspect starter unit
Measure the resistance at the locations
shown in the table below while the power
is turned OFF. Check that each measured
value does not greatly deviate from the
reference value.
Location
a. Confirm availability of 12-16 VDC
between 3L and M at the PLC module
PC-03. If 12 VDC is not available,
check the power supply transformer
and the capacitor (CA-06).
b. When starter is on, check the
availability of 12-16 VDC between .3
and M at the PLC module PC-03. If
there is no 12 VDC available, then the
PLC module (PC-03) may be faulty.
Reference value (68°F (20°C))
S terminal-Body ground
0.24 Ω
B terminal-Body ground
∞
M terminal-Body ground
0.01 Ω
S terminal-M terminal
0.24 Ω
S terminal-B terminal
∞
B terminal-M terminal
∞
2.
2.2. Inspect transformer
1. Check primary input voltage
Transformer operation check
a. Check if 208-230 VAC is available at
the primary side and 12 VDC at the
secondary side of the transformer. If
208-230 VAC is available at the
primary side, but 12 VDC is not
available at the secondary side, check
your diodes (DI-01, DI-02) and
capacitor (CA-06). If the diodes and
the capacitor are not faulty, the
transformer may be faulty.
11Ton Model 132.6.00.P.HA Service Manual
35
Problems and Diagnosis
3. Operation of the starter circuit
a. Turning the starter ON
A 12 VDC output from the PLC module PC03 turns the relay RE-06 ON.
After the Q2:3 (PLC module PC-03) is
energized, as long as there is power to the
unit there is always 12 VDC at the relay
terminal (RE-06) 87. of PLC module PC-03
12 VDC is output across PL-02-12 is applied
to the starter motor MT-04.
The starter drive voltage, 12 VDC, is the
output from the secondary side of the
transformer and applied to the starter motor
(MT-04).
11Ton Model 132.6.00.P.HA Service Manual
36
Problems and Diagnosis
3. Engine will not start
Problem
Possible cause
Fuel gas
Intake and
exhaust air
system failure
Abnormal
air/fuel
ratio
Blockage
in the
exhaust
system
Spark plug
failure
Engine start
failure
Fault code
# 15
Ignition system
failure
Compression
system failure
Noise, etc.
Engine coolant
pump failure
Outdoor fan motor
failure
Overload in
cranking
Ignition
failure
Specific Example
Electromagn Electromagnetic gas
etic gas
valve failure
valve does
There is no output
not open
voltage
Blockage in the air
Air
inlet
system
Clogged air filters
Gas mixer operation
Fuel system
failure
Freezing in exhaust
Blockage in
water drain hose
the exhaust
Broken or twisted
water drain
exhaust water drain
hose
hose
Blockage in the exhaust air heat
exchanger or the exhaust muffler
Deposit formation or wet plug
Improper spark plug clearance
Cap connector disconnected
High voltage cable failure
Failure of igniter, etc.
Inspection and Treatment
Inspect electromagnetic gas valve
Inspect/Replace air filters
Inspect throttle valve/fuel gas flow
control valve
3-10
Inspect exhaust water drain hose
Inspection/Adjustment exhaust water drain
hose
Inspect the exhaust air heat exchanger or the
exhaust muffler
Inspect spark plug
3-2
Inspection/Adjustment cap connector
Inspect high voltage cable
Inspect igniter, etc.
3-3
3-4
Ignition
Loose connection
Check connection
module
Cam speed
sensor and
Bad sensor
Check sensor and the cam board
board
Compression failure is assumed if crankshaft can be turned lightly by hand.
Valve
popping
Valve clearance failure
Check compression
up
Treatment for compression failure
Carbon deposit formation on valve or valve seat
due to carbon deposit
Engine speed sensor reading failure
Check for contact failure at the starter
drive system
12 VDC system terminal (PL-03-30) connector
contact failure
Malfunction caused by induction noise from the
Inspect high voltage cable
ignition system
Engine coolant pump motor failure
Inspect engine coolant pump
Outdoor fan motor failure
motor or capacitor
Due to low temperature, engine oil is so viscous that
the starter is not able to run the engine.
3-1
Inspect outdoor fan motor/capacitor
3-5
3-6
3-7
3-9
3-11
3-3
5-3
5-6
Inspect engine oil pan heater
3.1. Inspect electromagnetic gas valve
1. Check output voltage
Check the output voltage (12 VDC) to the
electromagnetic gas valve at the terminals
(PL-03-09 / 11) If the output voltage is not
normal check wiring.
2. Inspect electromagnetic gas valve unit
Disconnect the connector to the
electromagnetic gas valve and check the
continuity between the terminals (PL-03-09 /
11) on each of the two electromagnetic gas
valves for a magnet coil disconnection.
Standard resistance value
21.0 Ω
3.2. Inspect spark plug
1. Spark check the spark plug
a. Close the fuel gas valve.
b. Remove the spark plug.
c. Have the spark plug body contact to
11Ton Model 132.6.00.P.HA Service Manual
37
Problems and Diagnosis
the engine with the high voltage cable
(spark plug wire) connected to the
spark plug.
High voltage cable #1
High voltage cable #2
High voltage cable #3
5.7 ± 2.2 kΩ
4.6 ± 1.8 kΩ
3.5 ± 1.3 kΩ
3.4. Inspect igniter, etc.
1. Output voltage check of the igniter.
d. Enter Y1 stage to crank the engine and
check that the plug sparks.
2. Inspect spark plug electrodes
Supply power to the igniter. Then,
disconnect the spark coil connector, and
check the voltage (12 VDC) between the
plus (+) terminal of the connectors (PL-07-1 /
08-1/ 09-1) and the body ground.
Check for burnout, dirt or abnormal wear on
the electrode section of the spark plug.
Electrode clearance
standard value
0.016 to 0.039 inch
(0.4 to 1.0 mm)
2. Inspect ignition coil
NOTE: When mounting the spark plug, make
sure to tighten it first by hand. After that use
plug wrench to tighten it up to the specified
torque.
Tightening torque
Check that there is no disconnection or
internal short circuit in the primary coil of the
ignition coil.
15 to 22 lb.ft
(20 to 30 N.m)
3.3. Inspect high voltage cable (spark plug
wire)
Connection failure of the high voltage cable to
the connector or an internal disconnection of
the cable may cause malfunctions due to
noise influence including a sudden engine
stall, oil pressure or engine coolant
temperature abnormality from unknown
causes.
1. Inspect connection failure of the high
voltage cable connector to the spark
plug or coil.
2. Measure resistance at both sides of the
high voltage cable and check for any
abnormality such as a disconnection.
Standard resistance value
2.8 Ω (68°F (20°C))
3. Inspect engine speed sensor
Measure the resistance value between both
terminals (PL-05-01/02) of the engine speed
sensor.
Standard resistance value
1100±150 Ω
(68°F(20°C))
3.5. Inspect ignition module
Check for disconnection in the wiring from
the ignition module to the engine speed
sensor.
11Ton Model 132.6.00.P.HA Service Manual
38
Problems and Diagnosis
Check for 12 VDC at the igniter connection
PL-04-H.
3.6. Inspect engine speed sensor detection
board
Check the board for shorts.
center (TDC) mark as shown in the
illustration to the right.
3. Check that the intake rocker arm of No. 1
cylinder does not move when the crank
pulley is shifted approx. 20° to the left and
right. If the rocker arm moves, turn the
crank pulley 360° and realign its notch to
the TDC mark.
4. As shown in the illustration to the right,
adjust intake valves on No. 1 and No. 3
cylinders, as well as exhaust valves on
No. 1 and No. 2 cylinders by loosening the
adjust nuts.
5. Turn the crank pulley several turns by
hand.
6. As shown in the illustration to the right,
adjust intake valves on No. 2 cylinder and
exhaust valves on No. 3 cylinder by
loosening the nuts.
3.7. Check compression
Measure the compression of each engine
cylinder with a compression gauge to assure
correct engine output.
1. Close the fuel gas valve.
2. Remove the spark plug.
3. Insert part (5) of the adapter into the plug
hole and tighten it.
4. Set part (3) of the compression gauge to
part (4) of the adapter and turn part (3) in
the direction indicated by arrow symbol until
the turning effort becomes heavy. The
rubber portion of part (5) is firmly pressed
against the plug hole and thus fixed tightly.
5. Fully open the throttle of the gas mixer.
6. Install the compression gauge at a safe
location apart from moving parts.
7. Enter stage Y1 operation to crank the
engine to measure compression. Operate
the starter alone for 5 seconds to check.
8. Push part (1) to reset the gauge to "zero".
Repeat the above procedure for other
cylinders.
Reference
clearance:
0.014 ± 0.002 inch (hot status)
(0.35 ± 0.05 mm)
0.01 ± 0.002 inch (cold status)
(0.25 ± 0.05 mm)
3.9. Treatment for compression failure due to
carbon deposit
Reference value
203 psi (1.4 MPa) or more
[Rinse treatment]
3.8. Valve Clearance Inspection/Adjustment
1. Remove the cylinder head cover (valves
cover).
2. Align the notch indicating the top dead
center of the crank pulley to the top dead
When carbon deposits are formed on the
valve seat or valve and prevent the valve
from sealing up the combustion chamber,
clean the valve seats or valve in the manner
explained below with a valve cleaner.
11Ton Model 132.6.00.P.HA Service Manual
39
Problems and Diagnosis
1. Close the fuel gas valve.
2. Remove the spark plug and air intake
hose of gas mixer.
WARNING
Before attempting treatment for compression
failure due to carbon deposit, be sure to
disconnect the igniter connector.
Failure to do so may cause a fire.
3. Disconnect the connector from the
igniter.
4. Set the gas mixer throttle at 500 steps
position (fully opened position) Using the
TD 200 hand held.
- Set the TD 200 hand held to manual
operation
- Select clean throttle
- Set to 1
- After finishing set to 0
5. Cover the plug hole with a cloth.
6. Open the cylinder head cover (valves
cover) and turn the crank shaft by hand
and set it at the position where the intake
and exhaust valves of No. 1 cylinder do
not move, when the crank shaft is turned
60° in the left and right directions.
7. Turn the crank pulley 360°, then turn it
45° more by hand.
8. Supply valve cleaner into the gas mixer
through opening for 20 seconds and wait
for 10 minutes.
9. Turn the crank pulley 240°by hand.
10.
Supply valve cleaner into the gas
mixer through opening for 20 seconds
and wait for 10 minutes.
11.
Turn the crank pulley 240°by
hand.
12.
Supply valve cleaner into the gas
mixer through opening for 20 seconds
and wait for 10 minutes.
13.
Turn the crank pulley 3 or 4 turns
by hand to drain valve cleaner.
14.
Close the cylinder head cover
and operate the starter to crank the
engine. (Use TD 200 hand held)
15.
Reconnect the spark plug, air
intake hose and the igniter connector.
16.
Turn the crank pulley 2 or 3 turns
by hand.
17.
Disconnect the blow-by hose
between the gas mixer and the cylinder
head cover at the cylinder head cover
side, and run the engine.
18.
Supply 1/2 can of valve cleaner
to the gas mixer through the hose
disconnected in step 15 above.
NOTE: Supply valve cleaner intermittently
while making sure that there is no engine stall
or over speed.
19.
Reconnect the hose to the head
cover and keep the engine running until
no more white smoke is emitting from the
exhaust port. Then stop the engine.
20.
Check if the compression has
recovered sufficient pressure. If the
compression does not recover, repeat
steps 1 through 16.
CAUTION
Take extra precaution while cleaning a part by
running the engine. There are possibilities that
your fingers or clothing could be caught by the
crank pulley or other moving parts.
[Treatment in engine operation]
1. Disconnect hose (blow-by hose)
connected to the gas mixer.
2. Run the engine.
3. Supply 1/2 can of valve cleaner to the
gas mixer through the end of the hose
disconnected in step 1 above.
