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1. Suction Suction Compression Compression Shoe Piston 15 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 The rotation of the swash plate results in a reciprocating piston movement horizontal to the drive shaft The cylinders which are arranged at 120 intervals around the drive shaft are each divided into 2 chambers providing 3 front and 3 rear bores As each piston performs suction and compression at either end the compressor operates as a 6 cylinder compressor 1 Product description General Valeo COMP TYPE TMXX PART NO XXXXXXXX X SERIAL NO XXXXXXXXXX OIL ZXL 100PG XXX cm HIGH SIDE 2 9MPaG LEAK TEST LOW SIDE 1 5MPaG REF HF C 134a MADE IN JAPAN O Operation condition table Surrounding der 120 C 248 F temperature Minimum 700 r min Maximum 6000 r min Continuous 6000 r min Speed 1 6
2. Keep open flame and inflammables away from the vehicle in which the air conditioner is being installed Fire is particularly dangerous during the gas leak inspection following installation WARNING Contact with flame and high temperatures can generate toxic gases Safety glasses Gloves 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 1 Do not misidentify 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 1 9 3 Handling instruction 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 Do not release refrigerant into the air a O O Ges AA 89 m I not be released into the air When removing A c lii refrigerant from the air conditioner system always N E use a refrigerant recovery unit made especially for IVAU E la HFC 134a VE Xx V 5 Recovery unit f Compressor handlin
3. Gnawing at pipe end Piping precautions 1 2 28 Position the O Ring against the bulge in the pipe when connecting hoses and pipes Coat the piping connections and the O rings with PAG oil CAUTION Always use the specified oil for HFC134a systems to coat the O rings Fit the nuts and unions tightly against the base of the companion pieces then hand tighten the nut as much as possible Then tighten to the specified torque 4 Troubleshooting Compressor troubleshooting When a problem occurs during the compressor operation it is often difficult to pinpoint exact 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 should it happen we hope this troubleshooting can help you solve the issue efficiently Below are listed most of the issues you may encounter while the A C is ON Please refer to the compressor troubleshooting tree to localize the malfunction symptom then look at the table p 30 32 for the appropriate counter measure Most of the malfunction symptoms can be classified in the following categories 1 Insufficient cooling capacity 2 Abnormal noise 3 Smoke In case of insufficient cooling capacity we recommend 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 33
4. Full charge of compressor oil Each compressor is delivered filled with a specified quantity of compressor oil as described on its label The total amount of oil your air conditioning system requires is provided by the system designer or supplier Compressor 1 The direction of rotation is clockwise or counter clockwise depending on clutch type 2 The compressor must be operated under the conditions shown in the operation condition table shown at left CAUTION The A C cycle components must be designed so that the pressure in the cycle does not exceed 2 07 MPaG 21 4 kgf cm2 299 psig 4 Inclination limit at installation The compressor must be installed on the vehicle within the range shown at left 1 Product description General Magnetic clutch Idle pulley Drive pulley 1 7 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 Vibration resistance There must not be any resonance under 250 HZ 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 Ratio of magnetic clutch to drive pulley When the compressor is driven from the pulley drive of the vehicle the magne
5. SERVICE MANUAL Valeo TM08 TM13 TMI5 amp TM16 Compressors added ll Copyright 2015 Valeo Japan CO LTD All rights reserved Foreword This service manual has been elaborated to help ser vice personnel to provide efficient and correct service and maintenance on the TM08 TMI3 TMI5 STMI6 model compressors for HFC 134a for automotive air conditioning This manual includes the operation specifications procedures for disassembly reassembly and inspection of the compressor WARNINGS The contents of this manual including illustrations drawings and specifications were the latest available at the time of printing Valeo Japan reserves the right to make changes in specifications and procedures at any time without notice VALEO JAPAN CO LTD The following warning signs are used in this service manual These are extremely important to ensure safe operation and to prevent body injuries and property damage They must be fully understood before starting the air conditioner maintenance WARNING CAUTION MEANING OF MARKS Maintenance must be properly done to avoid serious injury risks Improper maintenance can result in injury or property 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 conditioner maintena
