TM55-TM65 service manual 20141103.indd
Contents
1. 36 7 Service procedures Shaft seal assembly 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 Press using a press 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 with the shaft seal remover 4 Install the snap ring using the internal snap ring pliers 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 Nem 2 5 3 3 kgf m 18 24 Ibf ft 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 3 7 Service procedures Shaft seal assembly Oil filler plug 11 12 13 14 15 16 17 38 Fill the compressor with the specified am2. SERVICE MANUAL Valeo TM55 amp TM65 Compressors added I Copyright 2014 Valeo Japan CO LTD 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 Lip type shaft seal providing ultimate reliability amp performance Light amp Compact Ultimate Reliability Highest Performance valeo added TTT Foreword This service manual has been elaborated to help service personnel to provide efficient and correct service and maintenance on Valeo TM55 and TM65 compressors for bus air conditioning This manual includes the operation specifications procedures for disassembly reassembly and inspection of the compressor The contents of the 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 WARNINGS 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 Maintenance must be properly done to avoid serious injury risks Improper maintenance can result in i
3. 25 32 Nm 2 5 3 3 kgf m 18 24 Ibf ft 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 Ne m 1 5 1 8 kgf m 11 13 Ibf ft 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 Nem 2 5 3 3 kgf m 18 24 Ibf ft 15 Install the magnetic clutch see p 31 16 Run in the compressor see p 21 17 Perform the leak test see p 22 9 Service tools In addition to standard tools numerous special tools are necessary to service the Valeo TM55 amp TM65 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 To fix armature UJ Armature installer 43 44 assembly To install armature W Center pulley puller WWJ To remove pulley WW NJ W W O W A as JD A O UT UT Pulley installer To install pulley Pulley installer assemb
4. 4 The oil easily absorbs moisture when the container is open Therefore always seal the container immediately after use 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 ACsystemis openedfor repair orreplacement of any component e g evaporator condenser or receiver drier HA e any loss of charge refrigerant or oil is detected As long as it remains within the range of vision through the sight glass the oil quantity is sufficient Oil level can be read through the sight glass of he compressor see on the left 18 3 Handling instructions Oil passage Oil amount below oil passage level Oil level at inclination conditions Compressor lateral inclination and front lift
5. Hardness HRCA0 to 45 Material S45C Armature Puller 9 Service tools Pole Bolt mm H fa ea amp Unless otherwise specified the edges to be slight chamfering Should remove burrs and fluff Part Name Plate 9 Service tools Armature puller assy M16X2 0 Unless otherwise specified j Br the edges to be slight chamfering Ne Should remove burrs and fluff 5450 Pole Armature puller assy EX A section detailed view 10 1 7 A GE Hd gt EH mn pt Ooo M12X1 75 Unless otherwise specified the wines ta he sight cam fai gt amp Hardness Should remove burrs and fluff 5450 Bolt 10 Service parts 1 Compressor body service kits sets and parts Quantity OVERHAUL KIT O RING SET GASKET SET SHAFT SEAL 20014427 ET O RING SET 20014430 O ring body front amp rear head 10004833 569300 4000 GASKET SET 20014431 Gasket front head 20004779 Gasket rear head 20004780 Er Gasket bolt 9 per set 569310 6200 D SHAFT SEAL for service BR DE Shaft seal 20007461 EE OTHER COMPRESSOR PARTS gt See Product description Exploded view p 10 2 Connector assy 70011222 service parts Quantity Connector body 20011223 20011226 See Product description Exploded view p 10 3 Oil Quantity ZXL 100PG 250 cc 569900 0600 53 VALEO COMPRESSORS TM55 amp TMb5 for HFC 134a use S
