Valeo TM08 Service Manual Download

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Summary of Contents for TM08

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Page 3: ...n 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...

Page 4: ...Magnetic clutch running in 24 Leak test 25 Storing a repaired compressor 25 Refrigerant charging 26 Installation position 27 Installation precautions 27 Piping precautions 28 4 Troubleshooting 29 Comp...

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Page 6: ...ely 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 compresso...

Page 7: ...p As TM13 TM15 TM16 compressors have al most the same dimensions the best way to differentiate them quickly is by referring to the name plate Name plate COMP TYPE TM XX PART NO ZXXXXXXX X SERIAL NO XX...

Page 8: ...6 1 Product description Dimensions TM08 135 16 36 6 0 6 183 3 61 6 67 0 1 89 0 1 11 0 1 120 7 8 14UNF SUCTION 3 4 16UNF DISCHARGE 14 14 5 5 5 8 0 139 6 104 0 3 104 0 3 10 3 0 4 8...

Page 9: ...7 1 Product description Dimensions TM13 135 69 2 16 44 2 0 6 73 3 0 1 120 12 4 0 1 98 0 1 208 7 8 14UNF 3 4 16UNF DISCHARGE SUCTION 21 5 28 5 80 142 104 0 3 104 0 3 10 3 0 4 8 S D...

Page 10: ...8 1 Product description Dimensions TM15 135 16 39 6 0 6 64 6 83 3 0 2 14 35 0 05 0 15 112 0 1 215 8 120 7 8 14UNF SUCTION 3 4 16UNF DISCHARGE 80 142 104 0 3 104 0 3 10 3 0 4 8 21 5 28 5 D S...

Page 11: ...9 1 Product description Dimensions TM16 112 0 1 135 16 39 6 0 6 64 6 0 05 0 15 14 35 83 3 222 8 120 0 2 D S 7 8 14UNF SUCTION 3 4 16UNF DISCHARGE 21 5 28 5 80 142 104 0 3 104 0 3 10 3 0 4 8...

Page 12: ...4 Snap ring 5 Pulley assembly 6 Screw 7 Field coil 8 Bolt 9 Gasket 10 Snap ring 11 Shaft seal assembly 12 Front cylinder head 13 O ring 14 Gasket 15 Valve plate assy 16 Sunction valve 17 Pin 18 Cylin...

Page 13: ...8 MPaG Subcooling temperature SC 5 C Super heat temperature SH 10 C Valeo TM08 performance data table R134a TM08 Nc r min 1200 1800 2400 3000 Vol Eff 60 0 58 8 58 7 59 1 Capacity kW 1 57 2 31 3 08 3 8...

Page 14: ...oling temperature SC 5 C Super heat temperature SH 10 C Valeo TM13 performance data table R134a TM13 Nc r min 800 1200 1800 2400 3000 Vol Eff 58 3 63 0 65 7 63 7 61 1 Capacity kW 1 64 2 64 4 13 5 35 6...

Page 15: ...oling temperature SC 5 C Super heat temperature SH 10 C Valeo TM15 performance data table R134a TM15 Nc r min 800 1200 1800 2400 3000 Vol Eff 57 5 63 3 66 2 64 1 61 4 Capacity kW 1 81 2 98 4 65 6 03 7...

Page 16: ...oling temperature SC 5 C Super heat temperature SH 10 C Valeo TM16 performance data table R134a TM16 Nc r min 800 1200 1800 2400 3000 Vol Eff 64 9 67 6 65 5 62 9 59 3 Capacity kW 2 26 3 53 5 12 6 57 7...

Page 17: ...ate is rotated by the drive shaft and moves the pistons back and forth Piston Drive System The pistons in the cylinders are mounted on the swash plate through hemispherical shoes Each piston has a com...

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Page 20: ...Do not drive through water Water may damage the magnetic clutch thus preventing normal operation 3 Do not allow a compressor that has not been used for a long period to become wet 4 Always charge the...

Page 21: ...s 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 tempera...

Page 22: ...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 th...

Page 23: ...ion 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...

Page 24: ...lings etc 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 th...

Page 25: ...y is attached to the compressor Additionally alloftheoilcannotberemoved when draining the compressor as some remains as an oil film on the inside of the compressor and the system components Therefore...

Page 26: ...ible 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 5 Replace the oil 6 Repeat the leak test Ma...