6. Reassembled compressors must be run in after the leak test see next page 1 Check that the compressor contains the specified amount of oil 2 Interconnect the suction fitting and the dis charge fitting with the flexible hose 3 Connect the two connector ports using a flexible hose 4 Run the compressor at 500r min for 30 min utes to 60 minutes This operation may be performed by an electric motor or the engine of an automobile Replace the oil 6 Repeat the leak test CAUTION While the compressor is being run in in step 3 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 1 High pressure connector 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 500 rpm Operate the A C switch through the ON OFF cycle at least 50 times ON for 10 seconds and OFF for 10 seconds ON OFF 2 50 times 24 3 Handling instructions Leak test The compressor must be checked for refrigerant leaks after it is repaired The procedure is as fol lows Valve assembly 597017 1120 a 1 Using the valve assembly 597017 1120 fill the compressor with refrigerant through the suction s
7. 0 0 500 1000 1500 2000 2500 3000 3500 Compressor Speed rpm 1 4 1 Product description Swash plate system Valeo TM08 TMIS TMIS amp TMI6 are 6 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 discharge Drive shaft Radial bearing Thrust bearings x 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 Swash plate Piston Radial bearing Ji OR 7a vs A
8. 34 Compressor troubleshooting tree 1 Insufficient cooling capacity A Compressor is not running B Compressor is running C Compressor runs intermittently A Abnormal noise from compressor 2 Abnormal noise B Abnormal noise from magnetic clutch C Belt slipping noise A Magnetic clutch friction surface slipping B Magnetic clutch belt slipping C Smoke from magnetic clutch D Smoke from compressor 29 4 Troubleshooting 1 Insufficient cooling capacity No cool blow coming out Magnetic clutch slips when turning on the A C switch i Low pressure cut switch operates 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 Belt run off the pulley Center bolt is loose Center bolt is missing Compressor is running i normally i 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 Belt slipping The magnetic clutch does not engage Possible cause Compressor internal part damage Refrigerant shortage Lead wire short circuit or wiring connector not seated properly Thermal fuse if provided Hopened by high heat Belt slipping Compressor internal part damage or magnetic clutch damage Bolt drop off Armature dro
9. 5 Tightening torques Unit N m kgf m Ibf ft Tightening torque 3 8 24UNF M10 x 1 5 M8 x 1 25 13 0 15 0 1 3 1 5 9 6 11 1 3 4 16UNF Maximum torque 27 2 8 20 8 Fittings and ports 7 8 14UNF Maximum torque 37 3 8 27 1 14UNS Maximum torque 47 4 8 35 35 6 Service procedures Magnetic clutch Drive plate holder 597031 2600 Drive plate puller 597032 2621 Pulley puller Fa 597033 1000 Magnetic clutch Removal 1 Remove the center bolt using the drive plate holder 597031 2600 to prevent armature assembly rotation 2 Remove the drive plate using the drive plate puller 597032 2621 Remove the shims from the compressor drive plate or drive shaft 3 Remove the snap ring using external snap ring pliers 4 Position the center pulley puller at the end of the driveshaft 5 Attach a suitable pulley puller to the pulley Hook the puller claws to the edge of the pulley as shown 6 Tighten the center pulley puller bolt to remove the pulley CAUTION Do not clip the puller claws into the pulley groove to prevent pulley groove damage 36 6 Service procedures Magnetic clutch 597035 3820 8 Remove the three field coil compressor screws Then remove the field coil 7 Remove the field coil s lead wire bushing Remover 4 using the remover 597035 3820 CAUTION Do not hold the field