6. Magnetic clutch air gap too wide Compressor internal part damage or magnetic clutch damage Bolt drop off Armature drop off Refrigerant shortage Magnetic clutch friction surface slipping Loose connection of the LiImagnetic clutch electrical Circuit Belt slipping 7 Defective sensor Excess of refrigerant Loose connection of the magnetic clutch electrical Circuit Defective sensor HLow magnetic clutch voltage H The magnetic clutch engages Belt slipping 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 tthe 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 clutch after making sure it is defective Magnetic clutch belt slipping H Belt tension readjustment Replace the sensor after making sure it is defective Reduce the refrigerant i charge until reaching the Iright amount Condenser fan failure Replace the condenser after making sure it is defective Replace the magnetic clutch after making sure it is Idefective Replace the sensor after making sure it is defective 4 Troubleshooting 2 Abnormal noise Troub
7. 1500 cm 2 9MPaG HIGH SIDE 2 9 AK TEST a SIDE 1 5MPaG EFRIG HFC 134a L MADE IN JAPAN Tip As TM55 amp TM65 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 ZXL 100PG 1500 cm LEAK TEST LOW SIDE 1 5MPaG EFRIG HFC 134a MADE IN JAPAN 1 Product description Magnetic clutch Magnetic clutch VALEO TM55 amp TMO5 are available either as a compressor and magnetic clutch assembly or as a compressor body that can be fitted with compatible magnetic clutches The magnetic clutch design Valeo has been promoting for more than 20 years is now gradually adopted by 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 magnetic clutches ensures an unmatched reliability and the longest durability that perfectly matches the Valeo TM55 amp TM65 compressor qualities Specifications DIRECTION OF ROTATION
8. 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 TM55 amp TM65 magnetic clutch Compact and robust design Housing mounted magnetic clutch Improved robustness to vibration jee Bearing and pulley positionned to D reduce efficiently the moment of tilt 1 Product description Connectors Connectors 1 Fully open the shut off valve when operating the compressor e 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 Valve spindle seal Q Cap G Spindle 4 Service port connector Safety devices port 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 the service port connector are now opened Valve spindle seal D Cap G Spindle a Service port connector Safety devices port VIS KRISTI NS K EE 4 mme ee S O 3 Fully close the shut off valve when removing the c
9. 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 28 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 Ibf ft 1 Center bolt M10 x 1 25 25 30 2 5 3 1 18 22 2 Field coil screw M6 x 1 0 4 2 7 2 0 4 0 7 3 1 5 3 4 Oil filler plug M10 x 1 5 15 18 1 5 1 8 11 13 3 Bolt M10 x 1 5 25 32 2 5 3 3 18 24 5 Connector bolt M10 x 1 5 25 32 2 5 3 3 18 24 29 6 Service procedures Magnetic clutch 2 way stopper type 2 3 hole type 1 Armature holder Armature puller assembly Spanner Magnetic clutch Removal 1 Check your armature type see at left 3 hole type 1 2 way stopper type 2 2 Remove the armature CAUTION The armature removal process differs according to the armature type If it is a 3 hole type armature 1 a Remove the center bolt using an armature holder to pre
10. 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 19 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 1 3 Handling instructions 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 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
11. ERVICE MANUAL Version WW5565 14011 01EN Published by VALEO JAPAN CO LTD Printed in Japan Copyright 2014 VALEO JAPAN CO LTD For any inquiry regarding the present service manual contact us at vc oura sales valeo com Valeo TM55 amp TM65 Compressors for Bus Air Conditioning Valeo TM55 amp TM6 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 fl 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 2014 Valeo Japan CO LTD All Rights Reserved
12. and the front valve plate 8 Service procedures Cylinder heads 9 Alternately tap the two projections on the rear head using the remover and mallet to remove the rear cylinder head Tap lightly 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 Valve plate assembly 13 Remove the gear pump from the rear cylinder head or the end of the driveshaft Gear pump Rear cylinder head Inspection 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 Valve plate Cylinder head 8 Service procedures Escape groove TIN MEG Gear pump Gear pump Gasket Valve plate assembly Suction valve Cylinder heads 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