Page 27: ...ows 1 Using the valve assembly 597017 1120 fill the compressor with refrigerant through the suction side raising the refrigerant pres sure to at least 0 39 MPaG 5 kgf cm2 56 3 psig 2 Check the compres...

Page 28: ...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...

Page 29: ...y or all warranties may be rendred void Installation precautions The new compressor is filled with the specified quantity of compressor oil and nitrogen gas N2 When mounting the compressor on the vehi...

Page 30: ...st the base of the companion pieces then hand tighten the nut as much as possible Then tighten to the specified torque CAUTION Always use the specified oil for HFC134a systems to coat the O rings O ri...

Page 31: ...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...

Page 32: ...or not seated properly Magnetic clutch damage Magnetic clutch air gap too wide Belt slipping Bolt drop off Armature drop off Low magnetic clutch voltage Compressor internal part damage or magnetic clu...

Page 33: ...refrigerant Replace the condenser after making sure it is defective Condenser fan failure Replace the magnetic clutch after making sure it is defective Loose connection of the magnetic clutch electri...

Page 34: ...bnormal noise from the magnetic clutch Belt slipping noise Issue Symptom Possible cause Measure A B C D Magnetic clutch friction surface slipping The magnetic clutch slips does not engage when the com...

Page 35: ...refill with the right amount of refrigerant Receiver dryer is clogged Temperature difference between inlet and outlet pipes happens Dryer is covered with frost Replace parts Expansion valve is clogge...

Page 36: ...ective refrigerant flow control the thermal sensing tube is not closely in contact with the evaporator pipe Adjustment or replacement Air mixed in refrigeration cycle Just after compressor stops disch...

Page 37: ...5 16 7 20 7 1 7 2 1 12 3 15 3 4 Oil drain plug M8 x 1 25 13 0 15 0 1 3 1 5 9 6 11 1 5 Relief valve 3 8 24UNF 7 8 9 8 0 8 1 0 5 8 7 2 6 Connector fixing bolt M10 x 1 5 20 24 2 0 2 4 14 5 17 3 7 Oil fil...

Page 38: ...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 Posi...

Page 39: ...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 groov...

Page 40: ...nd press 4 Install the snap ring beveled edge up using external snap ring pliers 5 Install the armature assembly on the driveshaft together with the original shim s Press the armature assembly down by...

Page 41: ...s as specified If necessary adjust the clearance using shim s Adjusting shims are available in the following thickness Shim Part No Thickness 596541 1900 0 1 mm 0 0039 in 596541 2000 0 3 mm 0 0118 in...

Page 42: ...he oil filler plug and then drain the oil 3 Remove the five bolts securing the heads 4 Remove the snap ring using internal snap ring pliers 5 Insert the remover 597035 5520 into the shaft seal and tur...

Page 43: ...w 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 2 Fit the gu...

Page 44: ...round edge of the snap ring must face downward as shown on the left hand figure 2 Check the snap ring is properly installed as shown on the left hand figure 3 Install the oil drain plug wih a new O r...

Page 45: ...l 3 Remove the shaft seal as described in shaft seal removal on page 40 4 Remove the six bolts securing the heads 5 Alternately tap the two projections on the front head using the remover 597035 0500...

Page 46: ...plate and suction valve from cylinder shaft assembly 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...

Page 47: ...Install the rear valve plate on the rear suction valve 4 Coat the new gasket with clean compressor oil and install it on the rear valve plate 5 Coat the new O ring with clean compressor oil and instal...

Page 48: ...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...

Page 49: ...bly 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 page Application Drive plate...

Page 50: ...5 0500 43 44 To remove cylinder head and cylinder block Guide 597067 1102 41 42 46 To install shaft seal 9 Service tools Compressor tools Test and inspection tools Part name Part No Shape Reference pa...

Page 51: ...49 Notes...

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Page 55: ...13 TM15 TM16 for HFC 134a SERVICE MANUAL Version WW0816 15006 02EN Published by VALEO JAPAN CO LTD Copyright 2015 VALEO JAPAN CO LTD For any inquiry regarding the present service manual contact us at...

Page 56: ...vc dallas sales valeo com China No 2677 Shiji Avenue Eco Tec Dvt Zone 130031 Changchun Jilin PRC Phone 86 0 431 8499 2025 Fax 86 0 431 8499 2004 Email vc changchun sales valeo com Asia 39 Sendai Kumag...

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