NOTE: Make sure that there is no engine
stall or over speed.
4. Reconnect the hose.
5. Keep the engine running until no more
white smoke is emitting from the exhaust
port. Then stop the engine.
WARNING
Take extra precaution while cleaning a part by
11Ton Model 132.6.00.P.HA Service Manual
40
Problems and Diagnosis
running the engine. There are possibilities that your
fingers or clothing could be caught by the crank
pulley or other moving parts.
2-4
5-7
7-8
1-4
3.10.
Inspect throttle valve/fuel gas flow
control valve
[Throttle valve]
Disconnect the throttle valve connector and
measure resistance between each pair of
terminals of the stepping motor for adjusting
the throttle valve.
5-8
240Ω
Connector terminal arrangement (at the
valve side)
Motor coil resistance
Terminal No.
Resistance between terminals
(77°F (25°C))
1-2
2-3
4-5
120 Ω
A contact failure at the terminal of the starter
drive system (12 VDC system terminal (PL03-02)) may lead to an engine stall caused
by noise.
240 Ω
A contact failure tends to occur at the
following sections:
5-6
1-3
4-6
3.11.
Check for contact failure at the
starter drive system
Connector terminal arrangement (at the
valve side)
1. Condenser connection terminal section
2. Diode connection terminal or body ground
connection terminal section
3. Starter cord connection terminal section, etc.
[Fuel gas flow control valve]
Disconnect the fuel gas flow control valve
connector and measure resistance between
each pair of terminals of the stepping motor.
Terminal No.
1-2
Resistance between terminals
(77°F (25°C))
120Ω
11Ton Model 132.6.00.P.HA Service Manual
41
Problems and Diagnosis
4. Engine starts but stalls.
Problem
Possible cause
Insufficient
engine output
Engine
stall
Fault
code 12
Throttle control
system failure
Noise, etc.
Specific Example
Inspection and Treatment
If the engine stalls even if the throttle is open, insufficient engine output may be a cause of
engine stall.
Incorrect air ratio
Clogged air filters
Inspect air filters
Inspect throttle valve/fuel
Fuel system failure
3-10
gas flow control valve
Spark plug failure
Deposit formation or
Inspect spark plug
3-2
wet plug
Ignition system
Spark clearance is
failure
nonstandard.
High voltage cable
Inspect high voltage
3-3
failure
cable
Ignition timing failure
Check ignition timing
4-1
Valve popping up
Check compression
3-7
Compression
Carbon deposit
Treatment for
failure
formation on valve
compression failure due
3-9
or valve seat
to carbon deposit
Stepping motor failure Inspect throttle valve/fuel
Throttle operation
3-10
failure
gas flow control valve
Output failure
Engine speed sensor reading failure
Check for contact
failure at the starter
3-11
12 VDC system terminal (PL-03-02)
drive system
connector contact failure
Malfunction caused by induction noise
Inspect high voltage
3-3
from the ignition system
cable
4.1. Check ignition timing
1. Connect the pickup clip of the timing light
to the high voltage cable of the No. 1
cylinder.
Check the ignition timing by aiming the timing
light at the timing scale located behind the
crank pulley on the front side of the engine.
Engine speed
-1
1200 rpm (min )
11Ton Model 132.6.00.P.HA Service Manual
Ignition timing
18° ± 3°
42
Problems and Diagnosis
5. Engine coolant temperature abnormality
Problem
Possible cause
Specific Example
Inspection and Treatment
Insufficient engine coolant circulation amount may cause a large difference between the radiator inlet and outlet temperatures.
Engine coolant
circulation failure
Engine over
temperature
Fault code #
11
Insufficient engine coolant / Natural evaporation /
Leakage
Engine coolant pump
does not operate.
Engine coolant pump failure
Blockage in the engine
coolant system
Thermostat does not open.
5-1
Inspect engine coolant amount or
leakage location
5-2
Inspect engine coolant pump
5-3
Check engine coolant heat radiation condition (in cooling)
5-5
There is no output voltage.
Thermostat failure
* If the radiator temperature is high as a whole in spite of a normal temperature difference
between the inlet and outlet, heat dissipation from the radiator may be insufficient.
Air temperature is too high
Insufficient heat
dissipation
Radiator intake
Improper air circulation
(Short circuit)
Clogged radiator fins
Outdoor fan does not
operate.
Check engine coolant heat radiation condition (in cooling)
5-5
Cleaning the radiator fins
Outdoor fan motor failure
Inspect outdoor fan motor
5-6
There is no output voltage.
Sensor and signal
wire system failure
Engine coolant temperature sensor malfunction,
sensor failure, contact failure or disconnection
Inspect engine coolant temperature
sensor
5-7
Others
Lowered boiling point, radiator cap failure
Inspect radiator cap
5-8
5.1. Check engine coolant circulation
Check if engine coolant circulation is normal
by checking the difference between the
radiator inlet and outlet temperatures.
The temperature difference becomes larger
than normal if the amount of engine coolant
circulation is decreased due to a blockage in
the piping system.
Also check the temperature (engine outlet
coolant temperature) during operation.
Rough guide of difference between the radiator
inlet and outlet temperatures.
In cooling
Check engine coolant circulation
CAUTION
When refilling engine coolant, be sure to use AISIN
Coolant S in concentration of 50% volume with
distilled water.
5.3. Inspect coolant pump
1. Inspect engine coolant pump unit. Check
the operating sound during pump
operation. If the engine coolant pump is
not operating, replace it.
2. Check the LED at the .3 on the PLC
module PC-01. If the LED is not green,
the PLC module PC-01may be faulty.
50 to 82°F (10 to 28°C)
5.2. Inspect engine coolant amount or
leakage location
1. Check that the engine coolant in the
reserve tank has not reduced to the
"LOW" level.
2. Remove the radiator cap and check if the
water level is up to full.
3. Check for 208-230 VAC output from relay
RE-01to engine coolant pump. If 209-230
VAC is not available, the relay RE-01 may
be faulty.
5.4. Inspect thermostat
If the engine coolant circulation amount is
not normal even though the engine coolant
pump is normal, it is judged that the
11Ton Model 132.6.00.P.HA Service Manual
43
Problems and Diagnosis
thermostat is not opened correctly. Check
heck for
the thermostat operation.
02-05/ 06/ 07).
4. Check the output voltage (208/230 VAC)
for each measurement point of outdoor
fan contactor. If there is no voltage output
at these
e pins, check coil voltage for 24
VAC.
5. Check amperage, motor operation.
6. Check capacitor MFD.
5.7. Inspect engine coolant temperature
sensor
Thermostat (140°F (60°C) open)
Temperature at the start of opening
140 F (60°C)
140°
Temperature at full opening
163 F (73°C)
163°
Thermostat valve lift amount
1/4 inch (6 mm)
Thermostat (153°F (67°C) open)
Temperature at the start of opening
153 F (67°C)
153°
Temperature at full opening
176 F (80°C)
176°
Thermostat valve lift amount
1/4 inch (6 mm)
Check that there is no connector loosening
or contact failure. Also, measure the
resistance at the engine coolant temperature
sensor terminals and the engine coolant
temperature. Make sure these values are not
greatly deviated from the reference
characteristics.
Engine coolant temperature sensor
characteristics
5.5. Check engine coolant heat radiation
condition (in cooling)
Temperature °F (°C)
If the radiator temperature is high as a whole
in spite of a normal
mal temperature difference
between the inlet and outlet, check the
points shown below:
1. Is the radiator ambient temperature
excessively high due to improper air
circulation (short circuit) or other causes?
Is the radiator fins clogged or covered by
dirt?
Hot air from the adjacent outdoor unit
5.6. Inspect outdoor fan motor
If the outdoor fan does not operate
correctly, inspect it as shown below:
1. Check the operation by using the TD 200
hand held.
2. Check the outdoor fan motor contactor
(CF-01).
3. Check available connector terminals (PL
(PL-
Resistance value (k
(kΩ)
122 (50)
17.6
176 (80)
6.1
212 (100)
3.3
230 (110)
2.5
5.8. Inspect radiator cap
Make sure that the gaskets are not cracked
or deformed. Confirm that the operating
pressure of the radiator cap is 7.3 ± 1.5 psi
(0.05 ± 0.01 MPa).
Problems and Diagnosis
6. Oil pressure abnormality
Problem
Possible cause
Specific Example
Inspection and Treatment
When oil pressure is lost during operation
Low oil pressure
Oil pressure
abnormality
Fault code #
16
Insufficient oil
amount
Sensor signal
system failure
3-3
Starter drive
system
Contact failure and other cause
Check for contact failure at the
starter drive system
3-11
Oil level difference (inch) ×258
0.03 to 0.1fl oz/h
Standard value
6-3
Inspect high voltage cable
Standard value
(cm /h)
Inspect oil pressure switch
Contact failure and other cause
Running hours (hours)
=
6-2
Ignition system
(fl oz/h)
3
Inspect oil pressure
Sensor failure
Check oil consumption amount based on the
oil level lowering and data from the previous
inspection.
Consumption
6-1
Oil pressure
switch malfunction
6.1. Inspect oil consumption amount
=
Inspect oil consumption amount
Abnormal oil consumption
Clogged oil strainer
Noise, etc.
Consumption
Check for oil pressure and oil
leak
Oil level difference (mm) ×300
Contact failure
6.2. Inspect oil pressure
Oil pressure does not rise if oil supply is not
normal due to causes such as oil strainer
blockage.
Measure the oil pressure through the
mounting tap (PT 1/8) of the pressure switch
with a pressure gauge. Check the oil level
with oil level gauge. If the level is low (close
to the level "L"), add 2 to 3 L of oil.
Running hours (hours)
3
1.0 to 3.0 cm /h
Reference value
21.8 to 72.5 psi (150 to 500 kPa)
-1
(in 1800 rpm (min ))
6.3. Inspect oil pressure switch
Check the following while the system is
under shutdown condition:
Excessive oil consumption causes carbon
deposits on the spark plug electrode, which
leads to spark failure and eventually causes
an engine start failure.
1. Check that there is no contact failure due
to loosening, etc. at the oil pressure
switch terminal (PL-03-05/06).
2. Inspect the oil pressure switch to see if it
is functioning normally by checking
electric continuity between the terminals
(PL-03-05/06).
Oil pressure switch operation
Such a problem is considered to be caused
by the valve drive system (valve stem seal)
failure or piston ring failure.
Engine
Under shutdown condition
There is continuity
At operation
There is no continuity
11Ton Model 132.6.00.P.HA Service Manual
45
Problems and Diagnosis
7. Over speed
Problem
Over speed
Fault code #
14
Possible cause
Throttle does not
return.
Specific Example
Throttle valve operation
failure
Inspection and Treatment
Stepping motor
failure
Inspect throttle valve/fuel gas flow
control valve
Stuck throttle
Clean
3-10
8. High pressure abnormality in cooling operation
Problem
Possible cause
Specific Example
Outdoor fan
does not
operate.
Heat exchange at
the condenser
(outdoor section)
is disturbed.
Refrigerant high
pressure
abnormality
(In cooling
operation)
fault code # 21
and # 23
Refrigerant
system failure
Sensor and
signal wire
system failure
Engine system
failure
Inspection and Treatment
Obstacle (interference, etc.) /
There is no output voltage.
Outdoor fan motor/capacitor
failure
Deteriorated heat
exchange
Clogged coil fins / Obstacle
capacity
Used under severe environmental/
Intake air
installation conditions
temperature is
Improper air circulation (Short
too high
circuit), etc.
