SERVICE MANUAL - Valeo Compressors

1 Copyright 2017 Valeo Japan CO., LTD. All rights MANUALV aleo TM08, TM13, TM15 & TM16 Compressors -1-ForewordThis SERVICE MANUAL has been elaborated to help ser-vice personnel to provide efficient and correct SERVICE and maintenance on the TM08, TM13, TM15 & TM16 model Compressors (for HFC-134a) for automotive air MANUAL includes the operation specifications, procedures for disassembly, reassembly and inspection of the contents of this MANUAL , including illustrations, drawings and specifications were the latest available at the time of Japan reserves the right to make changes in specifications and procedures at any time without JAPAN CO., following warning signs are used in this SERVICE are extremely important to ensure safe operation and to prevent body injuries and property must be fully understood before starting the air conditioner !

2 Maintenance must be properly done to avoid serious injury ! Improper maintenance can result in injury or property following marks are used in this SERVICE MANUAL to facilitate correct air conditioner Procedures necessary to ensure the best air conditioner Information to optimize the air conditioner OF MARKS-2-Contents1-Product 32-Operation 183-Handling 19 Maintenance 19 Work 19 Refrigerant 19 Compressor 20 Compressor 20 Oil return 21 Oil 21 Oil 22 Oil 22 Replacement of 23 Running-in 24 Compressor 24 Magnetic clutch 24 Leak 25 Storing a repaired compressor .. 25 Refrigerant 26 Installation 27 Installation 27 Piping 284-Troubleshooting.

3 29 Compressor troubleshooting .. 29 Compressor troubleshooting tree .. 29 A/C cycle diagnosis by gauge 335-Tightening 356- SERVICE procedures - Magnetic 367-Services procedures - Shaft seal 408-Services procedures - Cylinder 439- SERVICE 47 Magnetic clutch SERVICE 47 Compressor 48 Test and inspection tools .. 48-3-1-Product description - CompressorMODELTM08TM13TM15TM16 TECHNOLOGYH eavy Duty Swash PlateDISPLACEMENT82cc / 5 in3 per / 8 in3 per / 9 in3 per / 10 in3 per OF CYLINDERS6 (3 double-headed pistons)REVOLUTION RANGE700-6000 rpmDIRECTION OF ROTATIONC lockwise & Counter clockwise (depending on clutch type)BORE36 mm ( in) mm ( in) mm ( in) mm ( in) mm ( in)SHAFT SEALLip seal typeLUBRICATION SYSTEMS plash lubricationREFRIGERANTHFC-134aOIL (QUANTITY)ZXL 100PG PAG OIL (150 in3)ZXL 100PG PAG OIL (180 in3) WEIGHT (w/o clutch) / / lbs / / lbsDIMENSIONS (w/o clutch)Length - Width - Height168-124-145 (mm) (in) 192-124-142 (mm) (in)

4 202-124-142 (mm) (in)207-124-142 (mm) (in)MOUNTINGA lternator/Ear mountDirect (side) & Ear MountCompressorsValeo TM08, TM13, TM15 & TM16 Application limits for HFC-134ate tc Saturated evaporating conditionsSaturated condensing : Condensing temperature te : Evaporating gas temperature-4-1-Product description - Magnetic clutchMagnetic clutchVALEO TM08, TM13, TM15 & TM16 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 Compressors and magnetic clutches have successfully passed the thousand hours of long validation tests in Valeo Compressors research center laboratory.

5 Operational excellence was demonstrated during hot season testing on field under challenging climates in the most stressful 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 TM08, TM13, TM15 & TM16 compressor qualities.*The specifications may vary with the also note that the maintenance procedures introduced in this SERVICE MANUAL apply only to magnetic clutches provided by single-plate dry clutchRATED VOLTAGE12 VDC & 24 VDCPOWER CONSUMPTION49 W maximumSTATIC TORQUE49 N m {36 lb ft}DIRECTION OF ROTATIONC lockwise & Counter clockwise (depending on clutch)WEIGHTA pprox kg { lbs}V-BELT TYPEV-groove (A or B) or V-ribbed (PK)

