Valeo TM55 Service Manual
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Valeo TM55 Service Manual

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SERVICE MANUAL
Valeo TM55 & TM65 Compressors
Copyright © 2019 Valeo Japan CO., LTD. | All Rights Reserved.

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Summary of Contents for Valeo TM55

  • Page 1 SERVICE MANUAL Valeo TM55 & TM65 Compressors Copyright © 2019 Valeo Japan CO., LTD. | All Rights Reserved.
  • Page 2 7 double-headed pistons architecture Oil fill-up plug for better ensuring smooth and quiet operations inner oil return Compact & robust design enabling Lip type shaft seal providing easy mounting configurations ultimate reliability & performance Light & Compact, Ultimate Reliability, Highest Performance...
  • Page 3 Valeo TM55 and available at the time of printing. TM65 compressors for bus air conditioning. Valeo Japan reserves the right to make changes in This manual includes the operation specifications, specifications and procedures at any time without procedures for disassembly, reassembly, and notice.

  • Page 4: Table Of Contents

    Contents 1- Product description ............... 3 Compressor speed (rpm) ..............7 Conversion factors ................7 2- Operation precautions ..............14 3- Handling instructions ..............15 Maintenance precautions ..............15 Work area ....................15 Refrigerant handling ................15 Compressor handling ...............16 Compressor removal ................16 Oil return operation .................17 Oil handling ..................17 Oil level at inclination conditions ............18...

  • Page 5: 1- Product Description

    18.1kg / 39.9 lbs (w/o Clutch) 341 - 194 - 294 (mm) DIMENSIONS 13.4 - 7.64 - 9.33 (in) Length - Width - Height MOUNTING Direct (side or base) Valeo TM55 & TM65 Application limits PSIA PSIG MPaA MPaG 2.75 2.65 1.68...
  • Page 6 Name plate As TM55 & TM65 compressors have the same dimensions, the best way to differentiate them quickly is by referring to the name plate. TM-XX COMP .
  • Page 7 1- Product description - Magnetic clutch Magnetic clutch VALEO TM55 & TM65 are available either as a compressor and magnetic clutch assembly or as a compressor body that can be fitted with compatible magnetic clutches. The magnetic clutch design Valeo has been promoting for more than 20 years is now gradually adopted by major market actors.
  • Page 8 1- Product description - Connectors Connectors 1. Fully open the shut-off valve when operating the compressor • Unscrew the cap. • Loose the valve spindle lock nut by turn. • Turn the spindle in the counterclockwise direction until it stops. The shut-off valve is now fully opened and the service port connector is closed.

  • Page 9: Compressor Speed (Rpm)

    34.56 1.58 P (kW) 7.35 8.43 9.17 9.95 11.02 11.35 Valeo TM55 & TM65 conversion factors The performance data at different rotation speed can be approximated with the conversion factors below. 1450 1000 2000 3000 4000 Compressor speed (rpm) - 7 -...
  • Page 10 1-Product description - Dimensions TM55 & TM65 compressors 6-M6x1.0,Dp13 PCD ∅ 90 12-M12x1.75,Dp26 - 8 -...
  • Page 11 1- Product description - Exploded view 1. Bolt 20. Bolt 2. Gasket 21. Gasket 3. Front cylinder head 22. Plate 4. Shaft seal assembly 23. Plate 5. Snap ring 24. Bolt 6. O-Ring 25. Sight glass 7. Gasket 26. O-ring 8.
  • Page 12 1- Product description - Swash plate system Swash plate system Valeo TM55 & TM65 are 14-cylinder swash plate type compressors. With this type of compressor, The drive shaft, which is driven by the engine the cylinders and pistons are arranged axially through the magnetic clutch, is equipped with a along the drive shaft.
  • Page 13 The compressor remains constantly lubricated thanks to the oil circulating together with the refrigerant. Valeo compressor innovative internal design ensures that almost no oil remains mixed with the refrigerant that is flushed into the air conditioning system.
  • Page 14 1- Product description Compressor 1. The direction of rotation is clockwise as viewed from the clutch side. 2. The standard compressor oil charge is specified for bus air conditioners. The oil quantity may differ depending on the type and use of compressor.
  • Page 15 1- Product description Compressor drive 1 mm Ratio of magnetic Clutch to drive pulley Magnetic clutch • When the compressor is driven from the pulley drive of the vehicle, the magnetic clutch to drive pulley ratio should avoid the range 1: Idle pulley 0.92~1.08 to limit vibration and resonance.

  • Page 16: 2- Operation Precautions

    2- Operation precautions 1. In the off season of air conditioner, operate the compressor for a few minutes from time to time. 2. Do not drive through water. Water may damage the magnetic clutch, thus preventing normal operation. 3. Always charge the A/C system with the specified quantity of refrigerant.

