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Valeo TMX Service Manual

Heavy duty fixed piston swash plate type compressor
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SERVICE MANUAL
Valeo TMX
Copyright 2020 Valeo, LTD. All rights reserved.

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Summary of Contents for Valeo TMX

  • Page 1 SERVICE MANUAL Valeo TMX Copyright 2020 Valeo, LTD. All rights reserved.
  • Page 2 The contents of this manual, including illustrations, drawings and specifications were the latest available at the time of printing. Valeo reserves the right to make changes in specifications and procedures at any time without notice.

  • Page 3: Table Of Contents

    Contents 1. Product description 2. Operation precautions 3. Handling instructions 3.1. Maintenance precautions 3.1.1. Working area 3.1.2. Refrigerant handling 3.2. Compressor handling 3.3. Compressor removal 3.4. Oil Management 3.4.1. Oil return operation 3.4.2. Oil handling 3.4.3. Oil contamination 3.4.4. Oil specification 3.4.5.

  • Page 4: Product Description P3

    Splash lubrication REFRIGERANT R134a or R1234yf OIL TYPE / AMOUNT * VC100YF PAG OIL / 130 cm RATED VOLTAGE 12V DC * Customer can order Valeo service oil package ➝ Part number: T428727 (1 CASE = 6 x 250 cc can)
  • Page 5 1 - PRODUCT DESCRIPTION - COMPRESSOR Compressor 1. The compressor must be operated within the green area shown on Table 1. 2. Inclination limit at installation The compressor must be installed on the vehicle within the range shown on Table 2. Table 1 ℉...
  • Page 6 Discharge Pressure: Pd = 1.52 MPaG ● ● Suction Pressure: Ps = 0.18 MPaG ● Subcooling temperature: SC = 5°C Super heat temperature: SH = 10°C ● Valeo TMX performance data table (R134a) : Nc (r/min) 1000 1500 2000 2500 3000 Vol. Eff. (%) 72.9...
  • Page 7 1 - PRODUCT DESCRIPTION - SWASH PLATE SYSTEM Valeo TMX is a 10 cylinders swash plate type compressors. 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, compression and discharge.

  • Page 8: Operation Precautions

    2 - OPERATION PRECAUTIONS Preventive Maintenance 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.

  • Page 9: Handling Instructions

    3 - HANDLING INSTRUCTIONS Maintenance precautions Working 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 10: Refrigerant Handling

    3 - HANDLING INSTRUCTIONS Refrigerant handling Safety glasses WARNING! Gloves 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 misidentify refrigerants If an HFC-134a (or HFO-1234yf) air conditioning system is mistakenly charged with another refrigerant, serious problems such as compressor Do not release refrigerant into the air...

  • Page 11: Compressor Removal

    3 - HANDLING INSTRUCTIONS Compressor removal When the compressor is operational 1. Perform the oil return operation (p.11). 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.

  • Page 12: Oil Contamination

    When system (oil) contamination is found Use only VC100YF PAG OIL during compressor replacement, flush the A/C system with a fluid that meets SAE Customer can order Valeo service oil package J2670 replace dryer ➝ Part number: T428727 (1 CASE = 6 x 250 cc accumulator).

  • Page 13: Oil Check

    3 - HANDLING INSTRUCTIONS Oil check The compressor oil must be checked and adjusted as follows when replace compressor or performance system service: 1. Perform the oil return operation (p.11). 2. Remove the old compressor from the vehicle. Remove used oil from the discharge and suction 3.

  • Page 14: Running-In Operation

    3 - HANDLING INSTRUCTIONS Running-in operation Connect the flexible hoses to suction and discharge port 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 (p.15).

  • Page 15: Magnetic Clutch Running P15

    3 - HANDLING INSTRUCTIONS Magnetic clutch running-in High pressure 1. Install the clutch on the compressor. pressure 2. Install the compressor on the test bench, and operate the compressor by running the system. 3. Maintain the compressor speed at 500 rpm. (50 times) Operate the A/C switch through the ON/OFF cycle at least 50 times (“ON”...

  • Page 16: 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 damage, do not shake or turn the refrigerant bottle upside-down.

  • Page 17: Installation Precautions

    3 - HANDLING INSTRUCTIONS Installation precautions Discharge Port The new compressor is filled with the specified quantity of compressor oil and nitrogen gas (N2). When mounting the compressor on the vehicle, please follow as below : 1. Loosen the discharge side connector’s cap and gently release nitrogen gas (N2) from the compressor.

  • Page 18: Piping Precautions

    3 - HANDLING INSTRUCTIONS Piping precautions O-ring positions 1. Position the O-Ring against the bulge in the CORRECT INCORRECT INCORRECT 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 HFC-134a...