Inappropriate
Overfilling
refrigerant
amount
Blockage in the check valves
Blockage in the
refrigerant flow
Clogged or broken pipe
path
Blockage in the dryer filter
Non-condensable
condensable gas incorporation into the
refrigerant system
Compressor failure
Refrigerant
Refrigerant high pressure switch
high pressure
failure, contact failure, or
switch
disconnection
malfunction
High pressure
High pressure switch failure,
sensor failure
contact failure, or disconnection
HPCO
Stepping
Throttle does
Throttle valve
motor failure
not return.
operation failure
Stuck throttle
Check refrigerant pressure
Inspect outdoor fan motor
motor/capacitor 5-6
Clean coil fins / Repair
Check environmental conditions
8-2
Inspection and adjustment of
refrigerant amount
10-1
Inspect check valve
valves blockage
Correct faulty parts
Inspect for dryer filter blockage
Low pressure
(psi (MPa))
High pressure
(psi (MPa))
In cooling
50 to 170
(0.345 to 1.172)
250 to 580
(1.72 to 4)
In heating
50 to 150
(0.345 to 1.034)
200 to 480
(1.38 to 3.31)
10-3
Inspect compressor
Inspect high pressure switch
8-4
Inspect refrigerant high pressure
sensor HPCO
8-5
Inspect throttle valve/fuel gas flow
control valve
Clean
3-10
8.2. Check environmental conditions
Check if the intake air temperature of the
outdoor coil is abnormally high due to
improper air circulation (short
short circuit
circuit) or
influence of other equipment.
Reference values of refrigerant
erant pressure
during operation.
Mode
8-3
Replacement of refrigerant
8.1. Check refrigerant pressure
Check the refrigerant pressure using the TD
200 hand held.. If the pressure is higher than
the standard value, there is a fault in heat
exchange at the condenser or in the
refrigerant system.
8-1
Temperature limit for operation
Outdoor coil intake
109°F (43°C )
air temperature
Problems and Diagnosis
8.3. Inspect check valve blockage
If the check valve becomes blocked, liquid
refrigerant remains in the condenser
reducing the heat dissipating area, which
leads to a rise in the refrigerant pressure.
Measure the temperature at the positions
upstream and downstream the check valve.
If the temperature difference between these
positions is large (9°F (5°C) or more), the
check valve is blocked. Replace the check
valve.
8.5. Inspect refrigerant high pressure
transducer
8.4. Inspect high pressure switch
1. Check electric continuity of high pressure
switch. Check the continuity between
connector terminals (PL-03-10/11) under
shutdown condition. If there is no continuity
or continuity breaks when the switch has
an impact, there is contact failure. Replace
the switch with a new one.
2. Check operation of the high pressure switch.
While observing the pressure value at the
high pressure detection port and electric
continuity from the connector terminal, find
the pressure at which the switch operates
(continuity is lost). (Contact is OFF at 610
psi (4.205 MPa).)
1. Check for contact failure of the connectors.
By disconnecting and connecting the
refrigerant high pressure transducer
connector on the circuit, check if the display
of the pressure in the TD 200 hand held is
restored. Repair if there is a contact failure.
2.
Check power supply voltage for the
refrigerant high pressure sensor.
Check that the power supply voltage for the
pressure sensor is 0-10 V.
3.
Check the output voltage of the refrigerant
high pressure transducer.
Measure the output voltage of the refrigerant
high pressure transducer. The output voltage
should be within the range of 0-10 V
11Ton Model 132.6.00.P.HA Service Manual
47
Problems and Diagnosis
9. High pressure abnormality in heating operation
Problem
Possible cause
Heat
exchange at
the
condenser
(indoor
section
) is
disturbed.
Specific Example
Obstacle (interference, etc.) / There is
no output voltage.
Check refrigerant pressure
Indoor blower motor failure
Check indoor blower motor resistance value
Deteriorated heat
exchange capacity
(air flow is blocked)
Clogged coil fins / Obstacle
Clean air filters
Dust or dirt on the air filters
Clean coil fins
Intake air
temperature is too
high
Used under severe environmental
Check and improve environmental conditions
conditions
Improper air circulation (Short circuit), etc.
Inspection of adjustment of
Overfilling
10-1
refrigerant amount
Blockage in the check valve
Inspect check valve blockage
8-3
Indoor blower does
not operate.
Inappropriate
refrigerant amount?
Refrigerant high
pressure
abnormality (In
heating operation) Refrigerant
fault code # 21 and system
failure
# 23
Transducer
and signal
wire system
failure
Engine
system
failure
Inspection and Treatment
Blockage in the
refrigerant flow path
Clogged or broken pipe
Non-condensable gas incorporation into the refrigerant
system
Outdoor expansion
Blockage in the outdoor expansion
valves failure (valve
valves
does not open)
Hot gas bypass
Operation failure (valve does not
valve operation
open.)
failure
8-1
Correct faulty parts
Incorporation of the air
Check if outdoor expansion valves
repeats blockage
9-2
Inspect hot gas bypass valve (in
heating)
9-1
Inspect high pressure switch
HPCO - Transducer
8-4
High pressure
switch malfunction
Switch failure
Refrigerant high
pressure
Transducer failure
Refrigerant high pressure Transducer
failure
Contact failure
Inspect refrigerant high pressure
Transducer
8-5
Throttle does not
return.
Stepping motor operation failure
Inspect throttle valve/fuel gas flow
control valve
3-10
Stuck throttle
Clean
Welding failure / Disconnection
9.1. Inspect hot gas bypass valve (in heating)
1. Check coil resistance at the hot gas
bypass valve terminal on the PLC
terminal Q 0.4 module PC-01.
Reference value
5.7 Ω
2. Check the hot gas bypass valve
operation with the hot gas bypass valve
open by checking the voltage at the
terminal on the PLC.(Applied voltage: 24
VAC)
3. Measure the pipe temperature at a point
downstream of the hot gas bypass valve.
a. The temperature is a little lower than the
discharge temperature in normal status.
b. If the valve is blocked, the temperature does
not rise when the valve opens.
9.2. Check if outdoor expansion valves
repeats blockage.
1. Make judgment by checking if the
temperature difference upstream and
downstream of the expansion valve is
normal.
11Ton Model 132.6.00.P.HA Service Manual
48
Problems and Diagnosis
10. Refrigerant low pressure abnormality
Problem
In
cooling
Possible cause
Heat exchange
at the
evaporator
(indoor
section) is
disturbed.
Indoor blower does
not operate.
Refriger
ant
low
pressure
abnormalit
y
fault
code #
24
Heat exchange
at the
evaporator
(outdoor
section) is
disturbed.
Deteriorated heat
exchange capacity
Intake air temperature
is too low.
Deteriorated sub heat
exchanger capacity
Inappropriate
refrigerant
amount
Cooling
and
heating
Refrigerant
system failure
Inspection and Treatment
Insufficient refrigerant
amount
Blockage in the
refrigerant flow path
Obstacle (interference, etc.) /
There is no output voltage.
Outdoor fan motor/capacitor
failure
In
cooling
8-1
Refrigerant low
pressure
transducer
malfunction
Hot gas bypass valve malfunction
Clean coil fins
Used under severe environmental/installation conditions
Check environmental conditions
Poor circulation of engine
coolant
Check the refrigerant low pressure using the
TD 200 hand held. If the pressure is lower
than the standard value, there may be a fault
in heat exchange at the evaporator or in the
refrigerant system.
Reference values of refrigerant pressure
during operation.
Mode
Low pressure
(psi (MPa))
High pressure
(psi (MPa))
In cooling
50 to 170
(0.345 to 1.172)
250 to 580
(1.72 to 4)
5-6
10-2
Inspect engine coolant pump
5-3
Inspect thermostat
5-4
Inspection and adjustment
refrigerant amount
10-1
Refrigerant leakage
Dryer filter clogged
Inspect for dryer filter blockage
10-3
Check if indoor/outdoor
expansion valve repeats
blockage
9-2
Check for check valve blockage
10-4
Inspect refrigerant low pressure
transducer
10-5
Inspect hot gas bypass valve
(in heating)
9-1
Thermostat failure
Insufficient filling
Indoor/outdoor expansion valve
Refrigerant low pressure
transducer failure
Contact failure / Disconnection
Operation failure (Blockage
condition)
Blockage
10.1.
Inspection and adjustment
refrigerant amount
Inspect outdoor fan
motor/capacitor operation
Clogged coil fins / Obstacle
Check valve
Refrigerant
low pressure
transducer
failure
Check refrigerant pressure
Check indoor blower motor resistance value
Deteriorated heat
Clean air filters
Clean coil fins
exchange capacity
Intake air temperature
Improper air circulation (Short circuit), etc.
8-2
is too high
Sub heat exchanger operation failure
Inspect sub heat exchanger
Outdoor fan does not
operate.
In
heating
Specific Example
Obstacle (interference, etc.) /
There is no output voltage.
Indoor blower motor failure
Dust or dirt on the air filters
Clogged coil fins or obstacle
In heating
10.2.
50 to 150
(0.345 to 1.034)
200 to 480
(1.38 to 3.31)
Check environmental conditions
Check if the intake air temperature of the
outdoor coil is abnormally low caused by
improper air circulation (short circuit) or
influence of other equipment.
Temperature limit for operation
Outdoor coil intake air
14°F (-10°C)
temperature
10.3.
11Ton Model 132.6.00.P.HA Service Manual
Inspect for dryer filter blockage
49
Problems and Diagnosis
If the dryer filter just before the expansion
valve is fully or partially blocked, the
refrigerant pressure becomes low.
Measure the temperature at positions
upstream and downstream of the dryer filter.
If the temperature difference between these
positions is large (9°F (5°C) or more), the
dryer filter is blocked. In this case, replace
the dryer filter.
10.4.
Check for check valve blockage
If the check valve is blocked, the refrigerant
pressure drops.
Measure the temperature at the positions
upstream and downstream the check valve.
If the temperature difference between these
positions is large (9°F (5°C) or more), the
check valve is blocked. Replace the check
valve.
10.5.
Inspect refrigerant low pressure
transducer
1. Check for contact failure of the
connectors on the PLC terminal (B) or
the connector PL-03-15 module PC-01.
Check if the display of the pressure in the TD
200 is restored by disconnecting and
connecting the refrigerant low pressure
transducer connector TD 200. If there is
contact failure, repair it.
2. Check the power supply voltage for the
refrigerant low pressure transducer at
the connector PL-03-14. The power
supply voltage for the pressure
transducer should be 24 V.
3. Check the output voltage of the
refrigerant low pressure sensor. The
output voltage of the refrigerant low
pressure transducer should be within the
range 0-10 V.
For the characteristic value, refer to the
refrigerant low pressure transducer item
listed in the table Diagnosis Items.
11Ton Model 132.6.00.P.HA Service Manual
50
Problems and Diagnosis
11. Refrigerant discharge temperature abnormality
Problem
Possible cause
Specific Example
Inspection and Treatment
* The higher the intake temperature of the compressor (high level of heating), the higher the
discharge temperature.
Insufficient
refrigerant amount
Too much heating
level (refrigerant
Intake temperature
of the compressor is circulation amount
is insufficient).
too high.
A hot gas leak into
the inlet side
Discharge
temperature
abnormality
(Discharge
temperature of the
compressor is too
high.)
fault code # 37
Blockage in the
refrigerant flow
path
Four-way changeover valve leakage
Leakage or
insufficient amount
Inspection and
adjustment
refrigerant amount
10-1
Blocked indoor
expansion valve
Check if indoor
expansion valve
repeats blockage
9-2
Clogged filters dryer
Inspect for filter dryer
blockage
10-3
Blocked check valve
Check for check
valve blockage
10-4
Four-way changeover valve operation
failure
Inspect four-way
changeover valve
11-1
* The higher the condensing pressure, the higher the discharge temperature.
Condensing
pressure is too high.