10. eff gt gt z Z o 80 be to 50 N r Ner 40 gt 30 2 gt 20 10 0 0 500 1000 1500 2000 2500 3000 3500 Compressor Speed rpm 12 1 Product description Performance TM15 me performance data below were measured under the following conditions Discharge Pressure Pd 1 52 MPaG Suction Pressure Ps 0 18 MPaG Subcooling temperature SC 5 C Super heat temperature SH 10 C Valeo TM15 performance data table R134a _ maw p 1200 1800 2400 3000 on 190 vas 175 ee Valeo TM15 performance data graph R134a 100 S 90 QU 80 FT S TZ Capacity NO D T 5 60 LL mel 40 Z WQ 2 oO Cc gt 30 amp u 20 O S 10 0 0 500 1000 1500 2000 2500 3000 3500 Compressor Speed rpm 13 1 Product description Performance TM16 me performance data below were measured under the following conditions Discharge Pressure Pd 1 52 MPaG Suction Pressure Ps 0 18 MPaG Subcooling temperature SC 5 C Super heat temperature SH 10 C Valeo TM16 performance data table R134a _ Mart fa 1200 1800 2400 3000 197 199 184 169 158 Valeo TM16 performance data graph R134a 100 S 90 Oo NN 80 Vol eff ee 70 OI et gt z Z g 60 N her 50 TS z 40 gt 2 30 2 gt 20 an S 10
11. 19 Oil filler plug 5 Pulley assembly 20 Sunction valve 6 Screw 21 Valve plate assy 7 Field coil 22 Gasket 8 Bolt 23 O ring 9 Gasket 24 Rear Cylinder Head 10 Snap ring 25 O ring 11 Shaft seal assembly 26 Relief Valve 12 Front cylinder head 27 Oil drain plug 13 O ring 14 Gasket 15 Valve plate assy 1 0 1 Product description Performance TM08 me performance data below were measured under the following conditions Discharge Pressure Pd 1 52 MPaG Suction Pressure Ps 0 18 MPaG Subcooling temperature SC 5 C Super heat temperature SH 10 C Valeo TM08 performance data table R134a Nc r min 1200 1800 2400 3000 vorn 0 oo see fur sor ac a power a Valeo TM08 performance data graph R134a 80 r 8 70 F 7 60 Vol eff 6 AT TT 50 r 5 40 Capacity 4 30 Volumetric Efficiency 20 10 Cooling Capacity kW Power kW COP 0 0 500 1000 1500 2000 2500 3000 3500 Compressor Speed rpm 11 1 Product description Performance TM13 me performance data below were measured under the following conditions Discharge Pressure Pd 1 52 MPaG Suction Pressure Ps 0 18 MPaG Subcooling temperature SC 5 C Super heat temperature SH 10 C Valeo TM13 performance data table R134a _ E 1200 1800 2400 3000 178 187 vas 176 Dra Valeo TM13 performance data graph R134a 100 S 90 Oo N 80 PTS S DP 70 Vol
12. cie nier 47 COMpPIresSON TOOLS ae re Ree ee Onn cnn ne ee eter renee mee ere ine sewer nee 084 48 Test and inspection TOONS Lemecomcinci sissemmssstiarsissiaiessmsmsnssetamimess 48 1 Product description Compressor Compressors moon maos Tais amis me Heavy Duty Swash Plate 0 53 in 0 84 in 0 94 in 1 05 in REFRIGERANT HFC 134a 3 ZXL 100PG PAG OIL OIL QUANTITY ZXL 100PG PAG OIL 150 cc 9 1 in 180 cc 11 03 in3 WEIGHT w o clutch 4 1kg 9 0 Ibs 4 4kg 9 7 lbs 4 6kg 10 2 lbs 4 9kg 10 8 Ibs DIMENSIONS w o clutch 168 124 145 mm 192 124 142 mm 202 124 142 mm 207 124 142 mm Length Width Height 6 6 4 9 5 7 in 7 6 4 9 5 6 in 8 0 4 9 5 6 in 8 1 4 9 5 6 in MOUNTING Direct side amp Ear Mount Valeo TM08 TMI3 TMI5 amp TMI6 Application limits for HFC 134a Saturated condensing conditions oa Condensing temperature Evaporating gas temperature Saturated evaporating conditions 3 1 Product description Magnetic clutch Magnetic clutch VALEO TM08 TM13 TMI5 amp TMI6 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 by other major market acto
13. 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 Armature assembly Pulley assembly Field coil pulley and armature must be replaced The contact surfaces 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 37 6 Service procedures Field coil Screws Pulley Installer Pulley assembly opens Press Snap ring External snap ring pliers Drive plate holder 597031 2600 Drive plate Adjusting shims 38 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 4 6 N m 0 4 0 6 kgf m 3 0 4 4 Ibf ft 2 Carefully place the the wire harness bushing 3 Install the pulley assembly using the pulley installer 597034 3301 and a hand press CAUTION Use only a press to install the pulley assembly Do not use a hammer A hammer will damage or deform the pulley Install the snap ring beveled edge up using external snap ring pliers Install the arm