13. armature assembly rotation Specified torque 25 30 Nem 2 5 3 1 kgf m 18 22 Ibf ft 6 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 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 Run in the clutch as described on page 21 33 6 Service procedures Magnetic clutch If you are not using a press 3 Install the pulley using a pulley installer assembly and a spanner Nr 3 pee ps CAUTION If the bolt of the pulley installer assembly is not screwed into the driveshaft it may result in damage 4 Once the pulley is fixed loose the collar and remove the pulley installer assembly Qu f QO 3 RA XXX LIQ 2626060 LRH CLS SNS 5 Install the snap ring beveled edge up using external snap ring pliers Snap ring External snap ring pliers 34 6 Service procedures Magnetic clutch 3 hole 2 way stopper armature armature Adjusting 3 hole armature 2 way stopper armature Armature installer 3 hole armature Armature holder Gap adjustment Thickness 6 Install the armature assembly on the driveshaft together with the original shim s 7 Install the armatu
14. bnormal noise from magnetic clutch C Belt slipping noise 3 Smoke A Magnetic clutch friction surface slipping B Magnetic clutch belt slipping C Smoke from magnetic clutch D Smoke from compressor l NJ as 4 Troubleshooting 1 Insufficient cooling capacity Trouble Compressor is not running No cool blow coming out No cool blow coming out 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 but the armature does not rotate Belt run off the pulley Center bolt is loose Center bolt is missing 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 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 L The magnetic clutch does Inot engage Possible cause Compressor internal part damage Refrigerant shortage Lead wire short circuit or wiring connector not seated properly 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 Magnetic clutch damage
15. cription Dimensions TM55 amp TM65 compressors without magnetic clutch BER O IZANA y OR DP DE PAC BOR LL DUT l Y ARNA FF amp A K ZONON R Vo 7 SON abi f ESS ay Qf Woo 2 A l Se W EP IV RI Vy VU LD I Il Q y i EE KIT S a Pr I Hr 27 gt Gr ROD AN NPS LI i oT ne ND ATV EE w Ee gt Z Se 56 56 5 1 Product description Exploded view Center bolt Armature assembly Adjusting shim Snap ring Pulley assembly Screw Field coil Bolt 9 Gasket 10 Front cylinder head 11 Shaft seal assembly 12 Snap ring 13 O Ring 14 Gasket 15 Valve plate assembly 16 Suction valve 17 Pin 18 Bolt 19 Cylinder shaft assembly PEN RE Eye bolt O Ring Oil filler plug Strainer Gasket Connector Bolt Gasket Plate Plate Bolt Sight glass O ring Snap ring Valve plate assembly Gasket 36 37 Gear pump Rear cylinder head 10 1 Product description Swash plate system Valeo TM55 amp TMb5 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 com
16. e 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 R RE 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 Nims NN y f 3 Handling instructions Leak test 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 Nem 2 5 3 3 kgf m 18 24 Ibf ft 2 Fill the compressor with refrigerant through the suction side raising the refrigerant pressure to at least 0 39 MPaG 5 kgf cm2 56 3 psig 3 Check the compressor for leaks using a leak detector Refrigerant charging In order to prevent a liquid charge and greatly in crease risks of compressor dammage do not shake or turn the refrigerant bottle upside down Storing d repaired compressor I
17. e shoes 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 1 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 Item conditions shown in the operation condition table shown at left SUIFOUNING yr der 120 C 248 temperature ERE Minimum 600 r min i Speed Maximum 4500 r min The A C cycle components must be Continuous 4000 r min designed so that the pressure in the cycle A Maximum 2 65 MPaG tn jg exceed 2 65 MPaG 28 kgf cm2 28kgf cm2 385 psig pl A Inclination limit at instal
18. eck 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 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 2 7 2 N m 0 4 0 7 kgf m 3 1 5 3 Ibf ft DA we gt A PUD G encre Sn di SZ PL Carefully place the wire harness strain relief If you are using a press Pulley Install the pulley assembly using the pulley installer installer and the 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 Pulley assembly 6 Service procedures 3 hole armature 1 Armature holder A N of S CA os S A J Coe Gap adjustment 0 3 0 7 mm Thickness gauge Magnetic clutch 4 Install the armature assembly on the driveshaft together with the original shim s and press it down 5 Install the armature bolt and tighten it to the specified torque using an armature holder for 3 hole armature or a spanner for 2 way stopper armature to prevent