Insufficient heat
dissipation (in
heating)
Intake air
temperature is too
high (in cooling)
Clogged indoor air filters
Clean the indoor air filters
Clogged indoor coil fins
Clean the indoor coil fins
Clogged outdoor coil fins
Clean the outdoor coils fins
Used under severe
environmental/installation conditions
Check environmental
conditions
8-2
Improper air circulation (Short circuit)
Compressor
failure
Compression failure of the compressor
Hot gas bypass
valve failure
Hot gas bypass
valve malfunction
Discharge
temperature
thermistor failure
Discharge temperature thermistor malfunction
Check operation condition
Operation failure (valve opening condition)
Foreign substance caught in the valve
Inspect hot gas
bypass valve
11-2
Inspect discharge
temperature sensor
11-3
11.1.
Inspect four-way changeover
valve
If the slide valve is locked at the middle
position due to the operation failure of the
four-way changeover valve, the hot gas
leaks into the inlet side, causing a rise of the
intake temperature and eventually, a rise of
the discharge temperature.
1. Check that a hissing noise is not
generated from the four-way changeover
valve unit during operation.
2. Check if there is a temperature
difference of refrigerant vapor on the low
pressure side between the inlet and
outlet of the four-way changeover valve.
11.2.
11Ton Model 132.6.00.P.HA Service Manual
Inspect hot gas bypass valve
51
Problems and Diagnosis
1. Check the coil resistance of the hot gas
bypass valve on the outdoor circuit
board.
Reference value
5.7 Ω
2. Check that the hot gas bypass valve is
closed, and check that there is no 24
VAC applied at the hot gas bypass valve
terminal on the PLC module PC-01
terminal .4.
3. Measure the temperature on the outlet
side of the electromagnetic gas valve,
when the hot gas bypass valve is open.
temperature during operation, to check if the
sensor is functioning normally
Characteristics of the discharge temperature
thermistor
Standard temperature °F (°C)
Resistance value (kΩ)
32 (0)
182.9
68 (20)
70.4
122 (50)
20.2
176 (80)
7.0
212 (100)
3.7
248 (120)
2.1
11.3.
Inspect discharge temperature
sensor
Using the data display of the TD 200 hand
held, read the temperature detected by the
discharge temperature sensor and the actual
11Ton Model 132.6.00.P.HA Service Manual
52
Problems and Diagnosis
12. Gas heat pump is operating but not cooling.
Problem
Possible cause
Specific Example
Inspection and Treatment
Compressor clutch failure
Compressor clutch
failure
Electromagnetic
clutch of the
compressor is not
engaged.
Contact failure
Check 12 VDC compressor
output at module PC-03 at
terminals Q 0.0 and Q 0.1
12 VDC module is not
outputting 12 VDC
Check transformer
Check connections
Protection circuit for the refrigerant system is
engaged, and avoidance control is active.
Indoor cabinet
temperature has
lowered extremely
(Freezing prevention
control for the indoor
coil is activated).
Insufficient air flow
volume
Gas heat pump is
operating but not
cooling.
Indoor heat
exchange
failure
Indoor blower motor
does not operate
normally.
Insufficient refrigerant
amount
Compressor
operates, but there
is no cool air flow.
Engine speed does
not increase.
(During avoidance
control, etc.)
12.1.
Refrigerant flow path
failure (Warm air is
coming out)
Check protection circuit engagement
condition or the avoidance control
condition.
Blocked indoor
expansion valve
Check if indoor expansion valve
repeats blockage
9-2
Clogged dryer filters
Inspect for dryer filter blockage
10-3
Blockage or clogging in other devices
Clogged indoor air filters
Clean indoor air filters
Clogged coil fins
Output voltage is not
normal.
Check indoor blower motor resistance value
Indoor blower failure
Insufficient filling
Check operation condition
Refrigerant leakage
Inspection and adjustment
refrigerant amount
Four-way changeover
valve unit failure
Inspect four-way changeover valve 12-2
10-1
Others
Operation failure of the indoor expansion valve
Check if indoor expansion valve
repeats blockage
9-2
Hot gas bypass valve does not close.
Inspect hot gas bypass valve
11-2
Under control to avoid excessive increase of high
pressure
High Pressure Abnormality in Cooling
Operation
Under control to avoid excessive increase in
discharge temperature
Refrigerant Discharge Temperature
Abnormality
Under control to avoid excessive increase in engine
coolant temperature
Engine Coolant Temperature Abnormality
Insufficient engine output
Engine Starts But Stalls.
Inspect compressor clutch
1. Check output voltage
Confirm that 12 VDC is applied.
12-1
There is no output
voltage.
No 12 volts to module
Equipment
protection function
is operating.
Inspect compressor clutch
Measure the resistance between the
electromagnetic clutch connector and the
ground, and check that there is no coil
disconnection or other faults.
2. Inspect compressor clutch
11Ton Model 132.6.00.P.HA Service Manual
53
Problems and Diagnosis
12.2.
Inspect four-way changeover
valve
If the four-way changeover valve fails to
switch and remains in the heating mode,
warm air is supplied even if the operation
mode is set to cooling.
NOTE: Measure the resistance after disconnecting
the connector.
Output voltage may be continuously applied
to the electromagnetic coil, or the four-way
changeover valve in the unit may have
failed.
11Ton Model 132.6.00.P.HA Service Manual
54
Problems and Diagnosis
13. Gas heat pump is operating but not heating
Problem
Possible cause
Specific Example
Inspection and Treatment
Compressor clutch failure
The compressor
clutch is not
engaged.
Compressor
clutch failure
Equipment
protection
HPCO
function is
operating.
Protection circuit for the refrigerant system is
engaged, HPCO and avoidance control is
active.
Check protection circuit engagement condition or the avoidance control condition.
Insufficient air
flow volume
Clean indoor air filters
Indoor heat
exchange
failure
Gas heat pump is
operating but not
heating
Gas heat pump is
operating but not
heating
Contact failure
There is no
output voltage.
Inspect compressor clutch
Check for 12 VDC
12-1
Control unit
Clogged indoor air filters
Clogged coil fins
Indoor blower
Output voltage is not normal.
motor does not
Check indoor blower motor resistance value
Indoor blower motor failure
operate
normally.
Measure the refrigerant pressure and temperature
Check operation condition
during operation, and check the refrigerant cycle.
Insufficient heat exchange by the evaporator
Inspect thermostat
5-4
Heat cannot
Engine coolant
Thermostat
be
remains in the
failure
recovered
radiator (The
Blockage in the
Inspect for blockage in engine coolant flow
from
thermostat
engine coolant
path
warmed
does
not
flow path
water.
operate.)
Insufficient air
Outdoor fan does
Inspect outdoor fan motor
5-6
Heat cannot
flow volume
not operate.
be
Intake air
Clogged fins
Clean coil fins
The compressor is
recovered
temperature is
operating, but fails from the air
Improper air circulation (Short circuit)
too low.
to output the rated
performance.
Insufficient
Insufficient filling
Inspection and adjustment
refrigerant
10-1
Refrigerant
refrigerant amount
amount
leakage
Insufficient
refrigerant
Blocked outdoor
Check if outdoor expansion
circulation
valves repeats blockage
9-2
Blockage in the expansion
amount
valves
refrigerant flow
path
Clogged dryer
Inspect for dryer filter blockage
10-3
filters
Operation failure of the outdoor expansion valves
Check if outdoor expansion
9-2
valves repeats blockage
Inspect hot gas bypass valve (in
Hot gas bypass valve does not close.
9-1
heating)
Engine speed does Under control to avoid excessive increase of high
Refer to High Pressure Abnormality in
not increase.
pressure
Heating Operation
(During avoidance
Under control to avoid excessive increase in
Refer to Refrigerant Discharge
control, etc.)
discharge temperature
Temperature Abnormality
Under control to avoid excessive increase in engine
coolant temperature
High pressure detection failure
(Transducer judges the high pressure
higher than the actual value, and the
engine speed does not increase.)
Refrigerant
high
pressure
transduce
r failure
Insufficient engine output
11Ton Model 132.6.00.P.HA Service Manual
Refer to Engine Coolant Temperature
Abnormality
Inspect refrigerant high pressure
transducer
8-5
Refer to Engine Starts But Stalls.
55
Problems and Diagnosis
14. Thermostat is not functioning correctly
Problem
No display coming
on.
Faulty temperature
display.
No change in the
temperature
settings.
Uncontrolled room
temperature.
14.1
Possible cause
Thermostat is
not being
powered.
Improper
location for the
thermostat.
Upper or lower
temperature limits
were reached.
Remote
temperature
sensing is not
working.
Specific Example
Inspection and Treatment
Loose connections
Check the electrical
connections
14.1
Heat affecting the thermostat
Check thermostat
location
14.2
Check the
temperature
setpoints:
14.3
Check all remote sensors.
Check electrical connections
Check that the R terminal is connected to the
TR-01 transformer.
Confirm that 24 VAC between R and C
terminals on the PLC board.
If 24 VAC is not applied, check the fuse CB01; if the fuse is blown, replace it.
Confirm that the unit power switch is in the
On position; if not, set it to the On position.
Check the wiring connecting the thermostat
and the unit.
14.2
Check thermostat location
The thermostat should be installed in a
location where:
It is not subjected to hot or cold air stream
coming from the supply ducts.
It is not subjected to external heat source
such as heat from equipment or solar
radiation.
Proper air movement is available not behind
doors or in corners.
The wall behind the thermostat is not
subjected to heat from the other side.
14.3
Check setpoint
The temperature set points should be:
Heating limits are 40 to 90°F (7 to 31°C)
Cooling limits are 45 to 99°F (9 to 37°C)
11Ton Model 132.6.00.P.HA Service Manual
56
Replacement of Components
Section VII – REPLACEMENT OF MAIN COMPONENTS
1. Replacement of Engine Unit
[Necessary items]
Part name
Parts
Part No.
Quantity
Set, Engine ASSY
622041-13060
1
AISIN Coolant S
G0954-3252
1
AISIN Gas Engine Oil L-10000G
622461-20010
4
Tools
Hose pinch off pliers
Belt tension gauge
[Removal]
1. Remove the fuel gas hose. (Figure 1)
2. Drain engine oil. (Figure 2)
a. Clamp the engine oil hose 3 between the
engine and the sub oil pan with hose pinch
off pliers, at both sides of the joint.
b. Disconnect the joint and drain oil from the
engine.
c. Drain oil from the sub oil pan in the same
way.
d. Remove oil hoses 1 to 3 between the
engine and the sub oil pan.
e. Remove air cleaner and the sub oil tank.
3. Drain engine coolant. (Figure 1, Figure 3)
a. Clamp the engine coolant hose at 2 points
(at the exhaust air heat exchanger inlet and
the engine outlet).
b. Clamp the air bleed hose.
c. Drain engine coolant from the engine
through the engine coolant drain valve.
d. Remove the hose of exhaust air heat
exchanger inlet, and drain engine coolant in
exhaust air heat exchanger.
e. Remove the 2 engine coolant hoses and
the air bleed hose from the engine.
4. Disconnect the harnesses. (Figure 1 to
Figure 3)
a. Starter (at 2 points)
b. Gas mixer (at 2 points)
c. Engine speed sensor (at 2 points)
d. Engine oil pressure switch
e. Ignition coil (at 3 points)
f. Engine coolant temperature sensor
Wooden block
Cloth
Torque wrench
Hose clamp pliers
Remove the exhaust air pipe and the bolts
and nuts of exhaust air heat exchanger stay.
Remove the exhaust air heat exchanger.
6. Remove the compressor belt. (Figure 2)
Loosen the tension bolts and fixing bolts of
the compressor bracket. Remove the
compressor belt.
7. Remove the flywheel (by removing 6
bolts). (Figure 2)
8. Remove the air intake hose. (Figure 1)
9. Remove the starter. (Figure 1)
10. Remove the reinforcement brackets (on
both sides). (Figure 3)
11. Loosen both compressors. (Figure 1)
a. Hoist the compressor bracket with
appropriate sling, etc. (Or place a wooden
block under the bracket.)
b. Remove the 6 bolts fixing the compressor
bracket to the engine, and remove the
bracket from the engine.
