Valeo TM08 Service Manual
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Valeo TM08 Service Manual

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Summary of Contents for Valeo TM08

  • Page 3 The contents of this manual, including illustrations, vice personnel to provide efficient and correct service drawings and specifications were the latest available and maintenance on the TM08, TM13, TM15 & TM16 at the time of printing. model compressors (for HFC-134a) for automotive air Valeo Japan reserves the right to make changes in conditioning.

  • Page 4: Table Of Contents

    Contents 1-Product description................... 2-Operation precautions................3-Handling instructions................................Maintenance precautions ....................Work area .................. Refrigerant handling .................. Compressor handling .................. Compressor removal..................Oil return operation ....................Oil handling ..................Oil contamination ....................Oil check................Replacement of components .................. Running-in operation.

  • Page 6: 1-Product Description

    1-Product description - Magnetic clutch Magnetic clutch VALEO 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 actors.
  • Page 7 1-Product description - Name Plate Name plate To ensure that the compressor operates smoothly, respect carefully the indications written on the name plate. Name plate As TM13, TM15 & TM16 compressors have al- most the same dimensions, the best way to differentiate them quickly is by referring to the COMP .
  • Page 8 1-Product description - Dimensions TM08 183.3 ±0.1 ±0.1 36.6 ±0.6 61.6 ±0.1 7/8-14UNF 3/4-16UNF SUCTION DISCHARGE +0.4 Ø 10.3 ±0.3...
  • Page 9 1-Product description - Dimensions TM13 ±0.1 12.4 ±0.1 44.2 ±0.6 69.2 73.3 ±0.1 21.5 28.5 3/4-16UNF 7/8-14UNF SUCTION DISCHARGE +0.4 Ø 10.3 ±0.3...
  • Page 10 1-Product description - Dimensions TM15 215.8 ±0.1 +0.05 14.35 -0.15 39.6 ±0.6 +0.2 64.6 83.3 21.5 28.5 7/8-14UNF 3/4-16UNF SUCTION DISCHARGE +0.4 Ø 10.3 ±0.3...
  • Page 11 1-Product description - Dimensions TM16 222.8 ±0.1 +0.05 14.35 -0.15 39.6 ±0.6 +0.2 64.6 83.3 21.5 28.5 7/8-14UNF 3/4-16UNF SUCTION DISCHARGE +0.4 Ø 10.3 ±0.3...
  • Page 12 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 19. Oil filler plug 5. Pulley assembly 20. Sunction valve 6. Screw 21. Valve plate assy 7.
  • Page 13 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 Vol. Eff. (%) 60.0...
  • Page 14 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) Nc (r/min) 1200 1800 2400 3000 Vol. Eff. (%) 58.3...
  • Page 15 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) Nc (r/min) 1200 1800 2400 3000 Vol. Eff. (%) 57.5...
  • Page 16 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) Nc (r/min) 1200 1800 2400 3000 Vol. Eff. (%) 64.9...
  • Page 17 1-Product description - Swash plate system Swash plate system Valeo TM08, TM13, TM15 & TM16 are 6 cylinder swash plate type compressors. With this type of The drive shaft, which is driven by the engine compressor, the cylinders and pistons are arranged through the magnetic clutch, is equipped with a axially along the drive shaft.

  • Page 20: 2-Operation Precautions

    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. 3. Do not allow a compressor that has not been used for a long period to become wet.

  • Page 21: 3-Handling Instructions

    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 •...

  • Page 22: Compressor Handling

    3-Handling instruction 2. Do not release refrigerant into the air Do not release refrigerant into Although HFC-134a is not subject to CFC regulations, the air 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.

  • Page 23: Oil Return Operation

    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.

  • Page 24: Oil Contamination

    3-Handling instructions Oil contamination Opacity Color change Foreign substances Unlike engine oil, no cleaning agent is added to Metal filings the compressor oil. Even if the compressor is run for a long period (approximately 1 season), the oil never becomes turbid as long as there is noth- ing wrong with the compressor or its method of use.

  • Page 25: Replacement Of Components

    Same as compressor and the system components. TM08 or more recovered Therefore, refer to the table at left when TM13 under recharging the compressor with oil. Excess TM15 oil adversely affects the cooling capacity and the compressor.

  • Page 26: Running-In Operation

    3-Handling instructions Running-in operation Flexible hose Whenever moving parts have been replaced, it is necessary to run-in both the compressor and the magnetic clutch. Compressor running-in Reassembled compressors must be run-in after the leak test (see next page). 1. Check that the compressor contains the specified amount of oil.

  • Page 27: Leak Test

    3-Handling instructions Leak test Valve assembly The compressor must be checked for refrigerant (597017-1120) leaks after it is repaired. The procedure is as fol- lows. 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/cm , 56.3 psig}.

  • Page 28: Refrigerant Charging

    3-Handling Instructions 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.

  • Page 29: Installation Position

    3-Handling Instructions Installation position 45˚ 45˚ 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 10˚...

  • Page 30: Piping Precautions

    3-Handling Instructions Piping precautions O-ring positions CORRECT INCORRECT INCORRECT 1. Position the O-Ring against the bulge in the pipe when connecting hoses and pipes. 2. Coat the piping connections and the O-rings O-ring Pipe bulge with PAG oil. Apply oil thoroughly to these areas CAUTION! Always use the specified oil for HFC134a Piping connection...

