here - Valeo Compressors
Contents
1. a Ie Lal i E S LA EL 4 HN 12 M12x1 75Dp 26 69 1 Product description Exploded view Center bolt Armature assembly Adjusting shim Snap ring Pulley assembly Screw Field coil Bolt 9 Gasket 10 Front cylinder head 11 Shaft seal assembly 12 Snap ring 13 O Ring 14 Gasket 15 Valve plate assembly 16 Suction valve 17 Pin 18 Bolt at OS See 19 Cylinder shaft assembly 20 O Ring 21 Plate 22 Plate 23 Bolt 24 O Ring 25 Oil filler plug 26 Strainer 27 Gasket 28 Connector 29 Gasket 30 Bolt 31 Sight glass 32 Snap ring 33 Valve plate assembly 34 Gasket 35 Gear pump 36 Rear cylinder head 11 1 Product description Swash plate system Valeo TMA3 is a 10 cylinder swash plate type compressor With this type of compressor the cylinders and pistons are arranged axially along the drive shaft The pistons operate within the cylinders and are driven by2. gt 5 Ae 11 Fill the compressor with the specified amount of clean compressor oil through the oil filler 12 Install the oil filler plug with a new O ring and tighten it to the specified torque Specified torque 15 18 N m 1 5 1 8 kgf m 11 13 Ibf ft 13 Install the strainer in the suction port When the connectors are installed 14 Fit plates connectors to the suction and discharge connections and tighten them to the specified torque Specified torque 25 32 N m 2 5 3 3 kgf m 18 24 Ibf ft 15 Install the magnetic clutch as described p 32 16 Run in the compressor as described p 22 17 Perform the leak test as described p 23 8 Services procedures Cylinder heads Front cylinder head Suction valve Gasket Cylinder heads Front amp Rear Disassembly 1 Remove the magnetic clutch assembly as described on page 30 2 Remove the four 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 4 Remove the five bolts securing the heads 5 Alternately tap the two projections on the front head using the remover and a mallet to remove the front cylinder head 6 Remove the front valve plate assembly and then the suction valve in that order 7 Remove and discard the O ring from the front cylinder head 8 Remove all gasket material from t
3. x KG af SERVICE MANUAL Valeo TMA3 Compressor k in minn eed ate ss A 4 gi PS 17 i Di d added Flexible port design Oil fill up plug for better Easier installation inner oil return 5 double headed pistons architecture ensuring smooth and quiet operations Compact amp robust design enabling Lip type shaft seal providing easy mounting configurations ultimate reliability amp performance Light amp Compact Ultimate Reliability Highest Performance valeo added WTI Foreword This service manual has been elaborated to help ser vice personnel to provide efficient and correct service and maintenance on the Valeo TMA3 compressor for HFC 134a for automotive air conditioning This manual includes the operation specifications procedures for disassembly reassembly and inspection of the compressor WARNINGS The contents of this manual including illustrations drawings and specifications were the latest available at the time of printing Valeo Japan reserves the right to make changes in specifications and procedures at any time without notice VALEO JAPAN CO LTD The following warning signs are used in this service manual These are extremely important to ensure safe operation and to prevent body injuries and property damage They must be fully understood before starting the air conditioner maintenance WARNING CAUTION MEANING OF MARKS
4. Therefore refer to the table on the left when recharging the compressor with oil Excess oil adversely affects the cooling capacity and the compressor 6 Install the oil filler plug and tighten it to the specified torque Specified torque 15 18 N m 1 5 1 8 kgf m 11 13 Ibf ft CAUTION The oil filler plug O ring must be replaced with a new one Replacement of components When replacing the system s component parts supply the following amount of oil to the compressor Component mounted Amount of oil 200 cm 12 2 cu in 120 cm 7 3 cu in 60 cm 3 7 cu in 60 cm 3 7 cu in After installing these component parts check the compressor oil See p 21 3 Handling instructions High pressure connector Running in operation Low pressure fo Whenever moving parts have been replaced it is necessary to run in both the compressor and the magnetic clutch O ring Compressor running in Reassembled compressors must be run in after the leak test see next page E 1 Check that the compressor contains the WY specified amount of oil 2 Install the compressor on the test bench 3 Install the high and low pressure connectors Z0011222 to the ports and tighten the bolts to the specified torque Specified torque 25 32 N m 2 5 3 3 kgf m 18 24 Ibf ft 4 Connect the two connector ports using a flex ible hose 5 Run the compressor at 1 000 rpm for at least 30 minutes 6 Repla
