SERVICE MANUAL
Contents
1. 1 Do not mistake refrigerants If an HFC 134a air conditioning system is mistakenly charged with another refrigerant serious problems such as compressor seizing may occur Therefore confirm before charging with refrigerant that the type of air conditioning system is an HFC 134a system 16 3 Handling instructions 2 Do not release refrigerant into the air Although HFC 134a is not subject to CFC regulations it can have effect on global warming and so should not be released into the air When removing Do not release refrigerant into the air SSA refrigerant from the air conditioner system always use a refrigerant recovery unit made especially for HFC 134a Compressor handling Do not strike drop or turn unnecessarily the compressor upside down If the compressor is knocked over or turned upside down rotate the magnetic clutch 5 or 6 times by hand to circulate the oil in the cylinder Sudden rotation with the oil still in the cylinder can cause valve damage and adversely affect durability Compressor removal When the compressor is operational 1 Perform the oil return operation see p 18 2 Recover the refrigerant from the system using a refrigerant recovery unit 3 Remove the compressor 4 Drain the oil from the compressor and close all open connections immediately 5 Check the oil quantity and the degree of contamination see p 192. a At Sell a ga 4 S N l 12 M12x1 75 Dp 26 140 Sight glass CA104 CA104 _ 500 i From field coil 1 Product description Dimensions TM 55 amp TM 65 compressors without magnetic clutch 6 M6x1 0 Dp13 PCD 2 90 12 M12x1 75 Dp26 44 1 Product description Exploded view 1 Center bolt 18 Cylinder shaft assembly 2 Armature assembly 19 Eye bolt 3 Adjusting shim 20 O Ring 4 Snap ring 21 Oil filler plug 5 Pulley assembly 22 Strainer 6 Screw 23 Gasket 7 Field coil 24 Connector 8 Bolt 25 Bolt 9 Gasket 26 Gasket 10 Front cylinder head 27 Sight glass 11 Shaft seal assembly 28 O ring 12 O Ring 29 Snap ring 13 Gasket 30 Valve plate assembly 14 Valve plate assembly 31 Gasket 15 Suction valve 32 Gear pump 16 Pin 33 Rear cylinder head 17 Bolt 10 1 Product description Valeo TM 55 amp TM 65 are 14 cylinder swash plate type compressors With this type of compressor the cylinders and pistons are arranged axially along the drive shaft The pistons operate within the cylinders and are driven by a swash plate to perform suction compression and discha
3. In the off season of air conditioner operate the compressor for a few minutes from time to time Do not drive through water Water may damage the magnetic clutch thus preventing normal operation Always charge the A C system with the specified quantity of refrigerant Keep the compressor clear of water projection while cleaning the vehicle 3 Handling instructions Maintenance precautions Work area Because the components of air conditioners are especially sensitive to moisture dirt and rust always observe the following Work indoors whenever possible Select a flat ground work area Keep the work area clean Select a work area with adequate ventilation CAUTION Refrigerant itself is not harmful but excessive accumulation in a closed area can cause oxygen deficiency Keep naked flame and inflammable away from the vehicle in which the air conditioner is being installed Fire is especially dangerous during the gas leak inspection following installation WARNING Contact with flame and high temperatures can generate toxic gases Refrigerant handling WARNING Direct contact with refrigerant can cause frostbite or blindness Always wear safety glasses and protective gloves Do not work with refrigerant close to your face
4. SERVICE MANUAL Valeo TM 55 amp TM 65 Compressors a added il Copyright 2010 Valeo Compressors All rights reserved Oil fill up plug for better inner oil return 7 double headed pistons architecture ensuring smooth and quiet operations Compact amp robust design enabling easy mounting configurations rr Lip type shaft seal providing ultimate reliability amp performance Light amp Compact Ultimate Reliability Highest Performance valeo added WTI Foreword This service manual has been elaborated to help service personnel to provide efficient and correct service and maintenance on the Valeo TM 55 and TM 65 compressors for bus air conditioning This manual includes the operation specifications procedures for disassembly reassembly and inspection of the compressor WARNINGS The contents of the manual including illustrations drawings and specifications were the latest available at the time of printing The right is reserved to make changes in specifications and procedures at any time without notice VALEO THERMAL SYSTEMS JAPAN CO LTD The following definitions and warning signs are used in this service manual These are extremely important to ensure safe operation Important points are described to prevent body injuries and property damage They must be fully understood before starting air conditioning maintenance WARNING CAUTION MEANING OF MARKS Maintenance must