14. cylinder head 1 2 1 o 11 12 13 46 Front cylinder head Place the cylinder shaft assembly on the bench with the front side up Install the front suction valve so that it matches the spring pins CAUTION Ensure each valve matches each cylin der s valve escape groove Install the front valve plate on the front suction valve Coat the new gasket with clean compressor oil and install it on the front valve plate Position the guide 597067 1102 on the shaft Coat the new O ring with clean compressor oil and install it on the front cylinder head Install the front cylinder head CAUTION Align the roll pins and tap the head light ly and evenly with a plastic hammer Mount the new gaskets on the through bolts Insert the six through bolts from the front cylinder head side and tighten them to the specified torque Each bolt should be gradually tightened in three or more stages to ensure the specified torque The bolts should be tightened in the order shown on the left hand figure Specified torque 16 7 20 7 N m 1 7 2 1 kgf m 12 3 15 3 Ibf ft Install the oil drain plug with a new O ring thinly coated with clean compressor oil and tighten it to the specified torque Specified torque 13 15 N m 1 3 1 5 kgf m 9 4 10 8 Ibf ft Fill the compressor with the specified amount of clean compressor oil through the suc
15. ap ring as shown on the left hand figure 2 Check the snap ring is properly installed as shown on the left hand figure Shaft seal NH IS PT 3 Install the oil drain plug wih a new O ring thinly coated with clean compressor oil and tighten it to the specified torque Specified torque 13 15 N m 1 3 1 5 kgf m 9 5 11 0 Ibf ft 42 8 Services procedures Cylinder heads Cylinder heads Front amp Rear Disassembly 1 Remove the magnetic clutch assembly as described on page 36 2 Remove the connector s caps and the drain plug and then drain the oil 3 Remove the shaft seal as described in shaft seal removal on page 40 Es 4 Remove the six bolts securing the heads Bolts 5 Alternately tap the tvvo projections on the front head using the remover 597035 0500 and mallet to remove the front cylinder head Tap lightly Remover 597035 0500 6 Remove the O ring from the front cylinder head and then remove all the gasket material from the cylinder head 7 Remove the valve plate and suction valve from the cylinder shaft assembly TA suction valve Valve plate 43 8 Services procedures Cylinder heads 8 To remove the rear cylinder head alternately tap the two projections on the front head using the re
16. approximately 1 season the oil never becomes turbid as long as there is noth ing wrong with the compressor or its method of use Inspect the extracted oil for any of the fol lowing Increased opacity of the oil Color change to red Presence of foreign matter metal filings etc WARNING When system oil contamination is found during compressor replacement flush the A C system with a fluid that meets SAE J2670 and replace the drier or accumulator Oil check The compressor oil must be checked as follows when being charged into a used system 1 Perform the oil return operation see p 21 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 contamination 5 Fill the compressor with the specified amount of oil see p 23 through the suction port or the oil filler plug in case of TM16 Charge specified quantity of compressor oil 22 3 Handling instructions Current Compressor is replaced Compressor unit cm amp cc is kept Factor Amount oil y Amount Charging to remove recovered from new charge compressor 90 Same as TM08 or more recovered TM13 150 ader TM15 lof s 108 Same as 72 or more recovered TM16 180 nder unit cu in Current Compressor is kept Compressor is replaced Amount to remove f
17. ature assembly on the driveshaft together with the original shim s Press the armature assembly down by hand Install the center bolt and tighten the bolt to the specified torque using the drive plate holder 597031 2600 to prevent armature assembly from the rotating Specified torque 12 14 N m 1 2 1 4 kgf m 8 7 10 Ibf ft CAUTION After tightening the center bolt check that the pulley rotates smoothly 6 Service procedures Magnetic clutch Gap adjustment gt NA Thickness gauge 7 Check that the clutch clearance is as specified If necessary adjust the clearance using shim s Adjusting shims are available in the following thickness Shim Part No 596541 1900 0 1 mm 0 0039 in 596541 2000 0 3 mm 0 0118 in 596541 2100 0 5 mm 0 0197 in Specified clearance 0 3 0 6 mm 0 012 0 028 in 8 Run in the clutch as described on page 24 39 7 Services procedures Shaft seal assembly Shaft seal assembly Removal 1 Remove the magnetic clutch assembly as AS 4 SS Ga a GZ K described on page 36 2 Remove the oil filler plug and then drain the oil SN 3 Remove the five bolts securing the heads SS 4 E 4 Remove the snap ring using internal snap ring pliers ere 5 Insert the remover 597035 5520 into the 597035 5520 shaft seal and turn it untill it hits the shaft seal case Then p
