Valeo TM31, Service Manual

Page 1: ...Copyright 2017 Valeo Japan CO LTD All rights reserved SERVICE MANUAL Valeo TM31 Compressor...

Page 2: ......

Page 3: ...to ensure the best air conditioner maintenance Note Information to optimize the air conditioner maintenance MEANING OF MARKS Foreword This service manual has been elaborated to help service personnel...

Page 4: ...nt of components 18 Running in operation 19 Compressor running in 19 Magnetic clutch running in 19 Leak test 20 Refrigerant charging 20 Storing a repaired compressor 20 4 Troubleshooting 21 Compressor...

Page 5: ...L QUANTITY ZXL 100 PG PAG OIL DH PS 500 cc 30 5 cu in WEIGHT 9 5 kg 21 lb w o Clutch w o oil DIMENSIONS with clutch Length Width Height 278 5 143 178 mm 10 94 5 63 7 in MOUNTING Direct side or base Va...

Page 6: ...dry clutch RATED VOLTAGE 24V DC or 12 V DC POWER CONSUMPTION 48 W maximum STATIC TORQUE 78 N m 8 0 kgf m 58 lbf ft DIRECTION OF ROTATION Clockwise viewed from clutch WEIGHT Approx 4 5 kg 10 lb V BELT...

Page 7: ...4 48 4 34 4 18 3 84 3 47 3 08 Q kW 21 22 18 70 16 54 14 85 11 66 9 06 6 93 60 1 58 P kW 5 18 5 00 4 79 4 59 4 17 3 72 3 27 Q kW 17 25 15 46 13 78 12 32 9 69 7 46 5 65 Valeo TM31 performance data R134a...

Page 8: ...nit mm Other connecting type TM31compressors with magnetic clutch 45 45 30 158 156 effective diameter 48 48 79 99 112 56 38 5 4 2 2 1 22 22 Approx 178 4 M8x1 25 2 1 4 2 167 116 Approx 244 Approx 278 5...

Page 9: ...shim 4 Snapring 5 Pulley assembly 6 Screw 7 Field coil 8 Bolt 9 Washer 10 Front cylinder head 11 Shaft seal assembly 12 Gasket 13 Valve plate assembly 14 Suction valve 15 O ring 16 Cylinder shaft ass...

Page 10: ...e drive shaft and moves the pistons back and forth Drive shaft Radial bearing Radial bearing Piston Thrust bearing Swash plate Radial bearing Thrust bearing Suction Compression Compression Suction Bal...

Page 11: ...passage in the shaft The oil then flows through ports in the shaft to lubricate the bearings and the shaft seal The area between the swash plate and the shoe disks is lubricated by the splashing acti...

Page 12: ...on The compressor must be installed on the vehicle within the inclination range shown at the left Compressor bracket 1 Install the bracket securely on the chassis frame or engine body As the engine vi...

Page 13: ...e 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 exce...

Page 14: ...High pressure control 2 65 MPaG 27 kgf cm2 384 psig or higher Low pressure control 0 18 MPaG 1 8 kgf cm2 26 psig or lower The dual pressure switch controls high and low pressure High pressure control...

Page 15: ...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 16: ...ction following installation Refrigerant handling 1 Do not misidentify refrigerants If an HFC 134a air conditioning system is mistakenly charged with another refrigerant serious problems such as compr...

Page 17: ...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 16 2 Recover the refri...

Page 18: ...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 sys...

Page 19: ...checked as follows when being charged into a used system 1 Perform the oil return operation see p 16 2 Remove the compressor from the vehicle 3 Remove the oil filler plug and drain the oil through the...

Page 20: ...mponents When replacing the system s component parts supply the following amount of oil to the compressor Component mounted Amount of oil Evaporator 100 cm3 6 1 cu in Condenser 60 cm3 3 7 cu in Receiv...

Page 21: ...to the specified torque Specified torque 20 24 N m 2 0 2 4 kgf m 14 17 lbf 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 Replac...

Page 22: ...psig 3 Check the compressor for leaks using a leak detector Refrigerant charging In order to prevent a liquid charge and greatly increase risks of compressor dammage do not shake or turn the refrigera...

Page 23: ...23 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 24: ...t Replace the compressor Fix the refrigerant leakage then fill with refrigerant until reaching the right amount Charge the battery or replace the magnetic clutch Replace the magnetic clutch after maki...