19. embly 36 8 Service procedures Cylinder heads rrnrrnrnrsnvvnsnvrnsnvrnrnvnnsnne 39 EE 0 EE 43 10 SEVICE DAS a EIEEE RAEE NEESER EE 53 Saturated condensing conditions 1 Product description Compressor Compressor TECHNOLOGY Heavy Duty Swash Plate DISPLACEMENT 550 cc 33 56 in per rev 635cc 38 75 in per rev NUMBER OF CYLINDERS 14 7 double headed pistons ee T SHAFT SEAL Lip seal type LUBRICATION SYSTEM Lubrication by gear pump REFRIGERANT HFC 134a OIL QUANTITY ZXL 100PG PAG OIL 1500 cc 0 40 gal or POE option CONNECTIONS Internal Hose Diameter WEIGHT DIMENSIONS Length Width Height MOUNTING Suction 35 mm 1 3 8 in Suction 35 mm 1 3 8 in Discharge 28 mm 1 1 8 in Discharge 35 mm 1 3 8 in 18 1kg 39 9 Ibs w o Clutch 341 194 294 mm 13 4 7 64 9 33 in Direct side or base Valeo TM55 amp TMO5 Application limits PSIA PSIG oF MPaA MPaG 398 384 180 2 75 2 65 tc Condensing temperature te Evaporating gas temperature Saturated evaporating conditions 1 Product description Compressor Name plate To ensure that the compressor operates smoothly be careful to respect the indications written on the name plate located on top of the compressor body 3 Valeo DMP TYPE TM 65 RT NO 20007261 A Name plate RIAL NO 001V000401 IL 21006
20. ered 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 device at outlet air is frozen up defective Adjust or replace the part Refrigerant piping is If any part between clogged or crashed the dryer and the compressor is clogged or crashed the low side pressure becomes vacuum Adjust or replace the part 4 Troubleshooting 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 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
21. ey 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 V belt tension must be adjusted to the tension specified by the belt maker 2 Operation precautions 1 In the off season of air conditioner operate the compressor for a few minutes from time to time M Se RE ARE RP 2 Do not drive through water Water may damage o F the magnetic clutch thus preventing normal ok operation 3 Always charge the A C system with the S specified quantity of refrigerant 4 Keep the compressor clear of water projection Z while cleaning the vehicle mop B ZA JEG NY l E i 0 CL SE og I 15 3 Handling instructions Safety glasses Gloves 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 open flame and inflammables away from the vehicle in which the air conditioner is being installed Fire is especially dangerous during the gas leak inspection following installation WARNING C
22. f 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 23 4 Troubleshooting Compressor troubleshooting 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 troubleshooting 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 troubleshooting tree to localize the malfunction symptom then look at the table p 24 25 for the appropriate 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 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 troubleshooting tree 1 Insufficient cooling capacity A Compressor is not running B Compressor is running C Compressor runs intermittently 2 Abnormal noise A Abnormal noise from compressor B A
23. ing at the same time are allowed so consider this factor during sight glass inspection distorted indication Oil level inspection should be conducted at low compressor speed or compressor stopped Sight glass cannot be used at high compressor speed because oil surface is not visible and a mixture of refrigerant and oil is formed A flashlight can be helpful to expose oil surface light up one of the sight glasses to read oil level at the opposite one CAUTION Be careful of rotating parts and high temperature parts Front Lifting In most of bus rear application the front end of the compressor is lifted to fit the inclination of the engine 1 Oil level at sight glass oil level is distorted 2 Oil amount quantity appears lower than recommended but the level is actually correct you do not need to add more oil Lateral Inclination 1 Oil level at sight glass one sight glass will look completely covered with oil while the other will look inferior to recommendation or even empty Oil amount in this case some of the oil is below oil passage level therefore you should consider adding some oil to fill in the dead volume that appears in the illustration on the left 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 o