  • Page 17: 3- Handling Instructions

    3- Handling instructions Maintenance precautions Work area Because the components of air conditioners are especially 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 18: Compressor Handling

    3- Handling instructions 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 19: 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 20: Oil Level At Inclination Conditions

    3- Handling instructions Oil level at inclination 15˚ 15˚ conditions Compressor lateral inclination and front lifting at the same time are allowed so consider this factor during sight glass inspection (distorted indication). 5˚ Oil level inspection should be conducted at low compressor speed or compressor stopped.

  • Page 21: Oil Contamination

    1. Perform the oil return operation (p.16). 2. Remove one of the oil drainer plugs and drain the oil through it. TM55 and TM65 feature three oil drainer plugs: • One on each side of the compressor under the sight glasses.

  • Page 22: Replacement Of Components

    3- Handling instructions unit: cm & cc CAUTION! Amount The specified oil quantity differs, depending Specified Amount Charging to remove on the type of air conditioner system. A charge recovered amount from new label describing the specified quantity is compressor attached to the compressor.

  • Page 23: Leak Test

    3- Handling instructions Leak test The compressor must be checked for refrigerant leaks after it is repaired. The procedure is as follows. 1. Fit the connectors to the suction and discharge connections, and tighten it to the specified torque. Specified torque: 25 - 32 N·m {2.5 - 3.3 kgf·m, 18 - 24 lbf·ft} 2.

  • Page 24: 4- Troubleshooting

    4- Troubleshooting Compressor troubleshooting When a trouble occurs during the compressor operation, it is often difficult to pinpoint exactly 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 in case it ever happens, we hope this troubleshooting can help you solve the issue efficiently.
  • Page 25 4- Troubleshooting 1. Insufficient cooling capacity Trouble Symptom Possible cause Measure Magnetic clutch slips when Compressor internal part Compressor is Replace the compressor turning on the A/C switch damage not running (No cool blow Fix the refrigerant leakage Low pressure cut switch coming out) Refrigerant shortage then fill with refrigerant until...
  • Page 26 4- Troubleshooting 2. Abnormal noise Trouble 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...

  • Page 27: 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.
  • Page 28 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...

  • Page 29: 5- Tightening Torques

    5- Tightening torques Unit: N·m {kgf·m, lbf·ft} Part Thread size Tightening torque 1. Center bolt M10 x 1.25 25 - 30 {2.5 - 3.1, 18 - 22} 4.2 - 7.2 {0.4 - 0.7, 3.1 - 5.3} 2. Field coil screw M6 x 1.0 3.

  • Page 30: 6- Service Procedures - Magnetic Clutch

    6- Service procedures - Magnetic clutch Magnetic clutch Removal 1. Check your armature type (see at left): • 3-hole type (1) • 2-way stopper type (2) 3-hole type (1) 2-way stopper type (2) 2. Remove the armature. Armature holder CAUTION! The armature removal process differs according to the armature type •...
  • Page 31 6- Service procedures - Magnetic clutch b. Remove the armature assembly using an armature puller. Remove the shims from the Armature puller compressor driveshaft or armature assembly. 3. Remove the snap ring (Z0010244) using external snap ring pliers. External snap ring pliers Snap ring 4.
  • Page 32 6- Service procedures - Magnetic clutch Magnetic clutch Inspection 1. If 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 grooved due to slippage, both the pulley and armature must be replaced.
  • Page 33 6- Service procedures - Magnetic clutch 4. Install the armature assembly on the driveshaft 3-hole Armature together with the original shim(s) and press it armature (1) holder down. 5. Install the armature bolt and tighten it to the specified torque using an armature holder Adjusting (for 3-hole armature) or a spanner (for 2-way shims...
  • Page 34 6- Service procedures - Magnetic clutch • If you are not using a press 3. Install the pulley using a pulley installer assembly and a spanner. CAUTION! If the bolt of the pulley installer assembly is not screwed into the driveshaft, it may result in damage.
  • Page 35 6- Service procedures - Magnetic clutch 6. Install the armature assembly on the driveshaft 3-hole 2-way stopper together with the original shim(s). armature armature Adjusting shims 7. Install the armature assembly using an 3-hole armature 2-way stopper armature armature installer assembly. Armature installer assembly...

  • Page 36: 7- Service Procedures - Shaft Seal Assembly

    7- Service procedures - Shaft seal assembly Removal Bolt 1. Remove the magnetic clutch assembly as described on page 29. 2. Remove the bolts securing the connectors, and then remove the connectors and strainer from the cylinder shaft assembly. 3. Remove the oil filler plug and then drain the oil.
  • Page 37 7- Service 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 38 7- Service procedures - Shaft seal assembly 11. Fill the compressor with the specified amount Oil filler plug of clean compressor oil through the oil filler. 12. Install the oil filler plug with a new O-ring, and O-ring tighten it to the specified torque: Specified torque: 15 - 18 N·m {1.5 - 1.8 kgf·m, 11 - 13 lbf·ft} 13.