5. Cylinder heads Front amp Rear Disassembly 1 Remove the magnetic clutch assembly as described on page 29 2 Remove the four bolts securing the connectors and then remove the connectors and strainer from the cylinder shaft assembly 3 Remove the oil filler plug and then drain the oil 4 Remove the seven bolts securing the heads 5 Alternately tap the two projections on the front head using the remover and mallet to remove the front cylinder head Tap lightly Remover Front cylinder head 6 Remove the front valve plate assembly and then the suction valve in that order 7 Remove and discard the O ring from the front cylinder head 8 Remove all gasket material from the front cylinder head and the front valve plate Suction valve Gasket 36 8 Service procedures Cylinder heads Tap lightly 4 Remover Rear cylinder head Gasket Suction valve Valve plate assembly Gear pump Rear cylinder head Valve plate Cylinder head 9 Alternately tap the two projections on the rear head using the remover and mallet to remove the rear cylinder head 10 Remove the rear valve plate assembly and then the suction valve in that order 11 Remove and discard the O ring from the rear cylinder head 12 Remove all gasket material from the rear cylinder head and the rear valve plate 13 Remove the gear pump from the rear cylinder head or the end of the driveshaft Inspection
6. with the front side up 2 Install the front suction valve so that it matches the spring pins CAUTION Ensure each valve matches each cylinder valve escape groove 3 Install the front valve plate on the front suction valve 4 Coat the new gasket with clean compressor oil and install it on the front valve plate 5 Position the guide on the shaft 6 Coat the new O ring with clean compressor oil and install it on the front cylinder head 7 Install the front cylinder head CAUTION Align the spring pins and tap the head lightly and evenly with a plastic hammer 8 Remove the guide 9 Install the seven bolts from the front cylinder head side and tighten them to the specified torque Specified torque 25 32 N m 2 5 3 3 kgf m 18 24 ft Ibs Tighten each bolt gradually in three or more stages to ensure the specified torque 10 Turn the drive shaft 2 3 times by hand to ensure that the shaft rotates smoothly 11 Fill the compressor with the specified amount of clean compressor oil through the oil filler 12 Install the oil filler plug with a new O ring and tighten it to the specified torque Specified torque 15 18 N m 1 5 1 8 kgf m 11 13 ft Ibs 13 Install the strainer in the suction port 14 Fit blanking plates connectors to the suction and discharge connections and tighten it to the specified torque Specified torque 25 32 N m 2 5 3 3 kgf m 18 24 ft Ibs 15 Install the
7. Check the front and rear valve plates for scratched bent or damaged parts Inspect both cylinder heads and both valves plates for nicks or burrs on the sealing surfaces Clean both cylinder heads and both valve plates or replace them if they are cracked or damaged Check that there are no clogged passages in the valve plates 3 8 Service procedures Cylinder heads Escape groove Rear cylinder head Valve plate assembly Gear pump Gasket Suction valve Reassembly Rear cylinder head 1 Place the cylinder shaft assembly on the bench with the rear side up 2 Install the rear suction valve so that it matches the pins CAUTION Ensure each valve matches each cylinder valve escape groove 3 Install the rear valve plate on the rear suction valve CAUTION Do not mistake the front and rear valve plates 4 Coat the new gasket with clean compressor oil and install it on the rear valve plate 5 Coat the new gear pump with clean compressor oil and install it on the end of the drive shaft Coat the new O ring with clean compressor oil and install it on the rear cylinder head Install the rear cylinder head When positioning the head ensure the gear pump is inserted into the hole in the cylinder head 8 Service procedures Cylinder heads Gasket Valve plate assembly Suction valve Front Cylinder Head 1 Place the cylinder shaft assembly on the bench
8. When the compressor is inoperable 1 Recover the refrigerant from the system using a refrigerant recovery unit if the shut off valves are removed with the compressor 2 Remove the compressor 3 Drain the oil from the compressor and close all open connections immediately 4 Check the oil quantity and the degree of contamination see p 19 17 3 Handling instructions 8 8 J Oe As long as it remains within the range of vision through the sight glass the oil quantity is sufficient Oil return operation Compressor oil mixed with refrigerant is circulating in the air conditioning system Perform the oil return operation to return this oil to the compressor before removing components from the system 1 Open the doors and windows and operate the blower motor at maximum speed 2 Operate the vehicle engine at idling during at least 20 minutes Note The maximum amount of oil cannot be recovered at higher speeds This operation also requires a warm ambient temperature Oil handling Oil specification Use only ZXL 100PG DH PS or POE oil Oil quantity inspection There is no particular need for frequent inspection or replacement although the oil must be inspected or replaced in the following cases At t
9. acerca csWianaentinteseactineds mieatinatensessnintecs 21 NS asec ariel E RE 22 Storing a repaired COMpresSSor jan cncesnccadcesancarncradcianenticendcheabacsteiens 22 4 Trouble shooting sine ts ussctscsacensenpdaestatbersensutsenstsetetadenacedarehanstaceas 23 Compressor trouble SOONG cccsssisncotsisaceetaaiacaenianvadessalaccontennencnaaionces 23 Compressor trouble shooting arDorescenCe seeseeceeseteeeeeeeseees 23 A C cycle diagnosis by gauge pressure ccesseseseseseteeeeeeeeeeneneeees 26 5 Tightening TOPICS 55s sacatccincatincotctcumea cvnncsendedaacesnnmeicsuucanunnisesbas 28 6 Service procedures Magnetic ClUtCh hn cee eeeeseeteeseseteeeees 29 7 Service procedures Shaft seal assembly cee eeeeeeeeeeteees 33 8 Service procedures Cylinder heads eeeeseccseseeeteeeeseteeeees 36 9 Service LOS orena ea a E E E EA 40 DO Service parts esrin neneiia iisisti 46 1 Product description Compressor Compressor Heavy Duty Swash Plate Length Width Height 13 4 7 64 9 33 in Valeo TM 55 amp TM 65 Application limits Saturated condensing temp we C 0 03 MPa 0 1 MPa 0 31 MPa 0 47 MPa 2 65 MPa 1 58 MPa 0 76 MPa _ 0 47 MPa T0 20 30 te C 10 0 Saturated evaporating temp te Condensing temperature C te Evaporating gas temperature C 1 Product description Compressor Name plate To ensure that the compressor operates smoothly b