18. e compressor is installed outside this range If the compressor is installed outside the range shown on the left hand figure any or all warranties may be rendred void Installation precautions The new compressor is filled with the specified quantity of compressor oil and nitrogen gas N When mounting the compressor on the vehicle please follow as below 1 Loosen the discharge side connector s cap and gently release nitrogen gas N from the com pressor 2 Turn the magnetic clutch s armature plate sev eral times by hand to distribute the oil which has settled in the cylinders 3 When installing the compressor in service sys tem the compressor should be installed after adjusting the amount of oil referring to oil check p 22 CAUTION Do not to let the oil escape 2 3 Handling Instructions O ring positions 9 Piping connection Compressor condenser connection CORRECT INCORRECT lt i O ring Pipe bulge Apply oil thoroughly to these areas Fa CORRECT Pipping connection procedure Union Nut p A INCORRECT Damage CH T gt
19. g Do not strike or unecessarily turn the compressor upside down If the compressor is knocked over or turned upside down during handling or installation rotate the armature plate 5 or 6 times by hand to circulate the oil Otherwise oil in the cylinder during compressor start up will cause valve damage and reduce durability Compressor removal When the compressor is operational 1 Perform the oil return operation see p 21 2 Recover the refrigerant from the system using a Compressor removal refrigerant recovery unit 3 Remove the compressor Oil inspection 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 21 Oil return operation Refrigrant recovery 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 22 20 3 Handling instructions Do not mix with other oils 21 Oil return operation Compressor oil mixed with refrigerant is circulating in the air conditioning system Perform the oil return operation t
20. ide raising the refrigerant pres sure to at least 0 39 MPaG 5 kgf cm 56 3 psig 2 Check the compressor for leaks using a leak detector 597001 1020 Gas leak detector 597001 1020 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 49 150 kPaG 0 5 1 5 kgf cm 7 1 21 psi 25 3 Handling Instructions 26 Refrigerant charging Countermeasures to avoid charging with the wrong refrigerant have been taken These include different shaped service valves different service tool thread sizes caution stickers and labels In order to prevent a liquid charge and greatly increase risks of compressor dammage do not shake or turn the refrigerant bottle upside down Initial Leak Check Using the leak detector check the system connec tions for leaks As the system pressure is not yet high only large leaks can be detected at this time 3 Handling Instructions Installation position The compressor should be installed in the vehicle within the range shown on the left hand figure If it is installed outside this range the compressor will be adversely affected This compressor is equipped with a pressure feed lubrication system which cannot function if th
21. igerant Condenser fan failure i Loose connection of the magnetic clutch electrical i circuit Defective thermostatic i switch 31 Measure Reduce the refrigerant charge until reaching the i right amount Replace the condenser after making sure it is defective Replace the magnetic clutch after making sure it is defective Replace the thermostatic switch after making sure it is defective 4 Troubleshooting 2 Abnormal noise the compressor lout Abnormal vibration after turning on the A C switch Abnormal noise from the L compressor body The magnetic clutch has a I 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 Jengages The magnetic clutch slips ldoes not engage when the compressor is running The magnetic clutch slips does not engage when the i compressor is running The magnetic clutch does i not engage Refrigerant oil is blowing Compressor installation bolt portion between the i compressor and the bracket Compressor body internal component damage Magnetic clutch damage A Gap ouide RR Adjust air gap or replace E magnetic clutch Magnetic clutch friction Blippery surface Replace the compressor if Belt slipping llocted Readjust the belt E ten