12. Dismount the engine.
a. Place a wooden block (approx. 2 inch (50
mm) thick) under the engine.
b. Remove the bolts that clamp the engine
mount feet to the base panel (M10, 2×2
points).
c. Remove the engine bracket (at 2 points:
Figure 3) from the engine mount, together
with the engine.
d. Dismount the engine.
5. Remove the exhaust air heat exchanger.
(Figure 2)
11Ton Model 132.6.00.P.HA Service Manual
57
Replacement of Components
[Reassembling]
1. Mount the removed gas mixer, manifold and
blow-by hose to a new engine. Replace the
old gaskets for the gas mixer and manifold
with new ones.
2. Reassemble the engine in the reverse order
of the removal. When installing the flywheel,
wrap the bolt with the sealing tape. Replace
the old gasket for the exhaust air pipe with a
new one.
Figure 1
Figure 2
NOTE: When placing the engine on the floor,
place wooden blocks, cloth or other
appropriate material on the floor and put the
engine on it carefully so that the pipes on the
bottom of the oil pan will not be damaged.
Belt tension
125 to 135 lbs
(560 to 600 N)
Tightening torque of
flywheel
29± 3 lb.ft
39 ± 4 N.m
3. Remove all hose pinch off pliers and then
open the radiator cap. After that, fill the
radiator with engine coolant to full capacity.
Engine coolant
50%
concentration
(volumetric concentration)
4. Supply the specified amount (9.2 gal (35 L))
of fresh engine oil through the oil filler port of
the sub oil pan.
5. Run the engine coolant pump using TD 200
Hand held and check the engine coolant
amount in the radiator. If the engine coolant
level lowers, fill up the radiator with engine
coolant.
Figure 3
6. Repeat step 5 above until engine coolant
level in the radiator does not lower any
more.
7. Run the engine and check that the engine
runs without problems such as leakage of oil
or engine coolant.
8. Stop the engine and measure the level of
the oil in the sub oil pan by the oil level
gauge 10 minutes after stopping the engine.
Specified amount
11Ton Model 132.6.00.P.HA Service Manual
Level "F" : + 0.8 to 0 inch
(+20 to 0 mm)
58
Replacement of Components
2. Replacement of Cylinder Head
[Necessary items]
Part name
Cylinder head set
Parts AISIN Coolant S
AISIN Gas Engine Oil L-10000G
Hose pinch off pliers
Tools Belt tension gauge
Gasket remover
Scraper
Plug Wrench
Part No.
Quantity
622048-33010
1
G0954-3252
1
622461-20010
Small amount
Torque wrench
Cloth
Hose clamp pliers
[Removal]
1. Drain engine coolant. (Figure 1, Figure 2)
a. Clamp the engine coolant hose (at 2 points).
b. Loosen the engine coolant drain plug valve
and drain the engine coolant.
c. Remove the 2 engine coolant hoses from the
engine.
2. Disconnect the harnesses. (Figure 1,
Figure 2)
a. Gas mixer (at 2 points)
b. Ignition coil (at 3 points)
c. Engine coolant temperature sensor
Figure 1
3. Disconnect the high voltage cable and
remove the spark plugs.
4. Loosen the 3 nuts and remove the cylinder
head cover.
5. Loosen the 3 nuts and remove the rocker
shaft ASSY and then remove the valve stem
cap. (Figure 3)
NOTE: Take care not to drop the valve stem
cap into the engine.
Figure 2
6. Remove the push rods.
NOTE: Place the push rods in the order they
are removed.
7. Remove the exhaust air heat exchanger
stay on the exhaust manifold.
8. Remove the exhaust air pipe.
9. Remove the air intake hose and oil hose.
10.Loosen the 14 bolts and remove the
cylinder head.
Figure 3
11Ton Model 132.6.00.P.HA Service Manual
59
Replacement of Components
[Reassembling]
1. Mount the accessory to a new cylinder
head. (Figure 4)
a. Intake manifold (with the gasket replaced)
b. Exhaust manifold (with the gasket replaced)
c. Ignition coil (There is another bolt on the back
side of #2 coil.)
d. Inlet water, outlet water (with the gasket
replaced)
e. Hoses
f. Stud bolt
Figure 5
2. Remove completely old gasket material
and dust adhering to the top surface of the
cylinder block with a scraper and gasket
remover.
Figure 6
NOTE:
• Make sure that dust does not enter the oil
inlet, engine coolant inlet and bolt hole.
• Never use a gasket remover on anything other
than metallic portions.
• If there is a water or oil spill in a bolt hole,
remove it with a cloth.
(If not, the spill may ooze when a bolt is
tightened, which may cause a sealing failure.)
Tightening torque of
cylinder head
25 Ib.ft
(34 N• m)
1. Mount a new cylinder gasket to the
cylinder block carefully in the correct direction,
and install the cylinder head. Tighten the 14
bolts in 2 steps in the sequence shown in the
illustration. (Figure 5, Figure 6)
2. Insert the push rods in the order of
removal.
3. Mount a stem cap onto the valve, and
install the rocker shaft ASSY. (Figure 7)
Figure 7
Tightening torque of rocker shaft ASSY
NOTE: Tighten the nuts so that adjust screw
comes into the cap of the push rod.
4. Adjust the valve clearance.
Reference
clearance:
Figure 4
14.75 Ib.ft
(20 N.m)
0.014 ± 0.002 inch (hot status)
(0.35 ± 0.05 mm)
0.01 ± 0.002 inch (cold status)
(0.25 ± 0.05 mm)
5. Install the removed parts shown below.
Cylinder head cover
Air intake hose / Oil hose
Exhaust air pipe (with the gasket replaced)
Exhaust air heat exchanger stay
Spark plug / High voltage cable
Harness (gas mixer / ignition coil / engine
coolant temperature sensor)
g. Engine coolant hose
a.
b.
c.
d.
e.
f.
6. Remove the hose pinch off pliers
11Ton Model 132.6.00.P.HA Service Manual
60
Replacement of Components
7. Open the radiator cap and fill the radiator
with engine coolant to full capacity.
Engine coolant
concentration
10.Using a compression gauge, check that
fuel gas is compressed to the specified
pressure.
50 %
(volumetric concentration)
8. Run the engine coolant pump using TD
200 and check the engine coolant amount in
the radiator. If the engine coolant level lowers,
fill up the radiator with engine coolant.
9. Repeat step 10 above until engine coolant
level in the radiator does not lower any more.
Specified compression value
203 psi (1.4 MPa) or
more
11.Run the engine and check that the engine
runs without problems such as leakage of oil
or engine coolant.
11Ton Model 132.6.00.P.HA Service Manual
61
Replacement of Components
3. Replacement of Compressor
[Necessary items]
Part name
Part No.
Parts
Compressor (supply kit) No.2
Dryer filter
Tools
R410A
NL10
Tools
Quantity
621030-20010 (fixed displacement)
DANFOSS DMB-165S
—
—
Vacuum pump
Scale
Manifold gauge
[Removal]
1. Remove the inlet port, outlet port and belt
from the compressor.
2. Remove the compressor from the engine
side bracket. (Figure 1)
2
1
24-lb
—
Belt tension gauge
Digital thermometer
Refrigeration
oil name
Specified amount to be supplied
NL10
Inlet side
Outlet side
1.7 fl oz. (50 cm3)
3
5 fl oz. (150 cm )
NOTE: Refrigeration oil can be supplied easily
by turning the clutch disc by hand.
[Reassembling]
1. Remove the compressor port cover, and
mount the new o-ring to the groove.
NOTE: Apply refrigeration oil to the o-ring,
and install it so
•Inlet side : Inner diameter 1.04 inch (26.4
mm),
Wire diameter 0.09 inch (2.3 mm)
•Outlet and reduction side :
Inner diameter 0.69 inch (17.4 mm), Wire
diameter 0.09 inch (2.3 mm)
2. Supply the specified amount of refrigeration
oil through inlet and outlet ports. (Figure 2)
3. Mount the compressor to the engine side
bracket.
Tightening torque
of compressor
mounting bolts
31 lb.ft
(42 N.m)
4. Mount the inlet and outlet ports on the
compressor and tighten the bolts on the
1 torque.
ports alternately to theFigure
specified
Figure 2
Figure 1
Tightening torque
of Inlet and outlet ports
bolts
11Ton Model 132.6.00.P.HA Service Manual
8.9 to 13.3 lb.ft
(12 to 18 N.m)
62
Replacement of Components
NOTE: When mounting a port, pay attention
so that o-rings will not be caught.
the centerline of the compressor groove is 0.3
inch (8 mm) or less when measured on the
crankshaft axis. (Figure 3)
6. Replace the old dryer filter (DANFOSS DMBDMB
165S) with a new one.
Tightening torque flare nuts
18.4 ± 3.7 lb.ft
(25.0 ± 5.0 N.m)
NOTE: Remove foreign objects at flare portion,
and apply refrigeration oil.
Figure 3
5. Mount the new compressor to the original
location, attach the belts, and adjust
alignment and tension. After attaching the
belt, turn the pulley several turns by hand
and check the tension again.
Reference value
7. Refill the compressor with the specified
sp
amounts of refrigerant.
8. Check that there is no leakage after
installation, and evacuate the compressor.
(for 1 hour or more)
Standard amount
25.5 to 25.4 lbs
(11.1 to 11.5 kg)
125 to 135 lbf (560
560 to 600 N)
NOTE: Make sure that misalignment between
the centerline of the crank pulley groove and
9. Check the operating condition by high
and low pressure and temperature
measuring of refrigerant after refilling.
4. Replacement of Compressor Clutch
Tools Torque wrench - Belt tension gauge
[Removal]
1. Turn off disconnect and pull the clutch power
2. Loosen compressor serpentine belt tension bolt
and remove the belt
3. Unscrew front nut on the clutch and remove
emove using
proper clutch removing tool
[Reassembling]
1. Replace the support nut and the belt
2. Tighten to proper tension and plug clutch
back in.
Replacement of Components
5. Replacement of Indoor Blower Assembly
Tools Torque wrench - Allen key
[Removal]
1. Lock out power to the unit
2. Loosen the motor base adjusting bolts,
move the motor slightly towards the
blower and remove the belts
3. Unscrew the blower pulley mounting
flange and remove the pulleys
4. Unscrew the blower flange and slide
ide the
blower assembly out.
[Reassembling]
1. Fasten blower flange screws
2. Unlock shaft locking collars and unlock
blower from shaft.
3. Slide shaft to get enough space for
motor and blower pulleys alignment.
4. Use the motor adjusting screw
screws, to
adjust the belt tension. T
The slack side of
the belt should give about 3/4
3/4″ per foot of
distance between the motor pulley and
the blower pulley.
5. Lock into place (both blower and shaft
collars)
6. Check for proper alignment—adjust
alignment
if
necessary
7. Check for proper amps and adjust belts
accordingly
6. Replacement of Indoor Blower Pulley and Belts
Tools Torque wrench - Allen key
[Removal]
1. Lock out power to the unit
2. Loosen the motor base adjusting bolts,
move the motor slightly towards the
blower and remove the belts
3. Measure distance between the blower
and the pulley mark the pulley location
on the blower shaft.
4. Unscrew the pulley mounting flange. Use
pulley
ley puller to remove if necessary
Replacement of Components
1. Replace with new pulley, adding key way
to the mark that was placed earlier
2. Tighten all locks
3. Replace belts and use
se the motor
adjusting screws, to adjust the belt
tension. The slack side of the belt should
give about 3/4″ per foot of distance
between the motor pulley and the blower
pulley.
4. Check for proper alignment and adjust if
necessary
5. Turn system back on
6. Recheck amps for tension, and make the
proper adjustments if necessary
[Reassembling]
7. Replacement of Indoor Blower Shaft
Tools Torque wrench - Allen key - caliper
[Removal]
1. Lock out power to the unit
2. Loosen the motor base adjusting bolts,
move the motor slightly towards the
blower and remove the belts.
