Valeo TM31 Service Manual
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Valeo TM31 Service Manual

Valeo TM31 Service Manual

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SERVICE MANUAL
Valeo TM31 Compressor
Copyright © 2017 Valeo Japan CO., LTD. All rights reserved.

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  • Page 1 SERVICE MANUAL Valeo TM31 Compressor Copyright © 2017 Valeo Japan CO., LTD. All rights reserved.
  • Page 3 TM31 (formerly at the time of printing. called DKS 32) compressor (for HFC-134a) for auto- Valeo Japan reserves the right to make changes in motive air conditioning. specifications and procedures at any time without This manual includes the operation specifications, notice.

  • Page 4: Table Of Contents

    Contents 1- Product description ............... 3 2- Operation precautions ..............13 3- Handling instructions ..............14 Maintenance precautions ..............14 Work area ....................14 Refrigerant handling ................14 Compressor handling ...............15 Compressor removal ................15 Oil return operation .................16 Oil handling ..................16 Oil contamination ................17 Oil check ...................17 Replacement of components ............18 Running-in operation ...............19...

  • Page 5: 1-Product Description

    9.5 kg (21 lb) (w/o Clutch w/o oil) 278.5 - 143 - 178 (mm) DIMENSIONS (with clutch) 10.94 - 5.63 - 7 (in) Length - Width - Height MOUNTING Direct (side or base) Valeo TM31 Application limits for HFC-134a PSIA PSIG MPaA MPaG 2.47 2.37 1.68 1.58...
  • Page 6 1- Product description - Magnetic clutch Specifications* TYPE Electromagnetic single-plate 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 TYPE...
  • Page 7 The performance data below were measured under the following conditions: • Compressor speed: 1450 rpm Suction gas temperature: 20 o C • Valeo TM31 performance data (R134a) Conditions Cooling capacity Q (kW) & Power consumption P (kW) Evap temp 12.5...
  • Page 8 1- Product description - Dimensions TM31compressors with magnetic clutch Unit: mm 4-M8x1.25 0.3~0.6 Approx 244 Approx 278.5 12-M10x1.5 Other connecting type 2-M8x1.25 - 6 -...
  • Page 9 1- Product description - Exploded view 1. Center bolt 16. Cylinder shaft assembly 2. Armature assembly 17. Oil filler plug 3. Adjusting shim 18. O-ring 4. Snapring 19. Strainer (option) 5. Pulley assembly 20. O-ring 6. Screw 21. Suction valve 7.
  • Page 10 1- Product description - Swash plate system Swash plate system Valeo TM31 are 10-cylinder swash plate type compressors. With this type of compressors, the The drive shaft, which is driven by the engine cylinders and pistons are arranged axially along through the magnetic clutch, is equipped with a the drive shaft.
  • Page 11 1- Product description - Lubrication The compressor is lubricated by a gear pump in the rear cylinder head which is connected to the compressor. Oil flow When the compressor starts operating, the gear pump draws oil from the reservoir and pumps it through an oil passage in the shaft.
  • Page 12 1- Product description Compressor Caps 1. The direction of rotation is clockwise as viewed from the clutch side. 2. Each compressor is delivered filled with a specified quantity of compressor oil as described on its label. The total amount of oil your air conditioning system requires is provided by the system designer or supplier.
  • Page 13 1- Product description Magnetic clutch 1. Voltage DC 24 V The terminal voltage of the magnetic clutch must exceed 21 V. DC 12 V The terminal voltage of the magnetic clutch must exceed 10.5 V. 2. Ratio of magnetic clutch to drive pulley 1 mm •...
  • Page 14 1- Product description Control switches Gas type thermo switch 1. Thermo switch A thermo switch is necessary. The following Capillary tube specification is recommended. Compressor OFF: Evaporator fin surface temperature of 0°C (32°F) or below. The thermo switch is used to prevent the evaporator from freezing.

  • Page 15: 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 16: 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 17: Compressor Handling

    3- Handling instructions 2. Do not release refrigerant into the air Do not release refrigerant into the air Although HFC-134a is not subject to CFC regulations, it can have effect on global warming and so should not be released into the air. When removing refrigerant from the air conditioning system, always use a refrigerant recovery unit made specifically for HFC-134a.

  • Page 18: Oil Return Operation

    3- Handling instructions Oil return operation Compressor oil mixed with refrigerant is circulating 強冷 自動 自動 in the air conditioning system. 電源 Perform the oil return operation to return this oil to the compressor before removing components from the system. 1.

  • Page 19: Oil Contamination

    3- Handling instructions Oil contamination • Opacity • Color change • Foreign substances Unlike engine oil, no cleaning agent is added • Metal filings to 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 nothing wrong with the compressor or its method of use.

  • Page 20: Replacement Of Components

    3- Handling instructions CAUTION! Current Compressor is Compressor The specified oil quantity differs, depending replaced is kept unit: cm & cc on the type of air conditioning system. A label describing the specified quantity is Amount attached to the compressor. Additionally, all Specified Amount Charging...