22. lished by VALEO JAPAN CO LTD Copyright 2015 VALEO JAPAN CO LTD For any inquiry regarding the present service manual contact us at vc oura sales valeo com 53 Valeo Tm08 TM13 TMI5 amp TM16 Compressors Valeo TM compressors High reliability Integration flexibility Great cooling capacity Enhanced performance Lower fuel consumption Compact amp robust design Improved field serviceability Reduced noise and vibrations Staggering value through innovation added II Asia China Europe Middle East amp Africa Americas 39 Sendai Kumagaya shi No 2677 Shiji Avenue Eco amp Tec Dvt 8 rue Louis Lormand ZA de l Agiot 2520 Esters Blvd 100 Saitama ken 360 0193 Japan Zone 130031 Changchun Jilin PRC 78321 La Verriere France Dallas TX 75261 United States Phone 81 0 48 539 3800 Phone 86 0 431 8499 2025 Phone 33 0 1 3013 5027 Phone 1 972 456 1077 Fax 81 0 48 539 3843 Fax 86 0 431 8499 2004 Fax 33 0 1 3461 5898 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 2015 Valeo Japan CO LTD All Rights Reserved
23. mover 5970350500 and mallet Remover 597035 0500 9 Remove the O ring from the rear cylinder head and then remove all the gasket material from the rear cylinder 10 Remove the valve plate and suction valve from cylinder shaft assembly Suction valve Inspection Check the front and rear valve plates for scratched bent or damaged parts Inspect both cylinder heads and both valve 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 none of the passages in the valve plates are blocked Front cylinder head Valve plate 44 8 Services procedures Cylinder heads Esca pe groove Suction valve Reassembly Rear cylinder head 1 2 45 Place the cylinder shaft assembly on the bench with the rear side up Install the rear suction valve so that it matches the roll pins CAUTION Ensure each valve matches each cylinder valve escape groove Install the rear valve plate on the rear suction valve CAUTION Do not mistake the front and rear valve plates Coat the new gasket with clean compressor oil and install it on the rear valve plate Coat the new O ring with clean compressor oil and install it on the rear cylinder head Install the rear cylinder head 8 Services procedures Cylinder heads Front
24. nce Contents T Product ES CUI ON a EE nota 3 2 gt 0per tion Pre Ga OINS osiris aaa o 18 Se LM CL DS COR ipes a a 19 Maintenance DIC CAUTIONS 5 ess sen ere oem teen 19 WOM AN ace ete Sates a 20020700 E IEEE E04 a EPO TREE NERES 19 Refrigerant HANG Gass eo SES ON 19 Compressor RSA deedee reikai iki 20 CODES OS aisr iini c donad demie ara rT dea iS 20 Oil return ODA ne 21 OA ARE CE 21 Oil contamination RS PRE eee Rene 22 OIl ENEK AR 2751 M 20004 70 102 22201214 2012 0 2010975 ERREE A 212 REE sibles 22 Replacement of CDD ceaeetectensecosenctexe 23 RUNDINGAN OD TAMIDOS a ed on 24 Compressor TUNANING IM 25808828 ressens ecran nc neo aiaia isine 24 Magnetic clutch Unes emma am em i ie eee eme sens 24 Re E E eases 25 Storing a repaired COMPICSS ON sssssssssssessssesessosesessesesessoseseesesesesseseseeseseseeseses 25 Refrigerant CEA a haine danne 26 Installation BOSTON cnet acecteaetemnesateacescteesedaeaasatemnecacsusetent 27 HSM SCO 27 Piping D C TONS re selon ensembles merda nal das 28 AFTrOUDIES OO PR bede 29 Compressor TOUDI S GAIN a smic en 29 Compressor troubleshooting HR sereinement 29 A C cycle diagnosis by gauge DESSUS trade 33 5 Tighitening OS easa iaai 35 6 Service procedures Magnetic clutch ana 36 7 Services procedures Shaft seal assembly 40 8 Services procedures Cylinder heads 43 SA AE R 47 Magnetic clutch service 1001S 2 nd sde
25. o 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 PAG DH PS Oil quantity inspection There is no particular need for frequent inspection or replacement although it is recommended to check operating refrigerent pressures and oil levels at the start of the season Please replace the refrigerant and restore the system oil and refrigerant charge to factory specifications if the AC system is opened for repair or replacement of any component e g evaporator condenser or receiver drier any loss of charge refrigerant or oil is detected 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 3 Handling instructions Opacity Color change Foreign substances __ Metal filings Oil contamination Unlike engine oil no cleaning agent is added to the compressor oil Even if the compressor is run for a long period
26. on 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 Expansion valve or thermal sensing tube of the Expansion valve is not fit on regularly Excess opening of the Expansion valve 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 fan 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 19 0 29 MPaG 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 34 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