Page 25: ...n slippery surface The magnetic clutch has a backlash and slips Abnormal noise from the magnetic clutch Belt slipping noise 3 Smoke Issue Symptom Possible cause Measure A B C D Magnetic clutch frictio...

Page 26: ...ant then refill with the right amount of refrigerant Receiver dryer is clogged Temperature difference between inlet and outlet pipes Dryer is covered with frost Replace parts Expansion valve is clogge...

Page 27: ...tive 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 dischar...

Page 28: ...d size Tightening torque 1 Center bolt M8 x 1 25 20 22 2 0 2 2 14 16 2 Field coil screws M6 x 1 0 4 2 7 2 0 4 0 7 3 1 5 3 3 Bolt M10 x 1 5 25 30 2 5 3 0 18 22 4 Oil filler plug M10 x 1 5 14 16 1 4 1 6...

Page 29: ...rotating 2 Remove the armature assembly 3 Remove the snap ring using external snap ring pliers 4 Position the center pulley puller 597033 1700 at the end of the driveshaft 5 Attach a suitable pulley...

Page 30: ...essive heat the armature and pulley must be replaced 2 Check the appearance of the pulley assembly If the contact surface of the pulley is excessively grooved due to slippage both the pulley and the a...

Page 31: ...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 lbf ft 2 Carefully place the wire harness bushing 3 Install the pulley assembly using the pulley install...

Page 32: ...the rotating Specified torque 20 22 N m 2 0 2 2 kgf m 14 16 lbf ft 7 Check that the clutch clearance is as specified If necessary adjust the clearance using shim s Adjusting shims are available in the...

Page 33: ...hen remove the connectors and strainer from the cylinder shaft assembly 3 Remove the oil filler plug and then drain the oil 4 Remove the five bolts securing the heads 5 Alternately tap the two project...

Page 34: ...5 Position the guide 597067 6100 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 8 Remove the guide 597067 610...

Page 35: ...ue 14 16 N m 1 4 1 6 kgf m 10 12 lbf ft 13 Install the strainer in the suction port When the connectors are installed 14 Fit plates to the suction and discharge connections and tighten them to the spe...

Page 36: ...onnectors and strainer from the cylinder shaft assembly 3 Remove the oil filler plug and then drain the oil 4 Remove the five bolts securing the heads 5 Alternately tap the two projections on the fron...

Page 37: ...ic hammer to remove the head 10 Remove the rear valve plate assembly and then the suction valve in that order 11 Remove and discard the O ring from the rear cylinder head 12 Remove all gasket material...

Page 38: ...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...

Page 39: ...4 Coat the new gasket with clean compressor oil and install it on the rear valve plate 5 Coat the new gear pump with clean compressor oil and install it on the end of the drive shaft 6 Coat the new O...

Page 40: ...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...

Page 41: ...groups those for magnetic clutch disassembly and reassembly those for compressor disassembly and reassembly and those for testing and running in operation MAGNETIC CLUTCH TOOLS Part name Part No Shape...

Page 42: ...l Guide 597067 6100 33 39 For installing shaft seal Part name Part No Shape Reference page Application Connector T44375C 19 For high pressure port Connector T44373C 19 For low pressure port O ring 569...

Page 43: ...41 9 Service tools...

Page 44: ...42 9 Service tools...

Page 45: ...569300 4000 n 1 GASKET SET 569941 1921 12 Gasket front head 569310 6000 n 1 23 Gasket rear head 569310 6100 n 1 9 Gasket bolt 7 per set 569310 6200 n 7 SHAFT SEAL for service 11 Shaft seal 569942 132...

Page 46: ...1 for HFC 134a use SERVICE MANUAL Version WW31 17012 01EN Published by VALEO JAPAN CO LTD Copyright 2017 VALEO JAPAN CO LTD For any inquiry regarding the present service manual contact us at vc oura s...

Page 47: ...86 0 431 8499 2025 Fax 86 0 431 8499 2004 Email vc changchun sales valeo com Asia 39 Sendai Kumagaya shi Saitama ken 360 0193 Japan Phone 81 0 48 539 3800 Fax 81 0 48 539 3843 Email vc oura sales vale...