3. Measure distance of shaft edge from
housing.
4. Measure pulley distance from shaft edge
and write it down
5. Unscrew the pulley mounting flange. Use
pulley puller to remove if necessary
necessary.
6. Unscrew shaft collars and the blower
locks
7. Remove shaft
[Reassembling]
1. Install new shaft
2. Place the shaft according to the
measurement made earlier.
earlier
3. Lock both collars and blower locks and
install pulley
4. Install belts and use the motor adjusting
screws, to adjust the belt tension. The
slack side of the belt should give about
3/4″ per foot of distance between the
motor pulley and the blower pulley.
5. Check for proper alignment and align if
necessary
6. Turn system back on
7. Check
eck for proper amps according to
tension
Replacement of Components
8. Replacement of Outdoor Fan Blade
Tools Torque wrench - Allen key - caliper
[Removal]
1. Lock out power to the unit
2. Remove fan guard
3. Measure the distance between the shaft
edge and the fan hub mark it on the
shaft.
4. Remove fan blade.
[Reassembling]
1. Install new fan blade at the height
marked before. The fan blades should be
centered in the shroud.
2. Check for fan pitch angle of 37.5°
3. Reinstall fan guard
4. Turn system back on
5. Check balance and rotation
9. Replacement of Motor
Tools Torque wrench - Ohmmeter
1. Lock out power to the unit
2. Mark all wiring and electrical connections
3. For the indoor blower motor: unscrew the
base plate mounting bolts and remove
the belts.
4. For the outdoor fan motor: remove the
grill and unscrew the cage bolts.
1. Replace motor and capacitor (if needed)
2. Rewire
3. Recheck
Replacement of Components
10. Replacement of Engine Coolant Pump
Part name
Parts
Coolant pump
Part No.
Quantity
623681-50010
1
Tools Torque wrench – Screw driver – Hose clamp pliers - Clamps
1. Lock out power to the unit
2. Mark all wires and unwire
3. Clamp inlet and outlet hoses before
removing the pump.
4. Replace pump and rewire
To add coolant:
1. Remove starter relay (RE-06) and Y1 terminal
to insure that unit does not operate during
this procedure.
2. Cycle WPR (Water Pump Relay (RE-01)
01))
3. Fill Coolant bottle with AISIN coolant (140
(14000039) 50/50 mix with distilled water, until it
tops off.
-Remove
Remove radiator cap on top of unit in order
to fill coolant bottle.
-Replace
Replace cap after coolant has been poured
into the coolant bottle.
4. Cycle WPR
5. Fill at radiator with coolant until
unti it tops off, and
replace cap.
6. Repeat steps 4-5
5 several times until the
coolant level remains topped off and is
completely bled
7. Put system into heating and monitor for over
temperature, and bleed system if this occurs.
NOTE:: you can clamp down hoses to
remove motor for little loss of coolant
11. Replacement of Transformer
Tools Torque wrench – Screw driver
1. Lock out main power to the unit
2. Label all appropriate wires before
removal
3. Disconnect wires, and unbolt
transformers from control panel or the
base of the unit
4. Replace with new transformers, and bolt
in same locations as previous
5. Reconnect appropriate wires according
to labels implemented in step 2
CAUTION
Use extreme caution when disconnecting
transformer from paneling. Transformer weighs
35lbs. Use caution while handling
Replacement of Components
12. Replacement of Line (Refrigerant)
Tools Vacuum pump - Torch - Brush - Welding rod - Nitrogen cylinder - Soap solution
1.
2.
3.
4.
Turn off the power to the unit
Recover refrigerant.
Purge with dry nitrogen at 8-12
12 psig.
Cut out or un-sweat
sweat the section of piping
to be removed
5. Replace the piping with the same size
6. Purge system with dry nitrogen at 8
8-12
psig.
7. Leak check with dry nitrogen at 600 psig.
8. Evacuate the circuit to 500 microns
9. Weigh in the specified charge with the
appropriate refrigerant at accumulation
only.
10. Turn on the power to the unit
11. Restart system and monitor pressures
for proper operation
13. Replacement of Capillary Tube
Tools Vacuum pump - Torch - Brush - Welding rod - Nitrogen cylinder - Soap solution
1. Recover refrigerant.
2. Inspect capillary tube for proper sizing
and length (see manufacturer guide).
3. Purge with nitrogen at 8-12 psig.
4. Remove old capillary tube.
8-12
5. Purge system with dry nitrogen at 8
psig.
6. Install new capillary tube
7. Leak check system (use soap solution
with dry nitrogen at 600 psig)
8. Evacuate system to 500 microns
9. Recharge to manufacturer specifications
through accumulation only
10. Recheck system
14. Replacement of Refrigerant Check Valve
Tools Vacuum pump - Torch - Brush - Welding rod - Nitrogen cylinder - Soap solution
1. Recover refrigerant.
2. Purge with nitrogen at 8-12 psig.
3. Remove check valve while taking
precautions to wrap TXV and any other
vital parts with wet rag and thermo trap.
4. Notice direction of flow on old check
valve. The flow direction is goes
downward to floor.
5. Replace with new going with the same
flow.
6. Use nitrogen at 8-12
12 psig and wet rags
when brazing.
7. Check for Leakage using dry nitrogen at
600 psig.
8. Evacuate to 500 microns.
9. Recharge to proper amount of refrigerant
at accumulation only.
10. Turn unit back on.
11. Recheck system.
Replacement of Components
15. Replacement of Reversing Valve
Tools Vacuum pump - Torch - Brush - Welding rod - Nitrogen cylinder - Soap solution
1.
2.
3.
4.
Recover refrigerant.
Purge with nitrogen at 8-12 psig.
Remove reversing valve
Replace with new like part, using dry
nitrogen at 8-12 psig while brazing
5. Wrap with rag and thermo-trap at points
6. Check for Leakage using nitrogen at 600
psig.
To recharge system:
1. Vacuum system to 500 microns.
2. Wait for 10 min.
3. Add refrigerant into liquid line at the
liquid port to required amount. Drier only.
Liquid only. Do not add at compressor.
4. Add at suction filter only. If proper
amount from vacuum cannot be added,
start system and slowly bleed in until
required refrigerant amount is met.
5. To finish filing while the unit is running,
add refrigerant in suction port upstream
of the accumulator.
6. Replace the liquid line dryer every time
you recharge the system.
16. Replacement of TXV Power Head
Tools Vacuum pump - Torch - Brush - Welding rod - Nitrogen cylinder - Soap solution
1. Turn off the power to the unit
2. Recover refrigerant.
3. Unclamp the corresponding expansion
bulb
4. Unscrew the power head and replace
with new.
5. Braze system with dry nitrogen at 8-12
psig.
6. Leak check system with dry nitrogen at
600 psig.
7. Evacuate system to 500 microns.
8. Weigh in the specified charge of the
appropriate refrigerant.
9. Restart system and monitor pressures.
17. Replacement of TXV
Tools Vacuum pump - Torch - Brush - Welding rod - Nitrogen cylinder - Soap solution
1.
2.
3.
4.
Turn off the power to the unit
Recover refrigerant.
Remove bulb (notice positioning).
Purge system with dry nitrogen at 8-12
psig.
5. Un-sweat the following:
Equalizer tube.
Both sides of TXV.
6. Set in new TXV.
7. Wrap with wet rag and use thermo trap
paste.
8. Install TXV and equalizer tube.
9. Purge system with dry nitrogen at 8-12
psig.
10. Place bulb in proper position.
11. Leak check system with dry nitrogen at
600 psig.
11Ton Model 132.6.00.P.HA Service Manual
69
Replacement of Components
To recharge system:
1. Vacuum system to 500 microns.
2. Wait for 10 min.
3. Add refrigerant into liquid line at the
liquid port to required amount. Drier only.
Liquid only. Do not add at compressor.
4. Add at suction filter only. If proper
amount from vacuum cannot be added,
start system and slowly bleed in until
required refrigerant amount is met.
5. To finish filing while the unit is running,
add refrigerant in suction port upstream
of the accumulator.
6. Replace the liquid line dryer every time
you recharge the system.
18. Adjustment of TXV
Tools
Torque wrench
1. Determine Superheat
a. Cooling
i. Measure Pressure at outlet of indoor coil
ii. Measure temperature at outlet of indoor
coil
iii. Convert measures pressure (PSIG) to
absolute pressure (PSIA) based on
location
iv. Look up pressure on R410a saturation
tables and note corresponding
temperature
v. Subtract measured temperature from table
temperature
10°
vi. If measured temperature is not 5-10
above table temperature, adjust superheat
b. Heating
i. Measure Pressure at outlet of outdoor coil
ii. Measure temperature at outlet of outdoor
coil
iii. Convert measures pressure (PSIG) to
absolute pressure (PSIA) based on
location
iv. Look up pressure on R410a saturation
tables and note corresponding
temperature
v. Subtract measured
sured temperature from table
temperature
vi. If measured temperature is not 7-10°
above table temperature, adjust superheat
2. Adjust Superheat
a. Remove cap on bottom of TXV covering
adjustment screw
b. Turn adjustment screw clockwise to
decrease, counterclockwise to increase
c. Based on amount of superheat
adjustment necessary, 2 full turns at a
time is allowable until ‘fine tuning’
d. Replace cap on bottom of TXV
3. Repeat steps 1 and 2 as necessary until
cooling superheat is 5--10°F and heating
superheat is 7-10°F
*Please
se see supplemental material
Thermodynamic
modynamic Properties of Suva 410a
Refrigerant in the back of the manual*
Periodic Maintenance and Inspection
Section VIII – PERIODIC MAINTENANCE AND INSPECTION
In addition to these materials, a quarterly procedure of replacing the air filters on the NextAire Packaged Gas
Heat Pump must be performed. Also, maintenance of engine components will be at least every 3 years or
6,000 hours of operations.
WARNING
Be absolutely certain to perform the following
operations before starting periodic maintenance
operations:
• Stop remote-controlled operation and wait
for at least one minute before turning off the
shut off disconnect.
• Shut off disconnect.
• Check to ensure exhaust pipe from the
engine is clear and free of obstructions.
CAUTION
Should overheating or overcooling of the conditioned
space occur, or the gas supply fail to shut off, shut off
manual gas valve to the appliance before shutting
off the electrical supply.
En cas de température excessive ou
refroidissement excessive, ou s’il est impossible de
couper l’alimentation en gaz, fermer le robinet
manuel d’alimentation en gaz de l’appareil avant de
couper l’alimentation électrique.
• Check that the return-air duct connection is
physically sound, is sealed to the appliance
casing, and terminates outside the
appliance.
• Check that the physical support of the appliance is sound without sagging, cracks, gaps,
etc. around the base so as to ensure proper
seal.
• Check that there are no obvious signs of deterioration of the appliance.
NOTE:
CAUTION
Do not use this appliance if any part has been
under water. Immediately call a qualified
service agency to inspect the appliance and to
replace any part of the control system and any
gas control which has been under water.
Ne pas se server de cet appareil s’il a été plungé
dans l’eau, complètement ou en partie. Appeler
un technicien qualifié pour inspecter l’appareil et
remplacer toute partie de système de contrôle
et toute commande qui ont été plungé dans
l’eau.
11Ton Model 132.6.00.P.HA Service Manual
71
Periodic Maintenance and Inspection
1. Periodic Maintenance and Inspection Items and Intervals
Periodic maintenance and part replacement are required for continued normal operation of the packaged gas heat
pump air-conditioning system.
Recommended maintenance and part replacement should be completed every 3 years or 6,000 operational
hours, whichever is less unless otherwise noted.
No.