27. p off Replace the compressor Poor compression Refrigerant shortage Magnetic clutch friction i surface slipping Loose connection of the magnetic clutch electrical i circuit Magnetic clutch belt slipping Defective thermostatic switch 30 Magnetic clutch damage Magnetic clutch air gap too wide Low magnetic clutch voltage Measure Replace the compressor Fix the refrigerant leakage then fill with refrigerant until reaching the right amount Replace the lead wire if it is defective Repair or replace the magnetic clutch Adjust air gap or replace magnetic clutch Check the voltage of batter Service system and replace the compressor Replace the compressor if it is locked Replace the compressor or the magnetic clutch Replace magnetic clutch Fix the refrigerant leakage then fill with refrigerant until reaching the right amount Check the voltage of battery or replace the magnetic clutch Replace the magnetic clutch after making sure it is Idefective Belt tension readjustment Replace the thermostatic switch after making sure it is defective 4 Troubleshooting Cool blow comes out only from time to time Both discharge and suction pressures are high The magnetic clutch slips or does not engage when the i compressor is running The magnetic clutch does i not engage Possible cause Excess of refr
28. rom new compressor Factory Amount oil recovered 55 Same as 3 7 or more recovered Under 6 6 Same as 4 4 or more recovered TM16 1 Under 33 6 6 j Charging amount 30cm 1 8cu in 23 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 6 Install the oil filler plug and tighten it to the specified torque Specified torque 13 15 N m 1 3 1 5 kgf m 9 4 10 2 Ibf ft CAUTION The oil filler plug O ring must be replaced with a new one Replacement of components When replacing the system s component parts supply the following amount of oil to the com pressor Component mounted Amount of oil 50 cm 3 cu in 30 cm 1 8 cu in After installing these component parts check the compressor oil Refer to page 22 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 Flexible hose Compressor running in
29. rs 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 magnetic clutches ensures an unmatched reliability and the longest durability that perfectly matches the Valeo TMO8 TMI3 TMI5 amp TM16 compressor qualities Specifications TMO8 TM13 TM15 amp TM16 DIRECTION OF ROTATION Clockwise amp Counter clockwise depending on clutch WEIGHT Approx 2 2 kg 4 9 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 1 Product description Name Plate D i V i Name plate TMXX XXXXXXX X X XX X X XX X X X XXX cm Name plate To ensure that the compressor operates smoothly respect carefully the indications written on the name plate Tip As TM13 TMIS amp TM16 compressors have al most the same dimensions the best way to differentiate
30. sion if the belt is loose Magnetic clutch air gap too Magnetic clutch friction Igreasy surface Belt alignment is not correct Magnetic clutch belt tension lis loose Coil open or shorted Refrigerant leaking uncoupled piping or piping the high pressure relief valve due to excess of refrigerant Measure Increase tightening torque of i the loose bolts Possible cause is loose Wide gap at the attaching Improve the compressor attaching portion i Replace the compressor Replace the magnetic clutch Check the voltage of battery or replace magnetic clutch Possible cause Measure i Adjust air gap or replace wide magnetic clutch Low magnetic clutch voltage Check the voltage of batter Clean friction surface or replace magnetic clutch Adjust the compressor installation position Clean or replace the belt Adjust belt tension Replace the magnetic clutch Magnetic clutch belt is greasy i Fix the refrigerant leakage then fill with refrigerant until burst having the right amount Reduce the refrigerant charge until reaching the i right amount Refrigerant blowing from 32 4 Troubleshooting 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 Ambien
31. t 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 Discharge pressure around 0 9 1 6 MPaG 10 17 kgf cm Suction pressure around 0 03 0 10 MPaG 1 3 2 0 kgf cm A MN Both discharge and Refrigerant shortage Connect gauge Recover refrigerant suction pressures are manifold to cycle then refill with the low right amount of refrigerant Receiver dryer is Temperature difference Replace parts becomes vacuum 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 from Outlet side of the Replace part the Expansion valve s expansion valve is not temperature sensing cooling tube Low side of gauge Expansion valve indicates vacuum operates to close 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 Troubleshooting Gauge pressure Cause Confirmati