10. be properly done to avoid serious injury risks Improper maintenance can result in injury or proper damage The following marks are used in this service manual to facilitate correct air conditioner maintenance Advice Procedures necessary to ensure the best air conditioner maintenance Note Information to optimize the air conditioning maintenance Contents 1 Product Ge STU UNO Nasi tsotts rsa censumiacsrainieeetonas ina taiessbeddesnsiasihisianoeed 3 2 Operation precautions sos cececnescvnatenssteqveahindacaesserschestesurtacmere Rees 15 3 Handling WSU WCTIO INS axstoaricstoinbasnssiadssnmadtsnananctinnsvedsnndvesiwiseodan 16 Maintenance precautions ge shea ese teciacteceausciesiechtantegenatpcaanaedesaieas 16 WOK Ue eh nurcie oa a E a a aiaa 16 Refrigerant nandling essiri eeii 16 Compressor handling s s sessnssesooeesoeoseseosessoeoseeosessoseeseseesessesee 17 COMPpressor reMOVval n sensnensesseseosesseeeseseesessesteststesessnsresnsreseesenee 17 Qil return SFO esses soreiaresse tsaeir raceea aikeista raain a oa 18 il handling isen S 18 Oil COMES MM AUN I 22 c25zacsacciccatacovizs clactpacenateelactiaciascmetactiecstocnebactioused 19 RUINS te isireses iseer han de eavesatinne R 19 Replacement of COMPONEINS 2aceccistadnaeidakmreiuadnaretkadien 20 RUNNINg IN ODOR ON i ccc es cacciecastteneettuaeatteiedeeacunieeiactehwcuatiebessees 21 Compressor TUNNING aromes ianea ne a as 21 Magnetic clutch PUIG Taste oes
11. bolt is loose Center Compressor is running normally No difference of temperature between discharge side and suction side see p 26 27 The magnetic clutch slips or does not engage when the compressor is running Refrigerant shortage Magnetic clutch friction surface slipping Loose connection of the LImagnetic clutch electrical circuit Magnetic clutch belt slipping Belt slipping The magnetic clutch does not engage Both discharge and suction pressures are high The magnetic clutch slips or does not engage when the compressor is running Excess of refrigerant Loose connection of the magnetic clutch electrical circuit Defective sensor Belt slipping Bolt drop off Armature drop off Measure Replace the compressor Fix the refrigerant leakage then fill with refrigerant until having the right amount Replace the lead wire if it is defective Repair or replace the magnetic clutch Adjust air gap or replace magnetic clutch Charge batter Replace the compressor if it is locked Replace the compressor or Ithe magnetic clutch Replace magnetic clutch Replace the compressor Fix the refrigerant leakage then fill with refrigerant until having the right amount Charge the battery or replace the magnetic clutch Replace the magnetic i clutch after making sure it is Idefective Defective sensor Belt tension readjust
12. magnetic clutches ensures an unmatched reliability and the longest durability that perfectly matches the Valeo TM 55 amp TM 65 compressor qualities Specifications DIRECTION OF ROTATION Clockwise viewed from clutch WEIGHT Approx 10 12 kg 22 27 Ibs V BELT TYPE V groove A or B or V ribbed PK The specifications may vary with the compressor Please also note that the maintenance procedures introduced in this service manual apply only to magnetic clutches provided by Valeo Valeo TM 55 amp TM 65 magnetic clutch Compact and robust design Housing mounted magnetic clutch Improved robustness to vibration Bearing and pulley positionned to reduce efficiently the moment of tilt Single level or multi level pulleys 1 Product description Connectors Connectors 1 Fully open the shut off valve when operating the compressor Unscrew the cap Loose the valve spindle seal by turn Turn the spindle in the counterclockwise direction until it stops The shut off valve is now fully opened and the service port connector is closed When finished tighten the valve spindle seal carefully and screw the cap 4 Q 2 Valve spindle seal oe Cap ae Le IT 3 G Spindle Service port connector 5 Safety devices port C ot 2 Open the service port connector when using a gauge manifold Turn the spindle in the clockwise direction by 1 2 turn to 1 turn The shut off valve and
13. Part No 20010245 0 2 mm 0 008 in 20010246 0 3 mm 0 012 in Specified clearance 0 3 0 7 mm 0 012 0 028 in 8 Runin the clutch as described on page 21 32 7 Service procedures Shaft seal assembly Remover Front cylinder head Press uniformly Shaft seal from above Front cylinder head Removal 1 6 33 Remove the magnetic clutch assembly as described on page 29 Remove the bolts securing the connectors and then remove the connectors and strainer from the cylinder shaft assembly Remove the oil filler plug and then drain the oil Remove the seven bolts securing the head using an hexagon 14 mm wrench Alternately tap the two projections on the front head using a remover and a mallet to remove the front cylinder head Remove the shaft seal assembly using a remover 7 Service procedures Shaft seal assembly Press using a press Front cylinder head Front cylinder head Inspection The shaft seal must not be reused Always use a new shaft seal when reassembling the compressor Ensure that the seal seat is free from lint and dirt that could damage the shaft seal lip Installation 1 Clean the portion of the front cylinder head where the shaft seal is to be assembled 2 Assemble the shaft seal on the remover 3 Coat the shaft seal well with compressor oil and install the shaft seal in the front cylinder head 4