24. lation The compressor must be installed on the vehicle within the range shown at left Front head forward leaning is prohibited Compressor mounting points The compressors mounting points should be tightened to the specified torque Specified torque 45 50 N m 4 6 5 1 kgf m 33 2 36 9 Ibf ft VA Compressor bracket 35 DI Ag 1 Install the bracket securely on the chassis EM r frame or engine body As the engine vibrations D may be severe the bracket and mounting bolts A sou AR D must be installed securely kg L ZAG 27 2 Vibration resistance aaa ga Vus must not be any resonance under 250 NM 13 1 Product description 1 14 Magnetic clutch 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 magnetic clutch to drive pulley ratio should avoid the range 1 0 92 1 08 to limit vibration and resonance Compressor speed must not exceed the specified speed CAUTION Pull
25. le Abnormal noise from the Licompressor body The magnetic clutch hasa backlash and slips Strange noise when the magnetic clutch engages Abnormal vibration after turning on the A C switch portion between the compressor and the bracket Compressor body internal component damage Magnetic clutch damage Air gap too wide Armature slips does Linot engage when the lcompressor is running Armature does not rotate 3 when magnetic clutch lengages Symptom 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 Inot engage the compressor Jout Refrigerant oil is billowing Possible cause Compressor installation bolt is loose Wide gap at the attaching Magnetic clutch friction surface slipping Belt slipping Possible cause Magnetic clutch air gap too wide Low magnetic clutch voltage Magnetic clutch friction surface is greasy Belt alignment is not correct Measure Increase tightening torque of the loose bolts IImprove the compressor attaching portion Replace the compressor Replace the magnetic clutch Adjust air gap or replace magnetic clutch Charge battery or replace magnetic clutch Replace the compressor if locked Readjust the belt tension if the belt is loose Meas
26. luff Pulley Installer Part Name 9 Service tools M10x1 25 Unless otherwise specified the edges to be slight chamfering Should remove burrs and fluff Collar I Material 3rd Angle Proj suraat i Heat Treatment I amp Hardness Assy Part Name Pulley Installer Ass Pulley Installer Assy M16x2 0 srd Angle Proj amp I amp Hardness HRC40 to 45 Part Name Bolt 9 Service tools Unless otherwise specified the edges to be slight chamfering Should remove burrs and fluff Unless otherwise specified the edges to be slight chamfering Should remove burrs and fluff M16x2 0 Pulley Installer Assy Section view A A 3rd Angle Proj Surface Treatment Br amp Hardness HRC58 Material SK3 Spacer Pulley Installer Assy amp Hardness HRC40 to 45 Collar 9 Service tools Unless otherwise specified mem ES ive cies ste es dei Ps amp Hardness Should remove burrs and fluff SK85 JIS Remover for cyl head Unless otherwise specified mm OO fi sees Das Pie dei ae SEE f amp Hardness Should remove burrs and fluff SUS304 Part Name Shaft Seal Guide 9 Service tools Section view A A Unless otherwise specified eee O n Heat Treatment Ho De QE ee en Should remove burrs and fluff Remover M12x1 75 Unless otherwise specified AE TS the edges to be slight chamfering g J Br Should remove burrs and fluff I amp
27. ly UJ To install pulley 46 47 To remove cylinder head and cylinder block Cylinder head remover Guide Shaft seal remover installer 35 38 39 A OO A OO 36 41 To install shaft seal To remove and insert the Shaft seal a O 35 36 To remove armature Armature puller Armature puller 50 51 assembly To remove armature eala Js UI 9 Service tools BS RS 180 Unless otherwise specified j B the edges to be slight chamfering SE Should remove burrs and fluff Armature Holder 3rd Angle Proj Mean o Km Part Name Armature Installer Ass 9 Service tools Armature Installer Assy M10x1 25 M14x2 0 Unless otherwise specified TAR PIG the edges to be slight chamfering g J B Should remove burrs and fluff amp Hardness HRC40 to 45 Material S45C Bolt Armature Installer Assy M14 x2 0 Unless otherwise specified ARE PS the edges to be slight chamfering g J Br Should remove burrs and fluff 8 amp Hardness HRCA0 to 45 Collar 9 Service tools N A Section view A A Unless otherwise specified 3rd Angle Proj surface treatment 00 the edges to be slight chamfering ent Should remove burrs and fluff er Pulley Puller Part Name TG Y o 53 Section view A A Unless otherwise specified ME MR SE the edges to be slight chamfering joe Should remove burrs and f