Maintenance Timing: (years)
Item
3
6
9
12
15
1
Changing engine Oil
△
△
△
△
△
2
Replacing oil filter
●
●
●
●
●
3
Replacing ignition spark plug
●
●
●
●
●
4
Replacing air filter element
●
●
●
●
●
5
Checking and replacing compressor drive belt
●
●
●
●
●
6
Checking and replacing indoor blower drive belt
●
●
●
●
●
7
Inspecting compressor clutch
8
Checking the engine coolant additive
9
Inspect engine coolant amount/engine coolant refilling
10
Checking for engine oil leakage
11
Checking for engine coolant leakage
12
Checking for exhaust gas leakage
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
13
Prevention of Carbon Deposit Formation on Valve or Valve Seat *
A
A
A
A
A
14
Valve Clearance Inspection/Adjustment
△
△
△
△
△
15
Fuel Gas Hose and Gas Hose Clamp Replacement
-
-
●
-
-
16
Fuel Gas Leak Inspection
17
Fuel Gas Inlet Inspection
△
△
△
△
△
△
△
△
△
△
18
Drain Oil Filter Replacement
●
●
●
●
●
19
Refrigerant Leak Inspection
20
Operation Noise Inspection*
21
Exhaust Water Drain Filter Refilling
△
△
△
△
△
△
△
△
△
△
△
△
△
△
△
22
Air filter replacement
Every three months
23
Economizer filter replacement
Every three months
24
Ignition components inspection
25
Coil Cleaning
△
△
△
△
△
Every six months
CAUTION
1. Conduct periodic inspection in accordance with the table above, every 3 years or every 6,000 hours, whichever
comes first.
2. Symbols: ●: Replacement, △: Inspection (adjustment, refilling) and *: Inspection to be carried out while the unit
is operating.
3. Symbol A means cleaning should be done with valve cleaner.
4. For the items requiring only "inspection (△)", it is necessary to replace a part if a problem is found in inspection.
5. When adding engine coolant, use AISIN Coolant S (G0954-3252: 1.1 gal (4 L can)) for long maintenance.
The specified concentration in 50 to 60 vol% (Engine coolant: 0.55, Water: 0.45). If an optical densitometer is
used to measure the concentration, reading of 40 to 48% of the densitometer corresponds to the specified concentration.
6. Engine oil should be refilled to replace only the amount used.
Use AISIN GHP Oil L-10000G for long maintenance or refilling.
7. Exhaust water drain filter should be refilled to replace only the amount used.
Do not fill past "FULL" marking.
(622585-10010: 2.2 lbs (1 kg) container / G3242-9740: 4.4 lbs (2 kg) container)
11Ton Model 132.6.00.P.HA Service Manual
72
Periodic Maintenance and Inspection
2. Parts Requiring Periodic Replacement
Part name
Maintenance kit
Part No.
Refer to Table 1).
Engine coolant additive (16.9 fl oz. (500 mL) container)
622463-3001
AISIN Gas Engine Oil L-10000G (2.6 gal (10 L) can)
622461-2001
Timing for replacement
Refer to Table 2).
Refill every 3 years
or 6,000 hours
Refill every 3 years
or 6,000 hours
Table 1) Periodic maintenance parts
Part name
Supply air filter
Economizer filter
Oil filter
Spark plugs
Intake air filter elements
Compressor belts
Indoor blower belt
Valve cleaner
Drain oil filter set
Fuel gas hose
Gas hose clamps
Engine mount
Part No.
Quantity
G3990-1760
622364-33020
622419-30010
622218-33010
6
3
1
3
2
1
--G0939-3110
622055-33010
G2451-7111*
G9512-3111*
Replacement / Use intervals
Every 3 months
Every 3 years or 6,000 hours
2
1
1
1
2
3
Every 9 years or 18,000 hours
* Included in 622011-33120 only.
Table 2) Drain oil filter set component parts
Part name
Drain oil filter No. 1
Drain oil filter No. 2
Part No.
622586-20010
622586-10010
Quantity
1
1
Exhaust water drain filter (2.2 lbs (1 kg)
container)
622585-10010
1
Gasket
621724-33020
1
Replacement / Use intervals
Every 3 years or 6,000 hours
Table 3) Engine mounts
Part name
Engine mount
Part No.
Quantity
Replacement / Use intervals
621191-50010
3
Every 9 years or 18,000 hours
11Ton Model 132.6.00.P.HA Service Manual
73
Periodic Maintenance and Inspection
3. Procedure and Method of Regular Inspection
3.1. Changing engine oil
1. Operate the engine for about 5 minutes
before changing the oil.
2. After stopping the engine, pull out the level
gauge from the oil sub-tank and then drain
the oil using an oil pump.
3. Add the specified amount (35 liters/ 37
quarts) of new engine oil from the oiling
port of the oil sub-tank.
4. After operating the engine for about 3
minutes, stop the engine and after
approximately 3 minutes, confirm the oil
level using the oil level gauge.
Changing
Period:
At least every 3 years or
6,000 operational hours
NOTE: Adhere to the local codes for proper
methods of waste oil, filter and rag disposal.
3.3. Replacing ignition spark plug
1. Hold the cap of the corresponding high
voltage cable (Spark plug wire) and
remove the cap. Next, remove the ignition
plug using a plug wrench.
2. Mount a new ignition plug, hand-fasten it
first and then refasten with a plug wrench.
At least every 3 years or
Changing Period: 6,000 operational hours
Oil level:
Range from 0 to 10mm
above full mark at 20°C
Range from 9 to 18mm
above full mark at 90°C
Changing
Period:
At least every 3 years or
6,000 operational hours
Tightening
torque:
15 to 22 lb.ft
(20 to 30 N.m)
WARNING
• Be sure to use Aisin-specified oil - L10000-G.
• Keep oils away from belting and pulleys.
• When clamping the hosing at the joint, confirm the
traces of clamping on the hosing and mount it
properly at its original position.
• Must be performed by a qualified service
agency.
3.4. Replacing air filter elements
3.2. Replacing oil filter
1. Remove the oil filter using an oil filter
wrench. Wipe off the dripped oil with a
waste cloth.
2. Apply engine oil to the surface of the Oring in a new oil filter, and be sure to handtighten the filter securely. Do not tighten
with oil filter wrench.
1. Loosen clamp on air hose on back of
breather box.
2. Remove hose.
3. Remove four screws from outside of sheet
metal panel and remove from unit.
11Ton Model 132.6.00.P.HA Service Manual
74
Periodic Maintenance and Inspection
4. On back of breather box, remove six
screws to access filter.
5. Clean the dust inside the air filter cap.
6. Remove old filter, replace it with new
elements and reassemble.
Changing
Period:
At least every 3 years or
6,000 operational hours
Reference
belt tension:
125 to 135 lbf
(560 to 600 N)
Tool required: Offset wrenches (12mm
and 14mm) and Belt tension gauge
Changing
Period:
At least every 3 years or
6,000 operational hours
3.5. Checking and replacing the
compressor drive belt
1. Loosen the right compressor (No.1)
bolts (4).
2. Loosen the adjust bolt.
3. Remove old belt.
4. Install new belt.
5. Attach tension gauge to belt and adjust
belt tension using the adjusting bolts.
6. Finger-tighten the compressor bolts.
7. Tighten the adjust bolt.
8. Retighten the compressor bolts.
9. Rotate engine to readjust belt.
10.Recheck belt tension at (560 - 600 N)
CAUTION
• Make sure not to touch the crank pulley,
compressor belts or any other moving parts
during engine cranking.
• Your fingers may be caught, if you touched
these moving parts.
3.6. Checking and replacing the indoor
blower drive belt
1. Lock out power to the unit
2. Loosen the motor base adjusting bolts,
move the motor slightly towards the
blower and remove the belts
3. Install belts and use the motor adjusting
screws, to adjust the belt tension. The
slack side of the belt should give about
3/4″ per foot of distance between the
motor pulley and the blower pulley.
4. Check for proper alignment and align if
necessary
5. Turn system back on
6. Check for proper amps according to
tension
Checking
Period:
At least every 3 years or
6,000 operational hours
3.7. Inspecting compressor clutch
1. Check that the compressor does not
generate unusual sounds during operation.
2. Make sure that when the
electromagnetic clutch is disengaged
the shaft of the compressor does not
rotate synchronously.
3. After stopping the engine, rotate the
shaft by hand and check that it rotates
smoothly.
Checking
Period:
11Ton Model 132.6.00.P.HA Service Manual
At least every 3 years or
6,000 operational hours
75
Periodic Maintenance and Inspection
3.8. Checking the engine coolant additive.
1. Refill the coolant reservoir with the
specified amount of coolantstrengthening agent. If the specified
amount of refilling is likely to cause the
FULL level to be exceeded, drain out
the coolant from the reservoir prior to
filling.
2. Add coolant until the FULL coolant level
in the reservoir has been reached.
Aisin coolant reinforcement.
• To add coolant, always use “Aisin Coolant S”.
• Add coolant with a concentration from 50% to
60% (by volume) with distillated water only.
3.10.
Checking for engine oil leakage
Inspect the engine and the sub oil pan for
any oil leak.
Checking
Period:
At least every 3 years or
6,000 operational hours
3.11.
Checking for engine coolant
leakage
Check the coolant hosing for cracking, deterioration,
loose hose clamps, coolant leakage, and other
unusual states.
Checking
Period:
At least every 3 years or
6,000 operational hours
Specified
Amount:
10.1 to 11.8 oz.
3
(300 to 350 cm )
CAUTION
• “Full” mark is inscribed on the reserve tank.
• For engine coolant additive, be sure to use the
AISIN coolant product.
3.9. Inspect engine coolant amount/
engine coolant refilling
Checking
Period:
3.12.
Checking for exhaust gas
leakage
With a gas leak tester, inspect the exhaust
air hose for exhaust air leak, which is caused
by disconnection, crack or deterioration of
the hose.
Checking
Period:
Add the engine coolant into the reserve tank
until the coolant level reaches the full mark.
Refill the reservoir with the specified amount
of coolant-strengthening agent. Use Aisin
Coolant S (G0954-3252) of the required
concentration to compensate for
insufficiency. The required concentration is
65 to 75 percent (coolant: 0.7, water: 0.3),
which is equivalent to a concentration of 53
to 60 percent in the case of measurement
with an optical concentration meter.
CAUTION
• Be absolutely certain to use the specified
At least every 3 years or
6,000 operational hours
At least every 3 years or
6,000 operational hours
CAUTION
Before starting inspection, check for fuel gas leakage. If
there is any abnormality, such as gas odor, be sure to
provide appropriate treatment.
3.13.
Prevention of Carbon Deposit
Formation on Valve or Valve Seat
Cleaning with a valve cleaner
1. Disconnect the mixer - T pipe blow by
hose from the T pipe.
2. Start the engine.
3. Inject about a half can of valve cleaner
from the disconnected blow by hose
into the mixer. Perform the injection
intermittently with care so as not to
allow the engine to stall or to
11Ton Model 132.6.00.P.HA Service Manual
76
Periodic Maintenance and Inspection
overspeed.
4. Reconnect the hose.
5. Let the engine run until no white smoke
comes out from the exhaust trapper,
and then stop the engine.
Cleaning
Period:
At least every 3 years or 6,000
operational hours
WARNING
Be extra careful to not get your fingers, clothes, etc.
caught in the pulley or other rotating parts when
cleaning.
3.14.
Valve clearance inspection/
adjustment
1.
2.
3.
4.
5.
6.
7.
8.
Start engine and allow it to warm.
Once warm, stop engine.
Remove the head cover.
Match the crank pulley to the top dead
center mark as shown in the view.
Make sure that when the crank pulley is
rotated by about 20 degrees horizontally,
the Intake rocker arm of the #1 cylinder
does not move. If the rocker arm moves,
rotate the crank pulley through one full turn
for matching to the top dead center.