14. Remove the shaft seal remover 5 Position the guide on the shaft 6 Coat the new O ring with clean compressor oil and install it in the front cylinder head 7 Install the front cylinder head CAUTION Align the pins and tap the head lightly and evenly with a plastic hammer 8 Remove the guide 9 Install the seven bolts from the front cylinder head side and tighten them to the specified torque Specified torque 25 32 N m 2 5 3 3 kgf m 18 24 ft Ibs Tighten each bolt gradually in three or more stages to ensure the specified torque 10 Turn the drive shaft 2 3 times by hand to ensure that the shaft rotates smoothly 34 7 Service procedures Shaft seal assembly ro 11 Fill the compressor with the specified amount Oil filler plug 5 of clean compressor oil through the oil filler O ring gt 9 12 Install the oil filler plug with a new O ring and tighten it to the specified torque Specified torque 15 18 N m 1 5 1 8 kgf m 11 13 ft lbs 13 Install the strainer in the suction port 14 Fit the blanking plates connectors to the suction and discharge connections and tighten them to the specified torque Specified torque 25 32 N m 2 5 3 3 kgf m 18 24 ft Ibs 15 Install the magnetic clutch as described on page 31 16 Run in the compressor as described on page 21 17 Perform the leak test as described on page 22 35 8 Service procedures Cylinder heads
15. an be classified in the following categories 1 Insufficient cooling capacity 2 Abnormal noise 3 Smoke In case of insufficient cooling capacity we recommand that you prepare a gauge manifold to measure the pressure of both discharge and suction sides for a detailed diagnosis by gauge pressure see p 26 27 Compressor trouble shooting arborescence A Compressor is not running A Abnormal noise from compressor A Magnetic clutch friction surface slipping 1 Insufficient cooling capacity 2 Abnormal noise B Magnetic clutch belt slipping C Smoke from magnetic clutch D Smoke from compressor 23 4 Trouble shooting Insufficient cooling capacity Trouble No cool blow coming out No cool blow coming out bolt is missing The magnetic clutch does Inot engage Symptom Magnetic clutch slips when turning on the A C switch Low pressure cut switch operate see p 26 27 The magnetic clutch slips or does not engage when the compressor runs The magnetic clutch engages but the armature does not rotate Possible cause Compressor internal part damage Refrigerant shortage Lead wire short circuit or wiring connector not seated properly Magnetic clutch damage Magnetic clutch air gap too wide ow magnetic clutch voltage H Compressor internal part Belt run off the pulley damage or magnetic clutch damage Center
16. ase refer to the clutch maker s service procedures Removal 1 2 Remove the armature using an armature puller to prevent armature assembly rotation Remove the armature assembly using an armature puller Remove the shims from the compressor drive shaft or armature assembly Remove the snap ring Z0010244 using external snap ring pliers Position the center pulley puller at the end of the driveshaft Attach a suitable pulley puller to the pulley Hook the puller claws to the edge of the pulley as shown Tighten the center pulley puller bolt to remove the pulley WARNING Removing the pulley will systematically damage the pulley bearing CAUTION Do not clip the puller claws into the pulley groove to prevent pulley groove damage 6 Service procedures Magnetic clutch 7 Remove the six field coil compressor screws Then remove the field coil CAUTION Do not hold the field coil by the harness Inspection 1 If the contact surface has been damaged by excessive heat the armature and pulley must be replaced 2 Check the appearance of the pulley assembly If the contact surface of the pulley is excessively grooved due to slippage both the pulley and armature must be replaced The contact surface of the pulley assembly must be cleaned with a suitable solvent before reinstallation 3 Check the field coil for a loose connector or cracked insulation 30 6 Servic
17. e careful to respect the indications written on the name plate located on top of the compressor body MP TYPE TM 65 A l RT NO Z0007261 A Name plate T RIAL NO 001V000401 ZL100PG 1500 cm or HIGH SIDE 2 9 a AK TEST LOW SIDE 1 5M e EFRIG HFC 134a MADE IN JAPAN Tip As TM 55 amp TM 65 compressors have the same dimensions the best way to differentiate them Compressors quickly is by referring to the name plate OMP TYPE TM XX ART NO ZXXXXXXX X ERIAL NO XXXXXXXXXX IL ZXL 100PG 1500 cm LEAKTEST EFRIG HFC 134a MADE IN JAPAN 1 Product description Magnetic clutch Magnetic clutch VALEO TM 55 amp TM 65 are available either as a compressor and magnetic clutch assembly or as a compressor body that customers can fit with compatible magnetic clutches The magnetic clutch design Valeo has been promoting for more than 20 years is now gradually adopted as well by other major market actors Our compressors and magnetic clutches have successfully passed the thousand hours of long validation tests in Valeo Compressors research center laboratory Operational excellence was demonstrated during hot season testing on field under challenging climates in the most stressful conditions Being able to rely on our robust magnetic clutch provides the best way to reduce fuel consumption without using additional unloading devices that decrease significantly the efficiency and durability of the compressor The range of Valeo