6 Specifications TM08, TM13, TM15 & TM16*-5-1-Product description - Name PlateName plateTo ensure that the compressor operates smoothly, respect carefully the indications written on the name TM13, TM15 & TM16 Compressors have al-most the same dimensions, the best way to differentiate them quickly is by referring to the name plateCOMP. TYPETM-XXPART XSERIAL 100PG 1500 cm3 LEAK. TESTHIGH SIDE SIDE HFC-134a MADE IN JAPANTMXXXXXXXXX X XXXXXXXXXXZXL 100PG XXX cm3 HFC-134a-6-1-Product description - Dimensions TM08135 () 7/8-14 UNFSUCTION3/4-16 UNFDISCHARGE14 14 ()104 + 8--7-1-Product description - Dimensions TM13135 ()7/8-14 UNF3 + 8-SD-8-1-Product description - Dimensions TM15135 + + ()120 7/8-14 UNFSUCTION3/4-16 UNFDISCHARGE80142104 + description - Dimensions TM16112 + () + + 8--10-1-Product description - Exploded view123456789101112131415161718202122232 4252627191.

7 Center bolt2. Armature assembly3. Adjusting shim4. Snap ring5. Pulley assembly6. Screw7. Field coil8. Bolt9. Gasket10. Snap ring 11. Shaft seal assembly12. Front cylinder head 13. O-ring 14. Gasket 15. Valve plate assy 16. Sunction valve17. Pin18. Cylinder shaft assembly19. Oil filler plug20. Sunction valve21. Valve plate assy 22. Gasket 23. O-ring24. Rear Cylinder Head25. O-ring 26. Relief Valve 27. Oil drain plug-11-1-Product description - Performance TM08 The performance data below were measured under the following conditions: Discharge Pressure: Pd = MPaG Suction Pressure: Ps = MPaG Subcooling temperature: SC = 5 C Super heat temperature: SH = 10 CValeo TM08 performance data table (R134a)TM08Nc (r/min)1200180024003000 Vol.

8 Eff. (%) (kW) (kW) TM08 performance data graph (R134a)Compressor Speed (rpm)Volumetric Efficiency (%)Cooling Capacity (kW) / Power (kW) / COP-12-1-Product description - Performance TM13 The performance data below were measured under the following conditions: Discharge Pressure: Pd = MPaG Suction Pressure: Ps = MPaG Subcooling temperature: SC = 5 C Super heat temperature: SH = 10 CValeo TM13 performance data table (R134a)TM13Nc (r/min)8001200180024003000 Vol. Eff. (%) (kW) (kW) Speed (rpm)Volumetric Efficiency (%)Cooling Capacity (kW) / Power (kW) / COPV aleo TM13 performance data graph (R134a)-13-1-Product description - Performance TM15 The performance data below were measured under the following conditions: Discharge Pressure: Pd = MPaG Suction Pressure: Ps = MPaG Subcooling temperature: SC = 5 C Super heat temperature: SH = 10 CValeo TM15 performance data table (R134a)TM15Nc (r/min)8001200180024003000 Vol.

9 Eff. (%) (kW) (kW) Speed (rpm)Volumetric Efficiency (%)Cooling Capacity (kW) / Power (kW) / COPV aleo TM15 performance data graph (R134a)-14-1-Product description - Performance TM16 The performance data below were measured under the following conditions: Discharge Pressure: Pd = MPaG Suction Pressure: Ps = MPaG Subcooling temperature: SC = 5 C Super heat temperature: SH = 10 CValeo TM16 performance data table (R134a)TM16Nc (r/min)8001200180024003000 Vol. Eff. (%) (kW) (kW) Speed (rpm)Volumetric Efficiency (%) Valeo TM16 performance data graph (R134a)Cooling Capacity (kW) / Power (kW) / COP-15-1-Product description - Swash plate systemValeo TM08, TM13, TM15 & TM16 are 6 cylinder swash plate type Compressors .

10 With this type of compressor, the cylinders and pistons are arranged axially along the drive pistons operate within the cylinders and are driven by a swash plate to perform suction, compression and plate systemThe drive shaft, which is driven by the engine through the magnetic clutch, is equipped with a swash drive shaft is supported by two radial bearings and two thrust swash plate is rotated by the drive shaft, and moves the pistons back and Drive System The pistons in the cylinders are mounted on the swash plate through hemispherical piston has a compression head at each end. The rotation of the swash plate results in a reciprocating piston movement horizontal to the drive cylinders, which are arranged at 120 intervals around the drive shaft, are each divided into 2 chambers providing 3 front and 3 rear each piston performs suction and compression at either end, the compressor operates as a 6 cylinder bearingThrust bearingSuctionCompressionCompressionSuct ionShoePistonRadial bearingPistonThrust bearingsDrive shaftRadial bearingSwash plate-16-1-Product description - GeneralCompressor1.