5. Defect of cooling fan rotation Malfunction of fan motor for condenser Defective refrigerant flow control the thermal sensing tube is not closely in contact with the evaporator pipe Just after compressor stops discharge pressure will come down immediately to 0 29 0 39 MPa 3 4 kgf cm Appreciable temperature difference at the clogged location Discharge and suction pressures balance immediately after the compressor stops Defective compression of compressor Recover refrigerant then refill with the right amount of refrigerant Clean up hand repair of fin and replacement Adjustment or replacement Evacuate air from cycle the charge with the adequate amount of refrigerant Clean up inside the cycle or replace the part Replace the compressor 5 Tightening torques Unit N m kgf m Ibf ft 9 6 Service procedures Magnetic clutch Magnetic clutch Removal 1 Check your armature type see on left e 3 hole type 1 2 way stopper type 2 3 hole type 1 2 way stopper type 2 CAUTION The Procedure applies to Valeo standard magnetic clutches only It may differ with other compatible magnetic clutches please refer to the clutch maker s service procedures Armature 2 Remove the armature holder CAUTION The armature removal process differs according to the armature type e If it is a 3 hole type armature 1 a Remove the c
6. Low magnetic clutch voltage Belt slipping Compressor internal part damage or magnetic clutch damage Bolt drop off Armature drop off No difference of temperature Refrigerant shortage Magnetic clutch friction surface slipping Loose connection of the magnetic clutch electrical circuit Belt slipping The magnetic clutch does not engage Defective thermostatic switch Excess of refrigerant Condenser fan failure Loose connection of the magnetic clutch electrical circuit Defective thermostatic switch Repair or replace the magnetic clutch Check the voltage of batter Replace the compressor if it is locked Replace the compressor or the magnetic clutch Replace magnetic clutch Fix the refrigerant leakage then fill with refrigerant until reaching the right amount Check the voltage of battery l or replace the magnetic clutch Replace the magnetic clutch after making sure it is defective Magnetic clutch belt slipping Belt tension readjustment Replace the thermostatic switch after making sure it is Idefective Reduce the refrigerant charge until reaching the right amount Replace the condenser after making sure it is defective Replace the magnetic E clutch after making sure it is defective Replace the thermostatic E switch after making sure it is defective 4 Troubleshooting 2 Abnorma
7. Maintenance must be properly done to avoid serious injury risks Improper maintenance can result in injury or property damage The following marks are used in this service manual to facilitate correct air conditioner maintenance Advice Procedures necessary to ensure the best air conditioner maintenance Note Information to optimize the air conditioner maintenance Contents A 3 O 16 3 Handling instructions 17 Maintenance DISCO Sinai 17 WA een ee 17 Refrigerant hand essen een 17 Compressor MANON erat 18 Compressor TEN ici 18 Ol return operatio einen 19 Orne Ln 19 Dil orn o e eo ue EEE 20 o een 20 Replacement of components an 20 Running IN opera OT ee 21 Compressor TURNO IT een 22 Magnetic clutch UNI en 22 E rennen 23 Remera calas 23 Storing a repaired COMpresSSor ee 23 MET A A een 24 Compressor troubleshooting neun 24 Compressor troubleshooting tree a ee 24 A C cycle diagnosis by gauge Presses 27 TAMU UNNI or au era 29 6 Service procedures Magnetic QUtCh uu uuuunn nenn 30 7 Services procedures Shaft seal assembly nee 36 8 Services procedures Cylinder headset aan 39 FINE WO een een 43 Magnetic clutch service 100 ci di 43 MSS e owes 44 Test and Inspection ODIE areas 44 TOFSOIVICE Balls es ee ren 45 Saturated condensing conditions 1 Product description Compressor Compressor MODEL TECHNOLOGY DISPLACEMENT NUMBER OF CYLINDERS REVOLUTION RANGE DIRECTION OF ROTATION BORE STROKE
8. a swash plate to perform suction compression and discharge Drive shaft Radial bearing Thrust bearings Swash plate Piston Swash plate system The drive shaft which is driven by the engine through the magnetic clutch is equipped with a swash plate The drive shaft is supported by two radial bearings and two thrust bearings The swash plate is rotated by the drive shaft and moves the pistons back and forth Radial bearing Suction dij _ Compression Compression Ty an Piston Piston Drive System The pistons in the cylinders are mounted on the swash plate through hemispherical shoes Each piston has a compression head at each end Swash plate rotation results in a reciprocating piston movement parallel to the drive shaft The cylinders which are arranged at 72 intervals around the drive shaft are each divided into 2 chambers providing 5 front and 5 rear bores As each piston performs suction and compression at either end the compressor operates as a 10 cylinder compressor 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 The oil then flows through ports in the shaft to lubricate the bearings and the shaft seal The area between the swash plate