18. e procedures Magnetic clutch Magnetic clutch Installation 1 Install the field coil on the compressor with the harness on top and tighten the mounting screws to the specified torque Specified torque 8 0 12 N m 0 8 1 2 kgf m 6 0 9 0 ft Ibs Field coil Carefully place the wire harness strain relief Press F Puey assembly Pulley 3 Install the pulley assembly using the pulley installer installer and a press CAUTION Use only a press to install the pulley assembly Do not use a hammer The use of a hammer may result in damage or deformation 4 Install the snap ring beveled edge up using external snap ring pliers Snap ring Internal snap ring pliers 31 6 Service procedures Magnetic clutch Anati Armature holder Adjusting shims Gap adjustment 0 3 0 7 mm Thickness gauge 5 Install the armature assembly on the drive shaft together with the original shim s Press the armature assembly down by hand 6 Install the armature bolt and tighten to the specified torque using an armature holder to prevent armature assembly rotation Specified torque 25 30 N m 2 5 3 1 kgf m 18 22 ft Ibs CAUTION After tightening the center bolt check that the pulley rotates smoothly 7 Check that the clutch clearance is as specified If necessary adjust the clearance using shim s Adjusting shims are available in the following thicknesses Shim
19. ed field serviceability Reduced noise and vibrations Staggering value through innovation AAA IITTI ATTA added fl EE28E 13010 Asia China Europe amp Middle East Africa Americas 39 Sendai Kumagaya shi No 2677 Shiji Avenue Eco amp Tec Dvt 6 rue Francois Cevert 2520 Esters Blvd 100 Saitama ken 360 0193 Japan Zone 130031 Changchun Jilin PRC BP71014 49015 Angers France Dallas TX 75261 United States Phone 81 0 48 539 3800 Phone 86 0 431 8499 2025 Phone 33 0 241686 234 Phone 1 972 456 1077 Fax 81 0 48 539 3843 Fax 86 0 431 8499 2004 Fax 33 0 241 686 239 Fax 1 972 456 1090 Email vc oura sales valeo com Email vc changchun sales valeo com Email vc angers sales valeo com Email vc dallas sales valeo com Copyright 2010 Valeo Compressors All Rights Reserved
20. es is lubricated by the splashing action of the oil flowing through the thrust bearings The compressor remains constantly lubricated thanks to the oil circulating together with the refrigerant Valeo compressor innovative internal design ensures that almost no oil remains mixed with the refrigerant that is flushed into the air conditioning system Refrigerant itself plays a lubricant role to prevent the compressor to be damaged in case of oil shortage Drive shaft Shaft seal Swash plate Radial bearing Gear pump Radial bearing Reservoir Sight glass Thrust bearings Oil passage Oil passage 12 1 Product description Compressor 1 The direction of rotation is clockwise as viewed from the clutch side 2 The standard compressor oil charge is specified for bus air conditioners The oil quantity may differ depending on the type and use of compressor Please refer to the label on the compressor Operation condition table 3 The compressor must be operated under the conditions shown in the operation condition table shown at left Under 100 C 212 F temperature CAUTION Minimum 600 r min Maximum 4500 r min Continuous 4000 r min pressure Maximum 1 96 MPa 20kgf cm2 284 psi The A C cycle components must be designed so that the pressure in the cycle does not exceed 1 96 MPa 20 kgf cm2 284 psi 4 Inclination limit at installation The compressor must be installed on the
21. est The compressor must be checked for refrigerant leaks after it is repaired The procedure is as follows 1 Fit the connectors to the suction and discharge connections and tighten it to the specified torque Specified torque 25 32 N m 2 5 3 3 kgf m 18 24 ft Ibs 2 Fill the compressor with refrigerant through the suction side raising the refrigerant pressure to at least 0 49 MPa 5 kgf cm2 71 psi 3 Check the compressor for leaks using a leak detector Storing a repaired compressor If it is necessary to store a repaired compressor for some time before installation evacuate the compressor and fill it with dry nitrogen gas through the suction fitting to raise the pressure to 30 100 kPa 0 3 1 0 kgf cm2 4 4 14 5 psi 22 4 Trouble shooting Compressor trouble shooting When a trouble occurs during the compressor operation it is often difficult to pinpoint exactly the cause of the malfunction As long as the compressor maintenance is done correctly there should not be any problem throughout the whole vehicle life but in case it ever happens we hope this trouble shooting can help you solve the issue efficiently Below are listed most of the troubles you may encounter while the A C is ON Please refer to the compressor trouble shooting arborescence to localize the malfunction symptom then look at the table p 24 25 for the appropriate measure Most of the malfunction symptoms c