Loosen the adjust nuts on the #1 and #3
cylinders intake valves and the #1 and #2
cylinders exhaust valves as shown, and
adjust each cylinder.
Rotate the crank pulley through 360
degrees.
Loosen the adjust nuts on the #2 cylinder
intake valve and the #3 cylinder exhaust
valves as shown, and adjust both cylinder.
Changing
Period:
Reference
clearance:
At least every 3 years or
6,000 operational hours
0.014 ± 0.002 inch (hot
status)
(0.35 ± 0.05 mm)
0.01 ± 0.002 inch (cold
status)
(0.25 ± 0.05 mm)
NOTE:
• Do not use feeler gauges of 0.2 mm
(0.008 inch) thickness or more. To
adjust clearances of 0.2 mm (0.008
inch) or more, be sure to use two
appropriate gauges in overlapped
form.
• Do not use corroded or bent feeler
gauges.
• When the engine has warmed,
perform adjustment for a valve
clearance that permits a 0.33 mm
(0.013 inch) gauge to be inserted and
does not permit a 0.38 mm (0.015
inch) gauge to be inserted.
3.15.
Fuel gas hose and Gas Hose
Clamp replacement
1. Remove the hose clamps and
11Ton Model 132.6.00.P.HA Service Manual
77
Periodic Maintenance and Inspection
disconnect the fuel gas hose.
2. Install new fuel hose.
3. Place new hose clamps over barbs and
tighten.
detected, repair the faulty point or replace the
part. If a leak point is not clearly located,
recover the refrigerantt and conduct the
pressure test with nitrogen gas.
Checking
Period:
At least every 3 years or
6,000 operational hours
Reference
value:
There should be no
vapor leak detected in
the gas leak test.
3.20.
Changing
.Period:
3.16.
At least every 10 years
or 20,000 operational
hours
Fuel gas leak inspection
Inspect the fuel gas hose for a crack or
deterioration, tightening condition of hose
clamps and others that could cause engine
coolant leak. Also check for fuel gas leak
with a gas leak tester.
Checking
Period:
3.17.
At least every 3 years or
6,000 operational hours
Fuel gas inlet inspection
Check the gas inlet for leakage, rust and
corrosion. If the fuel inlet is rusted or
corroded, replace it.
3.18.
Drain oil filter replacement
1. Disconnect the exhaust water drain hose
from the exhaust water drain filter box.
2. Remove the exhaust water drain filter box
and its screws.
3. Replace the drain oil filter and gasket with
a new one.
Changing
Period:
3.19.
At least every 3 years or
6,000
,000 operational hours
Refrigerant leak inspection
Inspect the refrigerant inlet/outlet (where the
refrigerant pipe is connected), etc. for vapor
Operational noise inspection
1. Check that the unit does not generate
unusual sounds during operation.
2. Listen very carefully for rattling sounds
from the cylinder head and for
interference sounds from rotating
sections around the engine.
3.21.
Exhaust water drain filter
refilling
1. Disconnect the exhaust water drain hose
hoses
from the exhaust water drain fil
filter box.
2. Remove the exhaust water drain filter box
from unit.
3. Refill the exhaust water drain filter with
neutralizer.
4. Reinstall exhaust water drain filter box.
5. Install necessary hoses.
Periodic Maintenance and Inspection
Checking
Period:
3.22.
At least every 3 years or
6,000 operational hours
Air filter replacement
1. Open panel labeled FILTER SECTION
using 3/8 ratchet / socket.. 4 screws will
hold panel onto unit.
2. Remove air filters by pulling air filter sliding
tool towards the outside of the unit and
removing each filter as they come out.
3. Install
nstall 3 new air filters (size 20x20x2 in
pleated)) on top of the air filter sliding tool,
follow arrow on filter for proper flow.
4. Write replacement
placement date on filters as they
are replaced.
5. Repeat steps 2-4 for bottom filters.
6. Reinstall panel marked FILTER SECTION.
Changing
period:
3.24.
At least every 3 months
Ignition components inspection
1. Inspect high voltage cables (Spark plug
wires) for cracks and/ or deterioration. If
cracks or deterioration
erioration is evident, all high
voltage cables (Spark plug wires) must be
replaced.
2. Inspect ignition coils for cracks in resin. If
cracks are evident in the res
resin,
components must be replaced.
3. Confirm the identification
entification number of the
high voltage cable (Spark plug wire) and
mount the cap property.
Checking
Period:
3.25.
At least every 3 years or
6,000 operational hours
Coil cleaning
Coils to be cleaned with water
1. Use water hose and nozzle
nozzle. Place the
nozzle in shower mode.
2. Wash coil in side to side manner from top to
bottom.
3. Wash all three outdoor coils u
until clean.
Cleaning
Period:
Changing
period:
3.23.
At least every 3 month
months
Economizer filter replacement
1. Remove economizer filters by removing
the two holding clips.
2. Reinstall 3 new air filters (size 20x20x2 in).
3. Write replacement date on filters as they
are replaced.
At least every 6 months
CAUTION
Do not bend fins while cleaning.
Technical Data for Repair
Section VIII – TECHNICAL DATA FOR REPAIR
1. Overall Bolts
Unit
Outdoor fan
Indoor Blower
Coolant pump
Transformer
Exhaust drain filter
Economizer
Item
Unit engine and outdoor compartment
Outdoor compartment
Radiator cap cover
Engine intake air filter
Engine oil pressure switch
Fan guard
Bracket
Basket
Mounting flange
Motor base
Shaft lock to rotor
Pulley flange
Base
Cover
Cover
Base
Mounting bolts
Filter
11Ton Model 132.6.00.P.HA Service Manual
Reference value
3/8”
5/16”
3/8”
3/8” / Philip
3/8”
9/16”
9/16”
3/8”
9/16”
5/16”
7/16”
3/8”
8 mm
1/2"
3/8”
Philip 18.4 ± 3.7 lb.ft (25.0 ± 5.0
N.m)
80
Technical Data for Repair
2. Engine System
Item
Compression
system
Ignition system
Each cylinder
Compression
Compression limit
Ignition timing
High voltage
cable resistance
Spark plugs
Fuel system
Lubrication
system
Tightening torque
[Size]
Electric
resistance
Belt tension
Air/Fuel ratio (O2meter)
#1
#2
#3
Spark plug gap
Tightening torque [Size]
Natural gas (
BTU)*1 2
Natural gas (
BTU)*1 2
Relief valve pressure
Amount
Engine oil
Type
Cylinder head cover (Valve cover)
Valve rocker shaft assembly
Fuel gas pressure
Engine oil pressure pump
Reference value
203 psi (1.4 MPa) or more
160 psi (1.1 MPa)
-1
18 ± 3°/100 rpm (min )
5.7 ± 2.2 kΩ
4.6 ± 1.8 kΩ
3.5 ± 1.3 kΩ
0.016 to 0.039 inch (0.4 to 1.0 mm)
15 to 22 lb.ft (20 to 30 N.m) [5/8”]
3 to 10%/2400 rpm (min-1)
0.3 psi (2.0 kPa)
71.1 psi (0.49 MPa)
9.2 gal (35 L)
AISIN Gas Engine Oil L-10000G
4.0 lb.ft (5.4 N.m) [10 mm]
14.8 lb.ft (20.0 N.m) [12 mm]
Cylinder head bolt
Flywheel bolt
Compressor mounting bolts
Compressor adjustment bolt/Locking nut
Compressor inlet and outlet ports
Exhaust heat exchanger brackets
25.1 lb.ft (34.0 N.m) [12 mm]
32.5 lb.ft (44.0 N.m) [14 mm]
31.0 lb.ft (42.0 N.m) [14 mm]
9 lb.ft (12.2 N.m) [14 mm]
8.9 to 13.3 lb.ft (12 to 18 N.m) [10 mm]
14.75 lb.ft (20 N.m) [12 mm]
Exhaust heat exchanger engine side port
Engine mounts/brackets
Engine coolant drain plug
Engine speed sensor
Engine oil pressure switch
Ignition coil
14.75 lb.ft (20 N.m) [12 mm]
31 lb.ft (42.0 N.m) [14 mm]
9.4 lb.ft (12.7 N.m) [10 mm]
5.9 lb.ft (8.0 N.m) [10 mm]
Speed sensor
Compressor belts
2.8Ω (Primary coil)
1100 Ω
125 to 135 lbs (560 to 600 N)
*1. Pipeline quality natural gas.
*2. Ask a gas company in America.
11Ton Model 132.6.00.P.HA Service Manual
81
Technical Data for Repair
3. Refrigerant System
Item
Reference value
Compressor oil
(Refrigerant oil)
NL10
0.53 gal (2 Liters)
Refrigerant gas
R410A
24.5 to 25.4 lbs
(11.1 to 11.5 kg)
When the refrigerant pump is
down
0 gal (0 cm3)
When recovering refrigerant
0.11 gal (400 cm3)
When recovering refrigerant
vapor
0.11 gal (400 cm )
Refilling amount of
compressor oil
When refrigerant pipe is cleaned
(refrigerant oil) when
repairing the
When an accumulator is replaced
refrigerant system
When an oil separator is
replaced
When other part is
replaced (except
compressor)
Remark
Note) Refilling of refrigerant oil at
the time of installation is not
necessary.
When parts that don't contain
refrigerant oil are replaced.
(Discharge pipe, thermostatic
expansion valve, dryer filter, etc.)
3
3
0.26 gal (1000 cm )
When a compressor (including
dryer filter) is replaced
3
0.26 gal (1000 cm )
3
0.53 gal (2000 cm )
Measured value
If the other parts are replaced
together, total of refilling amount
required for each replaced part
should be added.
4. Engine Coolant System
Item
140 °F (60 °C)
open
Thermostat valve
Engine coolant
Radiator cap
Engine coolant additive
Reference value
140 °F (60 °C)
Starts opening at
Opened fully at
Thermostat valve lift amount
Starts opening at
153 °F (67 °C)
Opened fully at
open
Thermostat valve lift amount
Engine coolant
163 °F (73 °C)
1/4 inch (6 mm)
153 °F (67 °C)
176 °F (80 °C)
1/4 inch (6 mm)
AISIN Coolant S
Color
Green
4.0 gal (15 L)
(including engine coolant in the reserve tank)
50%
7.3 psi (0.05 MPa)
10.1 to 11.8 fl oz. (300 to 350 cm3)
AISIN Coolant additive
Capacity
Volume concentration
Radiator cap pressure
Specified refilling amount
Type
11Ton Model 132.6.00.P.HA Service Manual
82
Technical Data for Repair
5. Thermistor Characteristics
Reference value
Temperature (°F(°C))
Resistance value (kΩ)
122 (50)
17.6
Item
Engine coolant temperature sensor
(10 kΩ) Thermistor
176 (80)
212 (100)
230 (110)
14 (-10)
32 (0)
50 (10)
6.1
3.3
2.5
47.54
29.49
18.79
68 (20)
86 (30)
104 (40)
122 (50)
140 (55)
32 (0)
12.26
8.194
5.592
3.893
3.27
182.9
68 (20)
122 (50)
176 (80)
212 (100)
248 (120)
14 (-10)
70.4
20.2
7.0
3.7
2.1
112.0
32 (0)
50 (10)
68 (20)
86 (30)
104 (40)
122 (50)
65.8
40.0
25.0
16.1
10.6
7.2
Outside air temperature sensor
Compressor discharge pipe temperature sensor
Supply air temperature sensor
6. Electrical System
Coil resistance
(Reference value)
Item
Electromagnetic gas valve coil (two)
Four-way changeover valve coil
Compressor clutch coil
Compressor Heater
Engine oil pan heater
Reference value
21 Ω
16.8 Ω ±
4 Ω ± 20%
1.667 kΩ ± 7%
---
Sub / main oil return coils
Hot gas bypass
5.7 Ω
5.7 Ω
11Ton Model 132.6.00.P.HA Service Manual
83
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