9. drier or accumulator Oil check The compressor oil must be checked as follows when being charged into a used system 1 Perform the oil return operation see page 19 2 Remove the compressor from the vehicle 3 Remove the oil filler plug and drain the oil through the oil filler plug and the high and low pressure connectors 4 Check the oil for contamination 5 Fill the compressor with the specified amount of oil through the oil filler plug see page 21 Charge specified quantity ar of compressor oil E 3 Handling instructions unit cm amp cc Current Compressor is Compressor replaced is kept P Amount to remove from new compressor Factory oil charge Amount recovered Charging amount 800 amount ba 500 or Same as more recovered 800 Under unit cu in Compressor is Current Compressor is kept replaced Amount to remove from new Factory oil charge Amount recovered Charging amount compressor 30 5 or Same as 48 8 amount more recovered a 2 48 8 Under 200cm 12 2cu in 120cm 7 3cu in CAUTION The specified oil quantity differs depending on the type of air conditioning system A label describing the specified quantity is attached to the compressor Additionally all of the oil cannot be removed when draining the compressor as some remains as an oil film on the inside of the compressor and the system components
10. magnetic clutch C Belt slipping noise 2 Abnormal noise A Magnetic clutch friction surface slipping B Magnetic clutch belt slipping C Smoke from magnetic clutch D Smoke from compressor 4 Troubleshooting Compressor is not running No cool blow coming out No cool blow coming out Insufficient cooling capacity Symptom Magnetic clutch slips when turning on the A C switch l Low pressure cut switch operates see p 27 28 The magnetic clutch slips or does not engage when the compressor runs The magnetic clutch engages but the armature does not rotate Belt run off the pulley Center bolt is loose Center bolt is missing Compressor is running normally between discharge side and suction side see p 27 28 The magnetic clutch slips or does not engage when the compressor is running Both discharge and suction pressures are high The magnetic clutch slips or does not engage when the compressor is running The magnetic clutch does not engage Possible cause Measure ae internal part replace tambor amage Refrigerant shortage Lead wire short circuit or wiring connector not seated properly Fix the refrigerant leakage then fill with refrigerant until reaching the right amount Replace the lead wire if it is defective Magnetic clutch damage Magnetic clutch air gap too Adjust air gap or replace wide magnetic clutch
11. the internal snap ring pliers Remove the shaft seal assembly using the remover 7 Services procedures Shaft seal assembly Shaft seal Press using a press Remover 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 Installation Clean the portion of the front cylinder head where the shaft seal is to be assembled Assemble the shaft seal on the remover Coat the shaft seal well with compressor oil and install the shaft seal in the front cylinder head with the shaft seal remover Install the snap ring using the internal snap ring pliers Position the guide on the shaft Coat the new O ring with clean compressor oil and install it in the front cylinder head Install the front cylinder head CAUTION Align the roll pins and tap the head light ly and evenly with a plastic hammer Remove the guide Install the five bolts from the front cylinder head side and tighten them to the specified torque Specified torque 25 32 N m 2 5 3 2 kgf m 18 24 Ibf ft Tighten each bolt gradually in three or more stages to ensure the specified torque 10 Turn the drive shaft 2 3 times by hand to ensure that the shaft rotates smoothly 7 Services procedures Shaft seal assembly Oil filler plug p B O ring
12. 33 2 36 9 Ibf ft Compressor bracket 1 Install the bracket securely on the chassis frame or engine body As the engine vibrations may be severe the bracket and mounting bolts must be installed securely Vibration resistance There must not be any resonance under 250 HZ 1 Product description General Magnetic clutch Idle pulley Drive pulley 15 Magnetic clutch 1 Voltage DC 24V 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 Ratio of magnetic clutch to drive pulley When the compressor is driven from the pulley drive of the vehicle the magnetic clutch to drive pulley ratio should avoid the range 1 0 92 1 08 to limit vibration and resonance Compressor speed must not exceed the specified speed CAUTION Pulley ratio is the ratio of the magnetic clutch diameter to the drive pulley diameter Pulley alignment tolerance is less than 1mm 0 04 in Pulley groove V groove or V ribbed The belt tension must be adjusted to the tension specified by the belt maker 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 O P O amp amp op