22. ght amount of refrigerant Suction pressure a becomes vacuum Receiver dryer is Temperature difference Replace parts clogged between inlet and outlet pipes happens Dryer is covered with frost Expansion valve is Expansion valve was Clean or replace part clogged covered with frost Enclosure leakage Outlet side of TXV is Replace part from TXV temperature not cooling sensing tube Low side of gauge TXV operates to close indicates vacuum the valve opening Temperature sensing Evaporator becomes Adjust or replace the device at outlet air is frozen up part defective Refrigerant piping is If any part between Adjust or replace the clogged or crashed the dryer and the part compressor is clogged or crashed the low side pressure becomes vacuum 4 Trouble shooting Gauge pressure Cause Confirmation method Action to take indication Both discharge and suction pressures are high Discharge pressure is high and suction pressure is low Discharge pressure is low and suction pressure is high Excess of refrigerant Condenser cooling malfunction Misaligned TXV or thermal sensing tube of TXV is not fit on regularly Excess opening of TXV Air mixed in refrigeration cycle Refrigerant cycle is clogged between compressor and condenser Defect of the compressor valve or gasket Connect gauge manifold to cycle Condenser becomes muddy and fins are clogged and collapsed Defect of cooling fa
23. he start of the season Every 5 000 km 3 200 miles or every 5 months for vehicles that are in constant use When gas leaks from hoses or pipes When gas or oil leaks from the compressor When there is any malfunction other than the above When the evaporator condenser or receiver drier is replaced When refrigerant is suddenly discharged from the system Handling precautions 1 The oil must be free from dust metal filings etc 2 Do not mix oils 3 The moisture content must not exceed 1 000 ppm PAG oil only 4 The oil easily absorbs moisture when the container is open Therefore always seal the container immediately after use PAG oil only 18 3 Handling instructions Oil contamination Unlike engine oil no cleaning agent is added to the compressor oil Even if the compressor is run for a long time the oil never becomes turbid as long as there is nothing wrong with the compressor or its method of use Inspect the extracted oil for any of the following Increased opacity of the oil Color change to red Presence of foreign matter metal filings etc Oil check The compressor oil must be checked as follows when being charged into a used system 1 Perform the oil return operation p 18 2 Remove the compressor from the vehicle 3 Remove the oil filler plug and drain the oil through the oil filler plug and the high and low pressure connectors 4 Check the oil for contamina
24. ial SK105 JIS Installer Unless otherwise specified surface Treatment the edges to be slight chamfering Heat Treatment Should remove burrs and fluff Material SK85 JIS Remover for cyl head 9 Service tools Unless otherwise specified surface Treatment the edges to be slight chamfering Heat Treatment Should remove burrs and fluff 5US304 Section view A A Unless otherwise specified 3rd Angle Proj Surface Treatment L s Heat Treatment the edges to be slight chamfering oq at Treaime ache fie Should remove burrs and fluff Material 545C Remover 9 Service tools 3rd Angle Proj Surface Treatment 7 Heat Treatment ardness c4 amp Hard Material Part Name Armature Puller Ass Armature puller assy Unless otherwise specified 3rd Angle Proj Sutface Treatment the edges to be slight chamfering i Heat Ireatment Should remove burrs and fluff C Material Part Name P a t e 9 Service tools Armature puller assy M16X2 0 J Unless otherwise specified surface Treatment Br the edges to be slight chamfering Heat Treatment Pay Should remove burrs and fluff Material Armature puller assy A section detailed view 10 1 M12X1 75 Unles
25. ing burst 25 Measure Improve the compressor attaching portion Charge battery or replace magnetic clutch Replace the compressor if locked Readjust the belt Itension if the belt is loose Measure Adjust air gap or replace magnetic clutch Charge batter Clean friction surface or replace magnetic clutch Adjust the compressor jinstallation position Clean or replace the belt Adjust belt tension Replace the magnetic clutch Fix the refrigerant leakage then fill with refrigerant until having the right amount 4 Trouble shooting A C cycle diagnosis by gauge pressure Following is a diagnosis procedure to connect gauge manifold to A C cycle measure suction and discharge pressures and analyze the defects of the cycle Operation conditions of the A C cycle for pressure mesuring Ambient temperature 30 35 C Engine speed 1 500 rpm A C switch ON Blower speed high Temperature control full cold Gauge pressure Cause Confirmation method Action to take indication Pressure is normal A C cycle operates normally If there is any defect poor cooling performance there shall be another cause eee Discharge pressure around 1 0 1 7 Mpa 10 17 kgf cm Suction pressure around 0 13 0 20 Mpa 1 3 2 0 kgf cm Both discharge and Refrigerant shortage Connect gauge Recover refrigerant suction pressures are manifold to cycle then refill with the low ri