  • Page 31: 4-Troubleshooting

    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.
  • Page 32 4-Troubleshooting 1. Insufficient cooling capacity Issue Symptom Possible cause Measure Compressor internal part Magnetic clutch slips when Compressor is Replace the compressor damage turning on the A/C switch not running (No cool blow Fix the refrigerant leakage Low pressure cut switch coming out) Refrigerant shortage then fill with refrigerant until operates (see p.26-27)
  • Page 33 Troubleshooting Issue Symptom Possible cause Measure Compressor Reduce the refrigerant Both discharge and suction runs Excess of refrigerant charge until reaching the pressures are high intermittently right amount (Cool blow Replace the condenser after comes out only Condenser fan failure making sure it is defective from time to time) The magnetic clutch slips or...
  • Page 34 4-Troubleshooting 2. Abnormal noise Issue Symptom Possible cause Measure Abnormal vibration after Compressor installation bolt Increase tightening torque of Abnormal turning on the A/C switch is loose the loose bolts noise from the compressor Wide gap at the attaching Improve the compressor portion between the attaching portion compressor and the bracket...

  • Page 35: A/C Cycle Diagnosis By Gauge Pressure

    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: 1. Ambient temperature: 30 - 35 °C 2.
  • Page 36 4-Troubleshooting Gauge pressure Cause Confirmation method Action to take indication Both discharge and Excess of refrigerant Connect gauge Recover refrigerant, suction pressures are manifold to cycle then refill with the high right amount of refrigerant Condenser cooling Condenser becomes Clean up, hand repair malfunction muddy and fins are of fin and replacement clogged and collapsed.

  • Page 37: 5-Tightening Torques

    5-Tightening torques Unit: N·m {kgf·m, lbf·ft} Part Thread size Tightening torque 1. Bolt M6 x 1.0 12.0 - 14.0 (1.2 - 1.4, 8.9 - 10.3) 4.0 - 6.0 (0.4 - 0.6, 3.0 - 4.4) 2. Field coil screw M5 x 0.8 3. Through bolt M8 x 1.25 16.7 - 20.7 (1.7 - 2.1, 12.3 - 15.3) 4.

  • Page 38: 6-Service Procedures - Magnetic Clutch

    6-Service procedures - Magnetic clutch Magnetic clutch Drive plate holder Removal 597031-2600 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 Drive plate puller the compressor drive plate or drive shaft.
  • Page 39 6-Service procedures - Magnetic clutch 7. Remove the field coil’s lead wire bushing Remover using the remover (597035-3820). 597035-3820 8. Remove the three field coil/compressor screws. Then remove the field coil. CAUTION! Do not hold the field coil by the harness. Lead wire bushing Inspection 1. If the contact surface has been damaged by excessive heat, the armature and pulley must be replaced.
  • Page 40 6- Service procedures - Magnetic clutch Magnetic clutch Installation 1. Install the field coil on the compressor (with Field coil the harness on top) and tighten the mounting screws to the specified torque. Specified torque: 4 ~ 6 N·m Screws {0.4 ~0.6 kgf·m, 3.0 ~ 4.4 lbf·ft} 2. Carefully place the the wire harness bushing. Pulley Installer Pulley assembly Press...
  • Page 41 6- Service procedures - Magnetic clutch 7. Check that the clutch clearance is as specified. If necessary adjust the clearance using shim(s). Gap adjustment 0.3~0.6 mm Adjusting shims are available in the following thickness: Shim Part No Thickness 596541-1900 0.1 mm (0.0039 in) Thickness gauge 596541-2000 0.3 mm (0.0118 in)

  • Page 42: 7-Services Procedures - Shaft Seal Assembly

    7- Services procedures - Shaft seal assembly Shaft seal assembly Removal 1. Remove the magnetic clutch assembly as described on page 36. 2. Remove the 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.
  • Page 43 7- Services 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.
  • Page 44 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. Snap ring Internal snap ring pliers Note Guide 1.

  • Page 45: 8-Services Procedures - Cylinder Heads

    8- Services procedures - Cylinder heads Cylinder heads (Front & Rear) Bolts 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 “...
  • Page 46 8- Services procedures - Cylinder heads 8. To remove the rear cylinder head, alternately tap the two projections on the front head using the remover (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.
  • Page 47 8- Services procedures - Cylinder heads Reassembly Escape groove Rear cylinder head 1. Place the cylinder shaft assembly on the Suction valve bench with the rear side up. 2. Install the rear suction valve so that it matches the roll pins. CAUTION! Ensure each valve matches each cylinder valve escape groove.
  • Page 48 8- Services procedures - Cylinder heads Front cylinder head 1. Place the cylinder shaft assembly on the bench with the front side up. Valve plate 2. Install the front suction valve so that it matches the spring pins. O-ring CAUTION! Suction valve Ensure each valve matches each cylin- der’s valve escape groove.

  • Page 49: 9-Service Tools

    9- Service tools In addition to standard tools, numerous special tools are necessary to service the Valeo TM08, TM13, TM15 & TM16 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;...

  • Page 50: Compressor Tools

    9- Service tools Compressor tools Reference Part name Part No Shape Application page To remove the shaft Shaf Seal Remover 597035-5520 seal To remove cylinder Remover 43-44 597035-0500 head and cylinder block Guide 41-42-46 To install shaft seal 597067-1102 Test and inspection tools Reference Part name Part No Shape...
  • Page 51 Notes -49-...
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  • Page 55 VALEO JAPAN - TM08, TM13, 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 vc-oura-sales@valeo.com -53-...
  • Page 56 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 -54- Copyright © 2015 Valeo Japan CO., LTD | All Rights Reserved.

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Tm13Tm15Tm16

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