13. Pulley puller To remove pulley Pulley Installer To install pulley To remove the armature Armature puller assembly To fix the armature Armature holder 43 9 Service tools Compressor tools page Remover 39 40 To remove cylinder head and cylinder block To remove shaft seal To install shaft seal Valve assembly Gas leak detector AA 10 Service parts 1 Compressor body service kits sets and parts Quantity OVERHAUL KIT O RING SET GASKET SET SHAFT SEAL 1907749 a O RING SET 190750 O ring body front amp rear head 10011797 569300 4000 GASKET SET 1907754 13 33 Gasket front head amp rear head 20011492 9 Gasket bolt 9 per set 569310 6200 SHAFT SEAL for service PY Shaft seal 20011811 OTHER COMPRESSOR PARTS see Product description Exploded view p 11 2 Connector assy 20011222 service parts 28 see Product description Exploded view p 11 Item Quantity _ ZXL 100PG 250 cc 569900 0600 Notes A6 Notes 47 Notes 48 Notes A9 Notes 50 Notes 51 VALEO JAPAN TMA3 for HFC 134a use SERVICE MANUAL Version WW43 14011 01EN Published by VALEO JAPAN CO LTD Copyright 2014 VALEO JAPAN CO LTD For any inquiry regarding the present service manual contact us at vc oura sales valeo com 52 Valeo TM43 Compressor Valeo TMA3 Ber High rel
14. SHAFT SEAL LUBRICATION SYSTEM REFRIGERANT OIL QUANTITY CONNECTIONS Internal Hose Diameter WEIGHT w o clutch DIMENSIONS w o clutch Length Width Height MOUNTING O Discharge 28 mm 1 1 8 in Direct side or base Valeo TMA3 Application limits tc Condensing temperature te Evaporating gas temperature Saturated evaporating conditions 1 Product description Name Plate Name plate To ensure that the compressor operates smoothly be careful to respect the indications written on the name plate located on top of the COMP TYPE compressor body PART NO ZXXXXXXX X SERIAL NO XXXXXXXXXX ZXL 100PG 800 cm LEAK TEST HIGH SIDE 2 9MPaG LOW SIDE 1 5MPaG REFRIG HFC 134a MADE IN JAPAN THE DIRECTION OF ROTATION CLOCKWISE AS VIEWED FROM CLUTCH SIDE 1 Product description Magnetic clutch Magnetic clutch VALEO TMA3 is 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 major market actors Our compressors and magnetic clutches have successfully passed the thousand hours of long validation tests in Valeo Compressors research center laboratory Operational excellence was
15. and the shoe disks is lubricated by the splashing action of the oil flowing through the thrust bearings Oil also flows through ports in the pistons to lubricate the cylinders and the pistons Drive shaft Shaft seal Swash plate Radial bearing Gear pump Oil passage Radial bearing Reservoir Sight glass Thrust bearing Oil passage 13 1 Product description General Operation condition table Condition temperature Minimum 600 r min Speed Maximum 5500 r min Continuous 5000 r min 1 4 Compressor 1 2 The direction of rotation is clockwise as viewed from the clutch side The standard compressor oil charge is specified for passenger vehicles and truck air conditioners and the oil quantity differs depending on the type of compressor Please refer to the label on the compressor The compressor must be operated under the conditions shown in the operation conditions table shown on the left CAUTION The A C cycle components must be designed so that the pressure in the cycle does not exceed 2 65 MPaG 28 kgf cm2 384 3 psig Inclination limit at installation Valeo recommends the compressor to be installed on the vehicle within the inclination range shown on the left Front head leaning is prohibited Compressor mounting points The compressors mounting points should be tightened to the specified torque Specified torque 45 50 N m 4 6 5 1 kgf m
16. ations if the AC system is opened for repair or replacement of any component e g evaporator condenser or receiver drier any loss of charge refrigerant or oil is detected As long as it remains within the range of vision through the sight glass the oil quantity is sufficient Oil level can be read through the sight glass of he compressor see on the left Handling precautions 1 The oil must be free from dust metal filings etc 2 Do not mix oils 3 The moisture content must not exceed 1 000 ppm PAG oil only 4 The oil easily absorbs moisture when the container is open Therefore always seal the container immediately after use PAG oil only Do not mix with other oils Cap the container immediately 1 9 3 Handling instructions Opacity Oil contamination Color change f Foreign substances Unlike engine oil no cleaning agent is added to MSA the compressor oil Even if the compressor is run for along period approximately 1 season the oil never becomes turbid as long as there is nothing wrong with the compressor or its method of use Inspect the extracted oil for any of the following Increased opacity of the oil Color change to red Presence of foreign matter metal filings etc WARNING When system oil contamination is found during compressor replacement flush the A C system with a fluid that meets SAE J2670 and replace the