28. njury or proper damage MEANING OF MARKS 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 description 3 Compressor speed PM 7 Conversion factors 7 2 Operation precautions re ma 15 3 Handling instructions 16 Maintenance precautions risisazzi eiccqdeccicsercacrcassianessabererekosassneveeeereansss 16 VL 16 RR 16 COMID ESS ALe ao EEE 17 Compressor FEMOVAI 17 Oil tetur Operati OF a E ar TEE iANir aei 18 GUNG ENN 18 Oil level at inclination conditions 19 OS AO ne 19 Lateral Inclination n 19 Oil contamination soeenrrronrronrrrenrrrnvrrnnrnrnvrrsnrrenvnsenrsenverenvsenvessvnsen 20 CEE ER a E 20 Replacement of components 21 PU Le TATE IMOD OTIO eearri e E E 22 or 22 Magnetic CECI SIA a 22 PONG TO SU CR NN 23 Refrigerant CHAT GIN Giessctsvsesndesvccssnedentseneshcavenndeassadseedesdansaeheuncendarsces 23 Storing a repaired COMpreSSor se 23 4 Troubleshooting rrrvrronrronrronrrenrrnnvrnnvrnnvrenvrrnvrrnvnnennsenrsennsnnsn 24 Compressor troubleshooting ren 24 Compressor Fools MOO MME oe 24 A C cycle diagnosis by gauge pressure 27 TN TOPICS an ms 29 6 Service procedures Magnetic clutch 30 7 Service procedures Shaft seal ass
29. ompressor Turn the spindle in the clockwise direction until it stops Valve spindle seal KK RU xx Q C see a RE ODA p G Spindle 77772 L lt mer eee ee a Service port connector OO 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 Cooling Capacity Q and Power Consumption P O emp UC MPa Les mPa ow foon Q kw 14 73 19 68 23 88 29 30 37 23 40 31 12 75 5 80 10 53 P 40 co us ne 6 28 7 84 Valeo TM 65 performance data R134a 5 31 Q Q 0 5 uses 010 05 10 197 cg QW 1266 17 30 2080 25 28 3210 34 56 Valeo TM55 amp TM65 conversion factors The performance data at different rotation speed can be approximated with the conversion factors MPaG in KW Q paw 683 776 839 906 990 1011 Q kW below Conversion factors 0 1000 1450 2000 3000 4000 Compressor speed rpm 1 Product description Dimensions TM55 amp TM65 compressors with magnetic clutch 354 12 M12x1 75 Dp 26 111 8 140 Sight glass CB104 CA104 pel METT UE pe 7 I I nd 1808 h g i AA AIF 4 at SUT BI 1 Product des
30. 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 Coatthe 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 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
31. ontact 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 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 Do not release refrigerant into the air Aa TG A Recovery unit 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 refrigerant from the air conditioner system always use a refrigerant recovery unit made especially for HFC 134a Compressor handling 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 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
32. ount Charging to remove charge recovered amount from new 6 Install the oil filler plug and tighten it to the compressor specified torque 61 or Same as 61 amount Specified torque 15 18 N m 915 more recovered recovered 1 5 1 8 kgf m 11 13 Ibf ft der s CAUTION The oil filler plug O ring must be replaced with a new one compressor 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 installing these component parts check the compressor oil Refer to page 18 1 3 Handling instructions D Running in operation ay Whenever moving parts have been replaced it is N 2 necessary to run in both the compressor and the LER magnetic clutch JB O 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 Nem 2 5 3 3 kgf m 18 24 Ibf ft 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 th
33. ount of clean compressor oil through the oil filler Install the oil filler plug with a new O ring and tighten it to the specified torque Specified torque 15 18 Ne m 1 5 1 8 kgf m 11 13 Ibf ft Install the strainer in the suction port Fit the blanking plates connectors to the suction and discharge connections and tighten them to the specified torque Specified torque 25 32 Nem 2 5 3 3 kgf m 18 24 Ibf ft Install the magnetic clutch as described on page 31 Run in the compressor as described on page 21 Perform the leak test as described on page 22 8 Service procedures Cylinder heads Tap lightly Remover Front cylinder head Suction valve Gasket 39 Cylinder heads Front amp Rear Disassembly Remove the magnetic clutch assembly as described on page 29 Remove the four 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 heads Alternately tap the two projections on the front head using the remover and mallet to remove the front cylinder head Remove the front valve plate assembly and then the suction valve in that order Remove and discard the O ring from the front cylinder head Remove all gasket material from the front cylinder head