26. ling these component parts check the compressor oil Refer to page 18 20 3 Handling instructions Running in operation Whenever moving parts have been replaced it is necessary to run in both the compressor and the magnetic clutch Compressor running in Reassembled compressors must be run in after the leak test see next page 1 Check that the compressor contains the specific amount of oil 2 Install the compressor on the test bench 3 Install the high pressure connector and the low pressure connector to the ports and tighten the bolts to the specified torque Specified torque 25 32 N m 2 5 3 3 kgf m 18 24 ft Ibs 4 Connect the two connector ports using a flexible hose 5 Run the compressor at 1 000 rpm for at least 30 minutes 6 Replace the oil 7 Repeat the leak test CAUTION While the compressor is being run in in step 5 above check the outside temperature of the front head If the temperature exceeds 80 C 176 F stop the running in operation Resume the operation when the head has cooled Magnetic clutch running in 1 Install the clutch on the compressor 2 Install the compressor on the test bench and operate the compressor by running the system 3 Maintain the compressor speed at 700 rpm Operate the A C switch through the ON OFF cycle at least 50 times ON for 10 seconds and OFF for 10 seconds 21 3 Handling instructions Leak t
27. magnetic clutch see p 31 16 Run in the compressor see p 21 17 Perform the leak test see p 22 39 9 Service tools In addition to standard tools numerous special tools are necessary to service the Valeo TM 55 amp TM 65 compressors The use of these special tools enables prompt and correct compressor service The drawings and the specifications of the service tools listed below are enclosed in the following pages Service tools page page Armature holder 4 To fix armature peter pulley To remove pulley puller Pulley installer To install pulley Cylinder head To remove cylinder head and 42 remover cylinder block To install shaft seal Shaft seal remover To remove and insert the installer shaft seal Armature puller assy To remove armature AQ 9 Service tools Unless otherwise specified 3rd Angle Proj _ Surface Treatment i j 1 Heat Treatment HOF the edges to be slight chamfering eat Treatmen ang gt HTL Should remove burrs and fluff Material Unless otherwise specified Surface Treatment the edges to be slight chamfering Heat Treatment HQ HTL amp Hardness HRC40 to 45 Should remove burrs and fluff 9 Service tools 53 Section view A A Unless otherwise specified Surface Treatment the edges to be slight chamfering Heat Treatment Should remove burrs and fluff Mater
28. ment Replace the sensor after making sure it is defective Reduce the refrigerant charge until reaching the i fright amount Condenser fan failure Replace the condenser after making sure it is defective Replace the magnetic clutch after making sure it is defective Replace the sensor after making sure it is defective 4 Trouble shooting 2 Abnormal noise ied Trouble the compressor Symptom Abnormal vibration after turning on the A C switch Abnormal noise from the LIcompressor body The magnetic clutch has a backlash and Slips Strange noise when the magnetic clutch engages Armature slips does LInot engage when the compressor is running Armature does not rotate when magnetic clutch lengages The magnetic clutch slips does not engage when the compressor is running The magnetic clutch slips does not engage when the compressor is running The magnetic clutch does not engage Refrigerant oil is billowing lout Possible cause Wide gap at the attaching portion between the compressor and the bracket Magnetic clutch friction surface slipping Belt slipping Possible cause Magnetic clutch air gap too wide ow magnetic clutch voltage Magnetic clutch friction surface is greasy Belt alignment is not correct Magnetic clutch belt is Coil open or shorted Refrigerant leaking uncoupled piping or pip
29. n rotation Malfunction of fan motor for condenser Defective refrigerant flow control the thermal sensing tube is not closely in contact with the evaporator pipe Just after compressor stops discharge pressure will come down immediately to 0 29 0 39 MPa 3 4 kgf cm Appreciable temperature difference at the clogged location Discharge and suction pressures balance immediately after the compressor stops Defective compression of compressor 27 Recover refrigerant then refill with the right amount of refrigerant Clean up hand repair of fin and replacement Adjustment or replacement Evacuate air from cycle the charge with the adequate amount of refrigerant Clean up inside the cycle or replace the part Replace the compressor 5 Tightening torques Unit N m kgf m ft lbs 1 Center bolt M10 x 1 25 25 30 2 5 3 1 18 22 2 Field coil screw M6 x 1 0 8 12 0 8 1 2 6 9 3 Bolt M10 x 1 5 25 32 2 5 3 3 18 24 4 Oil filler plug M10 x 1 5 15 18 1 5 1 8 11 13 5 Connector bolt M10 x 1 5 25 32 2 5 3 3 18 24 28 6 Service procedures Magnetic clutch Armature holder Armature External snap ring pliers Snap ring Center pulley puller Pulley puller Magnetic clutch CAUTION This procedure applies to Valeo standard magnetic clutches only It may differ with other compatible magnetic clutches ple
30. rge Drive shaft Radial bearing Thrust bearings pall i Swash plate system Swash plate system The drive shaft which is driven by the engine through the magnetic clutch is equipped with a swash plate The drive shaft is supported by two radial bearings and two thrust bearings The swash plate is rotated by the drive shaft and moves the pistons back and forth Piston Swash plate Radial bearing Suction A p gt f Compression Piston Drive System The pistons in the cylinders are mounted on the swash plate through hemispherical shoes Each piston has a compression head at each end Swash plate rotation results in a reciprocating piston movement horizontal to the drive shaft The cylinders which are arranged at 51 4 intervals around the drive shaft are each divided into 2 chambers providing 7 front and 7 rear bores As each piston performs suction and compression at either end the compressor operates as a 14 cylinder compressor 11 1 Product description Lubrication The gear pump situated at the end of the drive shaft draws oil from the oil reservoir and lubricates the parts of the compressor Oil flow When the compressors start operating the gear pump draws oil from the reservoir and pumps it through an oil passage in the shaft The oil then flows through ports in the shaft to lubricate the bearings and the shaft seal The area between the swash plate and the sho