17. ce the oil 7 Repeat the leak test CAUTION While the compressor is being run in in step 5 above check the outside temperature of the front head If the temperature exceeds 80 C 176 F stop the running in operation Resume the operation when the head has cooled Magnetic clutch running in 1 Install the clutch on the compressor 2 Install the compressor on the test bench and operate the compressor by running the sys tem 3 Maintain the compressor speed at 500 rpm Operate the A C switch through the ON OFF cycle at least 50 times ON for 10 seconds and OFF for 10 seconds OFF 50 times 3 Handling instructions Gas leak detector 597001 1020 Leak test 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 Specified torque 25 32 N m 2 5 3 3 kgf m 18 24 Ibf ft 2 Fill the compressor with refrigerant through the suction side rising the refrigerant pressure to at least 0 39 MPaG 5 kgf cm 56 3 psig 3 Check the compressor for leaks using a leak detector Refrigerant charging In order to prevent a liquid charge and greatly increase risks of compressor dammage do not shake or turn the refrigerant bottle upside down Storing a repaired compres
18. compressor if locked Readjust the belt tension if the belt is loose Measure Adjust air gap or replace magnetic clutch heck the voltage of batter Clean friction surface or replace magnetic clutch Adjust the compressor installation position Clean or replace the belt Adjust belt tension Replace the magnetic clutch Fix the refrigerant leakage then fill with refrigerant until having the right amount Reduce the refrigerant charge until reaching the right amount 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 Ambient temperature 30 35 C Engine speed 1 500 rpm A C switch ON Blower speed high Temperature control full cold Gauge pressure Cause Confirmation method Action to take indication Pressure is normal A C cycle operates normally If there is any defect poor cooling performance there shall be another cause aw Discharge pressure around 1 0 1 7 Mpa 10 17 kgf cm Suction pressure around 0 13 0 20 Mpa 1 3 2 0 kgf cm Both discharge and Refrigerant shortage Connect gauge Recover refrigerant suction pressures are manifold to cycle then refill with the low right amount of refrigerant Suction pressure becomes vacuum Recei
19. demonstrated during hot season testing on field under challenging climates in the most stressful conditions Being 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 TMA3 compressor qualities Specifications TMA3 Valeo TM4A3 magnetic clutch Compact and robust design Housing mounted magnetic clutch Improved robustness to vibration Bearing and pulley positionned to reduce efficiently the moment of tilt Single level or multi level pulleys The specifications may vary with the compressor Please also note that the maintenance procedures introduced in this service manual apply only to magnetic clutches provided by Valeo 5 1 Product description Connectors Connectors 1 Fully open the shut off valve when operating the compressor Unscrew the cap Loose the valve spindle seal 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 When finished tighten the valve spindle seal carefully and screw the cap sae 7 A 1 1 valve spindle seal 7 Q ou Spindle az u E M ee ee 3 a Service port connector G Safety d
20. e on the rear suction valve CAUTION Do not mistake the front and rear valve plates Coat the new gasket with clean compressor oil and install it on the rear valve plate Coat the new gear pump with clean compressor oil and install it on the end of the drive shaft Coat the new O ring with clean compressor oil and install it on the rear cylinder head Install the rear cylinder head When positioning the head ensure the gear pump is inserted into the hole in the cylinder head 8 Services procedures Cylinder heads Front cylinder head 1 Place the cylinder shaft assembly on the bench with the front side up 2 Install the front suction valve so that it matches Front cylinder head O ring the spring pins I ein CAUTION A Ensure each valve matches each cylin Valve plate der s valve escape groove assembly 3 Install the front valve plate on the front suction Suction valve valve 4 Coat the new gasket with clean compressor oil and install it on the front valve plate 5 Position the guide 597067 6100 on the shaft 6 Coat the new O ring with clean compressor oil and install it on the front cylinder head 7 Install the front cylinder head CAUTION Align the roll pins and tap the head Pins lightly and evenly with a plastic hammer 8 Remove the guide 597067 6100 9 Install the five bolts from the front cylinder head side and tighten them to the
21. ective gloves Do not work with refrigerant close to your face 1 Do not misidentify refrigerants If an HFC 134a air conditioning system is mistakenly charged with another refrigerant serious problems such as compressor seizing may occur Therefore confirm before charging with refrigerant that the type of air conditioning system is an HFC 134a system 1 7 3 Handling instruction Do not release refrigerant into the air Ga 2 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 Compressor handling Do not strike or unnecessarily turn the compressor upside down If the compressor is knocked over or turned upside down during handling or installation rotate the armature plate 5 or 6 times by to circulate the oil Otherwise oil in the cylinder duing compressor start up will cause valve damage and reduce durability Compressor removal When the compressor is operational 1 Perform the oil return operation see p 19 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 Check the oil quant