34. pression and discharge Radial bearing Drive shaft Suction lt q lt Compression Piston Thrust bearings 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 D o ee Ped Vaal 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 th
35. r 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 WARNING When system oil contamination is found during compressor replacement gt 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 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 Check the oil for contamination 5 Fill the compressor with the specified amount of oil p 20 20 3 Handling instructions unit cm amp cc CAUTION FOUR The specified oil quantity differs depending Specified Amount Charging to remove on the type of air conditioner system A EE emourt ORNE label describing the specified quantity is attached to the compressor Additionally all eae ae 1500 of the oil cannot be removed when draining recovered amount the compressor as some remains as an oil recovered 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 unit CU in affects the cooling capacity and the Amount compressor Specified Am
36. re assembly using an armature installer assembly 8 Install the armature bolt and tighten to the specified torque using an armature holder or a spanner to prevent armature assembly rotation Specified torque 25 30 Nem 2 5 3 1 kgf m 18 22 Ibf ft 9 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 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 10 Run in the clutch as described on page 21 35 7 Service procedures Shaft seal assembly Removal 1 Remove the magnetic clutch assembly as described on page 29 2 Remove the 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 head using an hexagon 14 mm wrench 5 Alternately tap the two projections on the front head using a remover and a mallet to remove the front cylinder head Tap lightly Front cylinder head Snap ring Press uniformly from above Front cylinder head Ze Remover 6 Remove the snap ring using the internal snap ring pliers 2 Internal snap ring pliers Shaft seal 7 Remove the shaft seal assembly using a remover Remover
37. ure Adjust air gap or replace magnetic clutch Charge battery Clean friction surface or replace magnetic clutch Adjust the compressor installation position Magnetic clutch belt is clean or replace the belt greasy Magnetic clutch belt tension Jis loose Coil open or shorted Refrigerant leaking uncoupled piping or piping burst 26 adjust belt tension Replace the magnetic clutch Fix the refrigerant leakage 7 then fill with refrigerant until having the right amount 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 Ambient temperature 30 35 C Engine speed 1 500 rpm A C switch ON Blower speed high Temperature control full cold ee 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 Both discharge and Refrigerant shortage Connect gauge Recover refrigerant suction pressures are manifold to cycle then refill with the low right amount of refrigerant Suction pressure g becomes vacuum Receiver dryer is Temperature difference Replace parts clogged between inlet and outlet pipes happens Dryer is cov
38. vent armature assembly rotation b Remove the armature assembly using an armature puller assembly Remove the shims from the compressor driveshaft or armature assembly If it is a 2 way stopper type armature 2 a Remove the center bolt using a spanner to prevent armature assembly rotation 30 6 Service procedures Magnetic clutch b Remove the armature assembly using an armature puller Remove the shims from the compressor driveshaft or armature assembly 3 Remove the snap ring Z0010244 using external snap ring pliers LA External snap ring pliers NC 7 RE 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 Pulley puller as shown Tighten the center pulley puller bolt to remove the pulley Center pulley puller Gen G 2 DD CC LS Remove the six field coil compressor screws Then remove the field coil WARNING Removing the pulley will systematically damage the pulley bearing CAUTION A a Do not clip the puller claws into the pulley CZ A groove to prevent pulley groove damage CAUTION Do not hold the field coil by the harness 6 Service procedures Magnetic clutch Magnetic clutch Inspection 1 If the contact surface has been damaged by excessive heat the armature and pulley must be replaced 2 Ch
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