32. them quickly is by referring to the name plate 1 Product description Dimensions TMO8 0135 L 0120 16 36 6 0 6 61 6 67 01 7 8 14UNF SUCTION 3 4 16UNF DISCHARGE 139 6 1 Product description Dimensions TM13 208 LM mM Q y 16 44 2 06 J L 69 2 a ML 73 3 0 21 5 28 5 7 8 14UNF 3 4 16UNF SUCTION DISCHARGE 142 03 104 1 Product description Dimensions TM15 3 2158 112 0 1 1435 042 FA TT a fT m a L S HEIL REE 16 39 6 06 Lo 64 6 833 7 LN 142 1 Product description Dimensions TM Ib 3 4 16UNF DISCHARGE 21 5 7 8 14UNF SUCTION 1 Product description Exploded view 1 Center bolt 16 Sunction valve 2 Armature assembly 17 Pin 3 Adjusting shim 18 Cylinder shaft assembly 4 Snap ring
33. tic clutch to drive pulley ratio should avoid the range 1 0 92 1 08 to limit vibration and resonance The compressor speed must not exceed the specified speed CAUTION Pulley ratio is the ratio of the magnetic clutch diameter to the drive pulley diameter Pulley alignment tolerance is less than 1mm 0 04 in Pulley groove V groove or V ribbed The Belt tension must be adjusted to the tension specified by the belt maker 2 Operation precautions 1 During the off season of the air conditioner operate the compressor for a few minutes once a week 2 Do not drive through water Water may damage the magnetic clutch thus preventing normal operation TT 3 Do not allow a compressor that has not been JE NEA used for a long period to become wet D DN E 4 Always charge the A C system with the specified quantity of refrigerant 5 Keep the compressor clear of water projection while cleaning the vehicule 1 8 3 Handling instructions Maintenance precautions Work area As the components of air conditioners are particularly 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
34. tion side connector Install the magnetic cluch p 38 Run in compressor p 24 Carry out the leak test p 25 9 Service tools In addition to standard tools numerous special tools are necessary to service the Valeo TM08 TMI3 TM15 amp TMI6 compressor The use of these special tools enables prompt and correct compressor service The special tools are classified into three groups those for magnetic clutch disassembly and reassembly those for compressor disassembly and reassembly and those for testing and running in operation Magnetic clutch service tools Part name Part No Reference re page Drive plate holder 36 38 To fix drive plate Drive plate puller Pulley puller To remove armature To remove pulley To install pulley Installer 597034 3301 Lead wire bushing 0353820 remover To remove lead wire Center Pulley puller 597033 1700 To remove pulley 47 9 Service tools Compressor tools To remove the shaft seal Shaf Seal Remover 597035 5520 To remove cylinder Remover 597035 0500 head and cylinder block 597067 1102 41 42 46 To install shaft seal Test and inspection tools Valve assembly 597017 1120 JP For charging refrigerant Gas leak detector 597001 1020 D o For detecting gas leaks 48 Notes 49 Notes 50 Notes 51 Notes 52 VALEO JAPAN TM08 TMIS TM15 amp TM16 for HFC 134a SERVICE MANUAL Version WW0816 15006 02EN Pub
35. ull the remover up to remove the shaft seal 40 7 Services procedures Shaft seal assembly Guide CO K 59067 1102 Remover 597032 2501 597067 1102 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 Before installation refer to Inspection Clean the sealed section of the front cylinder head 1 41 Coat the new shaft seal and the front cylinder head with clean compressor oil If the slip faces are dirty clean them with thinners and after drying the clean faces apply clean compressor oil to them Fit the guide 597067 1102 onto the end of the drive shaft Insert the shaft seal through the guide into the front cylinder head Install the shaft seal as far as possible into the front cylinder head using the installing end of the remover 597032 5520 Remove the guide 597067 1102 from the drive shaft 7 Services procedures Shaft seal assembly 5 Install the snap ring using internal snap ring pliers Press the snap ring using the installing end of the remover 597032 5520 until a click is heard Note a 1 When installing the snap ring the round edge of the snap ring must face downward Sn

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