22. enter bolt using an armature holder to prevent armature assembly rotation Remove the armature assembly using an armature puller assembly Remove the shims from the compressor driveshaft or armature assembly Armature b e If it is a 2 way stopper type armature 2 a Remove the center bolt using a spanner to prevent armature assembly rotation Spanner gt 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 Ww Remove the snap ring 5803301900 using External snap MAK t li iing pliers aun S external snap ring pliers Snap ring 4 Position the center pulley puller at the end of the driveshaft Center pulley Al 5 Attach a suitable pulley puller to the pulley puller Sal Hook the puller claws to the edge of the TEN Pulley puller pulley as shown 6 Tighten the center pulley puller bolt to remove the pulley 7 Remove the six field coil compressor screws Then remove the field coil WARNING Removing the pulley will systematically damage the pulley bearing CAUTION Do not clip the puller claws into the pulley groove to prevent pulley groove damage CAUTION Do not hold the field coil by the harness 6 Service procedures Magnetic clutch Magnetic clutch Inspection 1 If the contact surface has been damaged by excessive heat the armatu
23. eration 4 JO Jo Xe SCHONE IG 3 Do not wet a compressor that has not been used for a long period 4 Always charge the A C system with the specified quantity of refrigerant 5 Keep the compressor clear of water projection while cleaning the vehicule 1 6 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 Select a work area with adequate ventilation CAUTION Refrigerant itself is not harmful but excessive accumulation in a closed area can cause oxygen deficiency Keep open flame and inflammables away from the vehicle in which the air conditioner is being installed Fire is particularly dangerous during the gas leak inspection following installation WARNING Contact with flame and high temperatures can generate toxic gases Safety glasses Gloves Refrigerant handling WARNING Direct contact with refrigerant can cause frostbite or blindness Always wear safety glasses and prot
24. evices port 2 Open the service port connector when using a gauge manifold Turn the spindle in the clockwise direction by 1 2 turn to 1 turn The shut off valve and the service port connector are now opened O Valve spindle seal cap Ben LM Fe 2 G 3 Spindle O Service port connector G Safety devices port 3 Fully close the shut off valve when removing the compressor Turn the spindle in the clockwise direction until it stops Valve spindle seal Cap Spindle a Service port connector G Safety devices port 1 Product description Connectors Flexible Port Design The design of TM43 has been developped to adapt any kind of air conditioning system specifications to optimize mounting position either inside engine room ADVICE Valeo Compressors recommends the following hose sizes INTERNAL DIAMETER Suction 35 mm 1 3 8 inch Discharge 0 28 mm 1 1 8 inch 1 Product description Performance The performance data below were measured under the following conditions Compressor speed 1450 rpm Subcooling temperature 5 C Super heat temperature 10 C Valeo TMA3 performance data R134a Cooling capacity Q kW amp Power consumption P kW Conditions Evaporating Temperature C condensing po fos o ps ow Ins Temperature Ps MPaG Va
25. he front cylinder head and the front valve plate 8 Services procedures Cylinder heads Gear pump Valve plate Rear cylinder head Cylinder head 9 To remove the rear cylinder head alternately tap the two projections on the front head using the remover 597035 0500 and mallet 10 Remove the O ring from the rear cylinder head and then remove all the gasket material from the rear cylinder 11 Remove the valve plate and suction valve from cylinder shaft assembly then remove all the gasket material from the valve plate 12 Remove the gear pump from the rear cylinder 40 head or the end of the driveshaft 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 Check that there are no clogged passages in the valve plates 8 Services procedures Cylinder heads Escape GI eS ey 2 We Valve plate assembly groove Gear pump Gasket Suction valve 41 Reassembly Rear cylinder head f Place the cylinder shaft assembly on the bench with the rear side up Install the rear suction valve so that it matches the roll pins CAUTION Ensure each valve matches each cylinder valve escape groove Install the rear valve plat
26. iability Integration flexibility Great cooling capacity Enhanced performance Lower fuel consumption Compact amp robust design Improved field serviceability Reduced noise and vibrations Staggering value through innovation IAE AA AAA AA AAA ACA Europe Middle East amp Africa 39 Sendai Kumagaya shi No 2677 Shiji Avenue Eco amp Tec Dvt 8 rue Louis Lormand ZA de l Agiot Saitama ken 360 0193 Japan Zone 130031 Changchun Jilin PRC 78321 La Verriere France Phone 81 0 48 539 3800 Phone 86 0 431 8499 2025 Phone 33 0 1 3013 5027 Fax 81 0 48 539 3843 Fax 86 0 431 8499 2004 Fax 33 0 1 3461 5898 Email vc oura sales valeo com Email vc changchun sales valeo com Email vc angers sales valeo com Copyright 2014 Valeo Japan CO LTD All Rights Reserved Americas 2520 Esters Blvd 100 Dallas TX 75261 United States Phone 1 972 456 1077 Fax 1 972 456 1090 Email vc dallas sales valeo com