  • Page 19: Troubleshooting

    4 - TROUBLESHOOTING Compressor troubleshooting As long as the compressor maintenance is done correctly, there should not be any problem throughout the whole vehicle life, but should it happen, this troubleshooting can help solving the issue. Below are listed most of the issues 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 counter measure.
  • Page 20 4 - TROUBLESHOOTING 1. Insufficient cooling capacity Issue Symptom Potential cause Counter measure Magnetic clutch slips when Compressor internal A. Compressor Replace the compressor turning on the A/C switch damage is not running (no cool blow Fix the refrigerant leakage coming out) Low pressure cut switch then fill with refrigerant...
  • Page 21 4 - TROUBLESHOOTING 1. Insufficient cooling capacity Issue Symptom Potential cause Counter measure Compressor is running Defective compressor Replace compressor B. Compressor is abnormally running (no cool No difference of Fix the refrigerant leakage blow coming out) temperature between then fill with refrigerant Refrigerant shortage discharge side and suction until reaching the right...
  • Page 22 4 - TROUBLESHOOTING 2. Abnormal noise Issue Symptom Potential cause Counter measure Abnormal vibration after Compressor installation Increase tightening torque A. Abnormal turning on the A/C switch bolt is loose of the loose bolts noise from the compressor Wide gap at the attaching portion between the Mount compressor compressor and the engine...
  • Page 23 4 - TROUBLESHOOTING 3. Smoke Issue Symptom Potential cause Counter measure A. Magnetic The magnetic clutch slips / Magnetic clutch air gap too Adjust air gap or replace clutch friction does not engage when the wide magnetic clutch surface slipping compressor is running Low magnetic clutch Check the voltage of...

  • Page 24: A/C Cycle Diagnosis By Gauge Pressure P24

    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 measuring: 1.
  • Page 25 4 - TROUBLESHOOTING Gauge pressure Cause Confirmation method Action to take indication Recover refrigerant, then Connect gauge manifold Excess of refrigerant refill with the right to cycle amount of refrigerant Condenser becomes muddy and fins are Condenser cooling clogged and collapsed. Clean up, hand repair of malfunction Defect of cooling fan...

  • Page 26: Service Procedures : Magnetic Clutch

    6 - SERVICE PROCEDURE - MAGNETIC CLUTCH Exploded view of Magnetic Clutch 1. Center bolt 2. Armature plate 3. Adjusting shim 4. Snap ring 5. Pulley assembly 6. Coil Screw 7. Field coil 8. Compressor body Clutch Assembly Specifications Tightening torques Air Gap (between Armature plate and Center Bolt...

  • Page 27: Removal

    6 - SERVICE PROCEDURE - MAGNETIC CLUTCH Magnetic Clutch Removal Step 1: Remove the center bolt using a drive ● plate holder (p.31) to prevent armature plate from rotation. Step 2: Remove the armature plate by hand or ● using a M8 screw if necessary. Step 3: Remove the snap ring using external ●...

  • Page 28: Inspection

    6 - SERVICE PROCEDURE - MAGNETIC CLUTCH Magnetic Clutch Removal Step 7: Remove the field coil lead wire bushing ● using a flat screwdriver (p.31). Step 8: Remove the three field coil/compressor ● screws. Then remove the field coil. CAUTION! Do not hold the field coil by the harness Inspection 1.

  • Page 29: Installation

    6 - SERVICE PROCEDURE - MAGNETIC CLUTCH Magnetic Clutch Installation Step 1: Install the field coil on the compressor ● (with the harness on top) and tighten the mounting screws to the specified torque (p.26). Step 2: Carefully place the the wire harness ●...
  • Page 30 6 - SERVICE PROCEDURE - MAGNETIC CLUTCH Magnetic Clutch Installation Step 5: Install the armature plate on the ● driveshaft together with the original shims. Press the armature assembly down by hand. Step 6: Install the center bolt and tighten the ●...

  • Page 31: Service Tools

    7 - SERVICE TOOLS Special service tools required for clutch assembly / disassembly Armature plate Lead wire bushing Pulley installer Pulley puller holder remover ● Armature plate holder → To fix the drive plate Lead wire bushing remover → To remove lead wire ●...
  • Page 32 Valeo TMX compressor TMX compressor benefits Staggering value through innovation ● Reduced noise and vibration ● Improved field serviceability ● Compact & robust design ● Lower fuel consumption ● Enhanced performance ● Higher cooling capacity ● Integration flexibility ● High reliability ●...

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