  • Page 39: 8- Service Tools

    8- Service tools In addition to standard tools, numerous special tools are necessary to service the Valeo TM55 & TM65 compressors. The use of these special tools enables prompt and correct compressor service. The drawings and the specifications of the service tools listed below are enclosed in the following pages.
  • Page 40 8- Service tools 3rd Angle Proj. Unless otherwise specified, Surface Treatment the edges to be slight chamfering. Heat Treatment - -HQF - HTL HRC40 to 45 & Hardness Should remove burrs and fluff. SS41 SS41 S45C Material Part Name Armature Holder Bolt Collar 3rd Angle Proj.
  • Page 41 8- Service tools Armature Installer Assy M14x2.0 M10x1.25 -0.2 Unless otherwise specified, 3rd Angle Proj. Surface Treatment the edges to be slight chamfering. HQ-HQf Heat Treatment Should remove burrs and fluff. HRC40 to 45 & Hardness S45C Material Part Name Bolt Armature Installer Assy x2.0...
  • Page 42 8- Service tools Section view A-A 3rd Angle Proj. Unless otherwise specified, Surface Treatment the edges to be slight chamfering. - - -HQ - HTL Heat Treatment HRC40 to 45 & Hardness Should remove burrs and fluff. S45C Material Part Name Center Pulley Puller Section view A-A 3rd Angle Proj.
  • Page 43 8- Service tools Bolt Spacer Collar 3rd Angle Proj. Material Surface Treatment Heat Treatment & Hardness Assy Material Part Name Pulley Installer Assy Pulley Installer Assy M10x1.25 M16x2.0 -0.25 Unless otherwise specified, 3rd Angle Proj. Surface Treatment the edges to be slight chamfering. HQ-HQf Heat Treatment Should remove burrs and fluff.
  • Page 44 8- Service tools Pulley Installer Assy Section view A-A Unless otherwise specified, 3rd Angle Proj. Surface Treatment the edges to be slight chamfering. HQ-HTL Heat Treatment Should remove burrs and fluff. HRC58 & Hardness Material Part Name Spacer Pulley Installer Assy M16x2.0 -0.35 Unless otherwise specified,...
  • Page 45 8- Service tools 3rd Angle Proj. Unless otherwise specified, Surface Treatment the edges to be slight chamfering. Heat Treatment & Hardness Should remove burrs and fluff. SK85 (JIS) Material Part Name Remover (for cyl. head) 3rd Angle Proj. Unless otherwise specified, Surface Treatment the edges to be slight chamfering.
  • Page 46 8- Service tools M12x1.75 -0.25 ±0.5 Unless otherwise specified, 3rd Angle Proj. Surface Treatment the edges to be slight chamfering. HQ-HQf Heat Treatment Should remove burrs and fluff. HRC40 to 45 & Hardness S45C Material Part Name Armature Puller - 44 -...
  • Page 47 8- Service tools Plate Pole Bolt 3rd Angle Proj. Surface Treatment Heat Treatment & Hardness Material Part Name Armature Puller Assy Armature puller assy (15) 2-C1.0 12-C1.0 2-C1.0 6-M12X1.75 M16X2.0 3rd Angle Proj. Unless otherwise specified, Surface Treatment the edges to be slight chamfering. Heat Treatment &...
  • Page 48 8- Service tools Armature puller assy (152) (35) (42) (57) (18) (12) R1.5 30° C1.0 M16X2.0 3rd Angle Proj. Unless otherwise specified, Surface Treatment the edges to be slight chamfering. - -HQ - HQf Heat Treatment HRC40 to 45 & Hardness Should remove burrs and fluff.

  • Page 49: 9- Service Parts

    9- Service parts 1. Compressor body service kits, sets and parts Item* Part name Reference Quantity O-RING SET Z0014430 O-ring body (front & rear head) Z0004833 O-ring drain 569300-4000 SHAFT SEAL (for service) Shaft seal Z0007461 *See Product description - Exploded view (p.10) 2.
  • Page 50 VALEO COMPRESSORS - TM55 & TM65 for HFC-134a use SERVICE MANUAL Version: EU5565-16002.01EN Published by: VALEO JAPAN CO, LTD. Printed in Japan Copyright 2016, VALEO JAPAN CO, LTD. For any inquiry regarding the present service manual, contact us at vc-oura-sales@valeo.com...
  • Page 51 Europe, Middle East & Africa 8, rue Louis Lormand ZA de l’Agiot 78321 La Verriere, France Phone: +33 (0) 1 3013 5027 Fax: +33 (0) 1 3461 5898 Email: vc-angers-sales@valeo.com Copyright © 2016 Valeo Japan CO., LTD. | All Rights Reserved.

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