  • Page 21: Running-In Operation

    3- Handling instructions Running-in operation High pressure Flexible hose connector T44375C Whenever moving parts have been replaced, it O-ring is necessary to run-in both the compressor and 569300-9200 the magnetic clutch. Low pressure connector Compressor running-in T44373C Reassembled compressors must be run-in after the leak test (see next page).

  • Page 22: Leak Test

    3- Handling instructions Leak test Valve assembly (597017-1120) The compressor must be checked for refrigerant leaks after it is repaired. The procedure is as follows. 1. Fit plates to the suction and discharge connections, and tighten it to the specified torque.

  • Page 23: 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 24 4- Troubleshooting 1. Insufficient cooling capacity Issue 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 25 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...

  • Page 26: 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 measuring: 1.
  • Page 27 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 28: 5- Tightening Torques

    5- Tightening torques Unit : N·m {kgf·m, lbf·ft.} Part Thread 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.

  • Page 29: 6- Service Procedures - Magnetic Clutch

    6- Service procedures - Magnetic clutch Magnetic clutch Drive plate holder 597031-3000 Removal 1. Remove the center bolt using the drive plate holder (597031-3000) to prevent the armature assembly from rotating. 2. Remove the armature assembly. 3. Remove the snap ring using external snap ring pliers.
  • Page 30 6- Service procedures - Magnetic clutch 5. Remove the lead wire bushing of the field Lead wire bushing coil using the remover (597035-3820). 6. Remove the three field coil/compressor Remover screws. Then remove the field coil. 597035-3820 CAUTION! Do not hold the field coil by the harness. Inspection 1.
  • Page 31 6- Service procedures - Magnetic clutch Magnetic clutch Lead wire bushing Installation 1. Install the field coil on the compressor Screws (with the harness on top) and tighten 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} Field coil 2.
  • Page 32 6- Service procedures - Magnetic clutch 5. Install the armature assembly on the Drive plate holder Drive plate 597031-3000 driveshaft together with the original shim(s). Press the armature assembly down by hand. 6. Install the center bolt and tighten to the Adjusting specified torque using the drive plate holder shims...

  • Page 33: 7- Service Procedures - Shaft Seal Assembly

    7- Service procedures - Shaft seal assembly Shaft seal assembly Removal 1. Remove the magnetic clutch assembly as described on page 27. 2. Remove the four bolts securing the connectors, and then remove the connectors and strainer from the cylinder shaft assembly. 3.
  • Page 34 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 35 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. O-ring 12. Install the oil filler plug with a new O-ring, and tighten it to the specified torque. Specified torque: 14 ~ 16 N·m {1.4 ~ 1.6 kgf·m, 10 ~ 12 lbf·ft} 13.

  • Page 36: 8- Service Procedures - Cylinder Heads

    8- Service procedures - Cylinder head Cylinder heads (Front & Rear) Disassembly 1. Remove the magnetic clutch assembly as described on page 27. 2. Remove the four bolts securing the connectors, and then remove the connectors and strainer from the cylinder shaft assembly. 3.
  • Page 37 8- Service procedures - Cylinder head 9. Screw two bolts into the opposite sides of Rear cylinder head the rear cylinder head and tap alternate bolts Bolts lightly with a plastic hammer to remove the head. CAUTION! Screw the bolts fully into the head to prevent rear head thread damage.
  • Page 38 8- Service procedures - Cylinder head Inspection Check the front and rear valve plates for scratched, 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 or damaged.
  • Page 39 8- Service procedures - Cylinder head Reassembly Escape groove Rear cylinder head 1. Place the cylinder shaft assembly on the 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 40 8- Service procedures- Cylinder head Front cylinder head Front cylinder head 1. Place the cylinder shaft assembly on the bench with the front side up. O-ring 2. Install the front suction valve so that it matches the spring pins. Gasket CAUTION! Valve plate assembly...

  • Page 41: 9- Service Tools

    9- Service tools In addition to standard tools, numerous special tools are necessary to service the Valeo TM31 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 42 9- Service tools Compressor tools Reference Part name Part No. Shape Application page For removing Remover 597035-0500 cylinder head and cylinder block For removing and Remover 597035-4700 installing shaft seal For installing shaft Guide 597067-6100 seal Test and inspection tools Reference Part name Part No.
  • Page 43 9 - Service tools - 41 -...
  • Page 44 9 - Service tools - 42 -...

  • Page 45: 10- Service Parts

    10- Service parts 1. Compressor body service kits, sets and parts Item* Part name Reference Quantity OVERHAUL KIT 5699306221 (O-RING SET + GASKET SET + SHAFT SEAL) O-RING SET 569920-4420 15,20 O-ring body (front & rear head) 569300-8900 O-ring drain 569300-4000 GASKET SET 569941-1921...
  • Page 46 VALEO JAPAN - TM31 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-sales@valeo.com...
  • Page 47 Phone: +1 972 456 1077 Fax: +81 (0) 48 539 3843 Fax: +86 (0) 431 8499 2004 Email: valeo.compressors.europe. Fax: +1 972 456 1090 sales.mailbox@valeo.com Email: vc-oura-sales@valeo.com Email: vc-changchun-sales@valeo.com Email: vc-dallas-sales@valeo.com Copyright © 2017 Valeo Japan CO., LTD. All Rights Reserved.

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