27. ity and the degree of contamination see p 19 amp 20 When the compressor is inoperable 1 Recover the refrigerant from the system using a refrigerant recovery unit if the shut off valves are to be removed with the compressor 2 Remove the compressor 3 Drain the oil from the compressor and close all open connections immediately 4 Check the oil quantity and the degree of contamination see p 19 amp 20 3 Handling instructions Oil return operation Compressor oil mixed with refrigerant is circulating Falen in the air conditioning system 7 ona 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 2 Operate the vehicle engine at idling during at least 20 minutes Note The maximum amount of oil cannot be recovered at higher speeds This operation also requires a warm ambient temperature Oil handling Oil specification Use only ZXL 100PG PAG DH PS or POE oil Oil quantity inspection There is no particular need for frequent inspection or replacement although it is recommended to check operating refrigerent pressures and oil levels at the start of the season Please replace the refrigerant and restore the system oil and refrigerant charge to factory specific
28. l noise Smoke from the compressor Abnormal vibration after turning on the A C switch Abnormal noise from the LIcompressor body The magnetic clutch has a backlash and slips Strange noise when the magnetic clutch engages Armature slips does Linot engage when the compressor is running Armature does not rotate when magnetic clutch lengages The magnetic clutch slips does not engage when the compressor is running The magnetic clutch slips does not engage when the compressor is running The magnetic clutch does not engage Jout Refrigerant oil is blowing Possible cause Compressor installation bolt is loose Wide gap at the attaching portion between the compressor and the bracket Compressor body internal component damage Magnetic clutch damage Air gap too wide Magnetic clutch friction Possible cause Magnetic clutch air gap too wide ow magnetic clutch voltage Coil open or shorted Refrigerant leaking uncoupled piping or piping burst Refrigerant blowing from the high pressure relief valve due to excess of refrigerant Measure Increase tightening torque of the loose bolts Improve the compressor attaching portion Replace the compressor Replace the magnetic clutch Adjust air gap or replace magnetic clutch Check the voltage of battery or replace magnetic clutch Replace the
29. leo TMA3 conversion factors Cooling Capacity and power consumption data at different rotation speed can be approximated with the conversion factors below Conversion factors 0 1000 1450 2000 3000 4000 5000 Compressor speed rpm 1 Product description Dimensions Approx 319 0160 132 12 M12x1 75Dp 26 Sight glass CB104 CA104 500 a From Field Coil L j ne i T agra B Wi ED 1 Product description Dimensions TM43 compressors without magnetic clutch 138 4 M6x1 0 Dp 13 PCDo90 15 31 1 57 54 20 5 91
30. ment 0 3 0 7 mm Thickness gauge 6 Install the armature assembly on the driveshaft together with the original shim s 7 Install the armature assembly using an armature installer assembly 8 Install the armature bolt and tighten to the specified torque using an armature holder or a spanner to prevent armature assembly rotation Specified torque 25 30 N m 2 5 3 1 kgf m 18 22 Ibf ft 9 Check that the clutch clearance is as specified If necessary adjust the clearance using shim s Adjusting shims are available in the following thicknesses Shim Part No 20010245 0 2 mm 0 008 in 35 Z0010246 0 3 mm 0 012 in Specified clearance 0 3 0 7 mm 0 012 0 028 in 10 Run in the clutch as described on page 22 7 Services procedures Shaft seal assembly Snap ring Internal snap ring pliers Press uniformly from Shaft seal above Remover Front cylinder head Shaft seal assembly Removal 1 6 Za Remove the magnetic clutch assembly as described on page 30 Remove the four bolts securing the connectors and then remove the connectors and strainer from the cylinder shaft assembly Remove the oil filler plug and then drain the oil Remove the five bolts securing the heads Alternately tap the two projections on the front head using the remover 597035 0500 and a mallet to remove the front cylinder head Remove the snap ring using
31. original shim s Press the armature assembly down by hand 6 Install the armature bolt and tighten it to the specified torque using an armature holder for 3 hole armature or a spanner for 2 way stopper armature to prevent armature assembly rotation Specified torque 25 30 N m 2 5 3 1 kgf m 18 22 Ibf ft 7 Check that the clutch clearance is as specified If necessary adjust the clearance using shim s Adjusting shims are available in the following thickness Shim Part No 20010245 0 2 mm 0 008 in 10010246 0 3 mm 0 012 in Specified clearance 0 3 0 7 mm 0 01 0 027 in 8 Run in the clutch as described on page 22 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 4 Once the pulley is fixed loose the collar and remove the pulley installer assembly 5 Install the snap ring beveled edge up using external snap ring pliers Snap ring 6 Service procedures Magnetic clutch 3 hole armature Y SO 3 hole armature 2 way stopper armature 2 way stopper armature Armature installer assembly 3 hole armature Armature holder 2 way stopper armature F Spanner Le Gap adjust