31. s otherwise specified 3rd Angle Proj Surface treatment Br Heat Treatment the edges to be slight chamfering i at eee Should remove burrs and fluff G Material Part Name B 0 t 10 Service parts 1 Compressor body service kits sets and parts Quantity OVERHAUL KIT O RING SET GASKET SET SHAFT SEAL 20014427 Le O RING SET 20014430 12 O ring body front amp rear head 20004833 n 20 O ring drain 569300 4000 n n 13 31 Gasket bolt 9 per set 569310 6200 _n SHAFT SEAL for service a e Shaft seal 20007461 Valve plate assy front Suction valve see Product description Exploded view p 10 1 9 2 Connector assy Z0011222 service parts ipi 2 20011227 20011228 see Product description Exploded view p 10 3 Oil Quantity ZXL100PG 250 cc 569900 0600 Notes 47 Notes AS VALEO COMPRESSORS TM 55 amp TM 65 for HFC 134a use SERVICE MANUAL Printing April 2010 Published by VALEO THERMAL SYSTEMS JAPAN CO LTD Printed in Japan Copyright 2010 VALEO THERMAL SYSTEMS JAPAN CO LTD For any inquiry regarding the present service manual contact us at vc oura sales valeo com Valeo TM 55 amp TM 65 Compressors for Bus Air Conditioning Valeo TM 55 amp TM 6 High reliability Integration flexibility Great cooling capacity Enhanced performance Lower fuel consumption Compact amp robust design Improv
32. the service port connector are now opened fa 2 Valve spindle seal A Cap es TEETE e 3 G Spindle Service port connector Safety devices port 3 Fully close the shut off valve when removing the compressor Turn the spindle in the clockwise direction until it stops Valve spindle seal Cap Q Spindle Service port connector Safety devices port 1 Product description Performance The performance data below were measured under the following conditions Compressor speed 1450 rpm Suction gas temperature 20 C Valeo TM 55 performance data R134a Conditions Cooling capacity Qo Watt l ee e Cond C Pd Loue ea ae E AE a ee ee a Co ase o fasa eso fores 17220 aas 10554 Valeo TM 65 performance data R134a Conditions Cooling capacity Qo Watt Someta o Pd MPa E e aeee pi Co sar o fs fas foz 2350 18 650 14 700_ Co ase o foso arso 2470 fisso fisso mom Valeo TM 55 amp TM 65 conversion factors Power data at different rotation speed can be approximated with conversion factors below 1 Product description Dimensions TM 55 amp TM 65 compressors with magnetic clutch 354
33. tion 5 Fill the compressor with the specified amount of oil p 20 19 3 Handling instructions unit cm amp cc Amount to remove from new compressor 1500 1000 or Same as amount more recovered 1500 recovered Under unit cu in Amount to remove from new compressor Charging amount Specified Amount charge recovered Specified Amount Charging recovered amount 61 or Same as_ 61 amount 91 5 more recovered recovered CAUTION The specified oil quantity differs depending on the type of air conditioner system A label describing the specified quantity is attached to the compressor Additionally all of the oil cannot be removed when draining the compressor as some remains as an oil film on the inside of the compressor and the system components Therefore refer to the table at left when recharging the compressor with oil Excess oil adversely affects the cooling capacity and the compressor 1 Install the oil filler plug and tighten it to the specified torque Specified torque 15 18 N m 1 5 1 8 kgf m 11 13 ft Ibs CAUTION The oil filler plug O ring must be replaced with a new one Replacement of components When replacing the component parts of the system supply the following amount of oil to the compressor Component mounted Amount of oil 300 cm 18 3 cu in 200 cm 12 2 cu in 100 cm 6 1 cu in 100 cm 6 1 cu in After instal
34. vehicle within the range shown at left Compressor bracket 1 Install the bracket securely on the chassis frame or engine body As the engine vibrations may be severe the bracket and mounting bolts must be installed securely 2 Vibration resistance There must not be any resonance under 250 HZ 13 1 Product description Magnetic clutch 1 Voltage DC 24 V The terminal voltage of the magnetic clutch must exceed 21 V DC 12 V The terminal voltage of the magnetic clutch must exceed 10 5 V 2 Ratio of magnetic Clutch to drive pulley When the compressor is driven from the pulley l drive of the vehicle the magnetic clutch to drive Magnetic clutch pulley must not exceed the range 1 0 92 1 08 to avoid vibration and resonance Compressor speed must not exceed the specified speed CAUTION Pulley ratio is the ratio of the magnetic clutch as diameter to the drive pulley diameter Idle pulley Drive pulley 3 Pulley alignment tolerance is less than 1mm 0 04 in 4 Pulley groove V groove or V ribbed 5 The V belt tension must be adjusted to the tension specified by the belt maker 14 2 Operation precautions 15
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