32. re 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 the armature must be replaced The contact surface of the pulley assembly must be cleaned with a suitable solvent before reinstallation Check the field coil for a loose connector or cracked insulation Armature assembly Pulley assembly Field coil Installation 1 Install the field coil on the compressor 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 Ibf ft Screws 2 Carefully place the wire harness strain relief Field coil e If you are using a press Press Pulley Installer 3 Install the pulley assembly using the pulley installer and a hand press CAUTION Use only a press to install the pulley assembly Do not use a hammer A hammer will damage or deform the pulley Pulley assembly 4 Install the snap ring beveled edge up using external snap ring pliers External snap ring pliers if not using a press p 34 37 6 Service procedures Magnetic clutch 3 hole armature 1 Armature 2 way stopper armature 2 Spanner Gap adjustment 0 3 0 7 mm Thickness gauge 5 Install the armature assembly on the driveshaft together with the
33. sor If it is necessary to store a repaired compressor for some time before installation evacuate the compressor and fill it with dry nitrogen gas through the suction fitting to raise the pressure to 49 150 kPa 0 5 1 5 kgf cm 7 1 21 psi 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 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 25 26 for the appropriate counter measure Most of the malfunction symptoms can be classified in the following categories 1 Insufficient cooling capacity 2 Abnormal noise 3 Smoke In case of insufficient cooling capacity we recommend that you prepare a gauge manifold to measure the pressure of both discharge and suction sides for a detailed diagnosis by gauge pressure see p 27 28 Compressor troubleshooting tree A Compressor is not running B Compressor is running C Compressor runs intermittently 1 Insufficient cooling capacity A Abnormal noise from compressor B Abnormal noise from
34. specified torque Specified torque 25 32 N m 2 5 3 2 kgf m 18 24 Ibf ft Tighten each bolt gradually in three or more stages to ensure the specified torque 10 Turn the drive shaft 2 3 times by hand to ensure that the shaft rotates smoothly 11 Fill the compressor with the specified amount of clean compressor oil through the oil filler 12 Install the oil filler plug with a new O ring and tighten it to the specified torque Specified torque 15 18 N m a 1 5 1 8 kgf m 11 13 Ibf ft er 13 Install the strainer in the suction port When the connectors are not installed 14 Fit the blanking plates 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 Ibf ft 15 Install the magnetic clutch see p 32 16 Run in the compressor see p 22 17 Perform the leak test see p 23 4 9 Service tools In addition to standard tools numerous special tools are necessary to service the Valeo TMA3 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 those for compressor disassembly and reassembly and those for testing and running in operation Magnetic clutch service tools Part name Shape Reference Application page Center
35. ver dryer is Temperature difference Replace parts clogged between inlet and outlet pipes happens Dryer is covered with frost Expansion valve is Expansion valve was Clean or replace part clogged covered with frost Enclosure leakage from Outlet side of the Replace part the Expansion valve s Expansion valve is not temperature sensing cooling tube Low side of gauge Expansion valve indicates vacuum operates to close the valve opening Temperature sensing Evaporator becomes Adjust or replace the device at outlet air is frozen up part defective Refrigerant piping is If any part between Adjust or replace the clogged or crashed the dryer and the part compressor is clogged or crashed the low side pressure becomes vacuum 4 Troubleshooting Gauge pressure Cause Confirmation method Action to take indication Both discharge and suction pressures are high Discharge pressure is high and suction pressure is low Discharge pressure is low and suction pressure is high Excess of refrigerant Condenser cooling malfunction Misaligned Expansion valve or thermal sensing tube of the Expansion valve is not fit on regularly Excess opening of the Expansion valve Air mixed in refrigeration cycle Refrigerant cycle is clogged between compressor and condenser Defect of the compressor valve or gasket Connect gauge manifold to cycle Condenser becomes muddy and fins are clogged and collapsed
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